Sealed Locking Differential Control for Heat and Vibration
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Solution Overview
Problem
Existing electronic locking differential systems face challenges such as limited programmable capabilities, bulky profiles, and increased likelihood of component degradation due to harsh environmental conditions like heat and vibration, which affect the precision and reliability of the locking mechanism control.
Innovation Solution
A differential system incorporating an electromagnetic solenoid actuator with a coil assembly and a circuit board assembly that includes control circuitry and a sensor, enclosed in a sealed housing, allowing for compact and precise control of the locking mechanism, and featuring a power-saving mechanism to reduce temperature and degradation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electronic actuators are used in the differential system, then actuation speed and durability are improved, but the components are exposed to harsh environmental conditions (heat, vibration, oil) which increases the likelihood of component degradation
Solution Approach 1:
The controller is extracted from the harsh interior environment of the differential and relocated to a more favorable environment outside the differential housing. This separates the electronic control components from the high-temperature, high-vibration, and oil-exposed conditions inside the differential, thereby reducing component degradation while maintaining fast actuation performance.
Solution Approach 2:
A sealed housing structure acts as an intermediary barrier between the controller/sensor components and the harsh differential environment. This housing protects the electronic components from direct exposure to heat, vibration, and oil while allowing the system to maintain its locking functionality.
2Reliability
If the controller is spaced away from the sensor, then component degradation is reduced, but the controller exhibits a bulky profile which poses packaging challenges
Solution Approach 1:
The sensor is radially extended down a face of the coil assembly, nesting the sensing function within the existing coil assembly structure. This allows the controller to be positioned closer to the differential components without requiring additional external space, reducing the bulky profile while maintaining component separation for reliability.
3Reliability
If control circuitry is continuously powered, then locking functionality is maintained, but power consumption and temperature increase
Solution Approach 1:
The control circuitry is placed in periodic sleep states where power is reduced or eliminated for selected durations, while maintaining the ability to quickly activate locking functionality when needed. This periodic powering reduces overall power consumption and heat generation while preserving the reliability of the locking system through rapid wake-up capability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the precision and reliability of the locking mechanism, increases packaging efficiency, and extends the longevity of the control circuitry by reducing the risk of over-temperature conditions and lubricant interference, while maintaining locking functionality even in high-temperature environments.
Implementation Method 1
an electromagnetic solenoid actuator that includes a coil assembly and a piston. The piston is configured to selectively induce locking and unlocking of axle shaft speed differentiation
Data Source
AI summary
Methods and systems for a locking differential are provided. The locking differential system includes an electromagnetic solenoid actuator designed to induce locking and unlocking of the differential and a circuit board assembly designed to programmatically control the locking and unlocking functionality. The circuit board assembly includes a sensor and control circuitry enclosed in a continuous sealed enclosure, the sensor extends down the face of a coil assembly in the solenoid.