Slip Ring Coupling for Lockable Differential Actuator Packaging
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Solution Overview
Problem
Existing electronically lockable differential assemblies face challenges in packaging constraints, safety requirements, and reliability, particularly in electric vehicles, where innovative design and integration are needed to enhance performance and efficiency.
Innovation Solution
The proposed lockable differential assembly incorporates a rotatable lock plate, an actuator assembly with a stator and armature, and a slip ring assembly that transmits axial locking and return forces. This configuration allows for selective engagement and disengagement of the locking mechanism, improving control and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional locking mechanism is used in electronically lockable differential assemblies, then the basic locking function is achieved, but packaging constraints and integration complexity increase in electric vehicles
Solution Approach 1:
The actuator assembly is integrated directly into the differential assembly, merging the locking mechanism with the differential components. The actuator housing forms part of the differential assembly housing, and the armature is coupled to the lock plate through the slip ring assembly, creating a unified structure that reduces overall packaging space while maintaining functionality.
Solution Approach 2:
The slip ring assembly is nested within the actuator assembly, with the slip ring positioned between the armature and lock plate. The pins that rotationally couple the slip ring to the lock plate are integrated into the slip ring structure itself, creating a compact nested arrangement that minimizes space requirements.
2Device complexity
If the lock plate and actuator are directly coupled, then the structure is simplified, but relative rotation between components causes wear and reduces reliability
Solution Approach 1:
The slip ring assembly acts as an intermediary between the actuator armature and the lock plate. It permits relative rotation between these components while maintaining axial force transmission, thereby preventing direct contact and wear between the armature and lock plate, and improving component durability.
3Extent of automation
If electrical connections are made through rotating components, then power can be supplied to rotating parts, but electrical contact reliability deteriorates due to sliding contact
Solution Approach 1:
The slip ring serves as an intermediary for electrical power transmission to the rotating lock plate. By providing a continuous sliding contact surface, it enables reliable electrical connections while allowing rotation, thus maintaining power supply to rotating components without compromising contact reliability.
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 enables precise control over the locking state of the differential assembly, enhancing traction in low-traction conditions while minimizing hydraulic damping and energy consumption, thus addressing the challenges of packaging, safety, and reliability.
Implementation Method 1
a slip ring interfacing with the armature at a slip surface configured to permit relative rotation between the slip ring and the armature
Implementation Method 2
an actuator assembly including a stator and an armature, the actuator assembly configured to be switchable between an energized state and a de-energized state
Data Source
AI summary
A lockable differential assembly includes a lock plate that is rotatable about a rotational axis. The differential assembly also includes actuator assembly having a stator and an armature, the actuator assembly being switchable between energized and de-energized states. A slip ring assembly configured to axially translate based on the locked state or the unlocked state of the differential assembly is provided, including a slip ring that interfaces with the armature at a slip surface, and one or more pins rotationally coupling the slip ring to the lock plate. The slip ring assembly is configured to transmit an axial locking force and an axial return force between the actuator assembly and the lock plate.