Two-Step Differential Locking With Single-Actuator Clutch Control
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Solution Overview
Problem
Existing differential devices either lose torque transmission when one wheel loses traction or have complex structures using multiple clutches to achieve both limiting and locking differential motion, which complicates the design and affects reliability and weight.
Innovation Solution
A differential device utilizing a single actuator with a two-step mechanism, incorporating a friction clutch for limiting differential motion and a dog clutch for locking, controlled by a cam mechanism and driver disk to selectively engage and disengage clutches, allowing for both functions without increasing structural complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two sets of friction clutches and pressure devices are used to achieve both limiting and locking functions, then both functions can be realized, but the structure becomes terribly complicated
Solution Approach 1:
The patent merges the control mechanisms for both limiting and locking functions into a single actuator system. Instead of using two independent actuators with separate control systems, one actuator controls both the friction clutch and dog clutch engagement, significantly reducing structural complexity while maintaining full functionality.
Solution Approach 2:
The single actuator is designed with multi-functionality to control both clutch types. It can selectively engage the friction clutch for limiting differential motion or engage the dog clutch for locking, providing universal control capability that eliminates the need for separate dedicated actuators for each function.
2Adaptability or versatility
If multiple clutches are used to achieve limiting and locking functions, then both functions can be realized, but reliability decreases due to increased complexity
Solution Approach 1:
By combining the control of both clutches under a single actuator system, the patent reduces the number of potential failure points. Fewer independent components and control mechanisms mean fewer opportunities for system failure, thereby improving overall reliability while maintaining the ability to perform both limiting and locking functions.
3Adaptability or versatility
If multiple clutches and pressure devices are used, then both limiting and locking functions can be achieved, but weight increases
Solution Approach 1:
The patent combines both clutch mechanisms and their control systems into a single integrated differential assembly. By sharing common components such as the actuator, housing, and mounting structures, the overall weight of the differential device is reduced compared to having separate independent systems for limiting and locking functions.
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
Enables reliable and efficient torque transmission by simplifying the structure, allowing for seamless transition between limiting and locking differential motion using a single actuator, enhancing reliability and reducing weight.
Implementation Method 1
a first cam mechanism adjacent to the first pressure plate to press the first pressure plate toward the first clutch
Implementation Method 2
a friction clutch so coupled with the input member and the output gears as to limit the differential motion
Implementation Method 3
in combination with the second pressure plate constituting a second cam mechanism to engage the second clutch
Data Source
AI summary
A differential device is provided with: an input member; a gear set with output gears to transmit torque from the input member to the output gears while allowing differential motion therebetween; a first clutch for limiting the differential motion; a first pressure pressing on the first clutch; a first cam mechanism for pressing the first pressure plate toward the first clutch; a second clutch, when connected, drivingly connecting the output gears with the input member; a second pressure plate for engaging the second clutch; and a rotatable driver disk including a pressing member so coupled with the cam mechanism as to, from a first position to a second position, rotate the first cam mechanism together and to, from the second position to a third position, allow the first cam mechanism to create rotational difference relative to the pressing member, thereby engaging the second clutch.