Vehicle Power Switching Device Differential Locking Mechanism
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Solution Overview
Problem
Conventional vehicle power switching devices face difficulties in controlling the differential locking mechanism, leading to complex operation and ineffective locking due to the need for separate mechanisms for mode changes and differential locking, resulting in unsteady locking and increased manufacturing costs.
Innovation Solution
A vehicle power switching device with a power transmission unit and a driving unit that includes a controller, a first transmission mechanism, and a second transmission mechanism, allowing the first coupler to move between two-wheel drive, four-wheel drive, and differential locking positions, enabling easy control and effective locking of the differential by a solenoid or electric actuator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable and separate shaft mechanism are used to lock the differential, then the differential can be locked, but the control becomes difficult and requires operating two different members
Solution Approach 1:
The patent combines the differential locking function with the existing mode-changing mechanism. The first coupler that switches between two-wheel and four-wheel drive modes also performs the differential locking function when positioned appropriately. This merging eliminates the need for separate cable and shaft mechanisms, allowing control through a single member while maintaining reliable differential locking.
Solution Approach 2:
The first coupler is designed to perform multiple functions: it switches drive modes (two-wheel/four-wheel) and also locks the differential. By making this single component universal, the system reduces the number of separate control mechanisms needed, thereby improving ease of operation while maintaining the reliability of differential locking.
2Reliability
If a cable pulling mechanism is used to move the shaft and second-coupler pushing member, then the differential can be locked, but the initial small-distance pulling does not move the components effectively
Solution Approach 1:
The patent eliminates the cable pulling mechanism entirely by merging the differential locking function into the mode-changing mechanism. The first coupler directly engages with the differential assembly through splined connections, providing positive mechanical engagement that ensures sufficient displacement and reliable locking without relying on cable tension or initial movement thresholds.
Solution Approach 2:
The patent replaces the cable-based mechanical system with a direct splined connection system. Instead of using flexible cable tension to move components, the invention uses rigid splined engagements between the first coupler and the differential assembly, ensuring precise and sufficient displacement for effective differential locking.
3Reliability
If a sensor is added to detect the position of the second sliding block, then the locking effectiveness can be improved, but the manufacturing costs increase
Solution Approach 1:
The patent employs a self-indicating mechanical design where the position of the first coupler directly indicates the locking state. The splined connections and mechanical engagement provide inherent position feedback without requiring external sensors. This self-service approach ensures reliable locking effectiveness while avoiding the additional manufacturing costs of sensors and associated electronics.
Solution Approach 2:
The patent removes the need for sensors by extracting the position detection function from the electronic domain and embedding it in the mechanical structure itself. The physical configuration of the splined connections and coupler positions provides direct, observable indication of the locking state, eliminating expensive electronic detection components.
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 simplifies control of the vehicle power switching device, allowing seamless conversion between modes and effective differential locking without the need for a cable, enhancing operational ease and locking stability.
Implementation Method 1
a controller being one of a solenoid and an electric actuator
Data Source
AI summary
A power switching device includes a power transmission unit and a driving unit. The transmission unit includes a differential, an axle aligned with the differential, and a coupler sleeved movably on one of the differential and the axle. The driving unit includes a controller, a first transmission mechanism driven by the controller, and a second transmission mechanism driven by the first transmission mechanism. The controller is a solenoid or an electric actuator, and is operable to activate the second transmission mechanism. The coupler can be moved by the second transmission mechanism to interconnect the differential and the axle, so as to allow for co-rotation of the axle with the differential.