Design Robustness of Electronic Locking Differential for enhanced off-road performance

The Electronic Locking Differential (ELD) is a critical component for enhancing off-road vehicle performance by ensuring optimal traction in challenging terrains. This paper addresses intermittent engagement issues observed in the ELD system during off-road trials, which impacted its reliability and functionality. It presents a comprehensive study of design robustness improvements implemented to resolve these concerns and optimize the ELD’s performance, ensuring enhanced customer satisfaction in demanding off-road environments. The analysis begins with identifying factors contributing to the intermittent engagement and disengagement of the ELD system upon actuation. These factors include residual magnetism, material properties, temperature effects, and the stack-up characteristics of transfer path components under various boundary conditions. To address these challenges, three key design modifications were introduced: (1) reduction of residual magnetism through an increased air gap between the coil and gear carrier housing, (2) enhancement of spring preload by increasing the side gear groove depth, and (3) reduction of friction by decreasing lug diameter. These changes were rigorously evaluated through real-life customer use-case scenarios, ensuring their applicability in diverse operational conditions, including tilted positions and low voltage scenarios. Moreover, the modified design demonstrated enhanced robustness during wheel slip launch performance tests, requiring minimal torque reversal for ELD disengagement. This paper provides a detailed analysis of the design modifications, their implementation timelines, and the validation process. The findings highlight the importance of design optimization in overcoming functional challenges and achieving superior off-road performance. The proposed improvements not only resolve the identified issues but also contribute to the overall reliability and durability of the ELD system, making it a robust solution for off-road applications.