DOI: 10.30939/ijastech..1827614 ISSN: 2587-0963

Electromechanical eLSD for EV Drivelines: High-Density Torque Actuation and Low-Energy Brake Hold Mechanism

Siddhesh Pimpale
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Torque transfer is an integral aspect of the automotive industry, across all vehicle architectures including internal combustion engines, battery electric, hybrid, and hydrogen fuel cell to increase performance, efficiency, and vehicle stability in all driving conditions. Traditional differential mechanisms used for torque transfer to each wheel often fail to provide enough torque biasing under varying load conditions to maintain optimal wheel slip in low friction surfaces. This paper presents grounded design methodology for high performance electronic limited slip differential (eLSD) incorporating advanced controller architecture and brake hold functionality. The study unifies optimal sizing of torque amplification components with 1.2 Nm electronically controlled BLDC actuator and a 101.5 reduction gear ratio to achieve 2000 Nm locking torque. Analytical results determine an axial force requirement of ~25.7 kN, distributed across four load‑bearing balls at ~6.4 kN each. Hertzian stress evaluation identifies optimal ball diameters of 12 mm to maintain stresses below 4000Mpa, ensuring durability without involving exotic material and complex manufacturing process. Time‑domain simulations confirm sub‑200 millisecond engagement, validating the architecture for high‑bandwidth torque vectoring and vehicle‑stability interventions. An integrated controller and optional low‑energy brake‑hold mechanism reduce power consumption during sustained engagement by more than 90%. Overall, the proposed framework provides a rigorous analytical foundation for the design of compact, durable, and energy‑efficient eLSD systems for modern driveline applications.

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