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Precisely aligned, friction welded helical cone or hypoid ring gear and differential case assembly

A ring gear and differential case technology, applied in welding equipment, differential transmissions, belts/chains/gears, etc., can solve the increase in labor requirements and incidental costs of the hyperboloid ring gear/differential case assembly problem to avoid contamination

Active Publication Date: 2021-11-30
FORD GLOBAL TECH LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

Each of these factors undesirably increases the labor requirements and incidental costs of manufacturing / assembling the hypoid ring gear / differential case assembly

Method used

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  • Precisely aligned, friction welded helical cone or hypoid ring gear and differential case assembly
  • Precisely aligned, friction welded helical cone or hypoid ring gear and differential case assembly
  • Precisely aligned, friction welded helical cone or hypoid ring gear and differential case assembly

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Experimental program
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Embodiment Construction

[0019] As noted above, the different materials from which the two components are made (eg, steel or alloy for the ring gear 122 and ductile iron for the differential case 120 ) present engineering challenges in both connection / joining. In turn, the problem of precise alignment of the components must be addressed to provide proper meshing for the ring gear 122 and the hypoid pinion 119 .

[0020] Friction welding is a solid state welding process where heat is generated by applying mechanical friction on workpieces placed in contact with each other. During this process, additional lateral forces ("upset" forces) are applied to plastically displace and fuse the material of the workpiece. At high levels, molecules of dissimilar materials are subjected to sufficient frictional heat and pressure to form a bond. Because no material melting occurs, friction welding is not a welding process in the traditional sense, but is actually a forging technique. The fast joining time and the d...

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PUM

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Abstract

A method for manufacturing a ring gear / differential case assembly includes attaching a ring gear to a differential case. The ring gear and differential case are made of materials with different properties. The attaching includes placing a first portion of the ring gear in intimate contact with a first portion of the differential case to define a predetermined gap between another portion of the ring gear and another portion of the differential case. The ring gear first portion is attached to the differential case first portion by a friction welding process. The predetermined gap defines an outflow channel for receiving overflow material created by the upsetting step of the friction welding process. A differential assembly and a vehicle including the differential assembly are described.

Description

technical field [0001] The present disclosure generally relates to vehicle driveline assemblies. In particular, the present disclosure relates to a method for connecting a helical or hypoid bevel ring gear to a differential case, and a ring gear / differential case assembly provided in accordance with the method. Background technique [0002] By way of background and with reference to FIGS. 1A and 1B , a representative differential carrier 100 is shown, which is the portion of a vehicle powertrain responsible for transferring drive power from a vehicle engine to vehicle drive wheels. The illustrated embodiment of the differential carrier 100 is for a rear axle differential. However, this should not be considered limiting, as variations in differential types and designs are well known to those skilled in the art. [0003] The differential carrier 100 includes a gear assembly (generally indicated by reference numeral 102 ) driven by an input drive shaft 104 . The gear assembl...

Claims

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Application Information

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Patent Type & Authority Patents(China)
IPC IPC(8): F16H48/08F16H57/023F16H57/037
CPCF16H48/08F16H57/023F16H57/037F16H2048/085B23K20/12B23K2103/06B23K2101/008B23K2103/04B23K2103/18B23K20/129B23K20/227F16H48/40F16H2048/382F16H2048/385
Inventor 保罗·约翰·波加诺瓦斯基安德里亚斯·埃万盖洛斯·佩尔拉凯斯托马斯·G·诺伊曼马克·E·布里斯科托马斯·杰勒德·诺伊曼
Owner FORD GLOBAL TECH LLC