Mechanical differential assembly

Abstract

According to various embodiments, a mechanical differential assembly for a wheeled vehicle is disclosed, the mechanical differential assembly comprising a housing, a pinion gear operable to both rotate relative to an inner surface of the housing and be fixed relative to the inner surface of the housing, and a clutch portion fixed to the pinion gear.

Description

[0001] Cross-references to related applications

[0002] This application claims priority to U.S. Patent Application No. 17 / 683,519, filed March 1, 2022, and also to U.S. Provisional Application No. 63 / 157,254, filed March 5, 2021. The entire contents of the above applications are incorporated herein by reference. Technical Field

[0003] This disclosure relates to a powertrain system, and more specifically to a differential assembly for a vehicle. Background Technology

[0004] This section provides background information in connection with this disclosure, which is not necessarily prior art.

[0005] The vehicle can be used to traverse a selected area. The vehicle may include various drive or control systems, such as a power unit that may include a gas engine or an electric motor, and thus various control systems. In various embodiments, the vehicle may include a transmission and a steering control system. Furthermore, the vehicle may include a selected number of wheels or tracks, such as a four-wheeled vehicle. The wheels are powered by the power unit to move the vehicle.

[0006] The vehicle may further include additional systems connected to and / or controlled by multiple parts of the vehicle. Various control panels or mechanisms may be included to allow users to access or control systems using the vehicle. For example, the vehicle may include a powered winch to assist in various activities performed by the vehicle. Summary of the Invention

[0007] This section provides a general overview of the invention as disclosed herein, but is not a complete disclosure of its full scope or all its features.

[0008] A vehicle may have a selected power unit that provides power to ground-coupling components, such as wheels. In various embodiments, a vehicle may include two or more wheels. For example, a four-wheeled vehicle may include two pairs of wheels, commonly referred to as front wheels and rear wheels. The power unit may provide power to the wheels via a drive axle and a differential assembly. The power unit may be an internal combustion engine, an electric motor, a combination of both, or other suitable power unit systems. Therefore, unless specifically stated otherwise, references herein to any type of power unit (e.g., an engine) shall be understood as not specific to that type of power unit.

[0009] This differential assembly can redirect power from the drive shaft to multiple wheels, such as two wheels. The differential allows power to be applied to the wheels at different speeds. Therefore, the differential allows for efficient and smooth handling of the vehicle during driving (e.g., cornering). Thus, the differential can assist in providing more power to the faster-spinning wheel.

[0010] The differential can also be locked to provide equal torque or power to both wheels, even in certain situations. For example, a vehicle may be in a situation where one of the engine-driven wheels has very low traction relative to the other wheels. Therefore, providing power to the low-traction wheel will not allow or increase vehicle movement. Locking the differential can provide a mechanism to provide power to both wheels, allowing power to also be provided to the high-traction wheel.

[0011] With the differential locked, a component can be provided to engage the differential housing and a selected gear (referred to herein as a star gear or pinion) to allow power to be supplied to the higher traction wheel when the lower traction wheel is also present. Therefore, power can also be supplied to assist the vehicle in moving from a low traction state. The locking differential can be disengaged or unlocked when the difference in traction no longer exists. Thus, the differential can selectively lock or supply power based on the traction conditions relative to different wheels of the vehicle.

[0012] According to various embodiments, a mechanical differential assembly for a wheeled vehicle is disclosed, the mechanical differential assembly including a housing having an inner surface. The mechanical differential assembly also includes a pinion and a clutch portion, the pinion being operable to both rotate and be fixed relative to the inner surface of the housing, the clutch portion being fixed to the pinion. Furthermore, the mechanical differential assembly includes a locking member configured to engage the clutch portion and lock the pinion to the housing when the mechanical differential assembly is in a locked configuration.

[0013] Further applicability will become clear from the description provided herein. The descriptions and specific examples in this invention are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0014] The accompanying drawings described herein are for illustrative purposes only and do not represent all possible implementations, and are not intended to limit the scope of this disclosure.

[0015] Figure 1 These are environmental views of a vehicle according to various embodiments;

[0016] Figure 2 It is a detailed schematic diagram of the vehicle's wheel axles and differential assembly;

[0017] Figure 3A This is an exploded view of a differential assembly according to various embodiments;

[0018] Figure 3B yes Figure 3A An internal view of the assembly of the differential components;

[0019] Figure 4 yes Figure 3A A partial internal view of the differential assembly;

[0020] Figure 5 yes Figure 3A A partial exploded view of the differential assembly;

[0021] Figure 6 It is along Figure 2 Detailed cross-sectional view of line 6-6;

[0022] Figure 7 yes Figure 3A A partial detailed view of the interaction between different parts of the differential assembly;

[0023] Figure 8 This is a detailed view of the star gear of the differential assembly;

[0024] Figure 9 yes Figure 3A Detailed view of the cam or locking mechanism of the differential assembly;

[0025] Figure 10 This is an exploded view of a differential assembly according to various embodiments;

[0026] Figure 11 yes Figure 10 An internal view of the gear assembly of the differential assembly;

[0027] Figure 12 yes Figure 10 A partial internal view of the differential assembly;

[0028] Figure 13 yes Figure 10 An exploded view of the internal components of the differential assembly;

[0029] Figure 14 It is along Figure 12 The line 14-14 was cut Figure 10 A cross-sectional view of the differential assembly;

[0030] Figure 15 It is a differential assembly according to various embodiments;

[0031] Figure 16 yes Figure 15 A partial cross-sectional view of the differential assembly;

[0032] Figure 17 It was taken from section 17-17. Figure 15 A cross-sectional view of the differential assembly; and

[0033] Figure 18 yes Figure 15 Detailed view of the star gear and housing of the differential assembly.

[0034] Throughout the various views in the accompanying drawings, corresponding reference numerals indicate the corresponding parts. Detailed Implementation

[0035] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0036] Figure 1 An off-road / multi-purpose vehicle 12 is shown. However, vehicle 12 is merely exemplary and can include any suitable type of vehicle, such as on-road, off-road, multi-purpose, or suitable vehicles. In various embodiments, off-road vehicle 12 may include Polaris. and / or Polaris The vehicle, supplied by Polaris Industries, Inc. of Medina, Minnesota, may also be referred to as a side-by-side vehicle, an all-terrain vehicle (ATV), etc. Vehicle 12 may include various systems, such as a plow 14 movably attached to vehicle 12 via a support arm 16. Winch system 20 may also be configured with a line 18, also referred to as a cable or rope.

[0037] Vehicle 12 may include various components, such as those understood by those skilled in the art. For example, vehicle 12 may include ground portions or surface-mounted portions, such as one or more wheels 12w. Wheels 12w may be rotatably connected to vehicle 12 and / or portions of vehicle 12, such as a frame or bracket 12f. Vehicle 12 may further include passenger or user compartments 12p and auxiliary or cargo areas 12c. These compartments may be supported on or connected to frame 12f. Vehicle 12 may further be powered by a power unit 24. Hereinafter, the power unit may be referred to as motor 24 (e.g., electric motor) and / or engine 24 (e.g., internal combustion engine, such as a gasoline-powered engine). Various components may further include an alternator or generator for generating electricity and an energy storage system such as battery 26. Additionally, a fuel tank 28 may also be provided.

[0038] Continue to refer to Figure 1 And additional reference Figure 2The differential assembly 40 is illustrated relative to schematic left wheel axle 44a and right wheel axle 44b, and two corresponding wheels 12w', 12w''. As discussed further herein, axles 44a, 44b may also be referred to as short shaft sections. Axles 44a-44b may engage or be engaged with or connected to the shaft or shaft end or side gear of the differential assembly 40. Figure 3A and Figure 3B 48a, 48b. The differential assembly 40 may include various components, such as a housing assembly or bracket 52, which includes a first housing or bell-shaped housing 56 and a second housing or flatter housing portion 60. The two housing portions 56, 60 may be formed as separate components assembled to form the housing 52. Furthermore, the two housing portions may be identical or different. For example, the first housing portion 56 may be round or bell-shaped and the second component 60 may be flatter or shallower in shape. However, the housing assembly 52 may be formed in any suitable configuration as further discussed herein.

[0039] Housing portion 52, such as the bell-shaped portion 56 of housing portion 52, may include or define a ring gear assembly 64. Ring gear 64 may engage with housing 52 in any suitable manner, such as being formed or forged to housing 52, mounted or secured to housing 52, or engaged with housing 52 in any suitable manner. Typically, ring gear 64 may include multiple teeth. Teeth 66 of ring gear 64 may engage with a pinion or be engaged by a pinion 70. Pinion 70 may be connected to a pinion shaft 74, which may be connected to or extend directly from drive shaft 78. Drive shaft 78 may be driven by engine 24, as commonly understood by those skilled in the art. Differential assembly 40 may be included within a housing, such as shaft housing 80. Shaft housing 80 may include multiple portions accommodating various portions of shafts 44a, 44b and / or multiple portions of differential assembly 40.

[0040] Therefore, the differential assembly 40 can be interconnected with the drive shaft 78 to provide a selected amount of power to the shafts 44a and 44b via the differential assembly 40. Power from the shafts 44a and 44b can be transmitted to the wheels 12w' and 12w'". As discussed further herein, the differential 40 can operate to allow changes in the speed of the two wheels 12w' and 12w'" and / or to transmit a selected amount of torque to the higher traction wheel relative to the lower traction wheel.

[0041] See Figure 3A and Figure 3BThe differential assembly 40 may include housing portions 56 and 60, which may be connected together by a plurality of fasteners 90. The fasteners 90 may pass through holes formed in the housing portions 56 and 60 and be connected to secondary fasteners and / or fitted into threaded blind holes in the housing. For example, a fastener 90 may pass through a first hole 94 in housing portion 60 and engage with a threaded blind hole 98 in housing 56. However, it is understood that housing portions 56 and 60 may be assembled together in any suitable manner.

[0042] The differential assembly 40 may include shaft-end gears 48a, 48b. The shaft-end gears 48a, 48b may be fitted within the housing assembly 52 and / or include portions extending therefrom to engage corresponding shafts 44a, 44b. However, in various embodiments, housing portions 56, 60 may include shaft bores, such as shaft bores 102 through which corresponding shaft portions 44 may pass. These shaft portions may engage the shaft-end gears 48a, 48b.

[0043] The shaft-end gears 48a and 48b may include corresponding gear tooth portions 110 and back portions 114. As commonly understood by those skilled in the art, the tooth portion 110 may be defined as a bevel gear or bevel tooth. The bevel tooth design 110 may include selected dimensions, such as those provided on the shaft-end gears 48a and 48b.

[0044] The differential assembly 40 may further include one or more star gears 120. In various embodiments, such as... Figure 3A and Figure 3B As shown, the differential assembly may include two star gears 120a and 120b. Each of the star gears 120a and 120b may include a gear face or portion 124 and a cover portion 128. The cover portion 128 may also be referred to as the clutch portion 128. As discussed herein, a single discussion of these gear portions 124 and cover portions 128 shall be understood to refer to all star gears 120. In the discussion of this application, different star gears may be distinguished by the lowercase letter "a" or the lowercase letter "b". However, unless otherwise indicated, each star gear may include substantially the same portion. Furthermore, the differential assembly 40 may include two portions associated with different portions of the differential assembly, such as two portions of the shaft-end gears 48a and 48b, and other suitable portions as further discussed herein.

[0045] The differential assembly 40 may further include a locking member or portion 130. The locking member 130 may also be referred to as a cam member or portion 130. The locking member 130 may engage within a housing assembly, for example, within a first housing member 56 by one or more engaging pins or locking pins 134. The locking pin 134 may engage in a recess, such as an open or curved recess 138 formed in the locking member 130 and a recess 142 formed in the housing 56. Thus, the locking pin 134 may provide a keyed connection or interaction between the locking member 130 and the housing member 56. However, it is understood that the keyed connection may include integral portions, such as protrusions from the locking member 130 and recesses in the housing portion 56, rather than separate keyed portions.

[0046] As further discussed herein, locking member 130 may be held relative to housing member 56 and thus within differential assembly 40 for operably locking the two shafts 44a, 44b relative to each other, thereby supplying power from engine 24 to the respective wheels 12w', 12w". Locking member 130 may also include engagement surface or locking surface 150, as further discussed herein.

[0047] The differential assembly 40 may include various components that allow power transmission from the engine 24 to one or more of the wheels 12w. As discussed above, the differential assembly may include a plurality of respective shaft-end gears for engaging respective shafts, for example, via the housing portions 56, 60. The star gear 120 may engage or lock with a locking member 130 held relative to the housing assembly 52, such as housing member 56 with locking pin 134. Thus, the differential assembly 40 can transmit power from the engine 24, as further discussed herein. Also as discussed herein, the differential assembly 40 may lock to ensure equal power transmission to each wheel 12w', 12w'' via only one or more mechanical connections and interactions as discussed herein.

[0048] See also: Figure 4 The housing assembly 56 may include multiple gear portions, including a star gear 120 and a shaft-end gear 48. Furthermore, a locking member 130 may be retained relative to the housing assembly 56. Various portions (such as the cover 128 and multiple portions of the second shaft-end gear 48) may be retained within or at least partially surrounded by the housing member 60. However, for clarity of the present discussion, from Figure 4 Remove housing component 60 and second shaft end gear 48.

[0049] In the differential assembly 40, the star gear 120 can be held within the housing member 56, such as within its cavity. This cavity can be defined by an inner wall or surface 160 of the housing member 56 and an inner wall or surface 164 of the housing member 60. The inner surfaces 160, 164 defining the cavity allow for the positioning of components of the differential assembly relative to the housing assembly 52. Figure 4 As illustrated, locking member 48 includes a locking surface 150 that can engage a portion of cover 128. Specifically, cover 128 may include an outer surface 170 and an inner surface 174, the outer surface of which may retain or engage an inner surface 160 of housing member 56, the inner surface of which may also be referred to as cover locking surface 174. Cover locking surface 174 may engage locking member locking surface 150, as discussed further herein. Furthermore, outer surface 170 of cover 128 may retain star gear 120 relative to locking member 130 and relative to shaft end gears 48a, 48b. Thus, star gear 120 can be held in place within differential assembly 40 without a center pin or retaining pin. As discussed above, the inner surface may be arcuate, including substantially spherical. Outer surface 170 may also be arcuate and substantially match the curve or arc of inner surface 160. In various embodiments, housing member 56 may further include a generally cylindrical portion of inner surface 160, such as a portion adjacent to or surrounding locking member 130.

[0050] Continue to refer to Figures 1 to 4 And refer to other sources Figure 5 and Figure 6 The locking member 130 has a locking surface 150 that engages the cover locking surface 174 to lock the star gear 120 onto the housing assembly 52, which includes the housing member 56. The locking member 130 can wed the star gear between the locking member 130 and the inner surface 160 of the housing member 56 to engage or lock the differential assembly 50. Thus, as further discussed herein, the differential can be locked such that the star gear 120, and therefore the shaft-end gears 48a, 48b, do not rotate relative to the housing 52.

[0051] The star gear 120 may each include an external or housing locking surface 170, as discussed above. The external surface 170 may engage with the inner surface 160 of the housing member 56 and / or with the interior 164 of the housing member 60. When engaged, the star gear 120 may lock or engage with the housing assembly 52 to lock the differential assembly 40. Locking members 130 (such as at locking surface 150) may further engage the inner surface 174 of the cover 128 of the star gear 120. By engaging the star gear 120 (e.g., the outer surface 170) with the inner surface 160, the star gear 120 may lock with the housing or housing assembly 52.

[0052] As discussed above, and in Figure 7 As further illustrated, the star gear 120 includes a bevel gear face or tooth 124 that engages with the bevel teeth or face 110 of the shaft-end gear 48. When the corresponding gear teeth 124, 110 are engaged and the outer surface 170 engages with the housing surface 160, the star gear 120 can be locked to the shaft 44. Therefore, when the outer surface 170 of the cover 128 is locked or engaged with the inner surface 160, the differential assembly 40 can be locked in a locking configuration. The cover 128 has a locking portion or locking surface, and may also be referred to as a clutch, to induce engagement and fixation against relative movement upon application of a locking force or a selected locking force. In other words, as... Figure 6 and Figure 7 As illustrated, in the locking configuration of the differential assembly 40, the star gear 170 can be locked or has a clutch surface on the inner surface 160 of the engagement housing assembly 56, and the tooth surfaces 124, 110 can also be engaged to transmit force directly to the two shafts 44.

[0053] See also Figure 6 and Figure 7 The component includes an outer surface 170 of a star gear 120, which can engage an inner surface 160 of the housing 52. When the housing 52 is assembled, the inner surface 160 of the housing can be substantially spherical or have an outer surface defining a sphere. Thus, according to various embodiments, the curvature or radius of the inner surface 160 can be substantially constant.

[0054] As discussed above, when a locking force is applied, the star gear 120 can engage or lock with the inner surface 160. A locking force can be applied when the locking member 130 engages the star gear 120 (e.g., its cover 128). The locking member 130 includes a surface 150 that can engage a surface 174 of the cover 128. Figure 6 As illustrated, locking surface 150 may extend along axis or plane 200. Cover locking surface 174 of cover 128 may extend along surface or plane 204. An angle 210 may be defined between these two planes or between axes 200 and 204. Angle 210 may form a compression angle 210, or be referred to as a compression angle 210.

[0055] The compression angle can be selected based on different characteristics, such as having low torque differential locking and / or large torque differential locking. Furthermore, the angle can be selected based on the ease with which the unlocking locking member 130 engages with the star gear 120. In various embodiments, for example, the compression angle 210 can be from about 0 degrees to about 20 degrees. In various embodiments, the angle 210 can be selected within a range from a specified limit of about 0.05 degrees (°) to about 1 degree. However, it should be further understood that the angle can be selected as about 5 degrees, about 8 degrees, and / or about 20 degrees. Therefore, the angle range of angle 210 can be from about 3 degrees to about 8 degrees, including about 5 degrees.

[0056] Therefore, as discussed above, during the application of a torque difference to the differential assembly 40 between the two shafts 44a, 44b, the locking member 130 can engage the star gear 120. The greater the applied torque difference, the greater the likelihood that the locking member 130 can lock with the star gear 120 and lock the differential assembly 40. The lower the angle, the lower the applied torque difference required to lock the differential assembly 40. In other words, the lower the angle, the easier it is to lock the differential assembly 40.

[0057] In various embodiments, locking surfaces (e.g., locking surface 150 of locking member 130 and locking surface 170 of cover member 128) may define geometries to assist in securing or inducing locking of differential assembly 40. In various embodiments, compression angle 210 may be constant. However, in various embodiments, compression angle 210 may vary based on the variable radius of locking surface 150 of locking member 130 and / or locking surface 174 of star gear 120.

[0058] See Figure 8 and Figure 9 The star gear 120 may have a locking surface 170 formed on the interior of the cover 128, as discussed above. The star gear 120 may define or have a point 220, which may be located near the center of the star gear 120. In various embodiments, the inner surface or locking surface 170 of the star gear 120 may define multiple radii to the point or location 220, such as a first radius 224 and a second radius 228. The first radius 224 may be smaller than the second radius 228. It is understood that the radius of the locking surface 170 may include any suitable number of different radii, and the exemplary two radii 224, 228 are merely exemplary. For example, the locking surface 170 of the star gear 120 may have a continuously varying radius and may be understood to define multiple radii. In various embodiments, the center of these radii (i.e., the first radius 224 and the second radius 228) may be outside the star gear 120.

[0059] As discussed above, the locking surface 170 of the star gear typically engages a portion of the locking surface 150 of the locking member 130, as discussed above and in Figure 8 As illustrated in the diagram. Therefore, the locking surface 150 may also have a varying radius between edges or margins 234 formed in an intermediate region or portion (such as the intermediate portion 238 of the locking surface 170). The variable radius of the locking surface 170 may define or form a varying compression angle 210. In this way, the compression angle 210 may not be substantially constant over the entire surface of the locking surface 170 of the star gear 120. This variable radius at least partially provides a variable or changeable compression angle 210 and may allow the differential assembly 40 to engage or lock under a selected torque bias and unlock under a selected torque bias, such as a low torque bias relative to a high torque bias, so as to allow effective engagement and unlocking of the locking differential.

[0060] In addition, such as Figure 9 As illustrated, the locking member 130 may also have a central axis or point 250. The locking surface 150 may also include a variable radius, such as a first radius 254 and a second radius 258. It is understood that the radius of the locking surface 150 may include any suitable number of different radii, and the two exemplary radii 254, 258 are merely exemplary. Furthermore, the altered (also referred to as variable) radius of the locking surface 150 may also alter the compression angle 210 relative to the locking surface 170 and the inner surface 160 of the differential assembly 40.

[0061] Therefore, both the star gear 120 and the locking member 130 can include, or individually include, variable radii of the respective locking surfaces 170, 150. Thus, the compression angle 210 can vary based on the position of the locking member 130 relative to the star gear 120 and allow selected locking and unlocking of the differential assembly 40. Furthermore, the variable radius can be defined in various ways, such as by varying the radius as discussed above and / or selectively defined, such as as an involute relative to the respective locking surfaces 150, 170. The position of the locking member 130 relative to the star gear 120 can be oriented to define the variable angle 210. The elastic flexural force of the housing 56 can also affect the locking effect, such as the torque difference required to lock the differential assembly 40. Therefore, the locking effect is also affected by the torque input to the locking member (also referred to as the cam) 130 by the housing 56 and the final ring gear 64. Therefore, the differential assembly 40 can also be referred to as a torque-sensing differential assembly 40.

[0062] The variable radius and the resulting variable compression angle allow the compression angle to change depending on the relative position of the two locking surfaces. For example, the compression angle can decrease when the locking member 130 and the star gear 120 move closer together. This variable compression angle allows the differential assembly 40 to lock and unlock under different torque biases and even under negative torque biases of different wheels.

[0063] According to various embodiments, see first. Figure 10 and Figure 11 The diagram illustrates differential assembly 40'. Differential assembly 40' may be similar to the differential assembly 40 discussed above, and similar or identical parts will not be repeated in detail here. However, differential 40' may include different features that may differ from and / or be incorporated into and / or be alternatives to the differential assembly 40 discussed above.

[0064] For example, differential assembly 40' may include housing assembly 260. Housing assembly 260 may include a first housing portion 264, which may also be referred to as a bell housing. Housing 260 may further include a second housing member 268, which may be substantially flat or planar relative to the first housing portion 264. Assembled within housing assembly 260 may be multiple members or portions including two shaft gears or side gears (including a first side gear 272 and a second side gear 274). The two side gears may be substantially similar to side gears 48a, 48b, as discussed above. However, side gears 272, 274 may include dimensions such as those based on the geometry of housing assembly 260. Furthermore, differential assembly 40' may include multiple star gears, such as a first star gear 280, a second star gear 282, and a third star gear 284. These three star gears 280 to 284 can again be similar to star gear 120, as discussed above, but include different sizes and / or numbers relative to differential assembly 40' within differential assembly 40, as discussed above. Figure 10 As illustrated, the differential assembly 40' may include star gears 280 to 284 and locking member 300.

[0065] As illustrated here, for example, star gears 280 to 284 may include three star gears that can mesh with shaft gears 272, 274. Typically, each of star gears 280 to 284 may include a plurality of teeth 290 that engage with both side gears 272, 274 at side gear teeth 292, 294 respectively. As discussed above, differential assembly 40' may be assembled into vehicle 12, also as discussed above. The shafts of vehicle 12 may engage shaft gears 272, 274 in a substantially similar manner. Teeth 294, 292 of side gears 272, 274 may engage with teeth 290 of the corresponding star gears 280 to 284. Therefore, during the unlocked configuration of differential assembly 40', the wheels of vehicle 12 may rotate at different speeds relative to each other due to differential assembly 40'.

[0066] See also Figure 10 and Figure 11 See also Figure 12 and Figure 13 The diagram illustrates the internal transmission of the differential assembly 40'. Locking member 300 may include gaps 304, 306, and 308 to receive the tooth portions 290 of the star gears 280 to 284. Locking member 300 may further include a plurality of locking surfaces adjacent to or at least near a portion of the respective gaps 304 to 308. For example, locking member 300 may define or include a first locking surface 312 and a second locking surface 316 that engage a locking surface 320 defined as the inner surface of a cover or cover member 324 of the star gear 280. Cover 234 may further define an outer surface 328 that can engage an inner surface 332 of the housing, such as housing member 264. Thus, locking member 300 may engage the locking surface 320 of the star gear 280 in a manner similar to that discussed above to lock or secure the star gear 280 relative to housing 264. The locking member 300 is secured relative to the housing 264 by a key or a fixing portion (such as one or more pins or locking portions 301 similar to pin 134 discussed above). Pin 301 may be received between a first recess 302 in the locking member and a second recess 303 in the housing 264. As discussed above, the locking member 300 and / or the housing 260 may have integral parts rather than separate parts to lock and secure the locking member 300 relative to the housing 260. Therefore, when the locking member 300 is locked with the star gears 280 to 284, the differential assembly 40' can be locked as a unit to ensure equal speeds between the two wheels (e.g., wheels 12w' and 12w"), similar to the speeds discussed above. Furthermore, the locking member 300 can lock each of the star gears 280, 282, and 284 relative to the housing 260.

[0067] Each star gear may include a corresponding cover, such as cover 340 for star gear 282 and cover 344 for star gear 284. Each of covers 340, 344 includes a corresponding inner surface or locking surface 348, 352. Furthermore, locking member 300 may include a corresponding locking surface for each star gear locking surface 348, 352. For example, locking member 300 may include a third locking surface 360 ​​and a fourth locking surface 364 to engage the inner surface 348 of star gear 282. Additionally, locking member 300 may include a fifth locking surface 368 and a sixth locking surface 372 to engage the inner surface 352 of star gear 284. Therefore, locking member 300 can engage each of star gears 280 to 284 with a corresponding locking surface 312 to 372. The locking surfaces of locking member 300 can engage the locking surfaces of the corresponding star gears 280 to 284 in a manner similar to that discussed above.

[0068] Continue to refer to Figures 10 to 12 And refer to other sources Figure 13 The corresponding locking surface and inner surface 332 of housing 264 are discussed in more detail. Corresponding star gears 280 to 284 may include substantially similar geometries, therefore the discussion of star gear 280 herein is merely exemplary. Furthermore, the corresponding locking surfaces may also include substantially similar geometries as discussed herein. Thus, the exemplary reference star gear 280 and inner surface 320 (also referred to as the locking surface) may engage with the corresponding locking surfaces 312, 316 of locking member 300 or the corresponding locking surfaces 312, 316 of locked member 300. When the locking surfaces engage with each other, locking member 300 may engage and lock the star gear relative to the inner surface 332 of the housing to lock or engage differential assembly 40'.

[0069] Further reference Figure 14The locking surface 320 of the star gear 280 may have a variable or altered radius relative to point 370. For example, the locking surface 320 may include a first radius 374 and a second radius 378. The two radii may differ relative to point 370 and allow the locking member 320 to have a variable angle relative to the locking surface 312. Furthermore, the locking surfaces of the locking member 300 (such as locking surfaces 312 and 316) may also have selected radii, which may be equivalent to or similar to radii 374 and 378. The locking member 300 may include a center 380, and the locking surface 316 may include a first radius 384 and a second radius 388. It is understood that each locking surface of the locking member 300 may include a similar radius and / or include multiple (e.g., any suitable number of two or more) radii. Furthermore, the variable radius of the locking surface 320 of the star gear 280 and the locking surfaces of the locking member 300 may be defined as involute curves, as discussed above, and include radii that vary generally.

[0070] The corresponding locking surfaces and the corresponding variable radii allow a pressure angle 396 to be generated between the corresponding locking surfaces (e.g., locking surfaces 316 and 320), generally along a line or plane 390 and the outer surface 328 of the cover 324 which may be connected along the line or plane 394, or relative to the inner surface 332 of the housing defined by the line or plane and the outer surface of the cover which may be connected along the line or plane. Angle 396 may be substantially similar to or the same as the angle of the pressure angle (e.g., angle 210 discussed above). In various embodiments, for example, angle 396 may be from about 0 degrees to about 20 degrees. In various embodiments, this angle may be achieved due to the engagement of the corresponding locking surfaces caused by the corresponding locking surfaces of the differential assembly 40. Furthermore, different angles may be selected based on different torque biases and / or drive characteristics that the differential assembly 40 attempts to achieve, and the selected different angles may be included in the differential assembly.

[0071] In various embodiments, differential assembly 40' may include three star gears, such as star gears 280 to 284. Multiple star gears may be provided for different purposes, such as distributing forces relative to a larger number of components, surface areas, etc., within differential assembly 40'. However, differential assembly 40' may be allowed to produce a locking configuration similar to that discussed above. In various embodiments, differential assembly 40' may only be able to lock and unlock mechanically, including the portions discussed herein.

[0072] The differential assembly may further include a selected internal shape for the surface 332 of the housing 260. This interior may include multiple shapes and / or a single shape. For example, the housing portion 264 may include a cylindrical internal shape to generally accommodate the locking member 300 and a portion of the star gear. Furthermore, the inner surface 332 may define a rounded top to receive and contact a cover of the star gear. Therefore, the differential assembly 40' may include a variable-shape interior.

[0073] Turning Figure 15 The figure illustrates a differential assembly 40. The differential assembly 40 may include portions similar to those discussed above, additional portions, and / or alternatives to the differential assembly discussed above. Therefore, substantially identical or similar parts will not be described in detail again, but it should be understood that portions may be alternatively enhanced in each of the various embodiments, and / or alternatively provided in each of the various embodiments.

[0074] Typically, differential assembly 40” may include a housing 400, which may include various passages or openings, such as opening 404 which can also be covered after assembly. Differential assembly 40” may further include passages for shafts 44a, 44b to access differential assembly 40” and one or more side gears or shaft gears 410 and 414, respectively. Each shaft gear includes a plurality of teeth 416, 418. Retained relative to shaft gears 414, 410 are pinions or planetary gears 420 and 424. Each planetary gear also includes a plurality of teeth 428, 430.

[0075] Differential assembly 40” can operate in a manner similar to that discussed above, but does not include separate cams or locking members located at the center of differential assembly 40”. For example Figure 17 and Figure 18 As illustrated, the star gear 424 can be held within the housing 400 by a wall or external member 440. The housing assembly 400 may further include a clutch or locking member or portion 444. Both star gears 424 and 420 may further include a locking surface or inner surface 448 formed or defined by a cover or top 452, as discussed above.

[0076] The clutch or locking portion 444 may form or define a locking surface 458 that engages the surface 448 of the star gear 424. As discussed above, the locking surface 458 of the locking member 444 may extend or have a locking portion extending along the surface or plane 460. The inner surface 448 of the star gear 424 may also extend along the surface or plane 464. A compression angle 466 may be present between the two surfaces 460, 464. Angle 466 may be any suitable angle, such as those discussed above, ranging from about 0 degrees to about 20 degrees, and may form or define a pressure angle as discussed above within any suitable range.

[0077] These two surfaces (such as locking surface 458 and inner locking surface 448) may also have variable radii, as discussed above, to provide a variable angle 466 between the two surfaces. However, during operation, the locking differential assembly 40” can be operated to lock the pinion to the housing portion 440, thereby removing or pushing the locking portion 452 between the locking surface of the locking portion 444 and the housing portion 440. Therefore, the differential assembly 40” does not need to operate together with a separate locking member positioned within the differential assembly to allow the locking differential assembly 40”. Furthermore, the pinion or star gears 420, 424 can generally be locked relative to the housing 400 to lock the differential, thereby allowing equal speed transmission to the two shafts 44a, 44b.

[0078] The above task is intended as an illustrative example; the task can be performed sequentially, synchronously, simultaneously, continuously, during overlapping time periods, or in a different order depending on the application. Moreover, depending on the implementation and / or order of events, no task may be performed or no task may be skipped.

[0079] The foregoing description is illustrative in nature and is in no way intended to limit this disclosure, its application, or its use. The broad teachings of this disclosure can be implemented in many forms. Therefore, while this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become clear upon examination of the drawings, specification, and appended claims. As used herein, the phrases A, B, and C at least one should be interpreted as referring to the logic of using non-mutually exclusive OR logic (A or B or C), and should not be interpreted as referring to "at least one of A, at least one of B, and at least one of C". It is understood that one or more steps within the method may be performed in different orders (or simultaneously) without altering the principles of this disclosure.

[0080] Unless an element is explicitly described using the phrase “apparatus for…” or in the case of a method claim using the phrase “operation for…” or “steps for…”, the element described in the claim is not intended as an apparatus plus a functional element in the sense of 112(f) of the United States Code.

[0081] The above description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or limiting of this disclosure. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable and can be used in selected embodiments where applicable, even if not specifically shown or described. The same applies to variations in many ways. These variations should not be considered as departing from this disclosure, and all such modifications are intended to be included within the scope of this disclosure.

Claims

1. A mechanical differential assembly for a wheeled vehicle, comprising: A housing having an inner surface; A star gear, operable to rotate relative to the inner surface of the housing; A clutch portion, the clutch portion being fixed to the star gear, wherein the clutch portion and the star gear are formed as a single component; and A locking member configured to engage the clutch portion; The engagement of the locking member with the clutch portion causes the clutch portion to contact the inner surface of the housing, thereby locking the star gear and resisting rotation relative to the housing.

2. The mechanical differential assembly according to claim 1, wherein, The locking member is configured to engage the clutch portion and lock the star gear to the housing when the mechanical differential assembly is in a locked configuration.

3. The mechanical differential assembly according to claim 1, wherein, The clutch portion is a cover that extends a distance from the tooth portion of the star gear; The cover includes an inner surface configured to be engaged by the locking member.

4. The mechanical differential assembly according to claim 3, wherein, The inner surface of the cover includes a variable radius.

5. The mechanical differential assembly according to claim 4, wherein, The variable radius is an involute.

6. The mechanical differential assembly according to claim 3, wherein, The tooth portion of the star gear and the cover are a single component.

7. The mechanical differential assembly according to claim 3, wherein, The cover extends away from the toothed portion; The toothed portion is formed around the central axis of the star gear.

8. The mechanical differential assembly according to claim 7, wherein, The inner surface of the cover extends away from the toothed portion; The inner surface of the cover has a variable radius and a varying angle relative to the locking member; As the cover and the locking member move closer together, the pressure angle of the inner surface of the cover decreases, such that the curve of the inner surface of the cover decreases as the cover moves toward the locking member.

9. The mechanical differential assembly according to claim 8, wherein, The locking member defines a cam surface, wherein the pressure angle varies between the cam surface and the inner surface of the cover.

10. The mechanical differential assembly according to claim 3, wherein, The inner surface of the cover engages with the cam surface of the locking member; The angle between the cam surface and the inner surface of the cover relative to the housing forms a pressure angle.

11. The mechanical differential assembly of claim 10, wherein, The pressure angle is approximately zero to approximately 20 degrees.

12. The mechanical differential assembly according to claim 10, wherein, The pressure angle is approximately 5 degrees to approximately 12 degrees.

13. The mechanical differential assembly according to claim 3, wherein, The inner surface of the housing includes a first portion that is substantially spherical to engage the outer surface of the cover.

14. The mechanical differential assembly according to claim 13, wherein, The inner surface of the housing includes a substantially cylindrical second portion; The locking member is held within the second part.

15. The mechanical differential assembly according to claim 1, wherein, The locking member includes a first keyway and the housing includes a second keyway; The key component is positioned within the first keyway and the second keyway to rotatably secure the housing and the locking component.

16. The mechanical differential assembly according to claim 1, wherein, The star gear includes at least two star gears.

17. A mechanical differential assembly for a wheeled vehicle, comprising: A housing having an inner surface having a spherical portion; as well as A star gear having a toothed portion and a clutch portion, the clutch portion being fixed to the star gear and extending from the toothed portion, wherein the star gear is operable to both rotate and be fixed relative to the inner surface of the housing, wherein the clutch portion includes an inner clutch surface and an outer clutch surface; and A cam surface configured to engage the inner surface of the clutch and lock the star gear to the housing when the mechanical differential assembly is in a locked configuration, such that the outer surface of the clutch engages the inner surface of the housing; A pressure angle is formed between the cam surface and the inner surface of the clutch.

18. The mechanical differential assembly of claim 17, further comprising: A locking member that defines the cam surface.

19. The mechanical differential assembly according to claim 18, wherein, The inner surface of the clutch forms a variable radius and a varying angle relative to the cam surface of the locking member; As the clutch portion and the locking member move closer together, the pressure angle of the inner surface of the clutch decreases, such that the curve of the inner surface of the clutch decreases as the clutch portion moves toward the locking member.

20. The mechanical differential assembly according to claim 19, wherein, The star gear is locked to the inner surface of the housing under a selected torque difference between the first and second wheels of the wheeled vehicle.

21. The mechanical differential assembly according to claim 17, wherein, The star gear includes at least two star gears.

22. The mechanical differential assembly according to claim 21, wherein, The cam surface is defined by only one locking member.

23. A method of providing a mechanical differential assembly for a wheeled vehicle, comprising: A positioning star gear has a toothed portion and a clutch portion, the clutch portion being fixed to the star gear and extending from the toothed portion, wherein the star gear is operable to both rotate relative to and be fixed relative to the inner surface of the housing, wherein the clutch portion includes a clutch inner surface and a clutch outer surface; A positioning locking member having a cam surface, the locking member being configured to engage the inner surface of the clutch and lock the star gear to the housing when the mechanical differential assembly is in a locked configuration, such that the outer surface of the clutch engages the inner surface of the housing; and A pressure angle is formed between the cam surface and the inner surface of the clutch.

24. The method of claim 23, further comprising: The inner surface of the clutch is provided with a variable radius to form a varying angle relative to the cam surface of the locking member; As the clutch portion and the locking member move closer together, the inner surface of the clutch reduces the pressure angle, such that as the clutch portion moves toward the locking member, the curve of the inner surface of the clutch reduces the pressure angle.

25. The method of claim 23, further comprising: The star gear is provided to lock onto the inner surface of the housing under a selected torque difference between the first and second wheels of the wheeled vehicle.

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