System and axle assembly

Abstract

The utility model relates to a system which is used for an axle shell of a vehicle. In one example, a system includes a differential housing that includes a modular Soltzbury center section that includes a tube mount configured to receive a tube assembly via a press fit. In addition, the utility model further relates to an axle assembly.

Description

Technical Field

[0001] This description generally relates to axle assemblies in vehicles. Background Art

[0002] The axle assembly is adapted to transmit rotational power from the engine of the vehicle to the wheels of the vehicle. Typically, the axle assembly includes a differential assembly that is rotatably supported in a non-rotating housing (e.g., a carrier). The differential is connected between an input drive shaft extending from the vehicle engine / transmission and a pair of output axle shafts extending to the vehicle wheels. The axle shafts are contained in corresponding non-rotating beam housing portions (e.g., axle tubes), which are fixed to the center housing. Therefore, the differential causes the corresponding axle shaft to rotate due to the rotation of the drive shaft. The center housing and beam housing portions form an axle housing for these drivetrain components of the axle assembly, wherein there is a differential and an axle shaft supported for rotation.

[0003] One type of axle housing includes a unitized center housing construction, commonly referred to as a Salisbury or Spicer type (or style) axle assembly. In this construction, the center housing (which houses the differential assembly) is directly connected to two beam housing sections (which house the rotatable axle shafts). An opening is provided at the rear of the center housing to allow the differential to be assembled therein. During use, a cover closes this opening.

[0004] Another type of axle housing includes a separable center housing configuration. In this configuration, the axle housing portions are connected together by a center portion of the axle housing that is formed separately and spaced apart from the differential carrier. The center portion is typically hollow and cylindrical in shape with a large, generally circular opening formed therethrough. The overall shape of this type of axle housing (e.g., the generally circular shape of the center portion and the elongated beam housing portion extending therefrom) is typically similar to the shape of a banjo musical instrument. Therefore, this type of axle housing is often referred to as a banjo axle housing. In addition, the beam load of the vehicle weight is carried via an independent structure that is used to orient and rotatably support the differential assembly from it. Due to this separation of functions, the banjo axle is more suitable for supporting higher vehicle weights than a similarly sized Salisbury axle assembly. However, due to the internally sealed unitized center housing, the Salisbury housing can use less lubrication. Therefore, both types of axle housing assemblies may have disadvantages and benefits. Utility Model Content

[0005] In one example, the above problems are solved by a system including a differential housing including a modular Salisbury-style center section including a tube mount configured to receive a tube assembly via a press fit. In this way, the wall thickness of the tube mount can be adjusted while maintaining a common center section in a variety of vehicles including different vehicle loads.

[0006] It should be understood that the above utility model summary is provided to introduce a selection of concepts further described in the detailed description in a simplified form. It is not meant to identify key or essential features of the claimed subject matter, and the scope of the claimed subject matter is uniquely defined by the claims following the detailed description. In addition, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The above and other advantages of the present disclosure will be apparent to those skilled in the art when considering the following detailed description in light of the accompanying drawings, in which:

[0008] Figure 1 is a schematic diagram of an example vehicle powertrain;

[0009] Figure 2 shows a perspective view of a vehicle axle assembly;

[0010] Figure 3A shows a front perspective view of a modular center section of an axle housing;

[0011] Figure 3B showing a partial front perspective view of a modular center section of an axle housing;

[0012] Figure 3C shows a rear perspective view of a modular center section of an axle housing; DETAILED DESCRIPTION

[0013] The following description relates to a system for an axle assembly in a vehicle. For example, a vehicle may be composed of a plurality of axle assemblies such as Figure 1 The powertrain shown can include, for example, Figure 2 At least one axle assembly as shown. The axle assembly may include a modular center housing, Figures 3A-3C Different views of the modular center housing are shown.For example, the modular center housing can accommodate varying tube wall thicknesses while reducing lubrication requirements due to internal sealing. Figure 2-3C Shown approximately to scale. However, alternative dimensions may be used if desired.

[0014] Now go to Figure 1, the vehicle 100 shown includes a powertrain 101 and a transmission 103. The powertrain includes a prime mover 106 and a transmission 108. For example, the prime mover 106 can be an internal combustion engine or an electric motor, and is operated to provide rotational power to the transmission 108. The transmission 108 can be any type of transmission, such as a manual transmission, an automatic transmission, or a continuously variable transmission. The transmission 108 receives the rotational power generated by the prime mover 106 as input, and outputs the rotational power to the transmission 103 according to the selected gear or setting.

[0015] In some examples, such as Figure 1 As shown, the drive train 103 includes a first axle assembly 102 and a second axle assembly 112. The first axle assembly 102 can be configured to drive a first set of wheels 104, and the second axle assembly 112 can be configured to drive a second set of wheels 114. In some examples, the first axle assembly 102 is arranged near the front of the vehicle 100 and thus includes a front axle, and the second axle assembly 112 is arranged near the rear of the vehicle 100 and thus includes a rear axle. The drive train 103 is shown in a four-wheel drive configuration, but other configurations are possible. For example, the drive train 103 may include a front-wheel drive, a rear-wheel drive, or an all-wheel drive configuration. In addition, the drive train 103 may include one or more tandem axle assemblies. As such, the drive train 103 may have other configurations without departing from the scope of the present disclosure, and Figure 1 The configuration shown is for illustration and not limitation.In addition, the vehicle 100 may include additional wheels that are not coupled to the drive train 103 .

[0016] In such Figure 1 In some of the four-wheel drive configurations described, the drive train 103 includes a transfer case 110 configured to receive rotational power output by the transmission 108. A first drive shaft 113 is drivingly coupled to a first output 111 of the transfer case 110, and a second drive shaft 122 is drivingly coupled to a second output 121 of the transfer case 110. The first drive shaft 113 (e.g., a front drive shaft) transfers rotational power from the transfer case 110 to a first differential 116 of a first axle assembly 102 to drive a first set of wheels 104, while the second drive shaft 122 (e.g., a rear drive shaft) transfers rotational power from the transfer case 110 to a second differential 126 of a second axle assembly 112 to drive a second set of wheels 114. For example, the first differential 116 is drivingly coupled to a first set of axle shafts 118 coupled to the first set of wheels 104, and the second differential 126 is drivingly coupled to a second set of axle shafts 128 coupled to the second set of wheels 114. It is understood that each of the first set of axle shafts 118 and the second set of axle shafts 128 can be positioned in the housing. Figure 2-3C Embodiments of the axle assembly are described in further detail.

[0017] In some examples, additionally or alternatively, the vehicle 100 may be a hybrid vehicle including both an engine and an electric motor, each configured to supply power to one or more of the first axle assembly 102 and the second axle assembly 112. For example, one or both of the first axle assembly 102 and the second axle assembly 112 may be driven via power derived from the engine in a first operating mode (e.g., an engine-only mode) in which the electric motor does not operate to provide power, via power derived from the electric motor in a second operating mode (e.g., a pure electric mode) in which the engine does not operate to provide power, and via power derived from both the engine and the electric motor in a third operating mode (e.g., an electric assist mode). As another example, one or both of the first axle assembly 102 and the second axle assembly 112 may be an electric axle assembly configured to be driven by an integrated electric motor.

[0018] As described above, the axle assembly (e.g., Figure 1 The first axle assembly 102 and the second axle assembly 112 are configured to transfer power from a prime mover of the vehicle to wheels of the vehicle. However, it may be difficult to adapt existing axle assemblies to different vehicle load capacities and vehicle weights while improving assembly efficiency. For example, a Salisbury axle assembly may improve efficiency and reduce lubrication requirements due to its internally sealed center housing, while a banjo axle assembly may be adapted to support higher vehicle weights than a similarly sized Salisbury axle assembly due to its independent structure to support beam loads. However, a banjo axle assembly may have more lubrication requirements than a Salisbury axle assembly.

[0019] Therefore, refer to Figure 2-3C , showing components of a modular axle assembly that can adapt to varying vehicle loads while reducing lubrication requirements. Figure 2-3CAn example configuration with relative positioning of various components is shown. If shown as directly contacting or directly connected to each other, such elements can be referred to as directly contacting or directly connected, respectively, at least in one example. Similarly, at least in one example, elements shown as continuous or adjacent to each other can be respectively continuous or adjacent to each other. As an example, components placed as face-shared contact with each other can be referred to as face-shared contact. As another example, in at least one example, elements positioned to be spaced apart from each other with only a spacing space between them and no other components can be referred to as such. As another example, elements shown as above / below each other, on opposite sides of each other, or on the left / right of each other can be referred to as such relative to each other. In addition, as shown in the accompanying drawings, in at least one example, the topmost element or the point position of the element can be referred to as the "top" of the component, and the bottommost element or the point position of the element can be referred to as the "bottom" of the component. As used herein, top / bottom, upper / lower, above / below can be relative to the vertical axis of the accompanying drawings and used to describe the positioning of the elements of the accompanying drawings relative to each other. Therefore, in one example, the element shown as above other elements is vertically positioned above the other elements. As yet another example, the shapes of elements depicted in the accompanying drawings may be referred to as having such shapes (e.g., such as rounded, straight, planar, curved, rounded, chamfered, angled, etc.). In addition, in at least one example, elements shown as intersecting each other may be referred to as intersecting elements or intersecting each other. Further, in one example, elements shown as being within another element or outside another element may be referred to as such. It is understood that one or more components referred to as "substantially similar and / or identical" may differ from one another according to manufacturing.

[0020] In addition, to compare the relative orientation of different views, Figure 2-3C A coordinate system 299 is provided throughout. Coordinate axes 299 include an x-axis parallel to the horizontal axis, a y-axis parallel to the vertical axis, and a z-axis parallel to the lateral axis and orthogonal to each of the x-axis and y-axis. The direction of gravity is shown via arrow 299. Where applicable, contour lines of reduced line width are provided to roughly indicate depth and three-dimensional form. Figure 2-3C In the present invention, similar parts are numbered the same and will not be introduced repeatedly.

[0021] First refer to Figure 2 , shows a front perspective view 200 of a drive axle 210. The drive axle 210 includes a central axis 294, which is parallel to the x-axis of the coordinate axis 299. The drive axle 210 may be Figure 1 The first axle assembly 102 or the second axle assembly 112 is a non-limiting example. In an embodiment, the drive axle 210 is a rear axle, and therefore, the drive axle 210 may be Figure 1The central axis 294 may be the rotation axis of the first axle shaft 212 and the second axle shaft 214 of the drive axle 210. The first axle shaft 212 and the second axle shaft 214 may be configured to be mounted on a vehicle wheel and rotated, such as Figure 1 For example, the first axle shaft 212 and the second axle shaft 214 are arranged at opposite ends of the drive axle 210, and each includes a terminal hub that can be used to mount a vehicle wheel. The first axle shaft 212 includes a first hub 220, and the second axle shaft 214 includes a second hub 222.

[0022] The drive axle 210 also includes a center housing 230 that houses the differential 240. The center housing 230 is interchangeably referred to herein as a carrier 230. The center housing 230 includes a body portion 232 having a first tube mount 234 and a second tube mount 236, the first tube mount 234 being on a first end of the body portion 232 and the second tube mount 236 being on a second end of the body portion 232, the second end being opposite the first end relative to the center axis 294. As an example, the body portion 232 can be a single piece of metal die casting, including one or more of aluminum, steel, cast iron, or the like. In some examples, the first tube mount 234 can be larger (or smaller) than the second tube mount 236. For example, the first tube mount 234 can have a larger (or smaller) diameter and / or a longer (or shorter) length along the center axis 294 than the second tube mount 236. In other examples, the first tube mount 234 and the second tube mount 236 can be equal in size. In one example, the wall thickness of the first tube mount 234 and the second tube mount 236 can be adjusted based on the vehicle load. Even when the wall thickness of the tube mount is adjusted, the shape of the carrier 230 can be maintained. By doing so, in a fleet including vehicles of different vehicle loads, the research and manufacturing costs of the vehicle manufacturer are reduced.

[0023] The differential 240 can receive the drive shaft (e.g., Figure 1 The pinion 242 may receive an input from the second drive shaft 122 of the center housing 230, and the pinion 242 may rotate along an axis 296 that is perpendicular to the center axis 294 and parallel to the z-axis of the coordinate axis 299. The pinion 242 may extend through a cover portion 238 of the center housing 230, which is removably coupled to the body portion 232 via a plurality of fasteners 244. The plurality of fasteners 244 may include one or more bolts, screws, lugs, etc. arranged around the periphery of the cover portion 238 and the body portion 232. As an example, the cover portion may be die cast from the same or different material as the body portion 232 of the center housing 230. As will be described below with respect to Figures 3A-3CAs described above, the body portion 232 may be a single, continuous piece having a cavity for receiving the differential 240, with openings only at locations where the first tube mount 234, the second tube mount 236, and the cover portion 238 are attached.

[0024] An assembly direction is shown via arrow 295, which is parallel to axis 296, wherein the gear is arranged outside of the body portion 232 in the assembly direction. An assembly split line seam of the axle assembly may be arranged between the cover portion 238 and the body portion 232. There may be no other seams or other connection points as far as the center housing 230 is concerned. Therefore, the assembly split line seam may be the only assembly seam arranged between the cover and the center section of the housing.

[0025] The first tube mount 234 of the main body portion 232 is arranged on a side of the differential 240 that is biased toward the first axle shaft 212, and the second tube mount 236 of the main body portion 232 is arranged on a side of the differential 240 that is biased toward the second axle shaft 214. The axle rails of the drive axle 210 that accommodate the first axle shaft 212 and the second axle shaft 214 may be defined via the first axle tube 202 and the second axle tube 204, which are concentric about the central axis 294. The first axle tube 202 may be pressed into the first tube mount 234 of the main body portion 232. The second axle tube 204 may be pressed into the second tube mount 236 of the main body portion 232. That is, at least a portion of the first axle tube 202 may be positioned within the first tube mount 234 of the first body portion 232 such that an outer surface of the first axle tube 202 is in surface-sharing contact with an inner surface of the first tube mount 234 of the body portion 232, as will be described below with respect to Figure 3A and 3B Similarly, at least a portion of the second axle tube 204 may be pressed within the second tube mount 236 such that an outer surface of the second axle tube 204 may be in face-to-face contact with an inner surface of the second tube mount 236 of the body portion 232. The first axle tube 202 and the second axle tube 204 may be fixedly coupled to corresponding tube mounts of the body portion 232, such as by being welded in place.

[0026] The first axle tube 202 and the second axle tube 204 may include, for example, Figure 2The cylindrical shape shown includes a central cavity configured to accommodate a corresponding axle shaft. However, other shapes such as a square box tube are also possible. In some examples, the first axle tube 202 and the second axle tube 204 can have substantially the same size. In other examples, the length and / or diameter of the first axle tube 202 and the second axle tube 204 can be different from each other. For example, the length of the first axle tube 202 can be longer (or shorter) than the second axle tube 204. Additionally or alternatively, the diameter of the first axle tube 202 can be larger (or smaller) than the second axle tube 204.

[0027] In addition, each of the first axle tube 202 and the second axle tube 204 includes a wall thickness between the inner surface and the outer surface defining the central cavity. The wall thickness of the first axle tube 202 and the second axle tube 204 can vary based on vehicle load requirements. The body portion 232 of the center housing 230 can be adapted to accommodate axle tubes having different wall thicknesses. For example, due to the press-fit and welded connection between each axle tube and the corresponding tube mounting of the body portion 232, as described above, the same body portion 232 can be used for axle tubes having a smaller wall thickness and a larger wall thickness. As a result, the body portion 232 can provide a modular housing that can be adapted to a plurality of different drive axles, each of which is configured for a different vehicle load requirement. By including a larger tube wall thickness for vehicles with a higher vehicle load requirement, the durability of the axle can be increased to improve the durability of the vehicle. By including a smaller tube wall thickness for vehicles with a smaller vehicle load requirement, the vehicle weight can be reduced to improve the efficiency of the vehicle. In some examples, shims or other materials may be used in conjunction with the inclusion of a smaller diameter axle tube so that the configuration of center housing 230 is maintained across different vehicle types.

[0028] Continue to refer to Figure 2 , the first axle shaft 212 can be positioned to rotate within the first axle tube 202. The second axle shaft 214 can be positioned to rotate within the second axle tube 204. The first axle shaft 212 can extend through the first tube mount 234 to the differential 240, wherein the first axle shaft 212 can engage with a gear set (e.g., a planetary gear set) of the differential 240. Similarly, the second axle shaft 214 can extend into the second tube mount 236 of the body portion 232, wherein the second axle shaft 214 can engage with the second planetary gear set. In this way, the first axle shaft 212 can provide a first speed to the first wheel hub 220 and the wheels mounted thereon, and the second axle shaft 214 can provide a second speed different from or equal to the first speed to the second axle shaft 222 and the wheels mounted thereon. In one example, the speeds can be differentiated via adjusting the gears of the differential or planetary gear set, which can provide torque vectoring or other all-wheel drive capabilities.

[0029] The first axle shaft 212 may also extend through a first spindle 216 coupled to the first axle tube 202, and the second axle shaft 214 may extend through a second spindle 218 coupled to the second axle tube 204. The axle tubes 202 and 204 and the spindles 216 and 218 may together provide an axle housing. The first spindle 216 may be removably coupled to the first axle tube 202, and the second spindle 218 may be removably coupled to the second axle tube 204. The spindles 216 and 218 may rotatably support vehicle wheels on the axle housing while allowing the axle shafts to extend through the axle housing to rotatably drive the wheels. Although in Figure 2 2, but brake system components may be positioned about and mounted to the first and second spindles 218. Additionally, vehicle mounts may be positioned about the axle tubes 202 and 204 and / or spindles 216 and 218, such as a first bracket 206 removably coupled to the first axle tube 202 and a second bracket 208 of the second axle tube 204. For example, a vehicle mount may be used to physically couple the drive axle 210 to the underside of the vehicle.

[0030] It will be appreciated that in order to facilitate rotation of various components (e.g., axle shafts 212 and 214, pinion gears 242, and other differential components) and to provide sealing for lubrication, various bearings, backing rings, sealing rings (e.g., O-rings and snap rings), joints, washers, nuts, spacers, and other components may be included in drive axle 210.

[0031] Now refer to Figures 3A-3C , showing a front perspective view of the center housing 230 ( Figure 3A )、Partial front view stereogram( Figure 3B ) and rear view stereogram ( Figure 3C ). Figures 3A-3C Described together in this article.

[0032] The center housing 230 may include an interior 302 visible through an opening 306. A rim 304 may circumferentially surround the opening 306, wherein the rim 304 may include a plurality of openings 308. The plurality of openings 308 may include a plurality of fasteners (e.g., Figure 2 The cover portion (eg, cover portion 238 ) may seal the interior 302 of the center housing 230 .

[0033] The first tube side 310 may include a first tube passage 312 inside the first tube mount 234. A first axle tube (e.g., the first axle tube 202) may extend through the first tube passage 312 toward the interior 302. In one example, the first tube passage 312 may include one or more features, such as dams, ribs, or other features configured to alter the flow of lubricant. The first axle tube may be connected to the first axle tube via a first stop (e.g., Figure 2 The first stop member 235) is prevented from extending into the interior 302.

[0034] The second tube side 314 may include a second tube passage 316 inside the second tube mount 236. A second axle tube (e.g., the second axle tube 204) may extend through the second tube passage 316 toward the interior 302. In one example, the second tube passage 316 may include one or more features, such as dams, ribs, or other features configured to alter the flow of lubricant. The second axle tube may be connected to the second axle tube via a second stop (e.g., Figure 2 The second stop member 237) is prevented from extending into the interior 302.

[0035] In this manner, each of the first and second axle tubes may be press fit into the first and second tube mounts 234, 236, respectively. The first and second axle tubes may be secured in place via one or more of fasteners, adhesives, welding, fusing, etc. In one example, the first and second axle tubes are fusion welded in place.

[0036] The first tube mount 234 may also include a plurality of first openings 334, and the second tube mount 236 may include a plurality of second openings 336. The plurality of first openings 334 and the plurality of second openings 336 may be configured to receive lubricant to and / or drain lubricant from the first axle tube and the second axle tube, respectively. The plurality of first openings 334 and the plurality of second openings 336 may be arranged on the front faces of the first tube mount 234 and the second tube mount 236.

[0037] The first tube mount 234 may further include a first opening 335. The second tube mount 236 may further include a second opening 337. The first opening 335 and the second opening 337 may be arranged on the backside of the first tube mount 234 and the second tube mount 236. The first opening 335 may be opposite to the plurality of first openings 334. The second opening 337 may be opposite to the plurality of second openings 336.

[0038] The plurality of first openings 334 may include three openings arranged in a triangular shape, wherein the first opening 335 is aligned along the Z axis with only one of the plurality of first openings 334. The plurality of second openings 336 may include three openings arranged in a triangular shape, wherein the second opening 337 is aligned along the Z axis with only one of the plurality of second openings 336.

[0039] The housing 230 may include a plurality of ribs and lubrication channels disposed therein. The ribs and lubrication channels may reduce churning losses and improve overall efficiency by reducing friction experienced therein. The housing 230 may include a first upper rib 342 and a first lower rib 344 coupled to the first tube mount 234. The housing 230 may also include a second upper rib 346 and a second lower rib 348. The ribs may be oriented in a direction parallel to the x-axis. In one example, the ribs may support vertical axle loads. The size of the ribs may be adjusted based on the vertical axle loads, wherein the ribs are larger when the vertical axle loads of the vehicle are higher relative to other vehicles.

[0040] The first upper rib 342 and the first lower rib 344 may include a triangular shape and extend from the first tube mount 234 to the carrier (e.g., the center housing 230). The second upper rib 346 and the second lower rib 348 may include a triangular shape and extend from the second tube mount 236 to the carrier. In one example, the size and shape of each rib are the same as each other.

[0041] A plurality of main lubrication passages 350 may be arranged in a carrier that is mounted into a modular housing. A plurality of main lubrication passages 350 may be incorporated into the cover side of the housing aligned with the ring gear. The cast banjo style carrier may be configured to optimize oil volume and reduce churning losses.

[0042] In one example, the axle assembly includes a Salisbury arrangement and a banjo-style bearing where the housing is formed and the gears are mounted externally to the center section of the housing. The banjo housing can include a hold-down tube, allowing the housing to be coupled to existing bearing assemblies that mount to conventional stamped banjo housings. The cast housing center can support a number of different tube and bearing assembly configurations, such as a tube assembly with a Salisbury axle assembly.

[0043] The present disclosure provides support for a system including a differential housing including a modular Salisbury-style center section including a tube mount configured to receive a tube assembly via a press fit. A first example of the system also includes where the differential housing is a banjo-style housing, where the center section includes a circular shape and the tube mount includes an elongated shape. A second example of the system, which optionally includes the first example, also includes a plurality of ribs including a triangular shape, where each of the plurality of ribs is physically coupled to the center section and one of the tube mounts. A third example of the system, which optionally includes one or more of the previous examples, also includes where each of the tube assemblies is welded to one of the tube mounts. A fourth example of the system, which optionally includes one or more of the previous examples, also includes where the differential housing is arranged in various vehicles with different vehicle loads, where the center section is the same in each of the various vehicles. A fifth example of the system, which optionally includes one or more of the previous examples, also includes where one or more of the tube mounts and the tube assembly are sized in each of the various vehicles. A sixth example of the system, which optionally includes one or more of the previous examples, further includes wherein the assembly direction is orthogonal to a center axis of the drive axle.

[0044] The present disclosure provides additional support for an axle assembly including a modular differential housing including a first tube mount and a second tube mount, wherein a central section of the housing includes a circular shape and the first tube mount and the second tube mount include an elongated shape. A first example of an axle assembly also includes wherein the housing includes a single assembly split line seam. A second example of an axle assembly, which optionally includes the first example, also includes wherein the gear is mounted outside the central section. A third example of an axle assembly, which optionally includes one or more of the previous examples, also includes wherein the housing includes a central opening surrounded by a plurality of openings, and wherein the cover is physically coupled to the central opening via a plurality of fasteners engaged with the plurality of openings. A fourth example of an axle assembly, which optionally includes one or more of the previous examples, also includes wherein the axle arm is press-fitted into each of the first tube mount and the second tube mount. A fifth example of an axle assembly, which optionally includes one or more of the previous examples, also includes wherein the axle arm is welded to the first tube mount and the second tube mount. A sixth example of an axle assembly, which optionally includes one or more of the previous examples, further includes wherein the first tube mount and the second tube mount receive a square box tube axle arm. A seventh example of an axle assembly, which optionally includes one or more of the previous examples, further includes wherein the axle assembly is coupled to a rear drive unit or a front drive unit of a vehicle.

[0045] The present disclosure provides further support for an axle assembly for an electric vehicle, the axle assembly including a modular differential housing including a first tube mount and a second tube mount lateral to a center section, wherein the center section includes a circular shape, and the first tube mount and the second tube mount include an elongated shape and a rib physically coupled to the center section and one of the first tube mount and the second tube mount. A first example of an axle assembly also includes where the gear is mounted to the exterior of the center section, and where the assembly direction of the axle assembly is orthogonal to the center axis of one or more axle arms. A second example of an axle assembly, which optionally includes the first example, also includes where one or more axle arms are press-fit into the first tube mount and the second tube mount. A third example of an axle assembly, which optionally includes one or more of the previous examples, also includes where the wall thickness of the first tube mount and the second tube mount is adjusted based on vehicle load. A fourth example of an axle assembly, which optionally includes one or more of the previous examples, also includes where the axle assembly includes only one assembly split line seam disposed between an opening of the center section and a housing cover.

[0046] As used herein, unless otherwise indicated, the term "about" is to be interpreted as meaning plus or minus 5 percent of the range.

[0047] The appended claims particularly point out certain combinations and subcombinations believed to be novel and non-obvious. These claims may refer to "an" element or a "first" element or the equivalent thereof. Such claims should be understood to include combinations of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or characteristics may be claimed in this or a related application by amendment of the present claims or by presentation of new claims. Such claims, whether broader, narrower, equal, or different in scope to the original claims, are deemed to be included in the subject matter of the present disclosure.

Claims

1. A system, characterized in that: include: A differential housing comprising a modular Salisbury center section including a center housing connected to two axle tubes, wherein the center housing houses a differential assembly and the axle tubes house rotatable axle shafts, the modular Salisbury center section including tube mounts configured to receive the axle tubes via a press fit.

2. The system according to claim 1, characterized in that The differential housing is a banjo housing including a center housing through which the axle tubes are connected together, wherein the center section includes a circular shape and the tube mounts include an elongated shape.

3. A system according to any one of the preceding claims, characterised in that Also included is a plurality of ribs including a triangular shape, wherein each of the plurality of ribs is physically coupled to one of the center section and the tube mount.

4. The system according to any one of claims 1 and 2, characterized in that Each of the axle tubes is fusion welded to one of the tube mounts.

5. The system according to any one of claims 1 and 2, characterized in that The differential housing is arranged in vehicles with different vehicle loads, wherein the central section is identical in each of the vehicles.

6. The system according to claim 5, characterized in that One or more of the tube mount and the axle tube are sized in each of the vehicles.

7. The system according to any one of claims 1 and 2, characterized in that The assembly direction is perpendicular to the central axis of the drive axle.

8. A vehicle axle assembly, characterized in that: include: A modular differential housing includes a first tube mount and a second tube mount, wherein a central section of the housing includes a circular shape and the first tube mount and the second tube mount include an elongated shape.

9. The axle assembly according to claim 8, characterized in that: The housing includes an assembly split line seam, which is the only assembly seam disposed between the cover and the central section of the housing.

10. The axle assembly according to claim 8 or 9, characterized in that: A gear is mounted to the exterior of the center section.

11. The axle assembly according to claim 8 or 9, characterized in that: The housing includes a central opening surrounded by a plurality of openings, and wherein the cover is physically coupled to the central opening via a plurality of fasteners that engage the plurality of openings.

12. The axle assembly according to claim 8 or 9, characterized in that: An axle arm is press fit into each of the first tube mount and the second tube mount.

13. The axle assembly according to claim 12, characterized in that: The axle arm is welded to the first tube mount and the second tube mount.

14. The axle assembly according to claim 8 or 9, characterized in that: The first tube mount and the second tube mount receive square box tube axle arms.

15. The axle assembly according to claim 8 or 9, characterized in that: The axle assembly is coupled to a rear drive unit or a front drive unit of a vehicle.

Images