Split type differential mechanism shell system and drive axle

Abstract

The utility model relates to a split type differential mechanism shell system and a drive axle. The split type differential mechanism shell is divided into two parts at the axis position on the vertical plane. The split differential shell comprises a first shell part and a second shell part, the first shell part and the second shell part are coupled at a central interface on a vertical plane, and the central axis of the first shell part and the central axis of the second shell part are coaxial with the central axis of the driving shaft.

Description

Technical Field

[0001] An independent suspension rear axle that can be split on the differential housing. The differential and differential housing can be compatible with a front-wheel drive differential and an all-wheel power drive unit. Background Art

[0002] Vehicles such as sport utility vehicles (SUVs) or sedans may use a front-wheel drive device (FWD) in certain situations to improve the vehicle's passability when driving on the road. Such applications may include using front-wheel drive as part of an all-wheel drive (AWD) together with a rear drive unit (RDU). For example, in an urban environment, an all-wheel drive system can improve road control because road degradation, vehicle speed, or environmental conditions (such as weather like rain, snow, or ice) can reduce road passability.

[0003] However, in certain cases, the space provided by the vehicle's chassis (such as an off-road vehicle) for the RDU may be more limited. For example, compared to a sedan, the chassis of an SUV may have more materials and support features, thus reducing the packaging space available for all-wheel drive and the RDU compared to a sedan. The differential of the RDU (such as the rear differential) may use multiple brackets and caps as part of the overall housing. Features such as caps and bracket flanges can increase the packaging of the differential housing assembly. Summary of the Utility Model

[0004] The inventors of the present system have recognized these and other problems and have proposed a system that at least partially solves these problems. A system developed in one example includes a split differential housing that is split in half at an axis in a vertical plane. The split differential housing includes a first housing component that is coupled to a second housing component at an interface located at the center of the vertical plane, where the axis is coaxial with the central axis of the drive shaft. In this way, the split-designed housing can be more compact compared to an integral differential housing, enabling the rear differential device to be used in a chassis with limited space, such as the chassis of an off-road vehicle.

[0005] It should be understood that the above summary is to introduce concepts further described in the detailed description in a simplified form. It is not intended to identify the key or essential features of the claimed subject matter, the scope of which is uniquely determined by the claims that follow the detailed description. Moreover, the claimed subject matter is not limited to embodiments that solve any disadvantages noted above or in any part of this disclosure. Brief Description of the Drawings

[0006] Figure 1 Shows an example schematic diagram of a vehicle that may include the transmission of the present disclosure as part of the transmission.

[0007] Figure 2 shows an exemplary embodiment of a unitary housing for a rear differential in the prior art.

[0008] Figure 3 The first example of the split housing of the differential disclosed in the present disclosure is shown.

[0009] Figure 4 The second example of the split housing of the differential of the present disclosure is shown. DETAILED DESCRIPTION

[0010] The following description relates to the housing of a differential device. The housing can be an axle carrier, such as a variant of a Salisbury axle, which is a solid axle design characterized by a central differential mounted within the axle carrier and providing torque distribution between the wheels. The disclosed housing is a split differential housing that is split in half in a vertical plane. The split differential housing includes a first housing member connected to a second housing member at an interface located at the center of the vertical plane, with its axis coaxial with the central axis of the drive axle. The split differential housing can be fixed around the differential components, thereby surrounding or partially surrounding the differential components. The differential can be a rear differential device for a rear axle.

[0011] The rear differential device can provide rear-wheel drive (RWD) for the vehicle. The drive device of the vehicle can generate rotational energy and transmit the rotational energy through torque to the rear differential via at least one first drive shaft. The vehicle can have a front differential. The front differential can be mounted in a third housing that serves as an axle carrier. The third housing is separate from the split differential housing. The front differential can provide front-wheel drive (FWD) for the vehicle to some extent. The front differential and the rear differential can provide front-wheel drive (FWD) and rear-wheel drive (RWD) as part of an all-wheel drive (AWD) operation of the vehicle, which can be referred to as the AWD mode of the vehicle herein.

[0012] Figure 1 An exemplary schematic diagram of a vehicle is shown that can incorporate the transmission of the present disclosure as part of a transmission. Figure 2 shows an example of a unitary housing for a rear differential in the prior art. Figure 3 The first example of the split housing of the differential of the present invention is shown. Figure 4 The second example of the split housing of the differential of the present disclosure is shown.

[0013] It should also be understood that the specific components and systems illustrated in the drawings and described in the following specification are exemplary embodiments of the inventive concepts defined herein. For ease of discussion, the drawings are referred to collectively. Accordingly, like elements are generally denoted by like reference numerals herein and will not be repeated.

[0014] Figure 1Shows an example configuration schematic diagram of the relative positioning of each component. Figure 2 shows an example configuration of approximate positioning in the prior art. Figure 3-4 Shows an example configuration of approximate positioning. Figures 2-4 are shown approximately to scale, but other relative dimensions may also be used. As used herein, unless otherwise specified, the term "approximate" should be understood to be in the range of plus or minus five percent.

[0015] In addition, Figure 1-4 Shows an example configuration of the relative positioning of various elements. If the elements shown in the figure are in direct contact or directly coupled to each other, then in at least one example, these elements may be referred to as being in direct contact or directly coupled, respectively. Similarly, in at least one example, elements shown as adjacent or contiguous to each other may be adjacent or contiguous to each other, respectively. For example, elements in face-to-face contact with each other may be referred to as face-to-face contact elements. Another example is that in at least one example, elements are placed separately from each other with only space in between and no other elements, and may be referred to as being placed separately from each other. Also, elements shown above / below each other, on opposite sides of each other, or on the left / right side of each other relative to each other may be referred to as such elements. In addition, as shown in the figure, in at least one example, the topmost element or element point may be referred to as the "top" of the element, and the bottommost element or element point may be referred to as the "bottom" of the element. The top / bottom, upper / lower, above / below used herein may be relative to the vertical axis in the figure and are used to describe the relative positioning of the elements in the figure with respect to each other. Thus, in one example, an element shown above other elements is vertically positioned above the other elements. For another example, the shapes of the elements depicted in the figure may be referred to as having these shapes (e.g., circular, linear, planar, curved, round, chamfered, beveled, or similar shapes). In addition, in at least one example, elements shown intersecting each other may be referred to as intersecting elements or intersecting each other. In addition, in one example, an element shown inside or outside another element may be referred to as such an element. In addition, when describing each element, it may be related to the reference axis in the accompanying drawing.

[0016] Unless otherwise specified, a feature described as axial may be approximately parallel to the reference axis. Unless otherwise specified, a feature described as anti-axial may be approximately perpendicular to the referenced axis. Unless otherwise specified, a feature described as radial may surround the axis or extend outward from the axis, such as the reference axis, or a component or feature previously described as being radial to the reference axis.

[0017] A feature described as longitudinal may be approximately parallel to the longitudinal axis. The transverse axis may be parallel to the normal of the longitudinal axis. A transverse feature may be approximately parallel to the transverse axis and parallel to the normal of the longitudinal axis.

[0018] Now look at Figure 1, the vehicle 100 shown in the figure includes a power system 101 and a transmission system 103. The powertrain includes a prime mover 106 and a transmission 108. The prime mover 106 can be an internal combustion engine (ICE), an electric motor, etc., and provides rotational power to the transmission 108 during operation. 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 rotational power to the transmission system 103 according to the selected gear or setting. In addition, there may be other power devices in the vehicle besides the prime mover 106. In one example, the prime mover 106 is an internal combustion engine, and at least one second prime mover is connected to the transmission 108, where the second prime mover can be an electromechanical device such as an electric motor. The vehicle 100 can have a longitudinal axis 130. The powertrain 101 and the transmission system 103 can have a length parallel to the longitudinal axis 130. The vehicle 100 can also have a front side 132 and a rear side 134.

[0019] The prime mover 106 can be powered by energy from an energy storage device 105. In one example, the energy storage device 105 is a battery for storing electrical energy. An inverter 107 can be installed between the energy storage device 105 and the prime mover 106 to convert direct current (DC) to alternating current (AC). The inverter 107 can include various components and circuits, and its thermal requirements can affect the efficiency of the inverter.

[0020] The vehicle 100 can be a commercial vehicle, a light, medium or heavy vehicle, a passenger vehicle, an off-road vehicle, and a sport utility vehicle. In addition, the vehicle 100 and / or one or more of its components can also be used in the industrial, locomotive, military, agricultural, and aerospace fields. In one example, the vehicle 100 is a pure electric vehicle or a vehicle with a pure electric operating mode, such as a plug-in hybrid vehicle. Therefore, the prime mover 106 is an electric machine. In one example, the prime mover 106 is a motor / generator.

[0021] In some examples, such as Figure 1As shown, the drive system 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 one example, the first axle assembly 102 is disposed near the front of the vehicle 100 and thus includes a front axle, while the second axle assembly 112 is disposed near the rear of the vehicle 100 and thus includes a rear axle. The first axle assembly 102 can be closer to the front side 132 compared to the rear side 134. The second axle assembly 112 can be closer to the rear side 134 compared to the front side 132. The drive system 103 is a front-wheel drive system with all-wheel drive functionality. The rotational energy generated by a moving device (such as a prime mover 106) of the vehicle 100 can be delivered to the first axle assembly 102 at the front end of the vehicle 100. The drive system 103 is shown in a four-wheel drive configuration, but other configurations can also be employed. For example, the drive system 103 can include a rear-wheel drive or an all-wheel drive configuration. Additionally, the drive system 103 can also include one or more tandem axle assemblies. Thus, without departing from the scope of the present disclosure, the powertrain 103 can also have other configurations, Figure 1 The configuration shown is for illustration only and not for limitation. Additionally, the vehicle 100 can also include other wheels that are not connected to the drive system 103.

[0022] In certain four-wheel drive configurations, such as Figure 1As shown, the power transmission system 103 includes a transfer case 110 configured to receive rotational power output from a transmission 108. A first drive shaft 113 is drivingly connected to a first output end 111 of the transfer case 110, while a second drive shaft 122 is drivingly connected to a second output end 121 of the transfer case 110. The first drive shaft 113 (e.g., a front drive shaft) transmits the rotational power of the transfer case 110 to a first differential unit 116 of a first axle assembly 102 to drive a first set of wheels 104, and the second drive shaft 122 (e.g., a rear drive shaft) transmits the rotational power of the transfer case 110 to a second differential unit 126 of a second axle assembly 112 to drive a second set of wheels 114. For example, the first differential device 116 is drivingly connected to a first axle half shaft and a second axle half shaft, e.g., as a first set of axle shafts 118, and is drivingly connected to the first set of wheels 104. The second differential device 126 drives and couples to a first axle half shaft and a second axle half shaft, e.g., a second set of axles 128, and is coupled to the second set of wheels 114. The first set of axle shafts 118 and the second set of axle shafts 128 can each rotate about a rotational axis. For example, the rotational axis of the first axle assembly 102 can be a first rotational axis 127, and the rotational axis of the second axle assembly 112 can be a second rotational axis 129. It can be understood that each of the first set of shafts 118 and the second set of shafts 128 can be positioned within a housing. The first drive shaft 113 and the second drive shaft 122 can be positioned to extend parallel to a longitudinal axis 130. In one example of the vehicle 100 configuration, the second drive shaft 122 can be centered about the longitudinal axis 130. The second differential unit 126 can be part of a rear differential unit.

[0023] To some extent, the first differential device 116 can provide all-wheel drive for the vehicle 100 as part of the rotational power transmitted through the first drive shaft 113. Similarly, the second differential unit 126 can provide all-wheel drive for the vehicle 100 as part of the rotational power transmitted through the second drive shaft 122. The first differential device 116 and the second differential device 126 can respectively provide all-wheel drive and all-wheel drive as part of the all-wheel drive mode of the vehicle 100.

[0024] In some examples, additionally or alternatively, vehicle 100 can be a hybrid vehicle, including an engine and an electric machine, each configured to provide 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 can be driven by power from the engine in a first operating mode, in which the electric machine does not operate to provide power (e.g., engine-only mode); in a second operating mode, driven by power from the electric machine, in which the engine does not operate to provide power (e.g., electric-only mode); in a third operating mode, driven by power from the engine and the electric machine (e.g., electric assist mode). As another example, one or both of the first axle assembly 102 and the second axle assembly 112 can be an electric axle assembly, configured to be driven by an integrated electric machine.

[0025] In certain examples, the transmission 108 can also be a first transmission, further including a second transmission disposed on a second set of shafts 128. Here, the transmission 108 can be interchangeably referred to as the gearbox.

[0026] To compare the views shown in FIGS. 2-4, a set of reference axes 201 is provided. The reference axes 201 represent the y-axis, the x-axis, and the z-axis. In one example, the z-axis can be parallel to the direction of gravity, and the x-y plane can be parallel to the horizontal plane in which the differential housing assembly 202, the first differential housing assembly 302, and the second differential housing assembly 402 are located. When referring to the reference directions, positive can refer to the arrow directions of the y-axis, the x-axis, and the z-axis, and negative can refer to the opposite directions of the arrows of the y-axis, the x-axis, and the z-axis. Filled circles can represent the arrows and axes facing the view or the front view. Unfilled circles can represent the arrows and axes facing the opposite direction or the negative direction of the view.

[0027] FIG. 2 shows a first view 200 of an example of a differential housing assembly 202 in the prior art. The differential housing assembly 202 can be centered on an axis 212. The axis 212 can be the longitudinal axis of the differential housing assembly 202. The axis 212 can be parallel or collinear with the longitudinal axis of the vehicle, e.g., Figure 1 the longitudinal axis 130 of the vehicle 100 in. The differential housing assembly 202 can have a first side 204, a second side 206, a third side 208, and a fourth side 210. The third side 208 can serve as the front end of the differential housing assembly 202. The fourth side 210 can serve as the rear end of the differential housing assembly 202. The differential housing assembly 202 is a rear differential housing, such as a rear axle carrier, in which a differential mounted at the rear of the vehicle can be accommodated.

[0028] The differential housing assembly 202 in the prior art has a housing 214 and a cover 216 that can enclose the components of the rear differential. The housing 214 can be a one-piece housing that forms a cladding around the differential housing assembly. The housing 214 can be connected to the cap 216 at the interface 221. The first flange 218 of the cap 216 and the second flange 220 of the housing 214 can be fixed at the interface 221. The first flange 218 can be fixed to the second flange 220 by a plurality of fasteners 244. The first bracket 222 and the second bracket 224 can be mounted to the housing 214. The first bracket 222 can be mounted on the first side 204 of the surface of a plurality of first extensions 226 of the housing 214. The second bracket 224 can be mounted on the second side 206 at the surface of a plurality of second extensions 228 of the housing 214. The first bracket 222 and the second bracket 224 are connected to the housing 214 on both sides of the cap 216 relative to the axis 212, wherein the mounting surfaces of the brackets are substantially aligned with the cap 216. The first bracket 222 and the second bracket 224 can mount the differential housing assembly 202 to components of a vehicle, such as Figure 1 the vehicle 100 in

[0029] The differential housing assembly 202 can be an example of a carrier included in a Salisbury axle. A conventional Salisbury axle including the differential housing assembly 202, while suitable for certain heavy-duty applications, can be bulky and / or heavy, presenting packaging challenges for vehicles with space and / or weight constraints. As a further challenge, designs such as the differential housing assembly 202 can affect the sealing ability between the housing 214 and the cap 216 at the differential housing bearing holes (not shown in the figure, but see the hole 318 in the differential housing bearing holes of the disclosed housing). The disclosed split differential housing provides a durable and more compact layout, thus addressing some issues related to packaging, weight, and sealing ability. Figure 3 in

[0030] Figure 3 Example 300 showing a first differential housing assembly 302 according to the present disclosure is presented. The first differential housing assembly 302 can be centered on the axis 212. The axis 212 can serve as the longitudinal axis of the first differential housing assembly 302. The axis 311 can be normal to the axis 212. When drivingly connected to the first differential housing assembly 302, the axis 311 can serve as the central axis of the axle, such as the central axis of a drive axle. The first differential housing assembly 302 can have a first side 304, a second side 306, a third side 308, and a fourth side 310. The third side 308 can be the front end of the first differential housing assembly 302. The fourth side 310 can be the rear end of the first differential housing assembly 302. For example, the first differential housing assembly 302 can accommodate Figure 1the second differential unit 126 therein. In one example, the first differential housing assembly 302 is a rear differential housing, such as a rear axle carrier, which can accommodate a differential mounted at the rear of the vehicle.

[0031] The first differential housing assembly 302 is a split differential housing that is split in half at an axis in a vertical plane. The first differential housing assembly 302 has a first housing part 312 that is coupled to a second housing part 314 at an interface located at the center of the vertical plane, where the axis is coaxial with the central axis of the drive shaft. For example, the first housing part 312 and the second housing part 314 can be coupled at the interface 316. The interface 316 can be located at the center of a plane 315 that is axially aligned with the axis 311 and formed by the x - z axes. In one example, the axis 311 can be the second rotational axis 129 referred to Figure 1 above.

[0032] The first housing part 312 can be the front housing portion of the first differential housing assembly 302. The second housing part 314 can be the rear housing portion of the first differential housing assembly 302. The first housing part 312 can be the front housing closest to the third side 308 of the interface 316. The second housing part 314 can be the rear housing closest to the fourth side 310 of the interface 316. Relative to the axis 212, the longitudinal length of the first housing part 312 can be longer than that of the second housing part 314.

[0033] The carrier part is split in half between the first housing part 312 and the second housing part 314. The first housing part 312 can include a first carrier part 321. Similarly, the second housing member 314 can include a second carrier part 323. The first carrier part 321 and the second carrier part 323 can be located around and enclose the gear components of the differential, such as pinions, ring gears, first differential side gears, second differential side gears, and a plurality of spider gears. Compared with traditional carriers, this design may be more durable and fatigue - resistant.

[0034] In one example, the interface 316 is a split - line seam centered on the plane 315. When coupled at the interface 316, the first housing part 312 and the second housing part 314 can form a plurality of bearing holes or apertures, such as at least two holes, that can receive shafts and be coupled to shaft drives. For example, there is a first hole 318 on the first side 304 of the first differential housing assembly 302, and there is a second hole (such as Figure 4the second hole 418). The first hole 318 and the second hole may be radially distributed about the axis 311 and centered on the axis 311. The first bearing 319 may be concentric with the first hole 318. The first bearing 319 may surround and support the first half shaft. Similarly, the first hole 318 may receive and rotatably support the first half shaft. The first hole 318 may be a first half shaft mount, and the second hole may be a second half shaft mount. The arrangement of the bearing holes relative to the interface 316 of the first housing member 312 and the second housing member 314 may improve the sealing ability of the first differential housing assembly 302. For example, although the bearing holes are subject to severe separating forces, the T-joint design 398 may reduce the opening distance of the interface 316 when the bearing holes are stressed.

[0035] The first bracket 326 may be mounted to the second housing member 314. The first bracket 326 may be mounted on the fourth side 310. The first bracket 326 may be disposed opposite the interface 316. In one example, the first differential housing assembly 302 may have a single bracket in the form of the first bracket 326. The first bracket 326 may have a first fastener 328a and a second fastener 328b, which may mount the second housing member 314 and the first differential housing assembly 302 to a vehicle component, such as Figure 1 the vehicle 100 in. The vehicle component to which the first bracket 326 may be mounted may include a vehicle chassis. Compared with the prior art, using the first bracket 326 to mount to the vehicle chassis may greatly reduce the packaging space.

[0036] The first housing member 312 may include a pinion nose 320. The pinion nose end 320 may be located around a portion of the differential input shaft and a portion of the pinion. A cover 322 may be connected to the first side 304 of the pinion nose 320. The cover 322 may be fixed to the pinion nose 320 by a flange 324. The cover 322 may be a housing. The cover 322 may house components such as sensors, brakes, or other actuators and / or controller assemblies. The pinion nose end 320 may have an opening 330 facing the third side 308. The opening 330 may be approximately circular and centered on the axis 212. The opening 330 may be centered around the axis 212 such that the centerlines of the pinion nose 320 and the opening 330 may be approximately parallel and collinear with the axis 212. The opening 330 may be defined by an opening in the outer surface 335 of the first flange 332. The opening 330 may serve as an opening for the hole 331 of the pinion nose 320. The hole 331 may be defined by the generally cylindrical inner surface 329 of the pinion nose 320 and the opening of the opening 330. The opening 330 and the hole 331 may receive an output end, such as a shaft. The output end may transfer rotational energy to the differential components housed in the first differential housing assembly 302 through the torque generated by the vehicle drive device.

[0037] The first flange 332 may be located around the mouth 330. The first flange 332 may be fixed to a vehicle component to which the differential can be mounted. The input end 334 may be substantially concentric with the mouth 330. The pinion nose 320 and the first housing component 312 may be located around the input end 334. The input end 334 may be an input end that transmits rotational energy to a differential housed in the first differential housing assembly 302. For example, the input 334 may be a pinion shaft physically coupled to the pinion. In this example, the pinion may be meshed with, drivingly coupled to, and transmit rotational energy to the ring gear of the differential by torque. The above output end (e.g., a shaft) may be drivingly coupled to the input end 334 to transmit rotational energy to the input end 334 by torque.

[0038] In one example, the mounting frame 336 may be located below and connected to the pinion nose 320. The mounting frame 336 may mount the first housing component 312 to a vehicle component, such as the vehicle 100. The mounting frame 336 may mount the first housing component 312 to a vehicle component, such as the vehicle 100. For example, the mounting frame 336 may be connected to a vehicle component through a first mounting trunnion 338a and a second mounting trunnion 338b. For example, a plurality of fasteners may respectively supplement and pass through the first mounting trunnion 338a and the second mounting trunnion 338b. Then, the fasteners may be threadedly connected to complementary holes in the vehicle component. Alternatively, the fasteners may be connected or already mounted to the vehicle component. When passing through the first mounting trunnion 338a and the second mounting trunnion 338b and connected to the vehicle component, the fasteners may fix and mount the mounting frame 336 to the vehicle component, thereby mounting the first housing component 312 to the vehicle component.

[0039] The first hole 318 may be of a first diameter 342. The first diameter 342 may be the inner diameter of the first hole 318 and the outer diameter of the first bearing 319. The second diameter 344 may be the inner diameter of the first bearing 319. The second diameter 344 may also be greater than and near the outer diameter of the first shaft.

[0040] The first housing member 312 may have a second flange 346, and the second housing member 314 may have a third flange 348. The second flange 346 extends around and from the first carrier portion 321. The second flange 346 and the third flange 348 may extend outwardly relative to the axis 212. The second flange 346 may be fastened to the third flange 348 at the interface 316. The second flange 346 may be fixed to the third flange 348 by a plurality of fasteners. The plurality of fasteners may include a third fastener 350, a fourth fastener 352, a fifth fastener 354, a sixth fastener 356, a seventh fastener 358, and an eighth fastener 360. For example, each fastener may be of the same size. Another example is that some or all of the fasteners may be of different sizes. Each fastener may be complementary to the holes on the second flange 346 and the holes on the third flange 348. Each fastener may pass through the complementary holes on the second flange 346 and the complementary holes on the third flange 348. The complementary holes of the fasteners on the second flange 346 and the third flange 348 may have a center line that is substantially parallel to the axis 212 and extends through the materials of the second flange 346 and the third flange 348. The complementary holes of the fasteners on the third flange 348 may be through holes. For example, the second flange 346 may have a first hole 362, a second hole 364, a third hole 366, a fourth hole 368, a fifth hole 370, and a sixth hole 372 for the fasteners. In this example, the first hole 362 may be complementary to the third fastener 350, the second hole 364 may be complementary to the fourth fastener 352, the third hole 366 may be complementary to the fifth fastener 354, the fourth hole 368 may be complementary to the sixth fastener 356, the fifth hole 370 may be complementary to the seventh fastener 358, and the sixth hole 372 may be complementary to the eighth fastener 360. The first hole 362, the second hole 364, the third hole 366, the fourth hole 368, the fifth hole 370, and the sixth hole 372 may be through holes that extend through the material of the second flange 346 and are visible when the second flange 346 is fastened to the third flange 348.

[0041] The first housing member 312 may have a plurality of ribs that may mechanically support and distribute mechanical energy through the first housing member 312. For example, the first housing member 312 may have a first rib 374. The first rib 374 may extend from the first flange 332 to the first carrier portion 321. Similarly, there may be a plurality of ribs, such as a second rib 376, a third rib 378, and a fourth rib 380, that may extend from the starting point of the pinion nose 320 to the material of the first carrier portion 321. The second rib 376, the third rib 378, and the fourth rib 380 may be located closest to the first side 304.

[0042] In one example, multiple fasteners, such as a first ninth fastener 382a, a second ninth fastener 382b, a third ninth fastener 382c, and a fourth ninth fastener 382d, can be used to fasten the cover plate 322 to the pinion nose 320. Each fastener for securing the cover 322 to the pinion nose 320, such as the first ninth fastener 382a, the second ninth fastener 382b, the third ninth fastener 382c, and the fourth ninth fastener 382d, can be complementary to holes in the pinion nose and holes in the flange 324.

[0043] The first fastener 328a can have a first washer 386a and a second washer 388a. The first washer 386a and the second washer 388a can be located at opposite ends of a first shaft 390a of the first fastener 328a. The end of the first shaft 390a of the first fastener 328a can have a first head 392a that can support the first washer 386a. Similarly, the second fastener 328b can have a third washer 386b and a fourth washer 388b. The third washer 386b and the fourth washer 388b can be located at opposite ends of a second shaft 390b of the second fastener 328b. The second fastener 328b can have a second head 392b at the end of the second shaft 390b that can support the third washer 386b. The first washer 386a and the second washer 388a can exert pressure on and be adjacent to opposite sides of a mounting member (such as an automotive chassis) that the first fastener 328a can fasten to. The first shaft 390a can extend through an auxiliary hole in the mounting seat. When the mounting seat is fixed to the first fastener 328a, the first shaft 390a can support the mounting seat. Similarly, the third washer 386b and the fourth washer 388b can exert pressure on and be in contact with the other side of a fixed seat that the second fastener 328b fastens to. The second shaft 390b can extend through an auxiliary hole in the fixed seat. When the mounting seat is fixed to the second fastener 328b, the second shaft 390b can support the mounting seat.

[0044] Figure 4 An example 400 of a second differential housing assembly 402 is shown. The second differential housing assembly 402 can be an example embodiment of the differential housing of the present disclosure. The second differential housing assembly 402 can share features with the first differential housing assembly 302 and will not be described again for the sake of brevity. The second differential housing assembly 402 can be centered about an axis 212. The axis 212 can serve as the longitudinal axis of the second differential housing assembly 402. Similarly, when drivingly coupled to the second differential housing assembly 402, the axis 311 can serve as the central axis of the axle shaft, such as the central axis of a drive axle.

[0045] In one example, the second differential housing assembly 402 is a rear differential housing, such as a rear axle carrier, which can accommodate a differential mounted at the rear of the vehicle. For example, the second differential housing assembly 402 can accommodate Figure 1 the second differential unit 126 in Figure 3 . The second differential housing assembly 402 can also be a split housing assembly. The second differential housing assembly 402 can include a third housing part 412 and a second housing part 314. The third housing part 412 can be a second example of a front housing part similar to the first housing part 312 in

[0046] . The third housing part 412 can be a second example of the front housing portion of the second differential housing assembly 402. The second housing part 314 can be an example of the rear housing portion of the second differential housing assembly 402. The third housing part 412 has the features of the first housing part 312, such as the pinion nose 320, the first bracket part 321, and the first flange 332. However, the third housing part 412 can also have a plurality of other features different from the first housing part 312, such as the mounting support 414. Relative to the axis 212, the third housing part 412 is longer longitudinally than the second housing part 314. Figure 3 When coupled at the interface 316, the third housing part 412 and the second housing part 314 can form a plurality of holes, such as at least two holes, which can receive a shaft and be drivingly coupled to the shaft. For example, there is a second hole 418 on the second side 306 of the second differential housing assembly 402. The second hole 418 can be centered on the axis 311 and be radially positioned around the axis. The second bearing 419 can be coaxial with the second hole 418. The second hole 418 can have some of the same dimensions as the first hole 318 in Figure 1 , such as the same inner diameter. Similarly, the first hole 318 can be located on and opposite to the second hole 418 on the other side of the shaft 212. The second bearing 419 can surround and rotatably support the second half shaft. Similarly, the second hole 418 can receive and rotatably support the second half shaft. When the second half shaft is received by the second hole 418, its extending direction can be opposite to that of the first half shaft received by the first hole 318. The second half shaft and the first half shaft can be drivingly connected to one of a plurality of wheels (such as the second wheel 114 in

[0047] ) on opposite sides of the axis 212.The third housing member 412 of the second differential housing assembly 402 may have a mounting support 414. The mounting support 414 may be positioned around the pinion nose 320. The mounting support 414 may be along and relative to axis 212 between the flange and the interface 316. The mounting support 414 may have a first web 422 closest to the first side 304 and a second web 424 closest to the second side 306. The first web 422 and the second web 424 may be formed between a first cross beam 426 and a second cross beam 427. The first cross beam 426 may be located at the top of the third housing member 412. The second cross beam 427 may be located at the bottom of the third housing member 412. The first cross beam 426 may include a first flange 420 and a second flange 421. The second cross beam 427 may include a third boss 423 and a fourth boss 425. The first web 422 may be located between the first boss 420 and the third boss 423. The second web 424 may be located between the second flange 421 and the fourth boss 425. The first web 422 and the second web 424 may be materially connected to or formed by the first housing member 312.

[0048] The third housing member 412 of the second differential housing assembly 402 may be mounted to a vehicle, such as vehicle 100, by a second bracket 428 and a third bracket 430. The second bracket 428 and the third bracket 430 may be the first and second side mounting brackets of the third housing member 412, respectively. The second bracket 428 may be mounted to a component or feature of the vehicle by a third fastener 432. The third bracket 430 may be mounted to a component or feature of the vehicle by a fourth fastener 434. A plurality of fasteners may secure the second bracket 428 to the mounting support 414. Each of these plurality of fasteners may be threaded or passed through complementary holes extending through the material of the second bracket 428 and complementary holes extending through the material of the mounting bracket 414. Similarly, a plurality of fasteners may secure the third bracket 430 to the mounting support 414. Each of these plurality of fasteners may be threaded or passed through complementary holes extending through the material of the third bracket 430 and through complementary holes extending through the material of the mounting support 414. In one example, the second bracket 428 may be a first wing and the third bracket 430 may be a second wing symmetrically opposite the first wing, with the first wing and the second wing configured to be mounted to the vehicle chassis.

[0049] In one example, the second bracket 428 can be secured to the first web 422 by at least a fifth fastener 436. The third bracket 430 can be secured to the second web 424 by at least one sixth fastener 438. The fifth fastener 436 can extend through complementary holes in the second bracket 428 and a first complementary hole 437 in the mounting bracket 414. The sixth fastener 438 can extend through complementary holes in the third bracket 430 and a second complementary hole 439 in the mounting bracket 414. The first complementary hole 437 can be a through hole extending through the material of the first boss 420. The second complementary hole 439 can be a through hole extending through the material of the second boss 421. The first complementary hole 437 and the second complementary hole 439 can each have a centerline that is generally parallel to the axis 212. Additionally, there can be a third complementary hole 441 extending through the material of the fourth boss 425. The third complementary hole 441 can be a through hole. The third complementary hole 441 can be complementary to an additional fastener of the third bracket 430. The additional fastener of the third bracket 430 can extend through the complementary hole of the third bracket 430 and the third complementary hole 441 to secure the third bracket 430 to the mounting support 414. The third complementary hole 441 can have a centerline that is generally parallel to the second complementary hole 439. There can be an additional complementary hole extending through the third boss 423. The additional complementary hole can be a through hole that is complementary to an additional fastener of the second bracket 428. The additional fastener of the second bracket 428 can extend through the complementary hole of the second bracket 428 and the additional complementary hole of the third boss 423.

[0050] However, it can be understood that the number of fasteners, complementary holes in the second bracket 428, and complementary holes in the mounting bracket 414 used to secure the second bracket 428 to the mounting bracket 414 can be unrestricted. Compared with Figure 3 the embodiment of the second differential housing assembly 402 shown in, the number of fasteners, complementary holes in the second bracket 428, and complementary holes in the mounting support 414 used to secure the second bracket 428 to the mounting support 414 can be more or less. Similarly, it can be understood that the number of fasteners, complementary holes in the third bracket 430, and complementary holes in the mounting support 414 used to fasten the third bracket 430 to the mounting support 414 can be unrestricted. Compared with Figure 3 the embodiment of the second differential housing assembly 402 shown in, the number of fasteners, complementary holes in the third bracket 430, and complementary holes in the mounting support 414 used to fasten the third bracket 430 to the mounting support 414 can be more or less.

[0051] In addition, the third housing member 412 may have a plurality of ribs and other structures that can mechanically support and distribute mechanical energy through the third housing member 412. For example, the third housing member 412 may have a sixth rib 440, a seventh rib 442, an eighth rib 444, and a ninth rib 446 around the axis 212. The lengths of the sixth rib 440, the seventh rib 442, the eighth rib 444, and the ninth rib 446 may be substantially parallel to the axis 212. The sixth rib 440, the seventh rib 442, the eighth rib 444, and the ninth rib 446 may extend between and be connected to or formed of the material of the first carrier portion 321 and the mounting bracket 414. The sixth rib 440 and the seventh rib 442 may be connected to one face of the first cross member 426. Similarly, the eighth rib 444 and the ninth rib 446 may be connected to the second web 424. Between the eighth rib 444 and the ninth rib 446, a partial ring 448 may be bent around the axis 212 and the third housing member 412. The partial ring 448 may be connected to or formed of the material of the third housing member 412. The partial ring 448 may provide mechanical support for the eighth rib 444, the ninth rib 446, the second web 424, the pinion nose 320, and the first carrier portion 321.

[0052] The third housing member 412 may be fastened to the second housing member 314 at the interface 316 by a plurality of fasteners to form the second differential housing assembly 402. In one embodiment, the second housing member 314 may be fastened to the third housing member 412 at the interface 316 by a seventh fastener 452, an eighth fastener 454, a ninth fastener 456, a tenth fastener 458, an eleventh fastener 460, and a twelfth fastener 462. The seventh fastener 452, the eighth fastener 454, the ninth fastener 456, the tenth fastener 458, the eleventh fastener 460, and the twelfth fastener 462 may be positioned around the axis 212 and extend through complementary holes in the second housing member 314 and the third housing member 412. The complementary holes may be located on the third flange 348 of the second housing member 314 and the second flange 346 of the third housing member 412. Similarly, in one embodiment, the second housing member 314 may be fixed to the first housing member 312 by the seventh fastener 452, the eighth fastener 454, the ninth fastener 456, the tenth fastener 458, the eleventh fastener 460, and the twelfth fastener 462.

[0053] In one embodiment, the first bracket 326 can be fixed to the second housing member 314 by the thirteenth fastener 472, the fourteenth fastener 474, and the fifteenth fastener 476. The thirteenth fastener 472, the fourteenth fastener 474, and the fifteenth fastener 476 can respectively extend through complementary holes in the first bracket 326 and complementary holes in the second housing member 314. For example, the thirteenth fastener 472, the fourteenth fastener 474, and the fifteenth fastener 476 can pass through respective complementary holes in the first bracket 326 and the second housing member 314. When the 13th fastener 472, the 14th fastener 474, and the 15th fastener 476 are threaded, the first bracket 326 can be fastened to the second housing member 314.

[0054] Returning to the mounting bracket 414, the first crossbeam 426 portion of the mounting bracket 414 can have a first cavity 482a and a second cavity 482b. The first cavity 482a and the second cavity 482b can have an opening at the top of the first crossbeam 426 and extend downward through the material of the first crossbeam 426. The fifth rib 484 can separate the first cavity 482a from the second cavity 482b. The first cavity 482a can be closest to the first side 304 of the fifth rib 484. The second cavity 482b can be closest to the second side 306 of the fifth rib 484.

[0055] The third fastener 432 can have a third head 486. The fourth fastener 434 can have a fourth head 488. The third head 486 and the second bracket 428 can engage features of the bracket to which the third fastener 432 is fixed. The second bracket 428 can have a first indentation 490 that can support the features of the bracket. The fourth head 488 and the third bracket 430 can engage features of the mount to which the fourth fastener 434 can be fastened. The third bracket 430 can have a second indentation 492 that can support the features of the bracket. The fourth fastener 434 can be fixed to the third bracket 430 by a nut 494. Similarly, the third fastener 432 can be fixed to the second bracket 428 by a nut.

[0056] In this way, a rear differential carrier system with a split housing is provided, the housing consisting of a first housing part and a second housing part. The rear differential carrier can be mounted on a vehicle. The first housing can be a front housing closest to the front end of the vehicle compared to the second housing. The second housing can be a rear housing closest to the rear end of the vehicle compared to the first housing. The rear differential carrier can accommodate a rear differential on the vehicle's rear axle. The first housing and the second housing can be fixed at the interface to enclose the components of the rear differential. The first housing and the second housing can be fixed by a plurality of fasteners that can pass through complementary holes in a first flange of the first housing and a second flange of the second housing. The first flange and the second flange can share surface contact at the interface. The rear differential carrier can have two holes, each of which supports a half shaft of the axle. In one example, the rear differential carrier can be mounted to a component of the vehicle by a mounting bracket fixed to the first housing and a single bracket fixed to the second housing. In another example, the rear differential carrier can be mounted to a component of the vehicle by first and second side mounting brackets fixed to the first housing and a single bracket fixed to the second housing.

[0057] The first housing can include a pinion nose configured to receive an output from a mover to drive a coupling and transfer rotational energy to the rear differential by torque.

[0058] A vehicle equipped with a rear differential carrier can, to some extent, have both all-wheel drive and all-wheel drive simultaneously. The all-wheel drive is provided by the rear differential on the rear differential carrier. The all-wheel drive is provided by a front differential mounted on a front differential carrier. The front differential and the rear differential can provide all-wheel drive and all-wheel drive as part of the vehicle's all-wheel drive mode.

[0059] The technical effect of the disclosed system is that a durable and compact layout design can be achieved with fewer mounting brackets.

[0060] The present disclosure also provides support for a system that includes: a split differential housing that is bisected at an axis in a vertical plane, the split differential housing including a first housing component that is coupled to a second housing component at an interface located at the center of the vertical plane, wherein the axis is coaxial with the central axis of a drive shaft. In a first example of the system, the first housing component includes a pinion nose and a mounting bracket positioned around the pinion nose, the mounting bracket being coupled to a first wing and a second wing that is symmetrically opposite the first wing. In a second example of the system, optionally including the first example, the first wing and the second wing are configured to be mounted to a vehicle chassis. In a third example of the system, optionally including one or both of the first and second examples, the first housing component includes a pinion nose portion that is configured to be connected to a mounting frame. In a fourth example of the system, optionally including one or more or each of the first through third examples, the second housing component includes a bracket arranged opposite the interface, the bracket being configured to be mounted to the vehicle chassis by a first fastener and a second fastener. In a fifth example of the system, optionally including one or more or each of the first through fourth examples, the first housing component includes a first carrier portion and the second housing component includes a second carrier portion, the first carrier portion and the second carrier portion being configured to enclose the gear components of the differential. In a sixth example of the system, optionally including one or more or each of the first through fifth examples, the split differential housing further includes a carrier portion configured to enclose the differential gear components, wherein the carrier portion is bisected between the first housing component and the second housing component. In a seventh example of the system, optionally including one or more or each of the first through sixth examples, the interface is a split line seam centered on a plane parallel to the central axes of a first axle half shaft mount and a second axle half shaft mount. In an eighth example of the system, optionally including one or more or each of the first through seventh examples, the longitudinal length of the first housing component is greater than the longitudinal length of the second housing component. In a ninth example of the system, optionally including one or more or each of the first through eighth examples, the split differential housing is a rear axle carrier.

[0061] The present disclosure also provides support for a drive axle that includes: a differential device coupled to a first axle half shaft and a second axle half shaft, the first axle half shaft and the second axle half shaft rotating about a rotational axis, and a split differential housing that encloses and rotatably supports the differential device, the split differential housing being split in half in a vertical plane axially aligned with the rotational axis. In a first example of the system, the split differential housing includes a first housing member that is connected to a second housing member at an interface located at the center of the vertical plane. In a second example of the system, optionally including the first example, the drive axle is a rear drive axle. In a third example of the system, optionally including one or both of the first and second examples, the drive axle is a rear drive axle in an all-wheel drive configuration. In a fourth example of the system, optionally including one or more or each of the first through third examples, the first housing member includes a pinion nose end on which a first fin and a second fin are mounted, the first fin and the second fin being configured to connect to a vehicle chassis.

[0062] The present disclosure also provides support for a system that includes: a drive axle including a differential unit, and a split differential housing that includes a first housing member coupled to a second housing member, and a first axle half shaft mount and a second axle half shaft mount configured to rotatably support the drive axle, wherein the first axle half shaft mount and the second axle half shaft mount are split between the first housing member and the second housing member. In a first example of the system, the split differential housing is coupled at the center of an interface in a vertical plane parallel to the center axis of the drive axle. In a second example of the system, optionally including the first example, the system further includes: a first bearing concentric with the first axle half shaft mount and a second bearing concentric with the second axle half shaft mount. In a third example of the system (optionally including one or both of the first and second examples), the longitudinal length of the first bearing housing member is greater than the longitudinal length of the second bearing housing member. In a fourth example of the system, optionally including one or more or each of the first through third examples, the split differential housing is configured to house a rear-mounted differential of a vehicle.

[0063] In another formulation, a system for a front-wheel drive transmission system includes a rear differential device for providing all-wheel drive operation, the rear differential device being mounted in a split housing assembly that includes a first housing portion that is fastened to a second housing portion at an interface centered about the center axis of the rear drive axle, wherein a first side mounting bracket and a second side mounting bracket are connected to the first housing portion, and a center bracket is connected to the second housing portion.

[0064] It will be understood that the configurations disclosed herein are exemplary in nature and these specific examples are not limiting as many variations are possible. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0065] The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to "a" element or "a first" element or the equivalent thereof. These claims are to be understood to include one or more such elements, neither requiring nor precluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and / or properties may be claimed by modifying the present claims or presenting new claims in this or a related application. These claims, whether broader, narrower, the same, or different in scope from the original claims, are also regarded as included in the subject matter of the present disclosure.

Claims

1. A split differential housing system, characterized in that: include: The split differential housing is divided into two at an axis on a vertical plane, and the split differential housing includes a first housing component, which is coupled to a second housing component at an interface located at the center of the vertical plane, wherein the axis is coaxial with the central axis of the drive axle.

2. The system of claim 1, wherein the first housing component includes a pinion nose and a mounting bracket disposed about the pinion nose, the mounting bracket being connected to a first wing and a second wing symmetrically opposite the first wing.

3. The system of claim 2, wherein the first wing and the second wing are configured to be mounted on a vehicle chassis.

4. The system of claim 1, wherein the first housing component includes a pinion nose configured to couple with a mounting frame.

5. The system of claim 1, wherein the second housing component comprises a bracket disposed opposite the interface, the bracket being mounted to the vehicle chassis via a first fastener and a second fastener.

6. The system of claim 1, wherein: The first housing component includes a first carrier portion and the second housing component includes a second carrier portion, the first carrier portion and the second carrier portion accommodating a gear component of a differential.

7. The system of claim 1, said split differential housing further comprising a carrier portion that houses a gear component of the differential, wherein said carrier portion is bisected between said first housing component and said second housing component.

8. The system of claim 1, wherein the interface is a split line seam centered on a plane parallel to a central axis of the first shaft half-shaft mount and the second shaft half-shaft mount.

9. The system of claim 1, wherein a longitudinal length of the first housing component is greater than a longitudinal length of the second housing component.

10. The system of claim 1 wherein the split differential housing is a rear axle carrier.

11. A drive axle, characterized in that: include: a differential device connected to the first shaft half-shaft and the second shaft half-shaft, the first shaft half-shaft and the second shaft half-shaft rotating on the rotating shaft; as well as The split differential housing surrounds and rotatably supports the differential device, and the split differential housing is divided into two parts on a vertical plane aligned with the axial direction of the rotating shaft.

12. The drive axle of claim 11 wherein the split differential housing includes a first housing member connected to a second housing member at an interface centered in a vertical plane.

13. The drive axle of claim 11, wherein the drive axle is a rear drive axle.

14. The drive axle of claim 11, wherein the drive axle is a rear drive axle in an all-wheel drive configuration.

15. The drive axle of claim 12, wherein the first housing member includes a pinion nose having first and second wings mounted thereon, the first and second wings being connected to a vehicle chassis.

Images