Axle assembly with differential assembly with inverted differential bearings

Abstract

Axle assembly (36), comprising: a housing assembly (50) comprising a support housing (60) and a pair of axle tubes (62), wherein the support housing (60) has a support body (70) and a pair of tube supports (72) arranged on opposite transverse sides of the support body (70), the support body (70) having a wall defining a cavity and a pair of partitions (84), each of the partitions (84) being integrally, uniformly and inseparably formed with a remaining part of the wall and defining a through-hole (96) with a set of internal threads, the tube supports (72) being in fluid communication with the through-holes (96) and the cavity (80), each of the axle tubes (62) being received in one of the associated tube supports (72) and being rigidly connected to the support housing (60); a differential assembly (54) which is received in the cavity (80) and has a differential housing (130) with opposing transverse ends, wherein a bearing bore (160) is formed in each of the opposing transverse ends of the differential housing (130); a pair of differential bearings (162), each of the differential bearings (162) having an outer bearing race which is received in one of the associated bearing bores (160) and is coupled to the differential housing (130); A pair of bearing adjustment devices (210), each bearing adjustment device (210) having a threaded part (222) and a bearing support part (224), the threaded part (222) being threaded in engagement with the internal threads of an associated partition wall (84), the bearing support part (224) being arranged at a first end of the bearing adjustment device (210) opposite a second end on which the threaded part (222) is formed, the bearing support part (224) defining a projection (232) against which an associated differential bearing (162) rests, the bearing support part (224) supporting one side of the associated differential bearing (162) opposite the differential housing (130) such that each differential bearing is in a side-by-side relationship with the differential housing (130) and the associated bearing adjustment devices (210). is, wherein each of the bearing adjustment devices (210) further comprises a locking element (228) which is arranged axially between the associated differential bearing (162) and the second end, wherein the locking element (228) comprises a plurality of locking elements (240), wherein the axle assembly (36) has a pair of adjusting device locking elements (300), each of the adjusting device locking elements (300) being received into a corresponding locking element opening (88) formed in the wall of the support body (70), and with matching locking elements (304) engaging with a part of the locking elements (240) formed on the associated bearing adjusting devices (210).

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] This application claims the benefits of the preliminary US application No. 61 / 983,092, filed on April 23, 2014, the disclosure of which is incorporated herein by reference as set forth in its entirety. AREA

[0002] The present disclosure relates to an axle assembly with a differential assembly having inverted differential bearings. BACKGROUND

[0003] This section provides background information relating to the present disclosure, which may not necessarily reflect the state of the art.

[0004] In off-road applications, solid axle assemblies are considered to offer advantages over other axle types when operating in certain types of terrain, such as rock crawling. These advantages include increased durability as well as greater flexibility of the entire axle assembly when traversing uneven terrain. This allows the differential position to be adjusted as a function of the axle assembly's wheel position, thus better preventing contact between an obstacle and the differential housing. While existing solid axle assemblies are satisfactory for their intended use, the need for an improved solid axle remains in engineering.

[0005] Document US 8,534,925 B1 discloses an axle assembly comprising an axle housing, a casing, a bearing, a hollow bearing adjuster, and a locking system. SUMMARY

[0006] This section provides a general summary of the revelation and is not a comprehensive revelation of its entire scope or all of its properties.

[0007] In one form, the present disclosure provides an axle assembly comprising a housing assembly, a differential assembly, a pair of differential bearings, and a pair of bearing adjusting devices. The housing assembly has a support housing and a pair of axle tubes. The support housing has a support body and a pair of tube supports arranged on opposite transverse faces of the support body. The support body has a wall defining a differential cavity and a pair of partitions. Each of the partitions is integrally, uniformly, and inseparably formed with a remaining portion of the wall and defines a through-hole with a set of internal threads. The tube supports are in fluid communication with the through-holes and the differential cavity. Each of the axle tubes is received in an associated tube support and is rigidly connected to the support housing.The differential assembly is housed in the cavity and has a differential housing with opposing transverse ends. A bearing bore is formed in each of the opposing transverse ends of the differential housing. Each differential bearing has an outer bearing race that is received in an associated bearing bore and engages with the differential housing. Each bearing adjuster has a threaded portion and a bearing support portion. The threaded portion engages with the internal threads of an associated partition. The bearing support portion is located on a first end of the bearing adjuster, opposite a second end on which the threaded portion is formed. The bearing support portion defines a projection against which an associated differential bearing rests.The bearing support part supports one side of the associated differential bearing, which is opposite the differential housing such that each differential bearing is in a side-by-side relationship with the differential housing and an associated bearing adjustment device. Each bearing adjustment device further comprises a locking element arranged axially between the associated differential bearing and the second end, the locking element comprising a plurality of locking elements. The axle assembly further comprises a pair of adjustment device locking elements. Each adjustment device locking element is received in a corresponding locking element opening formed in the wall of the support body and engages with mating locking elements formed on the associated bearing adjustment device.

[0008] In another form, the present disclosure provides an axle assembly comprising a housing assembly, a differential assembly, a pair of differential bearings, and a pair of bearing adjusting devices. The housing assembly has a support housing and a pair of axle tubes. The support housing has a support body and a pair of tube supports arranged on opposite transverse faces of the support body. The support body has a wall defining a differential cavity and a pair of partitions. Each of the partitions is integrally, uniformly, and inseparably formed with a remaining portion of the wall and defines a through-hole with a set of internal threads. The tube supports are in fluid communication with the through-holes and the differential cavity. Each of the axle tubes is received in an associated tube support and is rigidly connected to the support housing.The differential assembly is housed in the cavity and has a differential housing with opposing transverse ends. A bearing bore is formed in each of the opposing transverse ends of the differential housing. Each differential bearing has an outer bearing race that is received in an associated bearing bore and engages with the differential housing. Each bearing adjuster has a threaded portion and a bearing support portion. The threaded portion engages with the internal threads of an associated partition. The bearing support portion is located on a first end of the bearing adjuster, opposite a second end on which the threaded portion is formed. The bearing support portion defines a projection against which an associated differential bearing rests.The bearing support part supports one side of the associated differential bearings, which is opposite the differential housing such that each differential bearing is in a side-by-side relationship with the differential housing and an associated bearing adjustment device. Each bearing adjustment device comprises a first tool coupling element configured to engage with a tool to allow the bearing adjustment device to be rotated relative to the support housing, each bearing adjustment device comprising a second tool coupling element that is different from the first tool coupling element. The second tool coupling element is configured to engage with a further tool to allow the bearing adjustment device to be rotated relative to the support housing.

[0009] In another form, the present disclosure provides an axle assembly comprising an axle housing, a differential assembly, a first differential bearing, a first bearing adjusting device, and an adjusting device lock. The housing assembly has a support housing, a pair of axle tubes, and a cover. The support housing has a support body and a tube support. The support body has a wall defining a cavity, a first partition, a cover flange, and a locking element opening. The first partition is integrally formed, uniform, and inseparably with a remaining portion of the wall and defines a through-hole with a set of internal threads. The cover flange delimits an open side of the cavity and has a flange element. The locking element opening is formed by the cover flange and intersects the cavity.The pipe support is in fluid connection with the through-bore and the differential cavity. The axle tube is received in the pipe support and is rigidly connected to the carrier housing. The differential assembly is received in the cavity and has a differential housing with opposing transverse ends. A bearing bore is formed in one of the transverse ends of the differential housing. The first differential bearing has an outer bearing race that is received in the bearing bore and coupled to the differential housing. The first bearing adjuster has a threaded portion, a bearing support portion, and a portion for the adjuster lock. The threaded portion engages with the internal threads of the first partition. The adjuster lock portion is arranged axially between opposing axial ends of the first bearing adjuster and has a plurality of circumferential, spatially separated locking elements.The adjusting device locking element is received in the locking element opening and has a plurality of matching locking elements that engage with a portion of the locking elements on the first bearing adjusting device. The cover engages sealingly with the flange element and rests against the adjusting device locking element to limit movement of the adjusting device locking element in the adjusting device locking opening in a direction away from the first bearing adjusting device.

[0010] Further areas of application will become apparent from the descriptions provided here. The descriptions and specific examples in this summary are intended for illustrative purposes only and are not meant to limit the scope of protection of this disclosure. DRAWINGS

[0011] The drawings described herein serve only to illustrate selected embodiments and not all possible implementations, and are not intended to limit the scope of protection of the present disclosure. Fig. Figure 1 is a schematic representation of a vehicle with exemplary axle assemblies constructed in accordance with the teaching of the present disclosure; Fig. Figure 2 is a perspective view from below of part of the vehicle. Fig. 1, which illustrates the rear axle assembly in detail; Fig. Figure 3 is a perspective exploded view from below of the rear axle assembly; Fig. Figure 4 is a sectional view of part of the rear axle assembly, extending along line 4-4 from Fig. 2 was taken; Fig. Figure 5 is a perspective exploded view of part of the rear axle assembly, showing part of the differential assembly and the locking mechanism in detail; Fig. Figure 6 is a perspective view of part of the rear axle assembly, showing in detail a bearing adjustment device and an adjustment device lock; Fig. Figure 7 is a perspective view of the adjustment device lock; Fig. Figure 8 is a sectional view of a portion of the rear axle assembly, extending along line 8-8 from Fig. 2 was taken; Fig. Figure 9 is a perspective view of a part of the rear axle assembly, which shows a part of a carrier housing in detail; Fig. Figure 10 is a perspective view of part of the rear axle assembly, showing an inner part of the carrier housing in detail; Fig. Figure 11 is a perspective, partially cut-away view of a lower part of the rear axle assembly.

[0012] Corresponding reference symbols indicate corresponding parts through all views of the drawings. DETAILED DESCRIPTION

[0013] With reference to Fig. Figure 1 of the drawings shows an exemplary vehicle 10 having a power transmission path 12 and a drive train 14. The power transmission path 12 can include a drive engine 20 and a transmission 22. The drive engine 20 can be an internal combustion engine or an electric motor and can be configured to provide rotational power to the transmission 22. The transmission 22 can be any type of transmission, such as a manual, automatic, or continuously variable transmission, and can be configured to provide rotational power to the drive train 14.

[0014] The drivetrain 14 can comprise a transfer case 32, a rear driveshaft 34, a rear axle assembly 36, a front driveshaft 38, and a front axle assembly 40. The transfer case 32 can receive rotational power from the transmission 22. The rear driveshaft 34 can be driven by a rear output 42 of the transfer case 32 and can transmit rotational power to the rear axle assembly 36. The rear axle assembly 36 can be configured to transmit rotational power to a set of vehicle rear wheels 44. The front driveshaft 38 can be driven by a front output 46 of the transfer case 32 and can transmit rotational power to the front axle assembly 40. The front axle assembly 40 can be configured to transmit rotational power to a set of vehicle front wheels 48.The rear and front axle assemblies 36 and 40 can be constructed in accordance with the teaching of the present disclosure. Since the front axle assembly 40 is generally similar to the rear axle assembly 36, only the rear axle assembly 36 is discussed in detail here.

[0015] With reference to Fig. 2 and Fig. Figure 3 shows the rear axle assembly 36 in detail. The rear axle assembly 36 can comprise a housing assembly 50, a drive pinion 52, a differential assembly 54, a ring gear 56, and a locking mechanism 58.

[0016] The housing assembly 50 can comprise a support housing 60, a pair of axle tubes 62, and a housing cover 64. The support housing 60 can be formed from any suitable material, such as an A206 aluminum alloy material (e.g., 206-T4, 206-T7), and can define a body part 70 and a pair of tube supports 72.

[0017] With regard to the Fig. 3 and Fig. 4. The body part 70 can define a cavity 80 configured to receive the differential assembly 54. The body part 70 can include a pinion support part 82, a pair of partitions 84, a first flange 86, and a pair of locking brackets 88. The pinion support part 82 is configured to receive a pair of pinion bearings 92 that support a shaft portion of the drive pinion 52 for rotation about a first axis 94 relative to the carrier housing 60. Each of the partitions 84 can be formed uniformly and integrally with a remainder of the carrier housing 60 such that they cannot be removed from the remainder of the carrier housing 60. Each of the partitions 84 can define a threaded opening 96 that can be arranged concentrically about a second axis 98 with one of the associated tube brackets 72.The first flange 86 is configured to interact with the housing cover 64 to close the cavity 80, and as such, the first flange 86 can generally extend around the circumference of the cavity 80. In the provided example, the first flange 86 also extends over the locking brackets 88. Each of the locking brackets 88 can define a recess that can extend through the first flange 86 at a location between one of the associated partitions 84 and the cavity 80. In the particular example provided, a partition 100 on the first flange 86 separates each of the locking brackets 88 from the cavity 80, but it is understood that the recesses defined by the locking brackets 88 could intersect the portion of the cavity 80 formed by the first flange 86.

[0018] The pipe supports 72 can be arranged on opposite transverse sides of the body part 70, and each of the pipe supports 72 can be configured to receive one of the associated axle tubes 62, for example in a press-fit manner. If desired, the axle tubes 62 can be attached to the pipe supports 72 in a manner, such as slug welding, which prevents axial movement of the axle tubes 62 relative to the pipe supports 72.

[0019] The housing cover 64 can be removably connected to the body part 70 of the support housing 60, essentially closing the cavity 80 formed in the body part 70. The housing cover 64 can define a second flange 110, a pair of abutment elements 112, and an actuator bracket 114. The second flange 110 can be configured to interact with the first flange 86 on the body part 70 to form a sealing connection. It is understood that a gasket (not explicitly shown) or sealing material can be incorporated between the first and second flanges 86 and 110 to form a seal between them. The abutment elements 112 can be configured in any desired way and can be arranged in series with the locking brackets 88 when the housing cover 64 is installed on the support housing 60.In the provided example, the abutment elements 112 are formed together with the second flange 110 such that the portions of the inner surface of the housing cover 64 defined by the second flange 110 and the abutment elements 112 are coplanar. It is understood, however, that the abutment elements 112 can be designed differently and that they can extend on either side of the plane defined by the inside of the second flange 110. The actuator bracket 114 can define a mounting flange 118 that can delimit an actuator opening 120 extending through the housing cover 64 and configured to provide a means for part of the locking mechanism 58 to access the structure mounted in the cavity 80. Part of the locking mechanism 58 can be secured to the housing cover 64 via the actuator bracket 114, as described in more detail below.

[0020] The differential assembly 54 can comprise a differential housing assembly 130, a pair of output elements 132, and a means 134 for transmitting force. The output elements 132 are rotatably arranged about the second axis 98 and can be driven by a pair of axle shafts (not explicitly shown).

[0021] With regard to the Fig. 4 and Fig. 5. The differential housing assembly 130 can comprise a housing body 140 and a cap 142, which can be firmly connected to each other by any desired means, including screw connectors. In the particular example provided, the cap 142 is welded to the housing body 140. The housing body 140 and the cap 142 can work together to define a differential cavity 146, which can accommodate the output elements 132, part of the locking mechanism 58, and the means 134 for transmitting force. The housing body 140 can have an annular housing wall 148, dimensioned to be received by the toothed ring 56, and a flange element 150, which can extend radially outward from the housing wall 148.The toothed ring 56 can be mounted on the flange element 150 in any desired manner, such as by means of a variety of screw connectors or by welding, and can mesh with the drive pinion 52 ( . Fig. 3) In the particular example provided, the ring gear 56 and the drive pinion 52 ( Fig. 3) aligned in the carrier housing 60 to form a hypoid gear with “high offset” in which the first axis 94 is arranged vertically above the second axis 98.

[0022] As in Fig. As best illustrated in Figure 4, the housing body 140 and the cap 142 can define bearing mounts 160 for a pair of differential bearings 162. In the particular example provided, each of the bearing mounts 160 is formed by recesses formed in the annular wall element 148 and the cap 142. The recesses define an outer annular wall element 166 and a projection 168. The recesses accommodate the differential bearings 162 such that the outer bearing race of each differential bearing 162 engages with the outer annular wall 166 and rests against the projection 168 of a corresponding recess. Constructing the differential housing assembly 130 in this manner (i.e., with inverted differential bearings) reduces the width of the differential housing assembly 130 compared to a conventionally constructed and assembled differential housing design.

[0023] With regard to the Fig. 3 and Fig. 5. The means 134 for power transmission can be any type of device or mechanism for transmitting rotational power between the differential housing assembly 130 and the output elements 132 and can include one or more clutches and / or differential gears. In the provided example, the means 134 for power transmission includes a differential gear with first and second helical axle gears 180 and 182 and a plurality of differential pinion sets 184. The first and second helical axle gears 180 and 182 can be accommodated in the differential cavity 146 and can be connected to the output elements 132 for common rotation about the second axis 98. The differential gear can be constructed with any number of differential pinion sets 184, but in the particular provided example, the differential gear has six (6) differential pinion sets 184.Each differential gear set 184 can have a first differential gear 190, a second differential gear 192, and a pair of brake shoes 194. The first differential gears 190 can be accommodated in first gear cavity parts 200 of the differential cavity 146 and can have helical teeth that mesh with the teeth of the first helical axle gear 180. The second differential gears 192 can be accommodated in second gear cavity parts 202 of the differential cavity 146. Each of the second differential pinions 192 can have helical teeth that can mesh with the teeth of the second helical axle shaft gear 182, as well as with the teeth of a corresponding first differential pinion 190. Each of the brake shoes 194 can be mounted on a shaft end 206 (. Fig. 3) a corresponding first and second differential pinions 190 and 192 can be accommodated and can be accommodated in an associated first and second cavity parts 200 and 202 to engage non-rotatably with the housing body 140 or the cap 142.

[0024] It is understood that welding the cap 142 to the housing body 140 could create deformations in the housing body 140, which could each affect the engagement of the first and second differential pinions 190 and 192 with the surfaces of the first and second cavity parts 200 and 202. In the particular example provided, the weld seam W ( Fig. 3) axially offset between the cap 142 and the housing body 140 and radially extending outwards from the first and second cavity parts 200 and 202 to reduce the risk of deformation caused by welding the cap 142 onto the housing body 140.

[0025] With regard to the Fig. 4 and Fig. 6 A pair of differential bearing adjusting devices 210 can be used to provide axle necks 212 on which the differential housing assembly 130 can rotate relative to the carrier housing 60, as well as to preload the differential bearings 162 and to position the differential housing assembly 130 in a lateral direction to ensure the engagement of the ring gear 56 with the drive pinion 52 ( Fig. 3) to effect. Each of the differential bearing adjusting devices 210 can define a central opening 220, which can extend longitudinally through the differential bearing adjusting devices 210, a housing coupling part 222, a bearing coupling part 224, a tool coupling part 226, and a locking part 228. The housing coupling part 222 can include an external threaded segment that can engage in threaded engagement with the threaded opening 96 in a corresponding partition 84 in the body part 70 of the support housing 60. The bearing coupling part 224 can include the axle neck 212, which is designed to engage with the inner bearing race of an associated differential bearing 162, and a projection 232, which is designed to bear against the inner bearing race of the associated differential bearing 162.The tool engagement element 226 is designed to engage with a tool (not shown) to allow a technician to rotate the differential bearing adjusting devices 210 relative to the carrier housing 60. In the particular example provided, the tool engagement element 226 comprises a hexagonal opening 236, which is aligned with a portion of the central opening 220 and is configured to engage with a suitably shaped tool, and a plurality of holes 238, spaced circumferentially, extending radially outward from the housing coupling part 222 over the projection 232. The former means of tool engagement may be suitable for mass production prior to the installation of the axle shafts (not explicitly shown), whereas the latter means of tool engagement may be suitable for repair or maintenance.It is understood, however, that redundant means for tool engagement need not be provided and that the means for tool engagement provided by the tool engagement element 226 could be designed differently. The locking part 228 can comprise a plurality of circumferentially spaced locking elements 240, which may be arranged around the circumference of the differential bearing adjusting devices 210. In the particular example provided, the locking elements 240 are designed in a negative manner (i.e., the locking elements 240 are defined by material that has been removed from or is not present on a portion of the differential bearing adjusting device 210), in which each of the locking elements 240 is a groove that generally extends parallel to a longitudinal axis of the differential bearing adjusting devices 210.However, experts understand that the locking elements 240 could be designed in a positive manner (i.e., the locking elements 240 can be defined by material present on a part of the differential bearing adjusting devices 210). The locking part 228 can be arranged axially along the length of the differential bearing adjusting devices 210 to be aligned with one of the locking brackets 88 in the carrier housing 60 when the differential assembly 54 is mounted on the carrier housing 60 and positioned laterally relative to the carrier housing 60 in a desired manner.

[0026] With regard to the Fig. 4, Fig. 6 and Fig. 7 A pair of adjusting device locks 300 can be used to prevent rotation of the differential bearing adjusting devices 210 relative to the carrier housing 60. Each of the adjusting device locks 300 can be formed from a suitable material, such as a plastic or powder metal material, and can have a locking body 302, a locking profile 304, and a locking flange 306. The locking body 302 is designed to be slidably inserted into the recess of one of the corresponding locking brackets 88 ( Fig. 3) to be received so that the adjusting device lock 300 is held in a predetermined position relative to the carrier housing 60. The locking profile 304 can be configured to engage with the differential bearing adjusting devices 210 to prevent rotational movement of one of the corresponding differential bearing adjusting devices 210 relative to the carrier housing 60. The locking profile 304 can comprise mating locking elements 310 that can engage with a portion of the locking elements 240 on one of the corresponding differential bearing adjusting devices 210. In the example provided, the locking profile 304 comprises a plurality of wedge elements configured to be received in a subgroup of the locking elements 240 that are aligned with the locking supports 88.The locking flange 306 can be dimensioned and positioned to contact the projection 232 on the differential bearing adjusting device 210 in order to prevent the adjusting device lock 300 from being fully inserted into the carrier housing 60 when the differential bearing adjusting device 210 is not positioned within predefined limits.

[0027] With additional reference to Fig. 8 The adjusting device locks 300 can be received in the locking brackets 88 so that the matching locking elements 310 on the locking profile 304 engage with the locking elements 240 on the differential bearing adjusting devices 210 when the differential bearing adjusting devices 210 have been positioned to preload the differential bearings 162 to a desired degree and to position the differential assembly 54 and the ring gear 56 laterally in the carrier housing 60 as desired.In situations where the differential bearing adjusting devices 210 are aligned relative to the carrier housing 60 such that the matching locking elements 310 engage matching with the locking elements 240, the outer ends 314 of the adjusting device locks 300 can be spaced from the abutment elements 112 in a desired manner so that the second flange 110 can be properly positioned relative to the first flange 86 (i.e. so that the housing cover 64 can be sealed against the carrier housing 60).In practice, a small gap can be arranged between the outer ends 314 of the adjusting device locks 300 and the abutment elements 112; however, the gap is relatively small, so that the adjusting device lock 300 cannot move relative to the differential bearing adjusting devices 210 and the housing cover 64 by an amount sufficient to allow the mating locking elements 310 to disengage from the locking elements 240. In situations where the differential bearing adjusting device 210 is oriented relative to the support housing 60 such that the mating locking elements 310 do not engage matingly with the locking elements 240, the outer ends 314 of the adjusting device locks 300 can be arranged at such a distance from the abutment elements 112 that the second flange 110 can be improperly positioned relative to the first flange 86 (i.e.,so that the housing cover 64 cannot be sealed against the carrier housing 60). A design in this way allows the adjusting device lock 300 to be "dropped" into the carrier housing 60 and eliminates the need for special assembly tools.

[0028] With further reference to Fig. 3. The height of the support housing 60 can be reduced by machining a plurality of surfaces 330 on the inside of the support housing 60 to ensure that there is a gap between the support housing 60 and the gear ring 56, and that the gap is smaller than would be possible with respect to superimposed tolerances and conventional casting tolerances to control the position of the inner surfaces 330. In the example provided, the gap between the inner surfaces 330 of the support housing 60 and the gear ring 56 is less than or equal to 2.0 mm (0.08 in), preferably less than or equal to 1.5 mm (0.06 in), and even more preferably less than or equal to approximately 1.0 mm (0.04 in).

[0029] With reference to Fig. 5. The locking mechanism 58 may comprise a first claw ring 350, a second claw ring 352, a plunger 354, a sleeve or locking collar 356, and an actuator assembly 358. The first and second claw rings 350 and 352 may be generally similar to the first and second claw rings described in detail in jointly assigned U.S. Patent No. 7,425,185, the disclosure of which is incorporated herein by reference, as fully detailed.In short, the first claw ring 350 can comprise a plurality of first front teeth formed on a surface of the second helical gear 182, which faces the cap 142, while the second claw ring 352 can be arranged between the first claw ring 350 and the cap 142 and can have a plurality of second front teeth and a plurality of locking elements 360 that can be received in locking recesses 362 formed by the cap 142. The locking elements 360 engage with the cap 142 to couple the second claw ring 352 to the cap 142 in a displaceable but non-rotatable manner.It is understood that coupling the second front teeth with the first, non-rotating front teeth couples the second helical axle gear 182 with the differential housing assembly 130, thereby locking the means 134 for power transmission and preventing a speed / torque difference between the output elements 132. The tappet 354 can comprise a plurality of legs 370 and a tappet body 372. Each of the legs 370 can be a pin-shaped structure that can be axially displaceably received in one of the locking recesses 362 in the cap 142 and bear against one of the locking elements 360. The tappet body 372 can be rigidly connected to the legs 370 and to the second claw ring 352. In the provided example, the plunger body 372 is formed from a metallic ring and a plastic material that is injection-molded around the metallic ring, the legs 370 and the locking elements 360 on the second claw ring 352 (i.e.h. connected in a holding manner). The legs 370 can be moved within the locking recesses 362 to position the second claw ring 352 in a first position in which the second front teeth are spaced apart from the first front teeth, so that rotation of the second helical axle gear 182 relative to the cap 142 is not restricted, and in a second position in which the second front teeth engage with the first front teeth to prevent rotation of the second helical axle gear 182 relative to the cap 142.

[0030] With regard to the Fig. 3 and Fig. 5. The locking sleeve 356 can be mounted on the differential housing, such as on the cap 142, and can be connected to the differential housing for common rotation. In the particular example provided, the locking sleeve 356 is non-rotatably connected to the cap 142 and is axially movable along the second axis 98 between a first sleeve position and a second sleeve position. In the particular example provided, the cap 142 defines a plurality of longitudinally extending ribs 380, and the locking sleeve 356 is profiled to match and slide along the ribs 380 but not rotate relative to the cap 142. The locking sleeve 356 can include a coupling surface 384 that can be firmly connected to the legs 370 of the plunger 354, and a circumferential groove 386.

[0031] The actuator assembly 358 may be similar to the actuator assembly disclosed in jointly pending and jointly assigned preliminary U.S. patent application No. 61 / 869,282, filed on August 23, 2013, entitled "Power Transmitting Component With Twin-Fork Actuator," the disclosure of which is incorporated herein by reference as detailed. In brief, the actuator assembly 358 may comprise an actuator housing 400, a motor 402, a gearbox 404, a threaded spindle (not expressly shown), a mounting rail 408, a fork rail (not expressly shown), a receiving assembly 412, a clutch fork 414, and a preload spring (not expressly shown). The actuator housing 400 is designed to accommodate at least some of the remaining components of the actuator assembly 358 and can be attached to the mounting flange 118 ( Fig. 3) the actuator holder 114 ( Fig. 3) be mounted to fit the actuator opening 120 ( Fig. 3) to close. The motor 402 can be an electric motor that can drive the threaded spindle through the gearbox 404. The mounting rail 408 and the fork rail can be rigidly connected to the actuator housing 400 and can generally be arranged parallel to a rotational and longitudinal axis of the threaded spindle. The mounting assembly 412 can be threaded in engagement with the threaded spindle and can have a receptacle and a retaining spring. The receptacle can be slidably mounted on the mounting rail 408 and the fork rail. The retaining spring can be arranged between the receptacle and the threaded spindle and can be designed to allow axial movement of the retaining spring relative to the receptacle in at least one direction. The coupling fork 414 can be slidably mounted on the fork rail and can have a pair of arms 420 that can be received in the circumferential groove 386 of the locking sleeve 356.The preload spring can be arranged on the fork rail between the clutch fork 414 and the receptacle. The preload spring can preload the clutch fork 414 along the fork rail in a predetermined direction relative to the receptacle assembly 412.

[0032] During operation, the motor 402 can be operated to drive the threaded spindle, thereby generating a corresponding movement of the receiving assembly 412 along the fork rail. A movement of the receiving assembly 412 in a first direction along the fork rail can generate a corresponding movement of the clutch fork 414, which can move the locking sleeve 356 (and thereby the plunger 354 and the second claw ring 352) towards the second sleeve position, such that the second claw ring 352 is moved to its second position.In the event that the movement of the clutch fork 414 in the first direction is stopped due to tooth-to-tooth contact of the second front teeth with the first front teeth, the preload spring can be compressed to allow the receiving assembly 412 to be positioned and to exert a force on the clutch fork 414 which causes the clutch fork 414 to move in the first direction (to generate a driving engagement of the second front teeth with the first front teeth) when the first front teeth have been rotatably positioned relative to the second front teeth in such a way as to allow the second claw ring 352 to move completely against the first claw ring 350.

[0033] The movement of the receiving assembly 412 in a second, opposite direction along the fork rail can generate a corresponding movement of the clutch fork 414, which can move the locking sleeve 356 (and thereby the plunger 354 and the second claw ring 352) towards the first sleeve position, such that the second claw ring 352 is moved to its first position. If the movement of the clutch fork 414 in the second direction is stopped due to a torque lock of the second front teeth with the first front teeth, the retaining spring can be compressed to allow the receiving assembly to be positioned and exert a force on the clutch fork 414, causing the clutch fork 414 to move in the second direction (to disengage the second front teeth from the first front teeth).

[0034] It is understood that the configuration of the bearing adjustment devices 210 shown herein allows the carrier housing 60 to be relatively narrow in width. For example, the locking sleeve 356 can be arranged concentrically around one of the differential bearings 162, so that the rear axle assembly 36 can be provided with locking capabilities without a corresponding need to widen the carrier housing 60. In this respect, at least a portion of the locking sleeve 356 can be radially aligned with at least a portion of one of the differential bearings 162, provided that the locking sleeve 356 is in at least one of the first or second sleeve positions such that a plane P, perpendicular to the second axis 98, extends through both the locking sleeve 356 and the differential bearing 162.

[0035] With renewed reference to the Fig. 1 and Fig. 3. Many of the components of the special rear axle assembly 36 described herein and shown in the accompanying drawings are configured so that they can also be used in the front axle assembly 40. Those skilled in the art understand that, because the output elements 132 of the differential assembly 54 must rotate in a common direction, the orientation of the carrier housing 60 must be rotated 180 degrees about the second axis 98 (i.e., mirrored about it) and optionally can be rotated 180 degrees about the first axis 94 (i.e., mirrored about it). In the special example provided, the carrier housing 60 is mirrored about both the first and second axes 94 and 98. A configuration in this way aligns the drive pinion 52 to receive rotational power from the transfer case 32 and also causes the drive pinion 52 and the ring gear 56 to mesh on an opposite lateral side of the first axis 94.A configuration of this kind also causes the ring gear 56 of the rear and front axle assemblies 36 and 40 to rotate in opposite directions (relative to the carrier housing 60). The latter point is significant because the ring gear 56 of the rear axle assembly 36 is used to provide lubrication to the pinion bearings 92 via splash lubrication. Splash lubrication involves the rotation of the ring gear 56 by means of a lubricant-containing oil pan in the carrier housing 60 and the subsequent outward flinging of the lubricant from the ring gear 56 due to centrifugal force as the ring gear 56 rotates in a predetermined direction (which corresponds to the operation of the vehicle in a predetermined, e.g., forward, direction).Typically, lubricant flung from a gear ring 56 via lubricant channels can be directed in a desired manner to lubricate various bearings within the rear axle assembly 36. However, if the direction of rotation of the gear ring 56 relative to the carrier housing 60 is changed, the lubricant flung from the gear ring 56 will run in a different direction relative to the carrier housing 60. Accordingly, we have configured the carrier housing 60 with alternating lubricant channels to provide lubricant for the pinion bearings 92 when the carrier housing 60 is oriented differently (e.g., mirrored about the first and second axes 94 and 98).Experts understand that in a situation where the carrier housing 60 is mirrored about the first and second axes 94 and 98, contact between the drive pinion 52 and the ring gear 56 will additionally disrupt the lubrication splashing when the vehicle is operated in the predetermined direction.

[0036] With regard to the Fig. 9, Fig. 10 to Fig. 11. The body part 70 of the carrier housing 60 can define a first lubricant channel 500 and a second lubricant channel 502. Optionally, the structure forming the first lubricant channel 500 and / or the structure forming the second lubricant channel 502 can be used to reinforce parts of the carrier housing 60. In the particular example provided, the structures forming the first and second lubricant channels 500 and 502 form ribs on the outer surface of the remainder of the carrier housing 60, reinforcing desired parts of the carrier housing 60. For example, the structure forming the second lubricant channel 502 is constructed to support the portion of the carrier housing 60 that is loaded by the drive pinion 50 during operation of the axle assembly when the vehicle is operated in a predetermined (e.g., forward) direction.

[0037] The first lubricant passage 500 can define a channel extending between the cavity 80 and the part of the carrier housing 60 on which the pinion bearings 92 ( Fig. 2) are mounted. The end of the first lubricant channel 500, which intersects the cavity 80, can be aligned to receive lubricant supplied by the toothed ring 56 ( Fig. 3) is thrown when the carrier housing 60 for the rear axle assembly 36 ( Fig. 1) is used and the vehicle 10 ( Fig. 1) is operated in a forward direction. Accordingly, the end of the first lubricant passage 500, which intersects the cavity 80, can be vertically positioned above the second axis 98 ( Fig. 5) be aligned. The first lubricant channel 500 can be inclined to align vertically with decreasing distance to the pinion bearing 92 ( Fig. 3) to fall off when the carrier housing 60 is used in the rear axle assembly 36 ( Fig. 1) is aligned. A configuration in this way allows the first lubricant flow 500 to be used to transport lubricant (by gravity) from the cavity 80 to the pinion bearings 92 ( Fig. 3) to direct, if the carrier housing 60 is intended for use in the rear axle assembly 36 ( Fig. 1) is aligned. If the carrier housing 60 is for use in the front axle assembly 40 ( Fig. 1) mirrored around the first and second axes 94 and 98, the first lubricant channel 500 is built to remove excess lubricant from the pinion bearings 92 ( Fig. 3) to be directed to cavity 80.

[0038] The second lubricant channel 502 can define a channel extending between the cavity 80 and the part of the support housing 60 on which the pinion bearings 92 ( Fig. 2) are mounted. The end of the second lubricant channel 502, which intersects the cavity 80, can be aligned to receive lubricant supplied by the gear part of the drive pinion 52 ( Fig. 3) is thrown when the carrier housing 60 for the front axle assembly 40 ( Fig. 1) is used and the vehicle 10 ( Fig. 1) is operated in a forward direction. Accordingly, the end of the second lubricant channel 502, which intersects the cavity 80, can be aligned vertically below the end of the first lubricant channel 500, which intersects the cavity 80, and on one side of the first axis 94 opposite the end of the first lubricant channel 500, which intersects the cavity 80. If the carrier housing 60 is for use in the rear axle assembly 36 ( Fig. 1) is aligned, the second lubricant channel 502 can be constructed to drain excess lubricant from the first lubricant channel 500 and can also be positioned to discharge lubricant onto the gear part of the drive pinion 52. If the carrier housing 60 is for use in the front axle assembly 40 ( Fig. 1) is aligned, lubricant can be flung from the gear part of the drive pinion 52 and can be taken up into the end of the second lubricant channel 502, which intersects the cavity 80; excess lubricant can be discharged into the cavity 80 through the open end of the first lubricant channel 500.

[0039] The preceding description of the embodiments has been provided for illustrative and descriptive purposes. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but where applicable, they are interchangeable and may be used in a selected embodiment, even if they are not expressly presented or described. They may also be modified in many ways. Such modifications must not be considered a derogation from the disclosure, and all such modifications are intended to be included within the scope of protection of the disclosure.

Claims

[1] Axle assembly (36), comprising: a housing assembly (50) comprising a support housing (60) and a pair of axle tubes (62), wherein the support housing (60) has a support body (70) and a pair of tube supports (72) arranged on opposite transverse sides of the support body (70), the support body (70) having a wall defining a cavity and a pair of partitions (84), each of the partitions (84) being integrally, uniformly and inseparably formed with a remaining part of the wall and defining a through-hole (96) with a set of internal threads, the tube supports (72) being in fluid communication with the through-holes (96) and the cavity (80), each of the axle tubes (62) being received in one of the associated tube supports (72) and being rigidly connected to the support housing (60); a differential assembly (54) which is received in the cavity (80) and has a differential housing (130) with opposing transverse ends, wherein a bearing bore (160) is formed in each of the opposing transverse ends of the differential housing (130); a pair of differential bearings (162), each of the differential bearings (162) having an outer bearing race which is received in one of the associated bearing bores (160) and is coupled to the differential housing (130); A pair of bearing adjustment devices (210), each bearing adjustment device (210) having a threaded part (222) and a bearing support part (224), the threaded part (222) being threaded in engagement with the internal threads of an associated partition wall (84), the bearing support part (224) being arranged at a first end of the bearing adjustment device (210) opposite a second end on which the threaded part (222) is formed, the bearing support part (224) defining a projection (232) against which an associated differential bearing (162) rests, the bearing support part (224) supporting one side of the associated differential bearing (162) opposite the differential housing (130) such that each differential bearing is in a side-by-side relationship with the differential housing (130) and the associated bearing adjustment devices (210). is, wherein each of the bearing adjustment devices (210) further comprises a locking element (228) which is arranged axially between the associated differential bearing (162) and the second end, wherein the locking element (228) comprises a plurality of locking elements (240), wherein the axle assembly (36) has a pair of adjusting device locking elements (300), each of the adjusting device locking elements (300) being received into a corresponding locking element opening (88) formed in the wall of the support body (70), and with matching locking elements (304) engaging with a part of the locking elements (240) formed on the associated bearing adjusting devices (210). [2] Axle assembly (36) according to claim 1, wherein the threaded part (222) of the bearing adjustment devices (210) is smaller in diameter than the projection (232) of the bearing support part (224). [3] Axle assembly (36) according to claim 1, wherein the locking elements (240) are spaced apart in the circumferential direction over a radial outer edge of the projection (232). [4] Axle assembly (36) according to claim 1, wherein the housing assembly (50) further comprises a cover (64) which is fixedly but removably connected to the carrier housing (60) to close one side of the cavity (80), and wherein the cover (64) covers the elements for the adjusting device lock (300). [5] Axle assembly (36) according to claim 4, wherein the cover (64) limits the movement of the elements for the adjusting device lock (300) in a direction away from the bearing adjusting device (210) in such a way that the matching locking elements (304) cannot detach from the part of the locking elements (240). [6] Axle assembly (36), comprising: a housing assembly (50) comprising a support housing (60) and a pair of axle tubes (62), wherein the support housing (60) has a support body (70) and a pair of tube supports (72) arranged on opposite transverse sides of the support body (70), the support body (70) having a wall defining a cavity and a pair of partitions (84), each of the partitions (84) being integrally, uniformly and inseparably formed with a remaining part of the wall and defining a through-hole (96) with a set of internal threads, the tube supports (72) being in fluid communication with the through-holes (96) and the cavity (80), each of the axle tubes (62) being received in one of the associated tube supports (72) and being rigidly connected to the support housing (60); a differential assembly (54) which is received in the cavity (80) and has a differential housing (130) with opposing transverse ends, wherein a bearing bore (160) is formed in each of the opposing transverse ends of the differential housing (130); a pair of differential bearings (162), each of the differential bearings (162) having an outer bearing race which is received in one of the associated bearing bores (160) and is coupled to the differential housing (130); A pair of bearing adjustment devices (210), each bearing adjustment device (210) having a threaded part (222) and a bearing support part (224), the threaded part (222) being threaded in engagement with the internal threads of an associated partition wall (84), the bearing support part (224) being arranged at a first end of the bearing adjustment device (210) opposite a second end on which the threaded part (222) is formed, the bearing support part (224) defining a projection (232) against which an associated differential bearing (162) rests, the bearing support part (224) supporting one side of the associated differential bearing (162) opposite the differential housing (130) such that each differential bearing is in a side-by-side relationship with the differential housing (130) and the associated bearing adjustment devices (210). is, wherein each of the bearing adjusting devices (210) comprises a first tool coupling element (236, 238) which is designed to engage with a tool in order to allow the bearing adjusting device (210) to be rotated relative to the carrier housing (60), wherein each of the bearing adjustment devices (210) comprises a second tool coupling element (238) which is different from the first tool coupling element (236), wherein the second tool coupling element (238) is designed to engage with a further tool to allow the bearing adjustment devices (210) to be rotated relative to the carrier housing (60). [7] Axle assembly (36) according to claim 6, wherein the first tool coupling element (238) is formed in the projection (232) on the bearing support part (224). [8] Axle assembly (36) according to claim 7, wherein the first tool coupling element (238) comprises a plurality of circumferentially spaced holes formed in the projection (232) and which generally extend parallel to a rotation axis (98) about which the bearing adjustment devices (210) are rotatably mounted on the carrier housing (60). [9] Axle assembly (36) according to claim 6, wherein the first tool coupling element (236) has a non-circular shape formed on an inside of at least one part of the bearing adjustment device (210). [10] Axle assembly comprising: A housing assembly (50) comprising a support housing (60), a pair of axle tubes (62), and a cover (64), wherein the support housing (60) has a support body (70) and a tube support (72), the support body (70) having a wall defining a cavity (80), a first partition (84), a cover flange (86), and a locking element opening (88), the first partition (84) being integrally, uniformly, and inseparably formed with a remaining portion of the wall and defining a through-hole (96) with a set of internal threads, the cover flange (86) adjoining an open side of the cavity (80) and having a flange element, the locking element opening (88) being formed through the cover flange (86) and intersecting the cavity (80), the tube support (72) being in fluid communication with the through-hole (96) and the cavity (80). is,wherein the axle tube (62) is received in the tube holder (72) and is firmly connected to the support housing (60); a differential assembly (54) which is received in the cavity (80) and has a differential housing (130) with opposing transverse ends, wherein a bearing bore (160) is formed in a first of the transverse ends of the differential housing (130); a first differential bearing (162) with an outer bearing race that is received in the bearing bore (160) and engages with the differential housing (130); a first bearing adjustment device (210) comprising a threaded part (222), a bearing support part (224) and an adjustment device locking part (228), wherein the threaded part (222) is in thread engagement with the internal threads of the first partition (84), wherein the adjustment device locking part (228) is arranged axially between opposite axial ends of the first bearing adjustment device and has a plurality of circumferentially spaced locking elements (210); and an adjusting device locking element (300) which is received in the locking element opening (88) and has a plurality of matching locking elements (240) which engage with a part of the locking elements (240) on the first bearing adjusting device (210); wherein the cover (64) engages sealingly with the flange element and rests against the adjusting device locking element (300) in order to limit movement of the adjusting device locking element (300) in the adjusting device locking opening in a direction away from the first bearing adjusting device (210). [11] Axle assembly (36) according to claim 10, wherein the bearing support part (224) defines a projection (232) against which the first differential bearing (162) rests, and wherein the locking elements (240) are formed in the projection (232). [12] Axle assembly (36) according to claim 11, wherein the threaded part (222) of the first bearing adjustment device (210) has a smaller diameter than the projection (232) of the first bearing support part (224). [13] Axle assembly (36) according to claim 10, wherein the first bearing adjustment device (210) comprises a first tool engagement element (236, 238) which is designed to engage with a tool to allow the first bearing adjustment device (210) to be rotated relative to the carrier housing (60). [14] Axle assembly (36) according to claim 13, wherein the first tool engagement element (238) is formed into a projection (232) on the bearing support part (224). [15] Axle assembly (36) according to claim 13, wherein the first tool engagement element (236) comprises a plurality of circumferentially spaced holes formed in the projection (232) and which generally extend parallel to an axis of rotation about which the first bearing adjustment device (210) is rotatably mounted on the carrier housing (60). [16] Axle assembly (36) according to claim 13, wherein the first tool engagement element (236) has a non-circular shape formed on an inside of at least a part of the first bearing adjustment device (210). [17] Axle assembly (36) according to claim 13, wherein the first bearing adjustment device (210) comprises a second tool engagement element (238) which is different from the first tool engagement element (236), wherein the second tool engagement element (238) is designed to engage with a further tool in order to allow the first bearing adjustment device (210) to be rotated relative to the carrier housing (60). [18] Axle assembly (36) according to claim 10, further comprising a drive pinion (52) comprising a pinion shaft and a pinion wheel, wherein the wall of the support body (70) defines a pinion bore into which a pinion shaft is received, wherein the differential assembly (54) has a ring gear (56) which is connected to the differential housing (130) for common rotation, and wherein the pinion wheel meshes with the ring gear (56).

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