DIFFERENTIAL GEAR

Description

Technical field

[0001] The invention relates to a differential or transfer case for a vehicle, as well as to an assembly method for a differential or transfer case and a use of the differential or transfer case in a vehicle which is driven by an internal combustion engine or for use in a vehicle which has at least one electric machine as a drive. State of the art

[0002] DE 10 2015 200 667 A1 relates to a clutch assembly with an electromagnetic actuator. The clutch assembly comprises a rotationally drivable transmission housing having at least one sleeve projection for rotatable mounting in a stationary housing. Furthermore, an output part is provided, which is rotatably arranged in the transmission housing, and a clutch, which is arranged in the power path between the transmission housing and the output part. The clutch has a first clutch part, which is held in a rotationally fixed and axially movable manner relative to the transmission housing, and a second clutch part, which is fixedly connected to the output part and is arranged in the transmission housing.A controllable actuator is provided for actuating the clutch, such that the first clutch part and the second clutch part can optionally be connected to one another for transmitting a torque, wherein the actuator has an annular electromagnet arranged coaxially to the sleeve extension of the transmission housing with a magnet housing and an axially movable piston.

[0003] DE 10 2015 200 465 A1 relates to a differential device for a vehicle. The differential device comprises a first housing section, wherein the first housing section is designed to support a sun gear and / or to support the differential device on a surrounding structure. Furthermore, a second housing section, a drive gear section, and a fastening part are provided, wherein the fastening part, the second housing section, and the drive gear section are connected to one another via a screw connection and form a screwed assembly. The screwed assembly forms a positive-locking receptacle, wherein the first housing section is received in the positive-locking receptacle.

[0004] DE 10 2012 213 405 A1 relates to a bevel gear differential for a vehicle. The bevel gear differential comprises an outer gear with a differential carrier, wherein the differential carrier is fixedly connected to the outer gear via at least one connecting region. The differential carrier has at least one web region on which a differential gear is arranged, wherein the rotational axis of the differential gear defines a differential axial direction in an axial plan view of the bevel gear differential. In the axial plan view, a compensation angle range of at least + / - 20° around the differential axial direction is freed from the at least one connecting region.

[0005] EP2578904A1 discloses a method for assembling a differential gear with a differential carrier according to the preamble of claim 1. Description of the invention

[0006] According to the invention, a method for assembling a differential gear with a differential carrier according to the claims is disclosed.

[0007] The solution proposed by the invention advantageously makes the differential or transfer case assembly significantly lighter and requires fewer components. The solution proposed by the invention enables much simpler assembly with significantly more precise, robust centering and fixing of the individual components of the differential or transfer case relative to one another.

[0008] Further following the solution proposed by the invention, the differential carrier of the differential or differential gear has a number of claws extending in the circumferential direction. The claws of the differential carrier are integrated into the differential carrier. This allows for a lighter and more robust connection between the large gear or a gear ring on the one hand and the differential carrier of the differential or transfer case on the other.

[0009] Following the solution proposed according to the invention, a large gear wheel of solid construction can be used as the large gear wheel, or alternatively, the large gear wheel, which according to the invention is positively connected to the differential carrier, can also be designed as a gear ring.

[0010] Advantageously, the large solid gear or the ring gear is provided with a number of recesses corresponding to the number of integrated claws formed on the differential carrier. The recesses on the large solid gear or the ring gear are formed in the material thereof and extend essentially in the circumferential direction of the large solid gear or the ring gear, preferably in an arcuate shape.

[0011] Further following the solution proposed by the invention, the recesses are designed with the number of integrated claws corresponding to the number on the large gear, either in solid construction or on the gear ring, and are defined by an inner recess arc, an outer recess arc, and recess radii. These are extremely easy to manufacture, which contributes to reducing production costs.

[0012] Further following the solution proposed by the invention, the claws integrated into the differential carrier of the differential or transfer case comprise at least one radial centering lug and at least one centering rounding extending in the tangential direction. By providing the at least one radial centering lug and the at least one centering rounding extending in the tangential direction, the solid large gear or the ring gear can be advantageously centered on the differential carrier.

[0013] In the assembled state of the large gear in solid construction or the gear ring and the differential cage, a positive connection between these two components is achieved by caulking, in particular by creating a peel caulking. Advantages of the invention

[0014] The differential or transfer case proposed according to the invention enables a compact, simple, weight-saving design, a longer guide length as well as better centering and, finally, easier assembly compared to previous solutions.

[0015] The design proposed by the invention reduces the number of components, resulting in the aforementioned weight savings. Furthermore, the differential or transfer case proposed by the invention allows for a good guide length, enables better centering, and significantly simpler assembly, as fewer assembly steps are required. With regard to the solid large gear, the ring gear, and its connection to the differential carrier, significantly more robust centering and a fixation between the aforementioned components that is easier to implement in terms of manufacturing technology can be achieved.

[0016] The solution proposed by the invention also allows for a better transmission ratio and a lower weight load, as connecting elements such as screws and holes that require precise manufacturing can be eliminated. Furthermore, the solution proposed by the invention eliminates the need for threaded hole machining and the screw-on assembly process. The skiving and caulking process proposed by the invention can also be performed in a highly automated manner in the broadest sense, which significantly reduces the manufacturing costs of the differential or transfer case proposed by the invention.

[0017] Tolerances arising from the joining of the large gear in solid construction or the gear ring with the differential carrier result from the manufacture of said components with clearance or transition fits. The two components are joined over a relatively short radial guide length and held together by screw connections, which can be avoided in the present context by the solution proposed by the invention. Furthermore, the connections between the said components, which were previously made by screw connections, have relatively high requirements for coaxiality, which can be met much more easily with the solution proposed by the invention compared to the use of screws for the connection.

[0018] The recesses in the gear ring or in the large gear in solid construction are designed with smaller radii at the four corners to reduce the influence of the notch effect. Short description of the drawings

[0019] The invention is described in more detail below with reference to the drawings.

[0020] It shows: Figure 1 a perspective view of a differential and transfer case, Figure 2 a perspective rear view of the differential carrier, Figure 3 a perspective top view of the differential carrier with integrated claws, Figure 4 a perspective view of a gear ring with curved recesses, Figure 5 an assembled assembly of gear ring and differential carrier, Figure 6 a section through a differential carrier on which a large gear wheel of solid construction or a gear ring is mounted, Figure 7 a top view of the arrangement according to Figure 6, Figure 8 shows an undeformed state, Figure 9 shows a caulking tool with which a peel caulking form-fitting connection is produced, Figure 10 shows a perspective view of a differential carrier with 5 integrated claws arranged distributed in the circumferential direction and Figure 11 shows a detailed view of an integrated claw of a differential carrier received in a recess. Versions

[0021] According to the illustration Figure 1 shows a perspective view of a differential or transfer case.

[0022] Figure 1shows a differential gear 10 comprising a differential carrier 12. A first axle shaft gear 18 is accommodated in the differential carrier 12, which drives a first axle shaft 14. Furthermore, a second axle shaft gear 20 is located in the differential carrier 12, via which a second axle shaft 16 is driven. Between the first axle shaft gear 18 and the second axle shaft gear 20, a first differential gear 22 and a second differential gear 24 are located on the differential carrier 12, via which the different travel paths can be compensated when cornering.

[0023] While a direction of rotation 26 of the two axle shafts 14 and 16 is aligned, the first differential gear 22 rotates within the differential carrier 12 in a direction of rotation 28 of the first differential gear, while the second differential gear 24 moves within the differential carrier 12 in an opposite direction of rotation 30 of the second differential gear 24.

[0024] Furthermore, according to the illustration Figure 1 It can be seen that a large gear 32, which is connected in a rotationally fixed manner to the differential carrier 12, is driven via a drive shaft 34, which can comprise a universal joint 36. A drive pinion 38 received on the drive shaft 34 meshes with the large gear 32. As can be seen from the perspective view according to Figure 1 As can be seen schematically, the large gear 32 and the differential carrier 12 are connected to one another in a rotationally fixed manner via a number of connecting elements 40, here designed as connecting screws.

[0025] In the differential and transfer case 10 proposed according to the invention, a differential cage 12 is used as shown in Figure 2 From the perspective rear view according to Figure 2It can be seen that circumferentially extending integrated claws 52, 54, 56, and 58 are formed on the differential carrier 12. The integrated claws 52, 54, 56, and 58 have a substantially arcuate shape and extend vertically upwards over the circumference of the differential carrier 12.

[0026] Figure 3 shows a perspective top view of the differential carrier 12 according to Figure 2 .

[0027] Figure 3 shows that the first integrated claw 52 is located at the 12 o'clock position, whereas the second integrated claw 54 is located at the 3 o'clock position. Similarly, the third integrated claw 56 is located at the 6 o'clock position, whereas the fourth integrated claw 58 is located at the 9 o'clock position on the differential carrier 12.

[0028] From the representation according to Figure 4 a plan view of a gear ring 60 is shown in more detail.

[0029] As shown in the top view Figure 4can be removed, a gear ring 60 is provided in the circumferential direction with a number of recesses 64, 66, 68 and 70, respectively. The gear ring 60 comprises on its outer circumference a toothing 62, which can be designed, for example, as a helical toothing, so that the smooth running of the gear ring 60 is improved due to the larger overlap. Figure 4 shows a first recess 64, a second recess 66, a third recess 68 and a fourth recess 70. The recesses are also curved, complementing the curved shape of the integrated claws 52, 54, 56, 58, which are formed on the differential carrier 12. The number of recesses 64, 66, 68, 70 in the ring gear 60 as shown in Figure 4 corresponds to the number of integrated claws 52, 54, 56 and 58, which are formed in the circumferential direction in the material of the gear ring 60.

[0030] Figure 5shows a perspective top view of the assembled state of the components gear ring 60 and differential carrier 12:

[0031] In the assembled state 72, the individual integrated claws 52, 54, 56, 58 of the differential carrier 12 are inserted into the recesses 64, 66, 68 and 70 of the ring gear 60. The curved end portions of the individual integrated claws 52, 54, 56, 58 protrude slightly beyond the upper surfaces of the recesses 64, 66, 68, 70. In the assembled state 72 according to the perspective view in Figure 5 the components ring gear 60 and differential carrier 12 with integrated claws 52, 54, 56, 58 are not yet joined together.

[0032] According to the representations Figures 6, 7 , 8 and 9 joining steps for creating a positive connection between the ring gear and the differential carrier 12 of the differential or transfer case 10 can be found.

[0033] Figure 6shows a longitudinal section through the differential carrier 12, on which a large gear 32 in solid construction or a gear ring 60 can be mounted. In Figure 6 In the state shown, for example, the first integrated claw 52 is inserted into a complementary, substantially circumferentially extending first recess 64 of the large gear 32 in solid construction or of the gear ring 60. As in Figure 5 As already shown, the upper side of the first integrated claw 52 protrudes beyond the upper side of the first recess 64. If a positive connection is established between the large gear 32 of solid construction or the gear ring 60 and the first integrated claw 52 of the differential carrier 12, a plastic deformation of the material of the first claw 52 occurs.

[0034] To implement the positive connection, an original joining geometry 80 is present; when the first integrated claw 52 is caulked or peel caulked, it assumes a caulked joining geometry 82.

[0035] In the caulked joining geometry 82, the plastically deformed claw material 84 fills, as in Figure 9 which essentially lie in the drawing plane according to Figure 4 extending arcuate first recess 64.

[0036] For the sake of completeness, it should be mentioned that the toothing 62, preferably helical, is located on the outer circumference of the large gear 32 of solid construction or on the gear ring 60. A toothing pitch diameter is designated by reference numeral 110.

[0037] Figure 7 shows the top view of the arrangement according to Figure 6 , i.e. a rotation of the Figure 6 by 90° into the drawing plane. In Figure 7It is shown that the toothing 62 is located on the outer circumference of the large gear 32 in the solid construction of the gear ring 60. This comprises a number of teeth 114 extending between a tooth root circle 108 and a tooth tip circle 112, each tooth 114 being delimited by two tooth flanks 116.

[0038] In the top view according to Figure 7 It is shown how the material of the first integrated claw 52 penetrates the first arcuate recess 64 in the material of the large gear 32 in solid construction or the gear ring 60. The first recess 64 is in the illustration according to Figure 7 bounded by the inner recess arc 104 and the outer recess arc 106.

[0039] According to the illustration Figure 8It can be seen that before the positive connection between the first integrated claw 52 of the differential carrier 12 and the large gear 32 in solid construction or the gear ring 16 is established, the material of the first integrated claw 52 has a number of radial centering lugs 100. Furthermore, tangential centering roundings 102 are formed on the first integrated claw 52 at their opposite ends in an arc shape (see also illustration according to Figure 11 ). In Figure 8 In the initial state shown, ie before the positive connection is made, the large gear 32 in solid construction or the gear ring 60 is fixed both radially and tangentially with respect to the respective integrated claws 52, 54, 56, 58, which are formed in the material of the differential carrier 12.

[0040] In Figure 9It is shown how a caulking tool 88 is applied in a force direction 96 extending essentially in the radial direction to the joined arrangement of the large gear 32 in solid construction or the gear ring 60 and the differential carrier 12. On the side of the caulking tool 88 facing the large gear 32 in solid construction or the gear ring 60, a first tip 90 and a second tip 92 are formed. Between the first tip 90 and the second tip 92, as seen in the circumferential direction of the caulking tool 88, a free space 94 extends. By the action of the caulking tool 88 on the Figure 9illustrated first integrated claw 52, ​​this is deformed and plastically deformed claw material 84 now fills the first recess 64, so that a positive connection can be established between the large gear 32 in solid construction or the gear ring 60 on the one hand and the first integrated claw 52 of the differential carrier 12 on the other hand. Figure 9 shows that the plastically deformed claw material 84 extends into the recess radius 98, so that the first recess 64, which extends essentially in the circumferential direction in an arc shape, is completely filled by the plastically deformed claw material of the first integrated claw 52 of the differential carrier 12. The same applies to the pairing of the second integrated claw 54 and the second recess 66, or the third integrated claw 56 and the third recess 68, as well as to the pairing of the fourth integrated claw 58 and the fourth recess 70.

[0041] Figure 10shows a perspective view of a differential carrier 12, in the circumference of which are the first integrated claw 52, ​​the second integrated claw 54, the third integrated claw 56 and the fourth integrated claw 58. Furthermore, the differential carrier 12 according to the perspective view in Figure 10 a fifth integrated claw 118.

[0042] According to the illustration Figure 11 the first integrated claw 52 is inserted in the still undeformed state into the first recess 64. In this state, the differential carrier 12 on the one hand and the large gear 32 of solid construction or the ring gear 60 on the other hand are centered with respect to each other in the radial and tangential directions. Figure 11shows that the radial centering lugs 100 located on the top side of the first integrated claw 52, ​​viewed in the radial direction, abut against the outer recess arc 106 of the first recess 64, while the two radial centering lugs 100 formed at a distance from one another on the underside of the first integrated claw 52 abut against the inner recess arc 104 of the first recess 64. Figure 11 shows further that the tangential centerings provided at the opposite ends of the first recess 64 also bear against the boundary surfaces of the first recess 64. In Figure 11 no plastic deformation of the claw material of the first integrated claw 52 has yet taken place.

[0043] Figure 11further shows the toothing 62 formed on the circumference of the large gear 32 in solid construction or on the gear rim 60, which is formed by a number of teeth 114, each delimited by tooth flanks 116. Reference numeral 108 denotes the tooth root circle, while 112 forms the tooth tip circle of the toothing 62. The invention further comprises a method for assembling a differential or transfer case 10, wherein at least the following method steps are carried out during assembly of the differential or transfer case 10: First, the large gear 32, designed in solid construction, or the gear rim 60 with recesses 64, 66, 68, 70 is joined to the claws 52, 54, 56, 58, 118 integrated into the differential head 12.A caulking tool 88 is then positioned above an integrated claw 52, ​​54, 56, 58, 118 inserted into a recess 64, 66, 68, 70, and a caulking force is applied in the radial direction 96. This is followed by a plastic deformation 84 of the material of the respective integrated claw 52, ​​54, 56, 58, 118 within the respective recess 64, 66, 68, 70. A positive, rotationally fixed connection is created between the large gear 32 in solid construction or the gear ring 60 on the one hand and the differential carrier 12 on the other hand, in particular by performing a skiving caulking.

[0044] By the above based on the Figures 1 to 11The illustrated design of the differential and transfer case 10 proposed according to the invention allows the number of components to be reduced, thereby making the assembly of the differential and transfer case 10 lighter. Due to the circumferentially extending integrated claws 52, 54, 56, 58 and 118, the guide length is significantly improved. Furthermore, by providing a number of radial centering lugs 100 on the claws 52, 54, 56, 58, a significantly better centering can be achieved before the skiving and caulking is carried out. Their design is relatively simple since the centering in the tangential and axial directions is maintained during the skiving and caulking. The design of the differential and transfer case 10 proposed according to the invention allows for better transmission efficiency and a lower weight load to be achieved because fewer components are required.Advantageously, the integrated claws 52, 54, 56, 58 are formed with a circumferential length that preferably corresponds to the width of the toothing 62 of the gear ring 60 or of the solid large gear 32. This provides good axial and radial guidance of the solid large gear 32 or of the gear ring 60. The tangential centering roundings 102 located at the end of the integrated claws 52, 54, 56, 58 improve the tangential centering accuracy.

[0045] The above invention is not limited to the embodiments described here and the aspects highlighted therein. Rather, numerous modifications are possible within the scope of the claims, which are within the scope of one skilled in the art.

Claims

1. Method for mounting a differential gearbox (10) having a differential cage (12) in which side gears (18, 20) and spider gears (22, 24) are accommodated, a side gear (18, 20) respectively drives a first axle shaft (14) or a second axle shaft (16), and a large gearwheel (32, 60) driven via a drive shaft (34) is connected to the differential cage (12) in a rotationally fixed manner, wherein the large gearwheel (32, 60) is connected to the differential cage (12) of the differential gearbox (10) in a form-fitting manner, wherein the method comprises at least the following method steps: a. providing a differential cage (12) having a number of integrated claws (52, 54, 56, 58, 118) extending in the circumferential direction, b. providing a large gearwheel (32) having a number of cutouts (64, 66, 68, 70) which corresponds to the number of claws (52, 54, 56, 58, 118) integrated in the differential cage (12), wherein the large gearwheel (32) is configured with a solid construction or as a ring gear (60), c. joining the large gearwheel (32) to the differential cage (12), wherein the individual integrated claws (52, 54, 56, 58) of the differential cage (12) are inserted into the cutouts (64, 66, 68 and 70) of the large gearwheel (32), d. producing a form-fitting, rotationally fixed connection between the large gearwheel (32) on the one hand and the differential cage (12) on the other, characterized in that the production of a form-fitting, rotationally fixed connection between the large gearwheel (32) on the one hand and the differential cage (12) on the other hand is performed by caulking and comprises the following steps: e. positioning a caulking tool (88) in each case above an integrated claw (52, 54, 56, 58, 118) inserted in a cutout (64, 66, 68, 70) and applying a caulking force in the radial direction (96) and f. plastically deforming (84) the material of the respective integrated claw (52, 54, 56, 58, 118) within the respective cutout (64, 66, 68, 70) by means of the caulking tool (88), so that the respective cutout (64, 66, 68, 70) is completely filled by the plastically deformed claw material (84) of the deformed claw of the differential cage (12).

2. Method according to Claim 1, characterized in that the cutouts (64, 66, 68, 70) are arcuate in form and are each delimited by an inner cutout arc (104), an outer cutout arc (106) and cutout radii (98), and in that the claws (52, 54, 56, 58, 118) integrated into the differential cage (12) have radial centring lugs (100) and tangential centring rounded portions (102), and in that, in the step of joining by applying the centring lugs (100) to the outer cutout arc (106) and the inner cutout arc (104) and by applying the tangential centring rounded portions (102) to the boundary surfaces of the respective cutouts (64, 66, 68, 70), centring of the large gearwheel (32) on the differential cage (12) is achieved.