Differential, a drive assembly having a differential, and a method for manufacturing a differential

Abstract

The invention relates to a differential (10) for a drive assembly of a motor vehicle having the features of claim 1, to a drive assembly having at least one such differential (10), and to a method for manufacturing such a differential (10).

Description

[0001] R.415471

[0002] - 1 -

[0003] Description

[0004] title

[0005] Differential, a drive arrangement with a differential, and a method for manufacturing a differential.

[0006] State of the art

[0007] The invention relates to a differential for a drive arrangement of a motor vehicle with features of claim 1, a drive arrangement with at least one such differential and a method for manufacturing such a differential.

[0008] A motor vehicle typically has a differential to distribute the torque generated by the engine to two output shafts. The torque is usually transmitted to the differential via a differential gear, which is mounted on a differential housing into which the two output shafts connect. The differential gear can be bolted or laser-welded to the differential housing, for example.

[0009] The disadvantage is that screwing and / or laser welding are costly and time-consuming.

[0010] Disclosure of the invention

[0011] According to the invention, a differential for a drive assembly of a motor vehicle is proposed, comprising a differential housing, a differential gear, and at least two ring segments. The ring segments are, in particular, ring-shaped. The differential housing, the differential gear, and the ring segments are welded together. In other words, the differential housing, the differential gear, and the ring segments are R.415471

[0012] - 2 - connected to each other by means of a welded joint, in particular by material bonding.

[0013] This allows for a cost-effective and stable, and in particular, material-bonded, connection between the differential carrier and the differential gear using simple means. A complex bolted connection is unnecessary. Thanks to the ring segments, a complete weld ring is not required, thus reducing material usage and therefore costs.

[0014] The ring segments can be arranged in a ring shape or along a circular path on the differential housing and / or differential gear. The ring segments can also be arranged in a ring shape or along a circular path between the differential housing and the differential gear. The ring segments can be welded together. The ring segments can be identical. It is also conceivable that at least two ring segments can be configured differently.

[0015] According to a further development of the differential, the differential basket, the differential gear and the ring segments can be welded together using capacitor discharge welding (KEEP).

[0016] This allows for the creation of a cost-effective and stable welded joint using simple means.

[0017] According to a further development of the differential, the ring segments can be arranged at a distance from each other. The ring segments can be arranged equidistantly.

[0018] This can reduce the amount of material required and therefore the costs.

[0019] According to a further development of the differential, the differential can comprise three ring segments. The three ring segments can be arranged at an angle of 120° to each other.

[0020] This allows for further optimization of the weld. R.415471

[0021] - 3 -

[0022] According to a further development of the differential, the ring segments can be oriented in a random, undefined orientation relative to one or more components. The ring segments can be oriented at a specific angular position relative to one or more components. The ring segments can be oriented relative to one or more reference features on one or more components. The component(s) can be part of the differential, the drive assembly, and / or the motor vehicle.

[0023] This allows the welding connection to be implemented as flexibly as possible.

[0024] According to a further development of the differential, the ring segments can have a round, circular, rectangular and / or triangular cross-section. Other geometric shapes for the cross-section of the ring segments are also conceivable.

[0025] This allows the welding connection to be implemented as flexibly as possible.

[0026] According to a further development of the differential, the ring segments can be manufactured using forming technology. The ring segments can be manufactured using forming technology. It is also conceivable that the ring segments could be manufactured using another manufacturing process.

[0027] This allows the ring segments to be implemented using simple means and / or cost-effectively.

[0028] According to the invention, a drive arrangement for a motor vehicle comprising at least one differential as described above is proposed.

[0029] Regarding the advantages achievable with the drive arrangement, reference is made to the relevant explanations concerning the differential. The measures described in connection with the differential and / or those explained below can be used for further development of the drive arrangement. R.415471

[0030] - 4 -

[0031] The drive arrangement can, for example, be designed as an e-axle or form part of an e-axle.

[0032] According to the invention, a method for manufacturing a differential as described above is proposed. The method comprises the following steps:

[0033] Providing the differential gear and differential carrier.

[0034] Pressing the differential gear onto the differential carrier and / or the differential carrier onto the differential gear by means of press joining.

[0035] The differential gear can be pressed onto the differential housing using a press fit. This allows for high alignment accuracy between the differential housing and the differential gear.

[0036] Regarding the advantages achievable with this method, reference is made to the relevant explanations concerning the differential. The measures described in connection with the differential and / or those explained below can be used to further develop the method.

[0037] Until the procedure is further developed, the process may include the following steps:

[0038] Providing the ring segments.

[0039] Welding of the differential basket, differential gear, and ring segments. This welding can be performed using capacitor discharge welding.

[0040] This allows for a cost-effective and stable, especially material-bonded, connection between the differential basket and the differential gear to be implemented using simple means.

[0041] Embodiments of the invention are explained below with reference to the accompanying drawings. They show schematically: R.415471

[0042] - 5 -

[0043] Figure 1 shows a side view of a differential and

[0044] Figure 2 shows a sectional view of the differential according to Figure 1.

[0045] In Figure 1, the differential is designated by the reference numeral 10. The differential 10 is designed for a drive arrangement of a motor vehicle, in particular an electrified vehicle or electric vehicle.

[0046] The differential 10 comprises a differential carrier 12, a differential gear 14, and several ring segments 16. The differential carrier 12, the differential gear 14, and the ring segments 16 are welded together. The differential carrier 12, the differential gear 14, and the ring segments 16 are thus metallurgically bonded to one another.

[0047] The ring segments 16 can be ring-shaped. The ring segments 16 can be arranged on or along a circular path. The ring segments 16 can be arranged along an inner circumference of the differential gear 14. The ring segments 16 can be arranged along an outer circumference of the differential housing 12.

[0048] The differential basket 12, the differential gear 14 and the ring segments 16 can be welded together by means of capacitor discharge welding.

[0049] The ring segments 16 can be arranged at intervals from each other. The ring segments 16 can be arranged equidistantly. It is also conceivable that the ring segments 16 can be arranged at different distances from each other.

[0050] The ring segments 16 can be oriented in a random or defined orientation to one or more components. The ring segments 16 can be oriented at a specific angular position to one or more components. The ring segments can be oriented relative to one or more datum features on one or more components. The component or components can be R.415471

[0051] - 6 -

[0052] be part of the differential 10, the drive arrangement and / or the motor vehicle.

[0053] Figure 2 shows a sectional view of the differential 10 according to section AA shown in Figure 1. The sectional view shown corresponds to a section along one diameter of the differential gear 14.

[0054] In the present case, the ring segments 16 each have a quadrilateral, in particular square, cross-section. The ring segments 16 can also have a round, circular, rectangular and / or triangular cross-section. Cross-sections with other geometric shapes are also conceivable.

[0055] The differential 10 in this case has three ring segments 16 (see Figure 1). The three ring segments 16 are arranged at an angle of 120° (equidistant) to each other. The three ring segments 16 are identical in this case. It is also conceivable that at least two of the ring segments 16 could be configured differently.

[0056] The ring segments 16 can be manufactured using forming techniques. In other words, the ring segments 16 can be manufactured using forming techniques. It is also conceivable that the ring segments 16 could be manufactured using another manufacturing process.

[0057] The following describes a method for manufacturing a differential 10 according to the above explanations, with reference to Figures 1 and 2. The differential 10 can be the one shown in Figures 1 and 2.

[0058] The procedure includes the following steps:

[0059] Providing the differential gear 14 and the differential basket 12.

[0060] Pressing (using a price-matching mechanism) the differential gear 14 onto the differential carrier 12 by means of a press fit. Alternatively or additionally, the differential carrier 12 can be pressed onto the differential gear 14 by means of a press fit. R.415471

[0061] - 7 -

[0062] The process may include the following steps:

[0063] Providing the ring segments 16. Welding the differential basket 12, the differential gear 14 and the ring segments 16 together. The welding can be carried out by means of capacitor discharge welding.

Claims

R.415471 - 8 - Claims 1. Differential (10) for a drive arrangement of a motor vehicle comprising: a differential basket (12), a differential gear (14), at least two ring segments (16), wherein the differential basket (12), the differential gear (14) and the ring segments (16) are welded together.

2. Differential (10) according to claim 1, characterized in that the differential basket (12), the differential gear (14) and the ring segments (16) are welded together by means of capacitor discharge welding.

3. Differential (10) according to claim 1 or 2, characterized in that the ring segments (16) are arranged at a distance from each other, in particular equidistantly.

4. Differential (10) according to one of the preceding claims, characterized in that the differential (10) comprises three ring segments (16) which are arranged in particular at an angle of 120° to each other.

5. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) are aligned in a random, undefined orientation to a component or several components, in a specific angular position to a component or several components or relative to a reference feature or several reference features on a component or several components. R.415471 - 9 - 6. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) have a round, circular, rectangular and / or triangular cross-section.

7. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) are manufactured by forming technology.

8. Drive arrangement for a motor vehicle comprising at least one differential (10) according to one of the preceding claims.

9. Method for manufacturing a differential (10) according to any one of claims 1 to 7 comprising the steps: Providing the differential wheel (14) and the differential basket (12); Pressing the differential gear (14) onto the differential basket (12) and / or the differential basket (12) onto the differential gear (14) by means of press joining.

10. The method of claim 9, characterized by the steps of: Providing the ring segments (16); Welding, in particular by means of capacitor discharge welding, the differential basket (12), the differential gear (14) and the ring segments (16) together.

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