Integrated Active Limited Slip Differential with Singular Thrust Bearing
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Solution Overview
Problem
Existing limited slip differentials for motor vehicles are complex and costly due to additional components like bearings and actuator assemblies, which increase the complexity and cost of the vehicle while reducing stability.
Innovation Solution
A simplified limited slip differential system with a friction clutch assembly and ball and ramp assembly positioned outside the differential case, utilizing a singular thrust bearing and differential bearings to reduce the need for additional components, allowing for reduced complexity and cost while maintaining stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components including a plurality of bearings and actuator assemblies are used in limited slip differentials, then the differential function can be reduced or eliminated to increase traction and control, but the cost and complexity of the limited slip differential and motor vehicle increase
Solution Approach 1:
The patent combines the actuator assembly and differential bearing into a single integrated unit that performs multiple functions. The actuator assembly includes a piston that directly engages the differential case through a thrust bearing, eliminating the need for separate actuator components and reducing overall system complexity while maintaining the limited slip differential function.
Solution Approach 2:
The actuator assembly serves multiple functions: it acts as both the actuating mechanism for the limited slip differential and the bearing support structure. The piston within the actuator assembly simultaneously provides thrust engagement and radial support through the integrated differential bearing, reducing the need for additional dedicated components.
2Reliability
If a friction clutch assembly is positioned within the differential case to selectively reduce or eliminate differential function, then traction in reduced friction environments can be increased, but the complexity of the limited slip differential increases due to additional components
Solution Approach 1:
The differential bearing is extracted from the traditional position within the differential case and relocated to the actuator assembly positioned outside the differential case. This extraction simplifies the differential case structure and reduces the number of components that must be precisely fitted within the case, thereby reducing overall system complexity while maintaining the friction clutch assembly's traction-enhancing function.
Solution Approach 2:
The thrust bearing acts as an intermediary element between the piston and the differential case, allowing the actuator assembly to engage the differential case without requiring direct contact. This intermediary mechanism enables the friction clutch assembly to function effectively while reducing the complexity of direct engagement mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively reduces the complexity and cost of the limited slip differential while maintaining vehicle stability and traction by using a friction clutch assembly and ball and ramp assembly to engage the clutch pack, allowing for efficient torque distribution between axle half shafts.
Implementation Method 1
Limited slip differentials use a friction clutch assembly or clutch positioned between a side gear and a differential case to selectively reduce or eliminate the differential function
Implementation Method 2
A ball and ramp assembly is positioned outside the differential case and includes a reaction member, an actuating ring and a plurality of balls positioned between the reaction member and actuating ring
Implementation Method 3
The differential bearing includes a roller and an outer race
Implementation Method 4
A singular thrust bearing is located within the differential housing and outside the differential case axially adjacent the actuating ring. The thrust bearing is in direct contact with thrust pins that extend through the differential case and axially abut the clutch pack
Data Source
AI summary
A limited slip differential system having a differential housing, a differential case disposed within the differential housing and a differential gear set supported within the differential case. A friction clutch assembly including a clutch pack is positioned within the differential case and axially adjacent the differential gear set. A ball and ramp assembly is positioned outside the differential case and includes a reaction member positioned within and fixed to the differential housing. A differential bearing is positioned axially between the reaction member and the differential housing and radially outward from the differential case. A singular thrust bearing is located within the differential housing and outside the differential case and applies an axial load from the actuator assembly to the clutch pack.