Axle Assembly With Integrated Ring Gear Bearing for Rotational Stability
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Solution Overview
Problem
Existing axle assemblies, such as Banjo-type and Salisbury-type axles, lack an improved design that enhances durability and efficiency, particularly in supporting the input pinion and differential assembly, leading to potential mechanical failures and reduced performance.
Innovation Solution
The proposed axle assembly incorporates a housing with an input pinion, ring gear, differential assembly, head and tail bearings, and a bearing adjuster, featuring a yoke flange and pinion shaft seal, which provides enhanced support and pre-loading mechanisms to improve rotational stability and sealing, while using materials like aluminum and sheet metal for structural components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional Banjo-type or Salisbury-type axle housings are used, then the axle assembly can be manufactured with standard designs, but the rotational stability and support for the input pinion and differential assembly are insufficient leading to mechanical failures
Solution Approach 1:
The axle housing is divided into two separate half-housings that are joined together, allowing independent optimization of each half and improved assembly flexibility. The bearing support system is segmented into head bearing and tail bearing assemblies that can be independently adjusted and maintained.
Solution Approach 2:
The bearing adjuster mechanism provides dynamic adjustment capability for bearing pre-load, allowing the system to adapt to varying operational conditions and maintain optimal rotational stability throughout the service life of the axle assembly.
2Stability of the object's composition
If the input pinion is supported by bearings without pre-loading mechanisms, then the assembly is simpler, but rotational stability and precision are reduced
Solution Approach 1:
The bearing adjuster is configured to apply pre-loading force to the head and tail bearings before operation, establishing optimal rotational stability and precision from the start of service. This preliminary action prevents excessive play and ensures accurate power transmission throughout operation.
Solution Approach 2:
The bearing pre-load force can be adjusted by rotating the bearing adjuster, changing the mechanical parameters of the bearing support system to optimize rotational stability for different operational requirements and compensation for wear over time.
3Reliability
If traditional sealing methods are used for the pinion shaft, then the design is simpler, but sealing effectiveness and protection against contamination are insufficient
Solution Approach 1:
A lip seal is introduced as an intermediary element between the pinion shaft and the external environment, providing effective sealing against contamination while allowing rotational movement. The seal lip contacts the pinion shaft surface to prevent ingress of contaminants without impeding rotation.
4Productivity
If the differential assembly is not pre-loaded, then the assembly is simpler, but performance and efficiency are reduced
Solution Approach 1:
The differential assembly is pre-loaded through the bearing adjuster mechanism before operation, ensuring optimal meshing of the ring gear and pinion gear. This preliminary action eliminates excessive backlash and ensures efficient power transmission from the start of service.
Solution Approach 2:
The pre-load force on the differential assembly can be adjusted by rotating the bearing adjuster, changing the mechanical parameters to optimize gear meshing and power transmission efficiency for different operational conditions and compensation for wear over time.
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
This design enhances the rotational stability and sealing of the axle assembly, reducing mechanical failures and improving performance by providing better support for the input pinion and differential components, and allowing for efficient power transmission.
Implementation Method 1
The tail bearing has a plurality of bearing elements, an inner race and an outer race. The bearing elements are received into a bearing groove formed into the pinion shaft.
Implementation Method 2
the pinion shaft seal having at least one lip seal that is sealingly engaged to the shaft portion
Implementation Method 3
the bearing adjuster being configured to move the first outer bearing race member axially toward the second outer bearing race member to pre-load the tail bearing
Implementation Method 4
a snap ring is received onto the second coupling portion and engages a shoulder formed on the first coupling portion to thereby inhibit axial movement of the yoke flange
Implementation Method 5
The ring gear is meshed with the pinion gear and is rotatable about a second axis that is transverse to the first axis
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to an axle assembly (22), including: a housing (30, 30b), an input pinion (32), a ring gear (34, 34b), a differential assembly (36), and a ring gear bearing (200, 200b), wherein the input pinion (32) has a pinion gear (90) and is received in the housing (30, 30b) for rotation about a first axis (40), wherein the ring gear (34, 34b) is meshed with the pinion gear (90) and is rotatable about a second axis (42) that is transverse to the first axis (40), wherein the differential assembly (36) has a differential case (240b) and a pair of output members (242), wherein the differential case (240b) is driven by the ring gear (34, 34b), wherein the ring gear bearing (200, 200b) supports the ring gear (34, 34b) for rotation relative to the housing (30, 30b) about the second axis (42), wherein the ring gear bearing (200, 200b) has a plurality of bearing elements (202), an inner bearing race (206, 206b) and an outer bearing race (204, 204b), wherein a bearing groove (210, 210b) is formed into the ring gear (34, 34b), and wherein the bearing elements (202) are received into the bearing groove (210, 210b) such that one of the inner bearing race (206, 206b) and the outer bearing race (204, 204b) is unitarily and integrally formed with the ring gear (34, 34b).