Differential Assembly with Auxiliary Tool for Spring Compression
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Solution Overview
Problem
The assembly of preload-type differentials with disc springs is challenging due to the difficulty in compressing the disc spring, which leads to misalignment of pinion shafts and increased assembly time and cost.
Innovation Solution
A differential design with recessed portions on the pinion shaft holder and an auxiliary tool that compresses the disc spring between the side gear and differential case, maintaining it in a compressed state to facilitate easy alignment and assembly of pinion shafts without interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the disc spring is compressed and maintained in a compressed state with an auxiliary tool, then the side gear can be pressed against the pinion gear to reduce backlash, but the auxiliary tool may interfere with the pinion shaft holder that is adjacent to the side gear
Solution Approach 1:
The patent extracts the interfering portion by providing a recessed portion on the pinion shaft holder that corresponds to the position of the auxiliary tool. This recessed portion allows the auxiliary tool to be inserted and maintain the disc spring in a compressed state without interfering with the pinion shaft holder, thereby resolving the contradiction between achieving backlash reduction and maintaining ease of assembly operation
2Ease of manufacture
If the disc spring is not compressed, then the assembly process is simpler, but the side gear will be pushed upward toward the pinion gear side causing misalignment of the pinion shaft center with the through-hole center
Solution Approach 1:
The patent applies preliminary action by compressing the disc spring before assembling the pinion shaft. The auxiliary tool is used to compress the disc spring and maintain it in a compressed state during the assembly process, ensuring that the side gear is properly positioned against the pinion gear. This preliminary compression action prevents misalignment of the pinion shaft center with the through-hole center, thereby achieving both assembly simplicity and alignment precision
3Manufacturing precision
If the pinion shaft is assembled while the disc spring is compressed, then the alignment of pinion shaft center with through-hole center is maintained, but the assembly operation becomes time-consuming and difficult
Solution Approach 1:
The patent introduces an intermediary device - the auxiliary tool - that facilitates the assembly process. The auxiliary tool is inserted into the recessed portion of the pinion shaft holder and used to compress and maintain the disc spring in a compressed state. This intermediary tool enables the pinion shaft to be assembled smoothly while maintaining alignment precision, thereby resolving the contradiction between alignment precision and assembly speed by providing a convenient means to maintain the compressed state during assembly
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 simplifies the assembly process, ensures concentric alignment of pinion shafts and through-holes, and reduces manufacturing costs by streamlining the assembly operation.
Implementation Method 1
the side gears are pressed against pinion gears by the elastic restoring force of the disc springs, thereby reducing backlash between the side gears and the pinion gears
Implementation Method 2
an auxiliary tool that compresses the disc spring between the side gear and differential case, maintaining it in a compressed state
Data Source
AI summary
A differential includes a pinion shaft holder, a differential case, a first side gear, a second side gear, a first spring and a second spring. The differential case includes a first side boss portion and a second side boss portion. The first spring is interposed between the first side boss portion and the first side gear. The second spring is interposed between the second side boss portion and the second side gear. A recessed portion is provided on the pinion shaft holder and is configured to avoid interference with an auxiliary tool. The auxiliary tool maintains one of the first spring and the second spring in the compressed state.