Differential Carrier Bearing Support for Larger Drive Pinions
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Solution Overview
Problem
Existing differential carrier assemblies face challenges in accommodating larger diameter drive pinions without increasing the size of the differential carrier body or adding weight, which limits the ability to provide faster gear ratios for improved fuel economy and reduced energy usage.
Innovation Solution
The design includes a removable differential bearing support that is positioned closer to the drive pinion and configured to extend adjacent to and below the second axis, with strategically placed mounting holes to accommodate a larger diameter drive pinion without enlarging the differential carrier body, allowing for more space and flexibility in gear ratios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the differential carrier body size is increased to accommodate a larger diameter drive pinion, then the gear ratio performance is improved, but the weight and size of the differential carrier assembly increases
Solution Approach 1:
The differential carrier assembly is divided into separate functional components: a stationary differential carrier body and a removable differential bearing support. This segmentation allows the bearing support to be optimized for accommodating larger drive pinions while the carrier body maintains its original size and weight, resolving the contradiction between adaptability and weight.
Solution Approach 2:
The differential bearing support extends below the second axis, utilizing the vertical dimension to provide additional space for larger diameter drive pinions. This dimensional approach allows increased gear ratio range without expanding the horizontal footprint or overall carrier size, thereby maintaining weight while improving adaptability.
2Adaptability or versatility
If the differential carrier body size is increased to accommodate a larger diameter drive pinion, then the gear ratio performance is improved, but the overall assembly size increases
Solution Approach 1:
By separating the bearing support from the carrier body, the invention allows the bearing support to be compact and optimized for its specific function of holding bearings and supporting the drive pinion. The carrier body volume remains unchanged, while the bearing support volume is minimized through its modular design, resolving the contradiction between adaptability and volume.
Solution Approach 2:
The differential bearing support is designed to fit within the existing differential carrier assembly structure, nesting the support component into the available space below the second axis. This nesting approach allows the system to accommodate larger drive pinions without increasing the overall assembly volume, as the bearing support utilizes otherwise unused space.
Data Source
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AI summary
A differential carrier assembly having a differential, a differential carrier, and a differential bearing support. The differential carrier has a bearing support mount that may extend from a mounting flange of the differential carrier. The differential bearing support is mounted to the bearing support mount and receives a bearing assembly that rotatably supports the differential.