Differential Gearbox Claw-Ring Gear Assembly for Lighter Fixation
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Solution Overview
Problem
Existing differential and transfer case assemblies for vehicles are heavy, require numerous components, and have complex assembly processes, leading to increased manufacturing costs and potential inaccuracies in centering and fixing of components.
Innovation Solution
The proposed method involves a differential or transfer case design with a differential carrier featuring integrated circumferentially extending claws. These claws interact with recesses on a large solid gear or gear ring, allowing for a lighter, more robust connection and simplified assembly through a skiving and caulking process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional screw connections and multiple components are used to connect the large gear and differential carrier, then the assembly is more robust, but the weight increases and assembly complexity increases
Solution Approach 1:
The patent merges the large gear and differential carrier into a single integrated component, eliminating the need for separate connection elements like screws and retaining clips. This integration maintains structural robustness while reducing the total number of parts and overall assembly weight.
Solution Approach 2:
The patent removes unnecessary intermediate connection components (screws, retaining clips) from the assembly, directly connecting the large gear to the differential carrier through an integrated design that extracts only the essential functional elements.
2Reliability
If traditional screw connections are used to fix the large gear and differential carrier, then the connection is secure, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The patent combines the fixation function directly into the integrated structure of the large gear and differential carrier, eliminating the need for separate fixation components and simplifying the assembly process to a single operation.
Solution Approach 2:
The patent extracts and removes the complex multi-step screw connection process, replacing it with a simplified integrated design that achieves secure fixation through the structural integration itself rather than through separate fastening operations.
3Ease of manufacture
If multiple separate components are used in the differential assembly, then the design allows for easier manufacturing of individual parts, but the overall assembly weight increases and centering precision decreases
Solution Approach 1:
The patent merges the large gear and differential carrier into one integrated component that can be manufactured as a single piece using modern casting or forging techniques, achieving both weight reduction and improved centering precision while maintaining ease of manufacture through standardized production processes.
4Ease of manufacture
If traditional connection methods with multiple components are used, then the assembly can be manufactured with standard processes, but the centering precision and fixation accuracy of components deteriorate
Solution Approach 1:
The patent combines the large gear and differential carrier into an integrated structure where the centering is inherently built into the design, eliminating the need for separate centering mechanisms and ensuring precise alignment through the unified geometry of the combined component.
Data Source
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AI summary
The invention relates to a differential or transfer gearbox (10) in a motor vehicle, a method of production and the use of the differential or transfer gearbox (10). The differential or transfer gearbox (10) comprises a differential case (12) in which differential side gears (18, 20) and differential gears (22, 24) are accommodated. Each differential side gear (18) drives a first axle shaft (14) or a second axle shaft (16). A ring gear (32, 60) is driven by an input shaft (34) and mounted for conjoint rotation with the differential case (12). The ring gear (32, 60) is interlockingly connected to the differential case (12) of the differential or transfer gearbox (10).