Integrated Differential Connecting Element Design
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Solution Overview
Problem
Prior differential gear designs are complex, space-intensive, heavy, and costly to manufacture, with oil filling only possible after assembly and potential oil loss during disassembly.
Innovation Solution
A compact differential design where the connecting element is integrated within the drive wheel, featuring a recess for easier assembly and oil-tight construction, with differential gears and axle wheels arranged to minimize space and weight, and using a housing that does not transmit torque.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a classic differential cage is used to house the connecting element, then the differential can be assembled, but it becomes complex to manufacture, requires a lot of space, and increases weight
Solution Approach 1:
The patent extracts and eliminates the classic differential cage structure from the design. Instead of housing the connecting element within a separate cage, the invention integrates the connecting element directly into the differential body, removing the unnecessary cage component and simplifying the overall structure while maintaining functionality
Solution Approach 2:
The patent merges the differential body and the connecting element into a unified integrated structure. The connecting element is formed as an integral part of the differential body, combining two previously separate components into one, thereby reducing part count, manufacturing complexity, and assembly steps
2Volume of moving object
If the connecting element is attached laterally to the circumference of the drive wheel, then assembly is possible, but it increases space requirements and weight
Solution Approach 1:
The patent applies the nesting principle by placing the connecting element inside the drive wheel structure rather than attaching it externally. The connecting element is positioned within the hollow interior of the drive wheel, nesting one component inside another to minimize external dimensions and space requirements while maintaining assembly accessibility through the open end
3Reliability
If the differential is assembled in a closed structure, then it is oil-tight, but oil filling can only occur after final assembly which increases time and risk of oil loss
Solution Approach 1:
The patent enables preliminary oil filling before final assembly by incorporating an open end that provides access to the interior cavity during the assembly process. This allows the oil filling operation to be performed in advance, before the differential is completely sealed, thereby reducing total assembly time and eliminating the risk of oil loss that would occur if filling had to wait until after sealing
Data Source
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AI summary
The invention relates to a differential, comprising at least one driving wheel (1), at least two axle wheels (2), at least one compensating wheel (3), and at least one connecting element (4), wherein the connecting element of at least the driving wheel is subjected to at least one first torque, and wherein the connecting element transmits at least one second torque to at least one of the at least two axle wheels. According to the invention, the driving wheel is designed such that the driving wheel at least partially encloses at least one inside space, and the connecting element is arranged at least partially inside the inside space enclosed at least partially by the driving wheel.