Differential Gear Three-Step Control Mechanism

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Solution Overview

Problem

Existing automobile differential gear systems require additional space and increased production costs due to separate control mechanisms for ON, OFF, and LOCK functions, with existing solutions either enlarging the control mechanism or duplicating components.

Innovation Solution

A three-step control mechanism using axial motion of a single member within a planetary gear carrier to achieve ON, OFF, and LOCK functions, eliminating the need for extra space and reducing production costs by integrating the locking mechanism between left and right gears or on the shaft of the gear connected with the clutch sleeve.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate control mechanisms are used for ON, OFF, and LOCK functions, then the control functions are achieved, but the device size and production cost increase

Engineering Contradiction:

Improvecontrol functionsVSAvoiddevice size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The patent combines the ON, OFF, and LOCK control functions into a single integrated control mechanism. The control assembly includes a single control arm that can engage different engagement members (first engagement member for ON/OFF, second engagement member for LOCK) to achieve all three functions, eliminating the need for separate control mechanisms and reducing overall device size.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The control arm serves multiple functions by selectively engaging different engagement members. A single control arm can control both the first engagement member (for ON/OFF functions) and the second engagement member (for LOCK function), making it a universal control component that performs multiple control tasks without requiring separate dedicated components for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If separate control mechanisms are used for ON, OFF, and LOCK functions, then the control functions are achieved, but the production cost increases

Engineering Contradiction:

Improvecontrol functionsVSAvoidproduction cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If the locking mechanism is installed behind the side gear on the inner rim of the outer shell, then the LOCK function is achieved, but the control mechanism size is enlarged

Engineering Contradiction:

ImproveLOCK functionVSAvoidcontrol mechanism size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent repositions the locking mechanism from a radial arrangement (behind the side gear on the inner rim) to an axial arrangement (within the planetary gear carrier between left and right gears). This dimensional change allows the locking mechanism to be integrated into the existing space between the planetary gears without increasing the radial or axial dimensions of the control mechanism.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The locking mechanism is nested within the planetary gear carrier structure, specifically positioned between the left and right planetary gears. This nesting approach allows the locking mechanism to utilize the existing space within the planetary gear assembly without requiring additional external space, thereby maintaining compact dimensions.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If the locking mechanism is installed behind the side gear on the inner rim of the outer shell, then the LOCK function is achieved, but the weight increases

Engineering Contradiction:

ImproveLOCK functionVSAvoidcontrol mechanism weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

5Reliability

If the locking mechanism is installed behind the side gear on the inner rim of the outer shell, then the LOCK function is achieved, but the production cost increases

Engineering Contradiction:

ImproveLOCK functionVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

Inventive Principle:

Principle #7Nested doll (Nesting)

Data Source

PatentEP1860344B8Differential gear system with a three-step control mechanism

Publication Date: 2010.04.07 NEW KAILUNG GEAR

AI summary

A differential gear system with a three-step control mechanism uses the axial motion of a single member to achieve three functions of ON, OFF and LOCK. The differential gear system has a locking mechanism installed in the planetary gear carrier (3) between two planetary gears thereof. Extra space for the locking mechanism is not necessary. It can be applied to differential gear systems with spiral bevel gears and with regular gears. The locking mechanism can be mounted between two planetary gears of the planetary gear carrier or on the shaft of the planetary gear corresponding to the other planetary gear connected with the clutch sleeve. Accordingly, the differential gear system with a three-step control mechanism comprises a left shaft (1), a right shaft (2) and a planetary gear carrier (3) between the left shaft (1) and the right shaft (2). The left shaft and the right shaft are respectively one-piece axles provided with end connecting sections.