Externally Mounted Plenum for Differential Hydraulic Actuation
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Solution Overview
Problem
Existing differential gear mechanisms face challenges in providing a simple arrangement to deliver hydraulic fluid to the piston for traction modifying differentials without substantial modification of existing hardware.
Innovation Solution
A bolt-on plenum assembly with a hydraulic coupling and motor is externally mounted on the transaxle housing, allowing hydraulic fluid to be pumped from the plenum assembly through a hydraulic coupling and into the differential casing to actuate the piston, thereby enabling the clutch assembly to operate in open, closed, or partially closed configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a piston and clutch pack are added to create a traction modifying differential, then the differential can control torque distribution to improve traction, but the complexity of the device increases and requires additional hydraulic fluid delivery components
Solution Approach 1:
The plenum assembly is designed as a separate, externally mountable component that can be added to existing differentials without modifying the core differential structure. This segmentation allows the hydraulic system to be added as a modular unit, reducing the complexity impact on the original differential design while still achieving traction control functionality.
Solution Approach 2:
The plenum assembly acts as an intermediary component that bridges the gap between existing differential designs and the required hydraulic actuation system. It provides the necessary hydraulic fluid storage and delivery mechanisms without requiring direct integration into the differential case, thus managing complexity while enabling new functionality.
2Ease of manufacture
If hydraulic fluid delivery components are integrated into the differential housing, then fluid delivery can be simplified, but substantial modification of existing hardware is required
Solution Approach 1:
The plenum assembly extracts the hydraulic fluid delivery functionality from the differential housing itself and places it in a separate, externally mounted component. This extraction allows the differential housing to remain relatively unchanged while still achieving simplified hydraulic fluid delivery through the externally mounted plenum that bolts onto the housing.
Solution Approach 2:
The plenum assembly is designed with universal mounting capabilities that can interface with various differential housing configurations. By providing standardized mounting features and flexible fluid delivery paths, it achieves ease of manufacture across different differential designs without requiring substantial modification of each specific hardware platform.
3Adaptability or versatility
If an externally mounted plenum assembly is used, then substantial modification of existing hardware is avoided, but additional mounting components and connections are required
Solution Approach 1:
The mounting system is segmented into standardized interface features on both the plenum assembly and the differential housing. This segmentation creates compatible connection points that can be implemented across different differential designs without requiring substantial modification, thus improving adaptability while managing mounting complexity through standardization.
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 solution allows for an integrated electronic limited slip differential without requiring significant modifications to the transaxle housing, providing efficient hydraulic fluid delivery to the piston and enabling the differential to function effectively in various traction conditions.
Implementation Method 1
The motor can be mounted on the plenum assembly housing and be configured to pump hydraulic fluid from the bolt-on plenum assembly, through the hydraulic coupling and into the differential casing to act onto the piston
Data Source
AI summary
A differential gear mechanism configured for use with a transaxle housing includes a limited-slip differential assembly including a differential casing defining first and second output shaft openings that receive respective first and second axle shafts. A piston is slidably disposed in the differential casing and configured to actuate a clutch assembly. A bolt-on plenum assembly is configured to bolt onto the transaxle housing and includes a plenum assembly housing, a hydraulic coupling and a motor. The plenum assembly housing defines an axle opening configured to receive one of the first and second axle shafts therethrough. The hydraulic coupling can be arranged on the plenum assembly housing at the axle opening. The motor can be mounted on the plenum assembly housing at the axle opening and be configured to pump hydraulic fluid from the bolt-on plenum assembly, through the hydraulic coupling and into the differential casing to act onto the piston.