Differential Assembly Ring Gear Mounting With Fewer Fasteners
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Solution Overview
Problem
Current vehicle differential assemblies face challenges in efficiently transmitting torque and allowing for differential rotational speeds to vehicle road wheels, often requiring complex and heavy constructions with multiple fasteners, which increase weight and cost.
Innovation Solution
A differential assembly design featuring a first and second case with nesting portions and a ring gear, where the first case is sandwiched between the second case and the ring gear, utilizing a fastener that extends through both cases into a fastener hole of the ring gear, and incorporating self-aligning features to simplify assembly and reduce the number of fasteners needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional differential assemblies use multiple fasteners to secure the ring gear to the case, then the assembly strength and reliability are improved, but the weight and device complexity increase
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated fastener system. The ring gear is secured to the case using only two fasteners instead of traditional multiple fasteners, merging the fastening function into a simplified configuration that maintains reliability while reducing complexity and weight.
Solution Approach 2:
The fastener design serves multiple functions simultaneously: it secures the ring gear to the case, provides alignment features through integrated alignment elements, and eliminates the need for separate alignment components. This multi-functional approach reduces the overall number of parts while maintaining assembly strength.
2Reliability
If traditional differential assemblies use multiple fasteners and complex construction, then the assembly strength is improved, but the weight increases
Solution Approach 1:
The patent extracts and eliminates unnecessary fasteners and complex structural elements from the traditional differential assembly. By using only two fasteners and integrating alignment features directly into the ring gear and case, the design removes excess weight while maintaining the required assembly strength through optimized fastener placement and design.
3Reliability
If traditional differential assemblies use complex construction with multiple fasteners, then the assembly strength is improved, but the manufacturing cost increases
Solution Approach 1:
The patent segments the fastening and alignment functions into distinct integrated features within the ring gear and case design. The alignment features are built into the ring gear teeth or mounting surfaces, and the fastening is achieved through strategically positioned fasteners, eliminating the need for complex multi-component assembly structures and reducing manufacturing cost.
4Reliability
If traditional differential assemblies use multiple fasteners, then the assembly strength is improved, but the device complexity and part count increase
Solution Approach 1:
The patent merges alignment features and fastening functions into the ring gear and case structure itself. The alignment features are integrated into the ring gear design, and only two fasteners are needed to secure the assembly, significantly reducing the part count compared to traditional designs that use multiple separate fasteners and alignment components.
Data Source
AI summary
A differential assembly includes a first case rotatable about an axis and defining a first mounting flange having a through hole and a second case abutting the first case to define a gear nest cavity therebetween. The second case further defines a second mounting flange having a through hole and formed to mate to the first mounting flange. The differential assembly also includes a ring gear mounted to the first mounting flange and fastener extending through the through hole of both the first mounting flange and second mounting flange into a fastener hole of the ring gear. Additionally, the first mounting flange is sandwiched between the second mounting flange and the ring gear.