Differential Sliding Sleeve Coupling for Compact Drivetrain Shifting
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Solution Overview
Problem
Existing differential modules in vehicle transmission systems are complex and lack compactness, with coupling mechanisms that are not optimally simplified or enhanced for additional functionalities.
Innovation Solution
A differential module with a sliding sleeve that directly collaborates with a sun gear via collaborating shapes, such as male and female splines, and additional guidance mechanisms like journal bearings, allowing axial and radial guidance, and dog clutch-type toothsets for efficient position transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a sliding sleeve is used with intermediate shaft portions to connect the sun gear and wheel-driving half-shafts, then the coupling functionality is achieved, but the structure becomes complex and less compact
Solution Approach 1:
The patent merges the sliding sleeve with the intermediate shaft portions by integrating the shaft portions directly into the sliding sleeve structure. The sliding sleeve now includes first and second shaft portions that are integral parts of the single component, eliminating the need for separate intermediate connection elements and reducing overall structural complexity while maintaining all coupling functionalities.
Solution Approach 2:
The sliding sleeve is designed as a multi-functional component that simultaneously performs multiple functions: it couples the first sun gear to the first wheel-driving half-shaft, couples the second sun gear to the second wheel-driving half-shaft, and provides selective engagement/disengagement capabilities. This universal design consolidates what would otherwise require multiple separate components into a single versatile element.
2Loss of energy
If traditional coupling mechanisms are used with multiple separate components, then the coupling is reliable, but the mechanical losses increase due to more friction points
Solution Approach 1:
By combining multiple separate coupling components into a single integrated sliding sleeve structure, the patent reduces the number of interfaces and contact points where friction occurs. The integral design eliminates additional bearing surfaces and connection interfaces that would otherwise generate mechanical losses, thereby improving energy efficiency while maintaining coupling reliability through the robust integrated structure.
3Volume of moving object
If a sliding sleeve constantly rotationally secured to a wheel-driving half-shaft is used, then the coupling is maintained, but the compactness and simplicity of the structure is reduced
Solution Approach 1:
The patent combines the sliding sleeve with the wheel-driving half-shafts by integrating shaft portions directly into the sliding sleeve. The first shaft portion is rotationally connected to the first wheel-driving half-shaft and the second shaft portion to the second wheel-driving half-shaft, creating a compact integrated assembly that reduces overall volume while simplifying the structural design by eliminating separate connection components.
Data Source
AI summary
A differential module having a first axis of rotation and including a planet carrier, a planet pinion pivotably mounted on the planet carrier, and a first and a second sun gear pivoting about the first axis of rotation. Also included are a first and a second wheel-driving half-shaft, the first wheel-driving half-shaft being rotationally connected to the first sun gear, and a sliding sleeve able to move between two axial positions. A first connection by means of collaborating shapes is created between the sliding sleeve and the second sun gear. The first connection by means of collaborating shapes is configured so that the sliding sleeve is permanently rotationally connected to the second sun gear and slides axially between the two axial positions.