Differential Module Sliding Sleeve for Four-Mode Half-Shaft Coupling
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Solution Overview
Problem
Existing differential modules in vehicle transmission systems are complex and lack efficient mechanisms for selectively coupling and decoupling wheel-driving half-shafts, leading to inefficiencies and mechanical losses.
Innovation Solution
A differential module with a sliding sleeve that can occupy four axial positions, allowing for selective coupling and decoupling of wheel-driving half-shafts, including a connected, locked, disconnected, and park position, using collaborating shapes and assistance springs for efficient transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional coupling means with sliding sleeve are used to selectively couple input element to output element, then the differential function is achieved, but the structure becomes complex and compactness is reduced
Solution Approach 1:
The single sliding sleeve is designed to perform multiple coupling functions by occupying different axial positions. It can couple the second wheel-driving half-shaft to the second sun gear (connected position), couple to the planet carrier or first wheel-driving half-shaft (locked position), couple the second sun gear to fixed structure (park position), or remain disconnected (disconnected position). This multi-functionality eliminates the need for separate coupling mechanisms for each function, thereby simplifying the overall structure while maintaining adaptability.
Solution Approach 2:
The patent merges multiple coupling functions into a single sliding sleeve component. Instead of having separate coupling mechanisms for connecting to the sun gear, planet carrier, and fixed structure, all these functions are integrated into one sliding sleeve that can selectively engage with different components based on its axial position, reducing structural complexity.
2Adaptability or versatility
If multiple coupling mechanisms are used to achieve different operational modes, then functionality is improved, but the device complexity increases
Solution Approach 1:
The sliding sleeve serves as a universal coupling component that can achieve four different operational modes (connected, locked, disconnected, park) by simply changing its axial position. This single component replaces what would traditionally require multiple separate coupling mechanisms, thereby improving operational versatility without increasing device complexity.
Solution Approach 2:
The sliding sleeve is designed to be axially mobile, allowing it to dynamically transition between different positions to achieve different coupling states. This dynamic capability enables a single component to perform multiple functions that would otherwise require several static components, reducing the overall number of parts while maintaining operational flexibility.
3Ease of operation
If the sliding sleeve constantly rotates secured to wheel-driving half-shaft, then coupling is achieved, but mechanical losses occur during rotation of unused components
Solution Approach 1:
The patent extracts the second wheel-driving half-shaft from the continuous rotation requirement by introducing a disconnected position for the sliding sleeve. When the differential function is not needed, the sliding sleeve can be positioned to disconnect the second wheel-driving half-shaft from the power transmission path, allowing it to remain stationary or rotate minimally, thereby eliminating mechanical losses associated with rotating unused components while maintaining coupling reliability when needed.
4Ease of manufacture
If traditional three-position sliding sleeve is used, then basic coupling function is achieved, but additional functionalities are missing
Solution Approach 1:
The sliding sleeve is designed with four axial positions instead of three, adding the park position functionality. In the park position, the sliding sleeve couples the second sun gear to a fixed structure, enabling vehicle immobilization. This additional position is achieved by extending the axial travel of the same sliding sleeve mechanism, requiring no fundamental redesign and maintaining manufacturing simplicity while significantly enhancing functional capabilities.
Solution Approach 2:
By making the sliding sleeve axially mobile across four positions, the system gains dynamic versatility. The sliding sleeve can selectively engage with different components (second sun gear, planet carrier, first wheel-driving half-shaft, or fixed structure) based on operational requirements, transforming a basic coupling mechanism into a multi-functional system without complicating the manufacturing process.
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 is a first and a second wheel-driving half-shaft, the first wheel-driving half-shaft being rotationally connected to the first sun gear. A sliding sleeve is configured to occupy, selectively, four axial positions for the coupling of the differential module.