Interaxle Differential Unit Pinion Gear Integration
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Solution Overview
Problem
Existing axle assemblies with interaxle differential units face challenges in durability due to the risk of pin fracture and separation from the central ring, and often require more complex assemblies with spiders, which increases assembly time and complexity.
Innovation Solution
The axle assembly design eliminates the spider by integrating the pinion gears directly onto the case, using a configuration with an inner and outer ring and ribs to support pinion pins and gears, allowing for a simpler and more durable interaxle differential unit with fewer parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional interaxle differential unit with spiders is used, then the pinion gears can be supported, but the pins are at risk of fracture and separation, reducing reliability
Solution Approach 1:
The patent removes the spider component from the interaxle differential unit, extracting the source of pin fracture and separation problems. The pinion gears are directly mounted to the case without requiring a spider, thereby eliminating the reliability issues associated with pin fracture and separation while simplifying the overall assembly.
Solution Approach 2:
The patent merges the pinion gear support function directly into the case structure. Instead of using a separate spider component to support the pinion gears, the case itself is designed with integrated support features, combining multiple functions into a single structure and eliminating potential failure points.
2Ease of operation
If spiders are used to support pinion gears, then the differential unit can function, but the assembly becomes more complex and assembly time increases
Solution Approach 1:
The spider component is completely removed from the assembly, reducing the number of parts that need to be manufactured, inventory-managed, and assembled. This extraction of the unnecessary component directly reduces assembly time and simplifies the overall device complexity.
Solution Approach 2:
The support function previously performed by the spider is merged into the case structure. The case is designed with integrated features that directly support the pinion gears, eliminating the need for a separate spider component and reducing the total number of parts in the assembly.
3Strength
If pinion pins are used to connect pinion gears to the central ring, then the differential can operate, but the pins may fracture and separate under stress
Solution Approach 1:
The pinion pins are removed from the design by eliminating the spider structure that required them. Without a spider, there are no separate pins connecting pinion gears to a central ring, thereby eliminating the fracture and separation problems associated with these pins.
Solution Approach 2:
The connection function between the pinion gears and the central structure is merged into an integrated design where the pinion gears are directly mounted to the case. This eliminates the need for separate connecting pins and reduces structural complexity while improving strength.
Data Source
AI summary
An axle assembly having an input shaft, an output shaft, and an interaxle differential unit. The interaxle differential unit includes first and second side gears, a case, and a pinion gear that is rotatably disposed on a pinion pin. The case extends from the input shaft. The pinion pin extends from the case and is spaced apart from the input shaft.