In-Profile Locking Motor Differential for Compact Utility Axles

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Solution Overview

Problem

Existing differential drive axles in utility vehicles and ATVs are too large and heavy, failing to meet the requirements of varied terrain conditions and complex operations, necessitating a more compact and lightweight solution that maintains functionality.

Innovation Solution

A mechanical locking differential with a drive lock motor supported by the differential housing, utilizing a gear train with a worm drive to output rotational motion, which is compactly integrated without increasing the differential's width, allowing for smooth operation and accessibility of the input bevel gear assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a conventional differential drive axle is used, then the vehicle can handle varied terrain conditions, but the differential becomes larger in size and heavier

Engineering Contradiction:

Improveterrain handling capabilityVSAvoiddifferential size

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The locking motor is positioned in the height dimension (vertical direction) rather than extending in the width dimension (horizontal direction). The motor is mounted on the top surface of the differential housing, utilizing the vertical space above the differential case to accommodate the motor and its drive mechanism, thereby avoiding width increase while maintaining terrain handling capability

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The locking motor and its associated gear train are nested within the existing differential housing structure. The motor is positioned above the differential case and integrated with the internal gear mechanisms, allowing the locking function to be incorporated without adding external volume to the differential assembly

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If a locking motor is added to the differential, then differential locking function is achieved, but the width of the differential increases

Engineering Contradiction:

Improvedifferential locking functionVSAvoiddifferential width

Core Design Contradiction:

ReliabilityVSLength of moving object

Solution Approach 1:

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The differential housing is designed with an asymmetric top surface that provides an inclined mounting surface for the locking motor. This asymmetric design allows the motor to be positioned at an angle, optimizing space utilization and ensuring the motor does not protrude beyond the differential's width boundaries

Inventive Principle:

Principle #4Asymmetry

3Volume of moving object

If the drive lock motor is integrated into the differential, then compact design is achieved, but accessibility of the input bevel gear assembly may be compromised

Engineering Contradiction:

Improvedifferential compactnessVSAvoidaccessibility of input bevel gear assembly

Core Design Contradiction:

Volume of moving objectVSEase of operation

Solution Approach 1:

The differential housing is designed with localized access features including removable covers or access panels positioned strategically to allow technicians to reach the input bevel gear assembly for maintenance and adjustment. The locking motor is positioned on the top surface with its own dedicated access area, while the side and rear portions of the housing maintain open access to the gear train and bevel gear components

Inventive Principle:

Principle #3Local quality

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

The solution provides a compact mechanical locking differential that maintains functionality while reducing the vehicle's width, protecting components and enhancing performance on harsh terrains by enabling efficient locking of differential engagement, thus improving the vehicle's maneuverability and reliability.

Implementation Method 1

the drive lock motor is coupled to a differential lock with a gear train that includes a worm drive, to output rotational motion on a lock output gear

Methodology Applied

Scientific EffectWorm drive: Worm Drive

Implementation Method 2

The lock output gear causes sliding motion of a rack and a rack follower, pressing the differential lock into or out of engagement

Methodology Applied

Scientific EffectRack and pinion mechanism: Rack and Pinion

Data Source

PatentUS10816071B2Locking differential with in-line, in-profile locking drive motor

Publication Date: 2020.10.27 ZHEJIANG CFMOTO POWER CO LTD

AI summary

A mechanical locking differential includes a drive lock motor supported by the differential housing. The drive lock motor is disposed opposite the input bevel gear assembly, higher than the differential input and the differential outputs. The drive lock motor is coupled to a differential lock with a gear train that includes a worm drive, to output rotational motion on a lock output gear. The lock output gear causes sliding motion of a rack and a rack follower, pressing the differential lock into or out of engagement. The drive lock motor assembly is disposed fully between the right and left extents of the differential.