Planetary Bevel Gear Differential With Automatic Limited Slip
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Solution Overview
Problem
Existing differentials, particularly those for medium and heavy commercial vehicles and off-road vehicles, fail to achieve automatic limited slip functionality and maximum driving torque in adverse weather conditions, leading to wheel slipping and loss of traction on slippery or icy surfaces, as they require manual intervention and have limitations in torque control.
Innovation Solution
A planetary bevel gear automatic limited slip differential with a pure mechanical structure, incorporating a planetary bevel gear controller with overrunning clutches and bevel gear meshing trains, automatically controls the rotational speed difference between wheels to prevent slipping and ensure maximum torque delivery, allowing for normal differential-speed steering under all-terrain and all-weather conditions without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a general differential is used, then normal differential speed is achieved on good pavement, but wheel slipping occurs on slippery or icy surfaces due to excessive rotational speed difference
Solution Approach 1:
The patent changes the operational parameters of the differential system by introducing a planetary bevel gear controller that dynamically adjusts the speed difference between left and right wheels. When wheel slip is detected, the controller modifies the differential action to limit the rotational speed difference, thereby maintaining traction on slippery surfaces while preserving normal differential function on good pavement.
Solution Approach 2:
The planetary bevel gear controller acts as an intermediary mechanism between the main differential and the drive wheels. It includes planetary gears, sun gears, and clutch mechanisms that mediate the torque distribution and speed difference control, preventing direct slip while maintaining the differential's core function.
2Reliability
If a differential lock differential is used, then limited slip function is achieved, but manual intervention is required making the system complicated
Solution Approach 1:
The planetary bevel gear controller is designed to automatically detect and respond to wheel slip conditions without manual intervention. The system uses the inherent mechanical relationships between the planetary gears, sun gears, and clutches to self-regulate torque distribution and limit speed difference, eliminating the need for manual operation while maintaining limited slip functionality.
Solution Approach 2:
The differential system incorporates mechanical feedback through the planetary gear mechanism that responds to rotational speed differences between wheels. When one wheel slips and rotates faster, the planetary gears automatically detect this speed difference and adjust torque distribution accordingly, creating a self-regulating feedback loop that prevents slip without manual input.
3Extent of automation
If high friction mechanisms are used in automatic limited slip differentials, then limited slip control is achieved, but maximum driving torque cannot be delivered due to friction losses
Solution Approach 1:
The patent replaces high-friction mechanical control mechanisms with a planetary bevel gear system that uses mechanical advantage and gear ratios to control limited slip. Instead of relying on friction-based clutches or brakes, the system uses the inherent mechanical properties of planetary gears to limit speed difference while minimizing energy loss and maximizing torque delivery to the drive wheels.
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 enables vehicles to maintain maximum driving torque and prevent wheel slipping on various terrains, ensuring smooth operation even on soft gravel, muddy, or ice-covered roads, by automatically adjusting wheel speeds within a controlled range, thus enhancing traction and stability without manual intervention.
Implementation Method 1
The two overrunning clutches are symmetrically arranged on both sides of the inner and outer bevel gear meshing gear train. Each of the two overrunning clutches includes an outer ring, and an inner ring. The inner ring and the outer ring of the each of the two overrunning clutches are engaged with or disengaged from each other through tooth engagement.
Implementation Method 2
The inner and outer bevel gear meshing gear train includes an inner planetary bevel gear control unit, and an outer planetary bevel gear control unit. The inner planetary bevel gear control unit includes multiple inner planetary bevel gears, and the outer planetary bevel gear control unit includes multiple outer planetary bevel gears.
Data Source
AI summary
A planetary bevel gear automatic limited slip differential includes five portions that are a main differential, a planetary bevel gear controller, a left drive axle shaft, a right drive axle shaft, and clutches. The planetary bevel gear controller includes an outer control unit and an inner control unit, the outer control unit includes four planetary bevel gears on an outer layer and a bevel gear fixed on a housing, and the inner control unit includes inner planetary bevel gears on an inner side and two bevel gears which have the same parameters and are meshed with the planetary bevel gears. The bevel gears are fixedly connected with outer rings of two overrunning clutches, respectively, and inner rings of the overrunning clutches and the right drive axle shaft are connected together by splines.