Segmented Differential Case Design for Structural Integrity
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Solution Overview
Problem
The one-piece structure of differential cases, which lacks openings, reduces stiffness and strength due to the presence of openings that allow passage of components, compromising the structural integrity of the differential case.
Innovation Solution
A differential device with a case capable of rotation, featuring a flange to receive the driving force, a shaft perpendicular to the case, and a differential gear set housed within, along with strategically positioned openings and a through hole to enhance structural support and allow passage of components, including a clutch assembly to lock differential motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If openings are provided in the differential case to allow passage of the gear set, then ease of manufacture and assembly is improved, but stiffness and strength of the differential case deteriorates
Solution Approach 1:
The differential case is divided into two separate cases: a first differential case housing the gear set and a second differential case housing the clutch assembly. These cases are connected via a connection portion, allowing each case to be manufactured and assembled independently while maintaining overall structural integrity. This segmentation eliminates the need for large openings in a single-piece case.
Solution Approach 2:
The first and second differential cases are nested together through the connection portion, with the gear set housed in the first case and the clutch assembly housed in the second case. This nested configuration allows compact arrangement of components while preserving the strength of each individual case by minimizing openings in each separate housing.
2Ease of manufacture
If a one-piece differential case structure is used, then manufacturing simplicity is improved, but stiffness and strength are reduced due to required openings
Solution Approach 1:
The differential case is segmented into multiple cases (first and second differential cases) that are connected together. Each case can be manufactured as a more compact, structurally sound unit with minimal openings, and then assembled together. This resolves the conflict between manufacturing simplicity and structural integrity by distributing the manufacturing complexity across multiple simpler components.
Solution Approach 2:
The invention transitions from a single three-dimensional case to multiple smaller three-dimensional cases connected in space. By adding the dimension of case separation and connection, the design achieves both manufacturing simplicity (each case is simpler) and structural integrity (each case maintains strength without large openings).
Data Source
AI summary
A differential device for differentially distributing a driving force to axles along an axis is disclosed. The differential device has a case being capable of rotation about the axis, which includes a flange configured to receive the driving force and a shaft crossing the case perpendicularly to the axis; an opening defined by a peripheral border on an outer periphery of the case so as to allow access into the case, lateral extremities of which is deviated from a center of the shaft toward a direction opposite to the flange along the axis; and a differential gear set housed in and drivingly coupled to the case, the differential gear set including an input gear rotatable around the shaft and output gears so combined with the input gear as to differentially distribute the driving force to the output gears, the output gears being drivingly coupled to the axles.