Three Output Differential Torque Coupling
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Solution Overview
Problem
Traditional high torque capacity differentials require a one-piece housing, which complicates assembly and increases manufacturing costs, limiting the development of efficient and cost-effective three output differentials.
Innovation Solution
A two-piece housing differential with a torque carrying key, where the housing is interconnected via a key member and cross member, allowing for rotational coupling and efficient torque transfer to multiple output members through a planetary gear set and side gears.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a one-piece housing is used for high torque capacity, then torque capacity is improved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The housing is divided into two separate pieces (first housing piece and second housing piece) that are assembled together using a fastening member. This segmentation allows for easier manufacturing and assembly while maintaining the structural integrity needed for high torque capacity through the torque carrying key connection.
2Strength
If a one-piece housing is used for high torque capacity, then torque capacity is improved, but manufacturing cost increases
Solution Approach 1:
The housing is divided into two separately manufacturable pieces that can be produced independently and then assembled. This reduces manufacturing complexity and cost compared to producing a single complex one-piece housing, while maintaining torque capacity through the torque carrying key mechanism.
Solution Approach 2:
A torque carrying key acts as an intermediary element between the two housing pieces, enabling torque transfer while allowing the housing to be constructed from separate, easier-to-manufacture components. This intermediary component solves both the structural and manufacturing challenges.
3Ease of manufacture
If a two-piece housing is used to simplify assembly and reduce cost, then ease of manufacture is improved, but torque capacity may be compromised
Solution Approach 1:
The torque carrying key serves as a specialized intermediary component that ensures high-torque-capable connection between the two housing pieces. This key is specifically designed to carry torque loads, preventing any compromise in torque capacity despite the housing being divided into two pieces.
Solution Approach 2:
The torque carrying key includes a curved surface that engages with corresponding features in the housing pieces, creating a mechanically strong connection capable of withstanding high torque loads while maintaining the two-piece construction for ease of assembly.
Data Source
AI summary
A differential for interconnecting an input member to a first, second, and third output member includes a housing interconnected with the input member and with the first output member, the housing having a first portion connected to a second portion, the first portion defining a first recess and the second portion defining a second recess, wherein the first recess and the second recess are aligned and cooperate to define a slot. A key member is disposed within the slot between the first portion and the second portion. A cross member is attached to the housing. A set of pinion gears is rotatable about the cross member. A set of side gears is intermeshed with the set of pinion gears, wherein one of the set of side gears is interconnected with the second output member and another of the set of side gears is interconnected with the third output member.