In-Line Torque-Biasing Differential With Adjustable Gear Ratios
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Solution Overview
Problem
Current torque vectoring systems in vehicles are complex, require monitoring systems, and necessitate disassembly for adjustments, making them costly and time-consuming, especially for high-torque applications like rock crawling, where optimal gear speed ratios are difficult to maintain under varying load conditions.
Innovation Solution
An in-line differential device with a housing, sun gear, outer ring gear, and planetary gears that provides infinite variable torque vectoring between predetermined high and low set points, featuring a locking mechanism for remote activation and a hydraulic coupling for efficient power transfer, allowing for dynamic gear ratio adjustment without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional torque vectoring systems are used, then torque control capability is improved, but device complexity increases and requires monitoring systems
Solution Approach 1:
The patent extracts the torque vectoring function from complex electronic monitoring systems and implements it through a purely mechanical differential device with adjustable gear ratios. The differential device itself performs torque biasing through its gear mechanism, eliminating the need for external sensors, controllers, and monitoring systems while maintaining torque control capability.
Solution Approach 2:
The patent replaces electronic control systems with a mechanical adjustment mechanism. The owner can manually adjust the gear ratio using a simple mechanical interface (such as a set screw or adjustment key) that changes the effective gear ratio without requiring electronic components, thereby substituting complex electronic-mechanical systems with a purely mechanical solution.
2Adaptability or versatility
If gear ratio changes are made to optimize performance, then vehicle performance is improved, but drivetrain rebuilding is required which is expensive and time-consuming
Solution Approach 1:
The patent makes the gear ratio dynamic and adjustable during the vehicle's service life. Instead of a fixed gear ratio that requires drivetrain disassembly to change, the differential device incorporates an adjustable mechanism that allows the owner to modify the gear ratio as needed, transforming a static component into a dynamic, adaptable system.
Solution Approach 2:
The patent enables the vehicle owner to perform gear ratio adjustments themselves without requiring professional mechanic intervention. The adjustment mechanism is designed to be accessible and simple to operate, allowing end-users to optimize their own vehicle performance by changing gear ratios without specialized tools or expertise.
3Manufacturing precision
If professional mechanic intervention is required for adjustments, then manufacturing precision is maintained, but ease of operation deteriorates
Solution Approach 1:
The patent designs the adjustment mechanism to be user-friendly and accessible to ordinary vehicle owners. The mechanism includes features such as accessible adjustment points, simple operating procedures, and tolerance-compensating designs that allow non-professionals to achieve adequate precision without requiring expert knowledge or specialized equipment.
Solution Approach 2:
The patent incorporates design features that are tolerant of adjustment variations. The mechanical system is designed with built-in compliance that allows for reasonable imprecision in user adjustments while still achieving functional performance, reducing the need for highly precise professional adjustment while maintaining operational effectiveness.
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
Enables precise control over vehicle performance, reduces costs by allowing owners to adjust torque settings without professional intervention, maintains optimal gear speed ratios under varying loads, and is mechanically efficient and simple to manufacture and service.
Implementation Method 1
a hydraulic coupling for efficient power transfer
Data Source
AI summary
A differential device may include a housing having an inner surface and an outer surface, said inner surface having an outer ring gear and said outer surface having a first receptacle and a sun gear positioned within the housing, the sun gear having a second receptacle positioned opposite the first receptacle. The differential device may further include an intermediate gear interposed between the sun gear and the outer ring gear, a bearing interposed between the inner surface of the housing and the sun gear, and a central axis intersecting the first receptacle and the second receptacle. The housing and the sun gear may be configured to rotate freely about the central axis.