Drive unit with torque vectoring and an axle disconnect and reconnect mechanism

• US 10,197,144 B2
• Filed: 01/20/2017
• Issued: 02/05/2019
• Est. Priority Date: 01/20/2017
• Status: Active Grant

• Current Assignee: Dana Heavy Vehicle Systems Group LLC (Dana, Inc.)
• Original Assignee: Dana Heavy Vehicle Systems Group LLC (Dana, Inc.)
• Inventors: Cooper, Kenneth E.
• Primary Examiner(s): Hlavka, David J
• Application Number:
  US15/411,555
• Publication Number:
  US 20180209527A1
• Time in Patent Office: 746 Days
• CPC Class Codes: B60K 17/02 characterised by arrangement, location, or kind of clutch
• CPC Class Codes: B60K 17/16 of differential gearing
• CPC Class Codes: B60K 17/165 provided between independent half axles B60K17/18, B60K17/20 take precedence
• CPC Class Codes: B60K 17/34 for driving both front and rear wheels, e.g. four wheel drive vehicles arrangement or mounting of control devices for changing number of driven wheels B60K23/08
• CPC Class Codes: B60K 17/344 having a transfer gear
• CPC Class Codes: B60K 17/35 including arrangements for suppressing or influencing the power transfer, e.g. viscous clutches differential gearing with locking devices F16H48/20
• CPC Class Codes: B60K 17/3515 with a clutch adjacent to traction wheel, e.g. automatic wheel hub
• CPC Class Codes: B60K 17/36 for driving tandem wheels
• CPC Class Codes: B60K 23/04 for differential gearing
• CPC Class Codes: B60K 23/08 for changing number of driven wheels , for switching from driving one axle to driving two or more axles B60K17/3515 takes precedence
• CPC Class Codes: B60K 23/0808 for varying torque distribution between driven axles, e.g. by transfer clutch
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• CPC Class Codes: B60Y 2300/82 Torque vectoring
• CPC Class Codes: B60Y 2400/421 Dog type clutches or brakes
• CPC Class Codes: B60Y 2400/424 Friction clutches
• CPC Class Codes: F16D 11/16 with clutching members movable otherwise than only axially F16D11/02, F16D11/08 take precedence
• CPC Class Codes: F16D 13/52 Clutches with multiple lamellae ; Clutches in which three or more axially moveable members are fixed alternately to the shafts to be coupled and are pressed from one side towards an axially-located member F16D13/385 takes precedence
• CPC Class Codes: F16D 21/00 Systems comprising a plurality of actuated clutches for synchronisation F16D23/04
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: F16H 48/22 using friction clutches or brakes
• CPC Class Codes: F16H 48/32 : using fluid pressure actuators
• CPC Class Codes: F16H 48/34 : using electromagnetic or electric actuators
• CPC Class Codes: F16H 48/36 : characterised by intentionally generating speed difference between outputs
• CPC Class Codes: F16H 48/40 : characterised by features of the rotating cases

Abstract

A differential assembly having a torque coupling unit and an axle disconnect. A first end portion of an intermediate portion of a differential case is integrally connected to a ring gear. Integrally connected to an inner surface of the intermediate portion of the case is a first plurality of clutch plates. Disposed within a hollow portion of the intermediate portion is a first and a second differential side gear that are meshing with one or more pinion gears. Drivingly connected to the first side gear is a first output shaft. A clutch can having a second plurality of clutch plates is drivingly connected to the first output shaft. Within the hollow portion of the intermediate portion of the case is a clutching assembly that selectively engages the second side gear. A first clutch actuator selectively engages the plurality of plates and a second clutch actuator selectively engages the clutching assembly.

Claims

1. A differential assembly, comprising:

a differential case having a first end portion, a large diameter intermediate portion and a second end portion;

wherein said large diameter intermediate portion has a first end portion, second end portion, a first end, second end, an inner surface and an outer surface defining a hollow portion therein;

wherein a first reduced diameter portion of said first end portion of said differential case is disposed adjacent to and axially outboard from said first end of said large diameter intermediate portion and a first radially extending wall connects said first reduced diameter portion of said first end portion of differential case to said first end of said large diameter intermediate portion of said differential case;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said first radially extending wall;

wherein a first reduced diameter portion of said second end portion of said differential case is disposed adjacent to and axially outboard from said second end of said large diameter intermediate portion and a second radially extending wall connects said first reduced diameter portion to said second end of said large diameter intermediate portion;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said second radially extending wall;

a first differential side gear, a second differential side gear and one or more differential pinion gears disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said first differential side gear is drivingly connected to a first differential output shaft having a first end portion and a second end portion;

wherein said second differential side gear is drivingly connected to a first end portion of a stub shaft and a second end portion of said stub shaft is rotationally connected top at least a portion of a first end portion of a second differential output shaft;

a dog clutch assembly having a first portion and a second portion disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said first portion of said clutching assembly extends axially outboard from an axially outboard side of said second differential side gear and a plurality of clutch teeth circumferentially extend from an inner surface of said first portion of said clutching assembly;

wherein said second portion of said clutching assembly is drivingly connected to and slidingly engaged with said first end portion of said second differential output shaft;

wherein a substantially cylindrical portion extends axially inboard from an axially inboard side of said second portion of said clutching assembly and a plurality of clutch teeth circumferentially extend from an outer surface of said substantially cylindrical portion of said second portion of said clutching assembly;

a clutch can in driving engagement with said second end portion of said first differential output shaft and is disposed within said hollow portion of said large diameter intermediate portion of said differential case;

a clutch pack comprising a first and a second plurality of clutch plates;

wherein said first plurality of clutch plates are drivingly engaged with said inner surface of said first end portion of said large diameter intermediate portion and said second plurality of clutch plates are drivingly engaged with an outer surface of said clutch can;

a first clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said first end portion of said differential case;

wherein said first clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said first radially extending wall in an axial manner to apply a force to said clutch pack causing said first and said second plurality of clutch plates to be at least variably frictionally engaged;

a second clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said second end portion of said differential case; and

wherein said second clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said second radially extending wall in an axial manner to apply a force to said second portion of said clutching assembly to selectively meshingly engage said plurality of clutch teeth on said second portion of said clutching assembly with said plurality of clutch teeth on said first portion of said clutching assembly.

2. The differential assembly of claim 1, wherein said first clutch actuation mechanism is a pneumatic actuator, a hydraulic actuator, an electromagnetic actuator or a ball and ramp actuator;

and

wherein said second clutch actuation mechanism is a pneumatic actuator, a hydraulic actuator, an electromagnetic actuator or a ball and ramp actuator.

3. The differential assembly of claim 1, further comprising a biasing member, wherein said biasing member is disposed between said second differential side gear and said and said second portion of said clutching assembly.

4. The differential assembly of claim 3, wherein said clutching assembly has a first position and a second position;

wherein in said first position said plurality of clutch teeth on said second portion of said clutching assembly are not meshingly engaged with said plurality of clutch teeth on said first portion of said clutching assembly defining a gap therebetween; and

wherein in said second position said plurality of clutch teeth on said second portion of said clutching assembly are meshingly engaged with said plurality of clutch teeth on said first portion of said clutching assembly.

5. The differential assembly of claim 1, further comprising a first bearing and a second bearing;

wherein said first bearing is disposed between said first clutch actuation mechanism and said first reduced diameter portion of said first end portion of said differential case; and

wherein said second bearing is disposed between said second clutch actuation mechanism and said first reduced diameter portion of said second end portion of said differential case.

6. The differential assembly of claim 1, further comprising a first thrust bearing and a second thrust bearing;

wherein said first thrust bearing is disposed between said first clutch actuation mechanism and said one or more thrust pins in said one or more openings of said first radially extending wall of said differential case; and

wherein said second thrust bearing is disposed between said second clutch actuation mechanism and said one or more thrust pins in said one or more openings of said second radially extending wall of said differential case.

7. The differential assembly of claim 6, further comprising a first radially extending thrust wall, a second radially extending thrust wall, a third trust bearing and a fourth thrust bearing;

wherein said first radially extending thrust wall is integrally connected to and extends radially outboard from an outer surface of said first reduced diameter portion of said first end portion of said differential case;

wherein said third thrust bearing is disposed between said first clutch actuation mechanism and said first radially extending thrust wall of said first reduced diameter portion of said first end portion of said differential case;

wherein said second radially extending thrust wall is integrally connected to and extends radially outboard from an outer surface of said first reduced diameter portion of said second end portion of said differential case; and

wherein said fourth thrust bearing is disposed between said second clutch actuation mechanism and said second radially extending thrust wall of said first reduced diameter portion of said second end portion of said differential case.

8. A differential assembly, comprising:

a ring gear;

a differential case having a first end portion, a large diameter intermediate portion and a second end portion;

wherein said large diameter intermediate portion has a first end portion, second end portion, a first end, second end, an inner surface and an outer surface defining a hollow portion therein;

wherein a first reduced diameter portion of said first end portion of said differential case is disposed adjacent to and axially outboard from said first end of said large diameter intermediate portion and a first radially extending wall connects said first reduced diameter portion of said first end portion of differential case to said first end of said large diameter intermediate portion of said differential case;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said first radially extending wall;

a first differential side gear, a second differential side gear and one or more differential pinion gears disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said second differential side gear is drivingly connected to a second differential output shaft;

wherein said first differential side gear is drivingly connected to a first differential output shaft having a first end portion and a second end portion and an outer surface;

a clutch can in driving engagement with said second end portion of said first differential output shaft and is disposed within said hollow interior portion of said large diameter intermediate portion of said differential case;

a clutch pack comprising a first and a second plurality of clutch plates;

wherein said first plurality of clutch plates are drivingly engaged with said inner surface of said first end portion of said large diameter intermediate portion and said second plurality of clutch plates are drivingly engaged with an outer surface of said clutch can;

wherein at least a portion of said first and said second plurality of clutch plates are disposed axially outboard from an axially outboard side and axially inboard from an axially inboard side of said differential ring gear;

a shaft having a second end portion that is rotationally connected said first end portion of said first differential output shaft;

a first clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said first end portion of said differential case;

wherein said first clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said first radially extending wall in an axial manner to apply a force to said clutch pack causing said first and said second plurality of clutch plates to be at least variably frictionally engaged;

a sliding collar disposed outside said differential case;

wherein a plurality of splines circumferentially extend from at least a portion of an inner surface of said sliding collar;

wherein said plurality of splines on said inner surface of said sliding collar are complementary to a plurality of splines circumferentially extending from at least a portion of said outer surface of said first end portion of said first differential output shaft and a plurality of splines circumferentially extending from at least a portion of an outer surface of said second end portion of said shaft;

a shift fork;

wherein at least a portion of a second end portion of said shift fork is disposed within a channel circumferentially extending along said outer surface of said sliding collar; and

an actuation mechanism applies a force onto a first end portion of said shift fork driving said sliding collar from a first position to a second position.

9. The differential assembly of claim 8, wherein said first clutch actuation mechanism is a pneumatic actuator, a hydraulic actuator, an electromagnetic actuator or a ball and ramp actuator.

10. The differential assembly of claim 8, wherein the actuation mechanism is a pneumatic actuator, a hydraulic actuator or an electromagnetic actuator.

11. The differential assembly of claim 8, wherein in said first position said shaft is disconnected from said first differential output shaft;

and

wherein in said second position said shaft is drivingly connected to said first differential output shaft.

12. The differential assembly of claim 8, further comprising a bearing, wherein said bearing is disposed between said first clutch actuation mechanism and said first reduced diameter portion of said first end portion of said differential case.

13. The differential assembly of claim 8, further comprising a first thrust bearing, wherein said first thrust bearing is disposed between said first clutch actuation mechanism and said one or more thrust pins in said one or more openings of said first radially extending wall of said differential case.

14. The differential assembly of claim 13, further comprising a first radially extending thrust wall and a second thrust bearing;

wherein said first radially extending thrust wall is integrally connected to and extends radially outboard from an outer surface of said first reduced diameter portion of said first end portion of said differential case; and

wherein said second thrust bearing is disposed between said first clutch actuation mechanism and said first radially extending thrust wall of said first reduced diameter portion of said first end portion of said differential case.

15. A differential assembly, comprising:

a ring;

a differential case having a first end portion, a large diameter intermediate portion and a second end portion;

wherein said large diameter intermediate portion has a first end portion, second end portion, a first end, second end, an inner surface and an outer surface defining a hollow portion therein;

wherein a first reduced diameter portion of said first end portion of said differential case is disposed adjacent to and axially outboard from said first end of said large diameter intermediate portion and a first radially extending wall connects said first reduced diameter portion of said first end portion of differential case to said first end of said large diameter intermediate portion of said differential case;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said first radially extending wall;

a first differential side gear, a second differential side gear and one or more differential pinion gears disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said first differential side gear is drivingly connected to a first differential output shaft;

wherein said second differential side gear is drivingly connected to a second differential output shaft having a first end portion, a second end portion and an outer surface;

a clutch can in driving engagement with said second end portion of said first differential output shaft and disposed within said hollow portion of said large diameter intermediate portion of said differential case;

a clutch pack comprising a first and a second plurality of clutch plates;

wherein said first plurality of clutch plates are drivingly engaged with said inner surface of said first end portion of said large diameter intermediate portion of said differential case and said second plurality of clutch plates are drivingly engaged with an outer surface of said clutch can;

wherein at least a portion of said first and said second plurality of clutch plates are disposed axially outboard from an axially outboard side of and axially inboard from an axially inboard side of said differential ring gear;

a shaft having first end portion that is rotatively connected to said second end portion of said second differential output shaft;

a first clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said first end portion of said differential case;

wherein said first clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said first radially extending wall in an axial manner to apply a force to said clutch pack causing said first and said second plurality of clutch plates to be at least variably frictionally engaged;

a sliding collar disposed outside said differential case;

wherein a plurality of splines circumferentially extend from at least a portion of an inner surface of said sliding collar;

wherein said plurality of splines on said inner surface of said sliding collar are complementary to a plurality of splines circumferentially extending from at least a portion of said outer surface of said second end portion of said second differential output shaft and said plurality of splines circumferentially extending from at least a portion of an outer surface of said first end portion of said shaft;

a shift fork;

wherein at least a portion of a second end portion of said shift fork is disposed within a channel circumferentially extending along said outer surface of said sliding collar; and

an actuation mechanism applies a force onto a first end portion of said shift fork driving said sliding collar from a first position to a second position.

16. The differential assembly of claim 15, wherein said first clutch actuation mechanism is a pneumatic actuator, a hydraulic actuator, an electromagnetic actuator or a ball and ramp actuator.

17. The differential assembly of claim 15, wherein the actuation mechanism is a pneumatic actuator, a hydraulic actuator or an electromagnetic actuator.

18. The differential assembly of claim 15, wherein in said first position said shaft is disconnected from said second differential output shaft;

and

wherein in said second position said shaft is drivingly connected to said second differential output shaft.

19. The differential assembly of claim 15, further comprising a bearing, wherein said bearing is disposed between said first clutch actuation mechanism and said first reduced diameter portion of said first end portion of said differential case.

20. The differential assembly of claim 15, further comprising a first thrust bearing, wherein said first thrust bearing is disposed between said first clutch actuation mechanism and said one or more thrust pins in said one or more openings of said first radially extending wall of said differential case.

21. The differential assembly of claim 20, further comprising a first radially extending thrust wall and a second thrust bearing;

wherein said first radially extending thrust wall is integrally connected to and extends radially outboard from an outer surface of said first reduced diameter portion of said first end portion of said differential case; and

wherein said second thrust bearing is disposed between said first clutch actuation mechanism and said first radially extending thrust wall of said first reduced diameter portion of said first end portion of said differential case.

22. A differential assembly, comprising:

a differential case having a first end portion, a large diameter intermediate portion and a second end portion;

wherein said large diameter intermediate portion has a first end portion, second end portion, a first end, second end, an inner surface and an outer surface defining a hollow portion therein;

wherein a first reduced diameter portion of said first end portion of said differential case is disposed adjacent to and axially outboard from said first end of said large diameter intermediate portion and a first radially extending wall connects said first reduced diameter portion of said first end portion of differential case to said first end of said large diameter intermediate portion;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said first radially extending wall into said hollow portion of said large diameter intermediate portion;

wherein a first reduced diameter portion of said second end portion of said differential case is disposed adjacent to and axially outboard from said second end of said large diameter intermediate portion and a second radially extending wall connects said first reduced diameter portion of said second end portion of differential case to said second end of said large diameter intermediate portion;

wherein at least a portion of one or more thrust pins extend through one or more openings extending from an inner surface to an outer surface of said second radially extending wall;

a first differential side gear, a second differential side gear and one or more differential pinion gears disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said first differential side gear is drivingly connected to a first differential output shaft having a first end portion and a second end portion;

wherein said second differential side gear is drivingly connected to a first end portion of a stub shaft and a second end portion of said stub shaft is rotatively connected to at least a portion of a first end portion of a second differential output shaft;

a clutching assembly having a first portion and a second portion disposed within said hollow portion of said large diameter intermediate portion of said differential case;

wherein said first portion of said clutching assembly comprises a plurality of clutch teeth circumferentially extending from an axially outboard side of said second differential side gear;

wherein said second portion of said clutching assembly is drivingly connected to and slidingly engaged with said first end portion of said second differential output shaft and a plurality of clutch teeth circumferentially extend from an axially inboard side of said second portion of said clutching assembly;

a clutch can in driving engagement with said second end portion of said first differential output shaft and disposed within said hollow portion of said large diameter intermediate portion of said differential case;

a clutch pack comprising a first and a second plurality of clutch plates;

wherein said first plurality of clutch plates are drivingly engaged with said inner surface of said first end portion of said large diameter intermediate portion and said second plurality of clutch plates are drivingly engaged with an outer surface of said clutch can;

a first clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said first end portion of said differential case;

wherein said first clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said first radially extending wall in an axial manner to apply a force to said clutch pack causing said first and said second plurality of clutch plates to be at least variably frictionally engaged;

a second clutch actuation mechanism disposed radially outboard from said first reduced diameter portion of said second end portion of said differential case; and

wherein said second clutch actuation mechanism drives said one or more thrust pins in said one or more openings of said second radially extending wall in an axial manner to apply a force to said second portion of said clutching assembly to selectively meshingly engage said plurality of clutch teeth on said second portion of said clutching assembly with said plurality of clutch teeth on said axially outboard side of said second differential side gear.