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

Patent metadata

Field	Value
Publication number	US-10197144-B2
Application number	US-201715411555-A
Country	US
Kind code	B2
Filing date	Jan 20, 2017
Priority date	Jan 20, 2017
Publication date	Feb 5, 2019
Grant date	Feb 5, 2019

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.

First claim

What is claimed is:

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 d

Assignees

• Dana Heavy Vehicle Sys Group

Inventors

• Cooper Kenneth E

Classifications

• F16H48/08

  comprising bevel gears · CPC title

• F16D13/52

  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 title

• B60K17/165

  provided between independent half axles (B60K17/18, B60K17/20 take precedence) · CPC title

• B60K23/04

  for differential gearing · CPC title

• B60K17/34

  for driving both front and rear wheels, e.g. four wheel drive vehicles · CPC title