US 12,352,345 B1Granted

Disconnecting differential side gear mechanism

AssigneeMAGNA Powertrain AG & Co KG

InventorsDusan Milacic, Sean Steele, Myron Samila, Stephen Yang, David Gelfand

Life of this patent

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Abstract

A disconnectable differential assembly has a reduced axial length and a side gear disconnectable from an axle shaft via a clutch unit. Various components of the disconnect mechanism are axially aligned and concentric to reduce the axial length. An output hub splined on the axle shaft and is actuatable, via an axially shiftable armature, into toothed engagement with the side gear via respective axially extending teeth. The output hub and armature include radially extending flanges that are axially adjacent and radially aligned with the teeth so that force is transmitted to the teeth at the same diameter. A thrust bearing is disposed between the flanges so that the output hub rotates relative to the armature. The side gear is supported for rotation on the axle shaft, and a bearing is disposed radially therebetween to improve radial alignment of the second side gear with the output hub.

Claims20

Dependent claims

An electrically powered drivetrain for a vehicle, comprising:

an electric motor;
a first axle shaft;
a second axle shaft;
a disconnecting differential assembly driven by the electric motor, comprising:
a differential case that rotates about a first axis;
a differential mechanism received in the differential case having a plurality of differential pinions and first and second side gears transmitting power between the differential case and the first and second side gears;
the first side gear rotationally fixed to the first axle shaft;
the second side gear with axially extending teeth;
an output hub with axially extending teeth which is rotationally fixed to the second axle shaft and axially shiftable relative to the second axle shaft toward and away from the second side gear;
a power operated disconnect mechanism operable in a disconnected mode to uncouple the output hub from the second side gear and in a connected mode to couple the output hub to the second side gear;
and
a control system for controlling operation of the power operated disconnect mechanism;
wherein the second side gear is supported for rotation on the second axle shaft with a bearing element disposed radially therebetween, and wherein the bearing element radially aligns the output hub and the second side gear for improved connecting and disconnecting therebetween.

10 more elements

An electrically powered drivetrain comprising:

an electric motor;
a disconnecting differential assembly driven by the electric motor, comprising:
a differential case that rotates about a first axis;
a differential mechanism received in the differential case having a plurality of differential pinions and first and second side gears for transmitting power between the differential case and the first and second side gears;
the first side gear rotationally fixed to a first axle shaft;
the second side gear having axially extending teeth;
an output hub having axially extending teeth which is rotationally fixed to a second axle shaft and is axially shiftable relative to the second axle shaft toward and away from the second side gear;
a power operated disconnect mechanism operable in a disconnected mode to uncouple the teeth on the output from the teeth on the second side gear and in a connected mode to couple the teeth of the output hub to the teeth of the second side gear;
a control system for controlling operation of the power operated disconnect mechanism;
an armature configured for axial movement relative to the second side gear, the armature configured to move the output hub into engagement with the second side gear;
and
a solenoid disposed radially outward from the armature and a plunger mounted to the armature, wherein actuation of the solenoid shifts the plunger and armature toward the output hub and the output hub toward the second side gear;
wherein the solenoid, the plunger, the armature, and a sleeve portion of the output hub are concentrically arranged and axially aligned to define a radial stack-up surrounding the second axle shaft.

10 more elements

An electrically powered drivetrain comprising:

an electric motor;
a first axle shaft;
a second axle shaft;
a disconnecting differential assembly driven by the electric motor, comprising:
a differential case that rotates about a first axis;
a differential mechanism received in the differential case and having a plurality of differential pinions meshed with first and second side gears for transmitting power between the differential case and the first and second side gears;
the first side gear being rotationally fixed to the first axle shaft;
the second side gear having axially extending teeth;
an output hub with axially extending teeth and which is rotationally fixed to the second axle shaft and axially shiftable relative to the second axle shaft toward and away from the second side gear;
a power operated disconnect mechanism operable in a disconnected mode to uncouple the teeth on the output hub from the teeth on the second side gear and in a connected mode to couple the teeth on the output hub to the teeth of the second side gear;
a control system for controlling operation of the power operated disconnect mechanism;
an armature configured for axial movement relative to the second side gear, the armature configured to move the output hub into engagement with the second side gear, the armature having a radially inwardly extending flange portion and the output hub having a radially outwardly extending flange portion such that the respective flange portions are radially aligned and axially offset such that an axial moving force is transmitted therebetween;
and
a thrust bearing disposed axially between the flange portions of the armature and the output hub, wherein the armature is rotationally stationary and the output hub is rotatable relative to the armature.

11 more elements

Dependencies are inferred from the claim text.

Facts

Application: 19/038,943Filed 28 Jan 2025 · continuation
Priority: 16 Apr 2021
Granted: 8 Jul 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification21 codes

B60K 17/16
Characterised by arrangement, location or kind of gearing: of differential gearing
B60K 23/08
Arrangement or mounting of control devices for vehicle transmissions, or parts thereof, not otherwise provided for: for changing number of driven…
B60K 17/02
Arrangement or mounting of transmissions in vehicles: characterised by arrangement, location, or kind of clutch
B60K 17/165
Of differential gearing: provided between independent half axles

Family

Application63/175,831Us provisional application · filed 16 Apr 2021
PCT/CA2022/050570Parent of this continuation · filed 13 Apr 2022
Application18/554,509Parent of this continuation
US 12,240,321 B2Parent of this continuation
US 2024/0198794 A1Published application
US 12,352,345 B1This patent

From the US filing history. Foreign family members aren’t listed.