Lightweight Differential

Paper #:
  • 2011-36-0105

Published:
  • 2011-10-04
Citation:
Hosokawa, R., Stevaux, R., and Martins, A., "Lightweight Differential," SAE Technical Paper 2011-36-0105, 2011, https://doi.org/10.4271/2011-36-0105.
Pages:
10
Abstract:
For environmental issues, the Automotive Industry is always looking for opportunities in terms of weight and size reduction. This consequently results in fuel consumption reduction.This new concept is more compact, lighter, quieter, more efficient and with higher performance. These attributes are possible by a completely new differential design.The architecture of this space-saving component is completely different from traditional differential designs. Instead of using conventional differential pinions, the Lightweight Differential has spur gears arranged as a planetary gear set in one plane, as used in automatic transmissions. This means that the required space and weight are significantly reduced and the potential torque capacity is noticeably increased.The lightweight or spur gear differential has enormous advantages. It's possible to save up to 30 percent weight compared with a classic bevel gear differential while creating up to 70 percent more axial space due to the streamlined design. In specific terms this means a reduction in mass of up to three kilograms per differential and 90 millimeters of additional space in the transmission.The Lightweight Differential is an appropriate response to the challenge of increasing engine torques and the space gained in the transmission creates more room for larger double clutches or transfer boxes, as well as electronic components for modern hybrid solutions.
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