DESC:FIELD OF THE INVENTION
[001] The present disclosure generally relates to a differential case unit and method of manufacturing thereof. More particularly, the present disclosure relates to the differential case unit for hub reduction axle and method of manufacturing thereof.
BACKGROUND
[002] The current practice is to use split type differential casing with separate unit in the automobile. In the split type differential casing design, an interconnection is required to connect left and right lobes of the unit. Because in current differential case system design, differential unit is located in both left-hand (LH) and right hand (RH) cases with having spherical shape. There is a need of machining system to done on both the different cases. Also, for aftermarket if failure occurs both LH and RH differential case needs to be replaced lead towards additional cost to customer and also hardware is required for crown mounting separately.
[003] The existing system is a split type of different case, in which housing for differential gears is provided in both LH and RH case. Therefore, the machining is required to be done in both casings in assembled condition with hardware. Further extra hardware is required for crown gear mounting in addition to conventional type spider is used. Above result into higher maintenance and service cost, since in case of failure both LH and RH differential case needs to be changed lead to greater assembly time
[004] Further limitations with existing system are that there is inaccuracy to get spherical diameter from machining and also appears to be heavy weight design. Due to heavy weight design, it has greater numbers of parts or components, which lead towards higher maintenance and service cost in addition to higher assembly line.
[005] However, the limitation or drawback of such system are such as it required high maintenance cost due to integration of greater numbers of parts into the system, which lead to higher machine cost. Also, this system required greater amount of time for assembly.
[006] Therefore, there is an unmet need to find an alternate low-cost robust single integrated differential casing unit for HRT to avoid integration of higher numbers of parts or components, which leads towards higher maintenance cost resulting into undesirable machine price with greater amount of assembly time.
BRIEF DESCRIPTION
[007] The present invention solves the aforementioned and other allied problems by the way of providing integrated differential casing unit for hub reduction tandem axle (HRT). The integrated differential casing unit for HRT is a new and unique system of a single piece hub casing with integrated differential casing unit. Further due to stiffness nature with single casing there may not minimal requirement of hardware for assembly resulting low-cost product.
[008] In one embodiment, the present subject matter discloses a cost effective single integrated differential casing system comprising an integrated differential casing system characterized by low-cost robust single integrated differential casing system to avoid integration of higher numbers of parts or components and discloses a method of manufacturing the same. The cost effective single integrated differential casing system as does not comprise a left lobe and a right lobe configured to engaged with each other through a connector in the split type differential casing system
[009] It is a light-weight design as compared to conventional spider unit. Further it is light weight design, reduced no hardware’s and reduced service cost, thereby this product ensures low aftermarket service and maintenance cost.
[0010] In another embodiment, the present invention provides the single types differential case unit instead of conventional spider unit, wherein dowel pins are used for locking. Here differential case is a new and unique concept. Further crown gear is mounted between different case of LH and RH on same hardware.
[0011] Further due to spherical casing in single RH casing result into lower machining cost & almost 100% accuracy. Therefore, the present system is cost effective and light weight. Also, if failure occurs, it is not required to change whole set, only single casing needs to be changed.
[0012] Both Casing can be made with different manufacturing technology & with different material. Due to this flexibility, RH is made with forging whereas LH is made with casting. Differential lock spline cutting & Induction hardening is easily manufactured now.
BRIEF DESCRIPTION OF DRAWINGS
[0013] Aspects of the present disclosure are illustrated by way of example(s), and not by way of limitation, in the accompanying drawings, wherein:
[0014] FIG. 1 exemplifying a split spider type of differential case unit of present invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0015] The present invention relates to the split spider type of differential case unit and method of manufacturing thereof. More particularly, the present disclosure relates to the split spider type of differential case unit for hub reduction tandem axle and method of manufacturing thereof.
[0016] Referring to FIG. 1 split spider type of differential case unit for hub reduction tandem axle. The split spider type of differential case unit of present invention is a new and unique system. Further due to stiffness nature with single casing there may not minimal requirement of hardware for assembly resulting low-cost product. It is a light-weight design as compared to conventional spider type design due to single part design. Further it is light weight design, reduced no hardware’s and reduced service cost, thereby this product ensures low aftermarket service and maintenance cost.
[0017] In an alternate fashion, the present invention provides the split spider type of differential case unit instead of conventional spider unit, wherein dowel pins are used for locking. Here differential case is a new and unique concept. Further crown gear is mounted between different case of LH and RH on same hardware.
[0018] Further due to spherical casing in single RH casing result into lower machining cost & almost 100% accuracy. Therefore, the present system is cost effective and light weight. Also, if failure occurs, it is not required to change whole set, only single casing needs to be changed.
[0019] Both Casing can be made with different manufacturing technology & with different material. Due to this flexibility, RH is made with forging whereas LH is made with casting. Differential lock spline cutting & Induction hardening is easily manufactured now.
[0020] Although the present disclosure is described in terms of certain preferred embodiments and examples, other embodiments and examples will be apparent to those of ordinary skill in the art, given the benefit of this disclosure, including embodiments and examples that do not provide all of the benefits and features set forth herein, which are also within the scope of this disclosure. It is to be understood that other embodiments may be utilized, without departing from the true spirit and scope of the present invention.
[0021] It is to be understood that other embodiments of the present disclosure will become readily apparent to those skilled in the art from the following detailed description, wherein it is shown and described only various embodiments of the disclosure by way of illustration. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive.
[0022] It would become abundantly clear to a person in the art, after reading this specification that the present subject matter also provides a differential case unit for hub reduction axle and method of manufacturing thereof. More specifically, the present subject matter discloses a differential case unit for hub reduction axle without departing from the spirit of the present subject matter. While the subject matter may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described herein. Alternate embodiments or modifications may be practiced without departing from the spirit of the present subject matter. The drawings shown are schematic drawings and may not be to the scale. While the drawings show some features of the subject matter, some features may be omitted. Alternatively, in some other cases some features may be emphasized while others are not. Further, the methods disclosed herein may be performed in manner and/or order in which the methods are explained. Alternatively, the methods may be performed in manner or order different than what is explained without departing from the spirit of the present subject matter. It should be understood that the subject matter is not intended to be limited to the particular forms disclosed. Rather, the subject matter is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter.
Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)

,CLAIMS:We claim:

1) A cost effective and robust single integrated differential casing unit comprising an integrated differential casing system characterized by low-cost robust single integrated differential casing system to avoid integration of higher numbers of parts or components.

2) The cost effective single integrated differential casing system as claimed in Claim 1, wherein said system avoid split type differential casing unit.
3) The cost effective single integrated differential casing system as claimed in Claim 1, wherein said system does not comprise a left side spherical lobe and a right-side spherical lobe configured to engaged with each other through a connector of the split type differential casing unit

Yours Faithfully

ANIL KUMAR PANDEY
(IN P/A 2359)
AGENT FOR THE APPLICANT(S)