DESC:FIELD OF THE INVENTION
[001] The present subject matter relates to an integrated pinion pack with FE bearing System for drive axle. More specifically, it relates to the pinion head and tail bearings in differential carrier assembly, which are used to take the axial loads and the variable pinion collar, which is selective fitment part used as per requirement of bearing preload and a method of manufacturing thereof.
BACKGROUND
[002] The differential carrier assembly mounts on drive axle housing, wherein two separate taper roller bearings are assembled on pinion shaft fitted with a collar in between them. Therefore, during assembly of bearings, to achieve required pre-loading, we need to change the collar as per required size, which are available in stock. This increases the assembly time, due selection of correct collar. Further, there are possible risks of bearing pre-load errors and it is difficult to achieve required pre-load values.
[003] Also, the differential carrier assembly provides a certain amount of energy losses of which taper roller bearings accounts for great amounts of losses. In addition to the number of parts required to do the assembly increases the inventory and assembly time.
[004] Currently, in 458DH the differential case is made with complex geometry to provide strength and rigidity as shown below resulting in churning losses which is providing us scope to make improved design. And with amboid offset (Offset above center), it is also required to provide lubrication at a greater height with same lubrication level.
[005] Hence there is an unmet need of integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line and also required minimum space to operate the vehicle in a cost-effective manner.
BRIEF SUMMARY
[006] The present invention solved the aforementioned and other problems by providing integrated pinion pack with FE bearing System for drive axle, wherein the an unitized bearing which is a combination of two taper roller bearings fitted together make an integrated system.
[007] The unitized pinion pack design with fuel efficient bearings has several advantages such as minimize the requirements of parts required to do the assembly increases the inventory and assembly time by the way of replacing two taper roller bearings with a unitized pinion packed FE bearing thus reducing time for variable collar selection. Also reduces the risks of bearing pre-load errors.
[008] The diff. case LH has been designed such that its geometry will provide a smooth flow of lubricant resulting in less turbulence hence less amount of churning losses.
[009] Further the differential carrier housing is provided with special oil galleries which will ensure proper lubrication to pinion and differential bearings. The smooth oil flow helps in providing better cooling property and better lubrication to all assembly components.
[0010] Another advantage of present invention is to overcome the challenge of packaging the unitized bearing inside the retainer, since new unitized bearing cannot be packaged into the existing bearing retainer; new retainer is designed with lock nut to hold the unitized bearings.

DESCRIPTION OF DRAWINGS
[0011] The present invention relates to relates to an integrated pinion pack with FE bearing system for drive axle. More specifically, it relates to the pinion head and tail bearings in differential carrier assembly which are used to take the axial loads. And the variable pinion collar which is selective fitment part used as per requirement of bearing preload and a method of manufacturing thereof.
[0012] FIG. 1 describes the system of the present subject matter
[0013] FIG. 1 relates to integrated pinion pack with FE bearing System for drive axle. More specifically, it relates to the pinion head and tail bearings in differential carrier assembly which are used to take the axial loads. And the variable pinion collar which is selective fitment part used as per requirement of bearing preload and a method of manufacturing thereof.
[0014] Here the unitized pinion pack design with fuel efficient bearings has several advantages such as minimize the requirements of parts required to do the assembly increases the inventory and assembly time by the way of replacing two taper roller bearings with a unitized pinion packed FE bearing thus reducing time for variable collar selection. Also reduces the risks of bearing pre-load errors.
[0015] The diff. case LH has been designed such that its geometry will provide a smooth flow of lubricant resulting in less turbulence hence less amount of churning losses.
[0016] Further the differential carrier housing is provided with special oil galleries which will ensure proper lubrication to pinion and differential bearings. The smooth oil flow helps in providing better cooling property and better lubrication to all assembly components.
[0017] 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.
[0018] 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.
[0019] It would become abundantly clear to a person in the art, after reading this specification that the present subject matter also provides a an integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line and method of manufacturing thereof. More specifically, the present subject matter discloses a an integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line comprising a unitized bearing which is a combination of two taper roller bearings fitted together make an integrated system characterized by the way of replacing two taper roller bearings with a unitized pinion packed FE bearing thus reducing time for variable collar selection effectively and 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) An integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line comprising a unitized bearing which is a combination of two taper roller bearings fitted together make an integrated system characterized by the way of replacing two taper roller bearings with a unitized pinion packed FE bearing thus reducing time for variable collar selection.
2) The integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line as claimed in Claim 1, wherein said system having differential case LH has been designed such that its geometry will provide a smooth flow of lubricant resulting in less turbulence hence less amount of churning losses.
3) The integrated pinion pack with FE bearing System for drive axle to reduce the complexity of assembling line as claimed in Claim 1, wherein differential carrier housing is provided with special oil galleries which will ensure proper lubrication to pinion and differential bearings. The smooth oil flow helps in providing better cooling property and better lubrication to all assembly components.

Yours Faithfully

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