DE-102024210763-A1 - Differential, a drive arrangement with a differential, and a method for manufacturing a differential.

Abstract

The invention relates to a differential (10) for a drive arrangement of a motor vehicle with features of claim 1, a drive arrangement with at least one such differential (10) and a method for manufacturing such a differential (10).

Inventors

• Simone Lombardo
• Daniel Weissinger
• Stefan Anspann
• Oliver Albrecht
• Christoph Lehmeier

Assignees

• Robert Bosch Gesellschaft mit beschränkter Haftung

Dates

Publication Date

20260513

Application Date

20241108

Claims (10)

1. Differential (10) for a drive arrangement of a motor vehicle comprising: - a differential basket (12), - a differential gear (14), - at least two ring segments (16), - wherein the differential basket (12), the differential gear (14) and the ring segments (16) are welded together.
2. Differential (10) according to Claim 1 , characterized in that the differential basket (12), the differential gear (14) and the ring segments (16) are welded together by means of capacitor discharge welding.
3. Differential (10) according to Claim 1 or 2 , characterized in that the ring segments (16) are arranged at a distance from each other, in particular equidistantly.
4. Differential (10) according to one of the preceding claims, characterized in that the differential (10) comprises three ring segments (16) which are arranged in particular at an angle of 120° to each other.
5. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) are aligned - in a random, undefined orientation to a component or several components, - in a specific angular position to a component or several components or - relative to a reference feature or several reference features on a component or several components.
6. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) have a round, circular, rectangular and/or triangular cross-section.
7. Differential (10) according to one of the preceding claims, characterized in that the ring segments (16) are manufactured by forming technology.
8. Drive arrangement for a motor vehicle comprising at least one differential (10) according to one of the preceding claims.
9. Method for manufacturing a differential (10) according to one of the Claims 1 until 7 comprising the steps: - Providing the differential gear (14) and the differential basket (12); - Pressing the differential gear (14) onto the differential basket (12) and/or the differential basket (12) onto the differential gear (14) by means of press joining.
10. Procedure according to Claim 9 , characterized by the steps: - providing the ring segments (16); - welding, in particular by means of condensation discharge injection welding, of the differential basket (12), the differential gear (14) and the ring segments (16) together.

Description

State of the art The invention relates to a differential for a drive arrangement of a motor vehicle with features of claim 1, a drive arrangement with at least one such differential and a method for manufacturing such a differential. A motor vehicle typically has a differential to distribute the torque generated by the engine to two output shafts. The torque is usually transmitted to the differential via a differential gear, which is mounted on a differential housing into which the two output shafts connect. The differential gear can be bolted or laser-welded to the differential housing, for example. The disadvantage is that screwing and/or laser welding are costly and time-consuming. Disclosure of the invention According to the invention, a differential for a drive arrangement of a motor vehicle is proposed, comprising a differential housing, a differential gear, and at least two ring segments. The ring segments are, in particular, ring-shaped. The differential housing, the differential gear, and the ring segments are welded together. In other words, the differential housing, the differential gear, and the ring segments are connected to one another by means of a welded joint, in particular a metallurgical bond. This allows for a cost-effective and stable, and in particular, material-bonded, connection between the differential carrier and the differential gear using simple means. A complex bolted connection is unnecessary. Thanks to the ring segments, a complete weld ring is not required, thus reducing material usage and therefore costs. The ring segments can be arranged in a ring shape or along a circular path on the differential housing and/or differential gear. The ring segments can also be arranged in a ring shape or along a circular path between the differential housing and the differential gear. The ring segments can be welded together. The ring segments can be identical. It is also conceivable that at least two ring segments can be configured differently. According to a further development of the differential, the differential basket, the differential gear and the ring segments can be welded together using capacitor discharge welding (KEEP). This allows for the creation of a cost-effective and stable welded joint using simple means. According to a further development of the differential, the ring segments can be arranged at a distance from each other. The ring segments can be arranged equidistantly. This can reduce the amount of material required and therefore the costs. According to a further development of the differential, the differential can comprise three ring segments. The three ring segments can be arranged at an angle of 120° to each other. This allows the welded joint to be further optimized. According to a further development of the differential, the ring segments can be oriented in a random, undefined orientation relative to one or more components. The ring segments can be oriented at a specific angular position relative to one or more components. The ring segments can be oriented relative to one or more reference features on one or more components. The component(s) can be part of the differential, the drive assembly, and/or the motor vehicle. This allows the welding connection to be implemented as flexibly as possible. According to a further development of the differential, the ring segments can have a round, circular, rectangular and/or triangular cross-section. Other geometric shapes for the cross-section of the ring segments are also conceivable. This allows the welding connection to be implemented as flexibly as possible. According to a further development of the differential, the ring segments can be manufactured using forming technology. The ring segments can be manufactured using forming technology. It is also conceivable that the ring segments could be manufactured using another manufacturing process. This allows the ring segments to be implemented using simple means and/or cost-effectively. According to the invention, a drive arrangement for a motor vehicle comprising at least one differential as described above is proposed. Regarding the advantages achievable with the drive arrangement, reference is made to the relevant explanations concerning the differential. The measures described in connection with the differential and/or those explained below can be used for further development of the drive arrangement. The drive arrangement can, for example, be designed as an e-axle or form part of an e-axle. According to the invention, a method for manufacturing a differential as described above is proposed. The method comprises the following steps: Providing the differential gear and differential carrier. Pressing the differential gear onto the differential carrier and/or the differential carrier onto the differential gear by means of press joining. The differential gear can be pressed onto the differential housing using a press fit. This allows for high alignment accuracy between the d