JP6565948B2 - Connection structure between differential gear and drive shaft, and vehicle manufacturing method - Google Patents

Description

  The present invention relates to a structure for coupling a differential gear and a drive shaft in a vehicle, and a method for manufacturing the vehicle.

  A differential gear, which is a differential device, is inserted in the drive system of the vehicle. A drive shaft is coupled to the differential gear. A coupling structure between the differential gear and the drive shaft according to the prior art will be described with reference to FIGS.

  As shown in FIG. 10, the differential gear 91 includes a differential case 910, a differential gear case 911, a pinion shaft 912, a differential pinion gear 913, and a differential side gear 914. The differential case 910 is provided with an opening at a position where the drive shaft 92 is inserted.

  The differential gear case 911 is housed in the differential case 910 and is supported rotatably with respect to the differential case 910. The differential pinion gear 913 is rotatably supported via a pinion shaft 912 with respect to the differential gear case 911.

  The differential side gear 914 has a cylindrical shape, and a gear portion provided on the outer peripheral portion meshes with the differential pinion gear 913.

  The drive shaft 92 is provided with a small diameter portion 92a, an intermediate portion 92b, and a large diameter portion 92c in this order in the Y direction, and the small diameter portion 92a is inserted into the differential case 910 from the opening. As shown in the enlarged portion of FIG. 10, a groove portion 92 d is formed in the circumferential direction in the small diameter portion 92 a of the drive shaft 92, and is coupled to the differential side gear 914 by a snap ring 93.

  A bracket 94 is fixed to the outer peripheral portion of the large diameter portion 92 c of the drive shaft 92. The bracket 94 is provided as a portion for engaging the inspection tool 95 when inspecting the coupling state of the differential side gear 914 and the drive shaft 92 in the differential gear 91. The inspection of the coupled state is performed by applying a force in the direction of arrow I to the inspection tool 95 engaged with the bracket 94 (Patent Document 1).

  As shown in FIG. 11, in the Y direction, an annular gap region exists between the differential case 910 and the large diameter portion 92c of the drive shaft 92, and a dust cover 96 and a seal member 97 are provided in this region. ing. The dust cover 96 is an annular metal member, and is fixed to the intermediate peripheral surface 92 f of the drive shaft 92.

  The seal member 97 includes a metal part 971, a rubber part 972, and a pressing spring 973, and is fixed to the differential case 910. The metal portion 971 is provided with an outer peripheral portion 971 a that covers the outer periphery of the drive shaft 92 in the gap region, and the rubber portion 972 is provided with an inner peripheral portion 972 a that contacts the inner peripheral portion of the dust cover 96. The seal member 97 has a configuration as a labyrinth portion as a whole by the outer peripheral portion 971a of the metal portion 971 and the inner peripheral portion 972a of the rubber portion 972a.

Japanese Patent Publication No.61-28928

  However, in the coupling structure of the differential gear 91 and the drive shaft 92 according to the above-described prior art, the bracket 94 must be provided for inspecting the coupling state of the differential side gear 914 and the drive shaft 92 in the differential gear 91, and the manufacturing cost Leads to a rise.

  The present invention has been made to solve the above-described problems, and is capable of reducing the manufacturing cost while enabling the inspection of the coupling state between the differential side gear and the drive shaft in the differential gear. An object of the present invention is to provide a coupling structure between a gear and a drive shaft and a method for manufacturing a vehicle.

  A coupling structure of a differential gear and a drive shaft according to an aspect of the present invention includes a differential gear, a drive shaft, and a seal member.

  The differential gear includes a differential case having an opening, and a differential pinion gear and a differential side gear that are housed in the differential case and mesh with each other.

  The drive shaft has a small-diameter portion and a large-diameter portion in the axial direction, the small-diameter portion is inserted into the differential case, and the large-diameter portion is disposed outside the differential case. The small-diameter portion of the drive shaft is coupled to the differential side gear, and an annular gap region is provided between the end surface of the large-diameter portion on the small-diameter portion side and the differential case.

  The seal member has an annular shape and is fixed to a portion of the differential case facing the opening. And the said sealing member has the outer peripheral part which covers the outer periphery of the said drive shaft in the said clearance gap area, The at least one part area | region of the circumferential direction in the said outer peripheral part is comprised with the flexible material.

In the coupling structure of the differential gear and the drive shaft according to this aspect, the end surface of the large-diameter portion is in a state where a portion formed of the flexible material in the outer peripheral portion is elastically deformed by application of an external force. Is exposed to the outside, so that an opening into which the tip portion of the inspection tool can be inserted is formed .

  In the said aspect, at least one part of the outer peripheral part in a sealing member is comprised with the flexible material. A portion made of a flexible material in the outer peripheral portion (hereinafter referred to as “flexible portion”) covers the outer periphery of the drive shaft in the gap region in a state where no external force is received. When it receives a force from the outside, it is elastically deformed.

When the flexible portion is elastically deformed by an external force as described above, the end surface of the large diameter portion is exposed to the outside, and an opening into which the tip portion of the inspection tool can be inserted is formed in the portion. . Therefore, in the said aspect, an inspection tool can be mounted | worn (engaged) with respect to the said end surface in a large diameter part, and it becomes possible to test | inspect the coupling | bonding state of a differential gear and a drive shaft with the said inspection tool. That is, in the above aspect, it is possible to inspect the coupling state of the differential gear and the drive shaft without bothering to provide the bracket 94 as shown in FIG. 10, and the manufacturing cost can be reduced.

  Therefore, in the coupling structure of the differential gear and the drive shaft according to the above aspect, the manufacturing cost can be reduced while the coupling state between the differential side gear and the drive shaft in the differential gear can be inspected.

  The differential gear and drive shaft coupling structure according to another aspect of the present invention further includes a dust cover in the above configuration.

  The dust cover is fixed to the outer peripheral surface of the drive shaft in the gap region, and suppresses intrusion of dust. The dust cover is disposed radially inward from the outer peripheral portion of the seal member, and has an outer peripheral portion that covers the outer periphery of the drive shaft in the gap region.

  In this aspect, the seal member is disposed radially inward from the outer peripheral portion of the dust cover, and further includes an inner peripheral portion that covers the outer periphery of the drive shaft in the gap region. As for the said inner peripheral part, the front-end | tip part of the said inner peripheral part is contacting the said outer peripheral part of the said dust cover.

  In the coupling structure of the differential gear and the drive shaft according to the above aspect, the seal member having the outer peripheral portion and the inner peripheral portion functions as a labyrinth member, and ensures high sealing performance at the joint portion between the differential gear and the drive shaft. Is superior to.

  The coupling structure of the differential gear and the drive shaft according to another aspect of the present invention is such that, in the above configuration, the outer peripheral portion of the seal member is in a state in which the distal end portion of the outer peripheral portion is reduced in diameter.

  In the coupling structure of the differential gear and the drive shaft according to the above aspect, since the tip portion of the outer peripheral portion of the seal member is reduced in diameter, mud and dust are less likely to enter the coupling portion of the differential gear and the drive shaft. Therefore, in the said aspect, it is advantageous in ensuring the high sealing performance in the coupling | bond part of a differential gear and a drive shaft.

The coupling structure of the differential gear and the drive shaft according to another aspect of the present invention is a coupling structure of the differential gear and the drive shaft, wherein the differential gear is housed in the differential case having an opening, and the differential case, A differential pinion gear and a differential side gear meshing with each other, and the drive shaft has a small diameter portion and a large diameter portion in an axial direction, the small diameter portion is inserted into the differential case, and the large diameter portion is The small-diameter portion of the drive shaft is connected to the differential side gear and is arranged outside the differential case, and an annular gap is provided between the end surface on the small-diameter portion side of the large-diameter portion and the differential case. region An annular seal member that is fixed to a portion of the differential case that faces the opening, and the seal member covers an outer periphery of the drive shaft in the gap region. And at least a partial region of the outer peripheral portion in the circumferential direction is made of a flexible material, and the portion of the outer peripheral portion made of the flexible material is elastically deformed by the addition of an external force. In this state, the end surface of the large-diameter portion is exposed to the outside, and the outer peripheral portion of the seal member is configured by a partial region in the circumferential direction with the flexible material, and the remaining region is the flexible region It is characterized by comprising a rigid material having higher rigidity than the material.

  In the coupling structure of the differential gear and the drive shaft according to the above aspect, since a part of the outer peripheral portion of the seal member is made of a rigid material, compared to a case where the entire outer peripheral portion is formed only by the flexible portion, Intrusion of mud and dust from the outside can be prevented more effectively. Therefore, in the said aspect, it is advantageous in ensuring still higher sealing performance.

  According to another aspect of the present invention, the differential gear and the drive shaft are coupled in the above configuration, wherein the flexible material is a rubber material, and the rigid material is a metal material.

  In the coupling structure of the differential gear and the drive shaft according to the above aspect, a rubber material is used as an example of a flexible material, and a metal material is used as an example of a rigid material. Therefore, a high seal is achieved while suppressing an increase in manufacturing cost. It is advantageous to secure the sex.

  The differential gear and drive shaft coupling structure according to another aspect of the present invention is the above-described structure, wherein the differential side gear has a cylindrical shape in which a gear portion is formed on an outer peripheral portion, and a circumferential shape is formed on the inner peripheral surface of the cylinder. A groove portion extending in the direction is engraved, and a groove portion extending in the circumferential direction is engraved at a tip portion of the small diameter portion of the drive shaft, and the coupling between the differential gear and the drive shaft is It is made by a snap ring fitted over a groove portion carved in the differential gear and a groove portion carved in the drive shaft.

  In the coupling structure of the differential gear and the drive shaft according to the above aspect, since the coupling between the differential gear and the drive shaft is performed using a snap ring, the differential gear and the drive shaft A reliable coupling between the two can be achieved.

  The differential gear and drive shaft coupling structure according to another aspect of the present invention may be configured such that, in the above-described configuration, the gap region is inserted at a tip portion of an inspection tool for inspecting a coupling state of the differential gear and the drive shaft. The portion made of the flexible material in the outer peripheral portion of the seal member is elastically deformed by insertion of the tip portion of the inspection tool.

In the coupling structure of the differential gear and the drive shaft according to the above aspect, when the tip portion of the inspection tool is inserted into the gap area, the portion of the seal member made of the flexible material is elastically deformed. Therefore, the tip portion of the inspection tool can be engaged with the end surface of the large-diameter portion of the drive shaft, and the coupling state between the differential gear and the drive shaft can be inspected without providing a bracket or the like separately.

  A vehicle manufacturing method according to an aspect of the present invention includes the following steps.

(I) Step of preparing a differential gear A differential gear having a differential case having an opening, and a differential pinion gear and a differential side gear that are housed in the differential case and mesh with each other is prepared.

(Ii) Step of fixing the sealing member Fixing the sealing member having an outer peripheral portion that is annular and projects in a cylindrical shape toward the outside of the differential case with respect to the portion facing the opening of the differential case. To do.

(Iii) Step of preparing a drive shaft A drive shaft having a small diameter portion and a large diameter portion in the axial direction is prepared.

(Iv) The step of coupling the small diameter portion of the drive shaft and the differential gear The small diameter portion of the drive shaft is inserted into the differential gear from the opening, and the end surface of the large diameter portion on the small diameter portion side The small diameter portion of the drive shaft and the differential gear are coupled together with an annular gap region formed between the differential case and the differential case.

(V) A step of inspecting a coupling state between the differential gear and the drive shaft A tip portion of the inspection tool is inserted into at least a part of the gap region, and the tip portion of the inspection tool is inserted into the large-diameter portion of the drive shaft. Is in contact with the end surface on the small diameter portion side, and in this state, a force in the axial direction is applied to the inspection tool to inspect the coupling state of the differential gear and the drive shaft.

(Vi) Step of extracting the inspection tool The inspection tool is extracted from the gap region.

  In the vehicle manufacturing method according to this aspect, at least a partial region in the circumferential direction of the outer peripheral portion of the seal member is made of a flexible material. And in this aspect, in the step of inspecting, by inserting a tip portion of the inspection tool, a portion made of the flexible material in the outer peripheral portion of the seal member is elastically deformed, and the part Due to the elastic deformation of the region, the tip portion of the inspection tool and the end face of the large diameter portion are in direct contact with each other.

  In the vehicle manufacturing method according to the above aspect, in the step (ii) of fixing the seal member, a seal member in which at least a part of the outer peripheral portion is made of a flexible material is employed. And (v) in the step of inspecting the coupling state between the differential gear and the drive shaft, the tip portion of the inspection tool is inserted to constitute the flexible material in the outer peripheral portion of the seal member. The portion is elastically deformed, and the tip portion of the inspection tool and the end surface of the large diameter portion are brought into direct contact with each other by elastic deformation of the partial region.

  Thereby, in the vehicle manufacturing method according to the above aspect, it is possible to inspect the coupling state between the differential gear and the drive shaft without having to bother to provide the bracket 94 as shown in FIG. Reduction can be achieved.

  Therefore, in the vehicle manufacturing supplementary method according to the above aspect, the manufacturing cost can be reduced while enabling the inspection of the coupling state between the differential side gear and the drive shaft in the differential gear.

  In the method for manufacturing a vehicle according to another aspect of the present invention, in the above method, the outer peripheral portion of the sealing member is configured such that a partial region in the circumferential direction is made of the flexible material, and the remaining region is the flexible material. In the step of inspecting, the tip portion of the inspection tool is placed in a region where the outer periphery is covered with the portion formed of the flexible material in the gap region. insert.

  In the vehicle manufacturing method according to the above aspect, (ii) in the step of fixing the seal member, a seal member in which a part of the outer peripheral portion is made of a rigid material is used, and (v) the differential gear and the drive shaft In the step of inspecting the bonding state of the inspection tool, since the tip portion of the inspection tool is inserted into the area where the outer periphery is covered with the part made of the flexible material in the gap area, only the flexible part is inserted. Compared to the case of configuring the outer peripheral portion, a structure that can more effectively prevent mud and dust from entering from the outside can be obtained.

  In each of the above aspects, it is possible to reduce the manufacturing cost while enabling the inspection of the coupling state between the differential side gear and the drive shaft in the differential gear.

1 is a schematic diagram illustrating a schematic configuration of a vehicle 1 according to a first embodiment. 2 is a schematic cross-sectional view showing a coupling portion between a differential gear 19 and a drive shaft 20. FIG. 3 is a schematic cross-sectional view showing the configuration of a dust cover 23 and a seal member 24 provided in a gap portion between a differential gear 19 and a large-diameter portion 20c of a drive shaft 20. FIG. FIG. 5 is a schematic process diagram showing a procedure for inspecting the coupling state between the differential gear 19 and the drive shaft 20. It is a schematic diagram which shows the engagement state of the inspection tool 50 to the end surface 20e of the large diameter part 20c in the drive shaft 20. FIG. 3 is a schematic cross-sectional view showing a state in which an inspection tool 50 is engaged with an end surface 20e of a large diameter portion 20c in the drive shaft 20. FIG. It is a schematic cross section which shows the structure of the dust cover 23 and the sealing member 34 which concern on 2nd Embodiment. It is sectional drawing which shows the structure of the dust cover 23 and the sealing member 44 which concern on 3rd Embodiment, (a) shows the structure in a part of the circumferential direction, (b) shows the structure in the other part of the circumferential direction. Indicates. FIG. 4 is a schematic diagram showing a state in which an inspection tool 51 is engaged with an end surface 20e of a large diameter portion 20c in the drive shaft 20. FIG. 6 is a schematic cross-sectional view showing a coupling portion between a differential gear 91 and a drive shaft 92 in a vehicle according to a conventional technique. FIG. 6 is a schematic cross-sectional view showing a configuration of a dust cover 96 and a seal member 97 provided in a gap portion between a differential gear 91 and a large diameter portion 92c of a drive shaft 92.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. The form described below is one embodiment of the present invention, and the present invention is not limited to the following form except for the essential configuration.

[First Embodiment]
1. Schematic Configuration of Vehicle 1 A schematic configuration of the vehicle 1 according to the first embodiment will be described with reference to FIG.

  As shown in FIG. 1, an engine 11 that is a power source is mounted on the + Z side (front side) of the vehicle 1. The engine 11 is, for example, a gasoline engine or a diesel engine. An automatic transmission 12 and a differential gear 13 are connected to the output side portion of the driving force of the engine 11 in this order.

  The driving force generated by the engine 11 is transmitted from the left and right drive shafts 14L and 14R to the left and right front wheels 15 via the automatic transmission 12 and the differential gear 13.

  The vehicle 1 according to the present embodiment is a four-wheel drive vehicle based on an FF vehicle (front engine / front drive vehicle), and the front wheels 15 are main drive wheels. Therefore, most of the driving force is distributed to the front wheels 15 on a flat road in a dry state.

  The vehicle 1 includes a power dividing mechanism (PTO; Power Take-Off) 16 that divides a part of the driving force generated by the engine 11 into a propeller shaft 17. An electronically controlled 4WD coupling 18 and a differential gear 19 as driving force distribution means are connected to the rear end portion of the propeller shaft 17, and a rear wheel 21 is connected via left and right drive shafts 20L and 20R. .

  Hereinafter, the left and right drive shafts 20L and 20R may be collectively referred to as “drive shaft 20”.

  As described above, the vehicle 1 is a four-wheel drive vehicle based on an FF vehicle, and the rear wheel 21 is a slave drive wheel.

  In the vehicle 1, a part of the driving force divided by the power split mechanism 16 is transmitted to the left and right rear wheels 21 via the propeller shaft 17, the electronic control 4WD coupling 18, the differential gear 19, and the drive shafts 20L and 20R. It is possible.

  Here, in the vehicle 1 according to the present embodiment, the distribution amount of the driving force can be freely changed by the electronic control 4WD coupling 18, and the front wheel: rear wheel = front and rear from 100: 100 depending on the road surface condition and the like. The torque distribution can be freely changed until the wheels are directly connected (generally, front wheels: rear wheels = 50: 50).

2. A coupling structure of the differential gear 19 and the drive shaft 20 A coupling structure of the differential gear 19 and the drive shaft 20 in the vehicle 1 will be described with reference to FIGS. 2 is a schematic cross-sectional view showing a portion indicated by an arrow A in FIG. 1 and a coupling portion between the differential gear 19 and the drive shaft 20, and FIG. 3 shows a configuration of the portion indicated by an arrow B in FIG. It is a schematic cross section shown.

  As shown in FIG. 2, the differential gear 19 includes a differential case 190, a differential gear case 191, a pinion shaft 192, a differential pinion gear 193, a differential side gear 194, and a bearing 195. The differential case 190 has openings on both sides in the Y direction, and the tip of the drive shaft 20 is inserted from each opening.

  The differential side gear 914 has a substantially cylindrical shape, and a gear portion is engraved on the outer peripheral surface portion. In the differential side gear 914, a gear portion carved on the outer peripheral surface portion meshes with the differential pinion gear 913.

  The drive shaft 20 is provided with a small diameter portion 20a, an intermediate portion 20b, and a large diameter portion 20c in this order in the axial direction (Y direction). The drive shaft 20 has a small diameter portion 20a inserted into the differential case 190, and is coupled to the inner side of the differential side gear 914 at the tip of the small diameter portion 20a.

  As shown in the enlarged portion of FIG. 2, the small-diameter portion 20 a of the drive shaft 20 has a groove portion 20 d cut in the circumferential direction, and is coupled to the cylinder inner side of the differential side gear 194 using a snap ring 22. ing. Although not shown in detail, the snap ring 22 is, for example, a C-type snap ring.

  In the drive shaft 20, a part of the intermediate portion 20 b and the large diameter portion 20 c are extended outward from the differential case 190.

  As shown in FIG. 3, in the Y direction, an annular gap region is formed between the differential case 190 and the end surface 20e of the large-diameter portion 20c of the drive shaft 20 (end surface on the side of the small-diameter portion 20a and the intermediate portion 20b). The dust cover 23 and the seal member 24 are provided in the region. The dust cover 23 is an annular metal member, and is fixed to the peripheral surface 20 f of the drive shaft 20. The dust cover 23 is bent at the outer peripheral portion toward the differential case 190 side. For this reason, the schematic cross-sectional view shown in FIG. 3 has a substantially U-shaped cross-sectional shape.

  The seal member 24 includes a metal part 241, a rubber part 242, and a pressing spring 243. The seal member 24 is fixed to the differential case 190 and slides on the drive shaft 20 and the dust cover 23.

  In FIG. 3, the metal part 241 is an annular member having an inverted L-shaped cross section. The rubber part 242 is provided in a state of extending in a cylindrical shape toward the outside in the Y direction (-Y side in FIG. 3) (a state of extending in a hook shape in the cross section). It has the outer peripheral part 242a which covers an outer periphery.

  Further, the rubber part 242 is provided in a bowl shape toward the outer side in the Y direction (-Y side in FIG. 3) on the radially inner side of the outer peripheral part 242a, and covers the outer periphery of the intermediate part 20b in the drive shaft 20. It also has an inner periphery 242b. The inner peripheral portion 242 b of the rubber portion 242 is configured such that the tip portion thereof comes into contact with a bent outer peripheral portion of the dust cover 23. The rubber part 242 has a configuration as a labyrinth part as a whole by having the outer peripheral part 242a and the inner peripheral part 242b.

  The pressing spring 243 presses the inner diameter portion of the rubber portion 242 toward the intermediate portion 20b of the drive shaft 20 (inward in the radial direction).

3. Manufacturing Method of Vehicle 1 A manufacturing method of the vehicle 1 will be described with reference to FIGS. In the following, the description will focus on the coupling of the drive shaft 20 to the differential gear 19 and the inspection of the coupling state of the differential gear 19 and the drive shaft 20 in the manufacturing method of the vehicle 1.

  FIG. 4 is a process diagram showing the steps of coupling the drive shaft 20 to the differential gear 19 and inspecting the coupled state in the manufacturing process of the vehicle 1. FIG. 5 is a schematic diagram showing a state in which the inspection tool 50 is engaged with the end surface 20e of the large diameter portion 20c in the inspection process of the coupling state between the differential gear 19 and the drive shaft 20. FIG. FIG. 6 is a schematic cross-sectional view showing a state in which the inspection tool 50 is engaged with the end face 20e of the large diameter portion 20c.

  First, the differential gear 19 is prepared. As described with reference to FIG. 2, the differential gear 19 includes a differential case 190, a differential gear case 191, a pinion shaft 192, a differential pinion gear 193, a differential side gear 194, a bearing, and the like housed in the differential case 190. 195.

  And with respect to the differential case 190 of the differential gear 19, the seal member 24 is fixed to the inner peripheral surface facing the opening.

  Further, in the present embodiment, as described with reference to FIG. 2, the drive shaft 20 having the small diameter portion 20a, the intermediate portion 20b, and the large diameter portion 20c in order in the axial direction (Y direction) is prepared. For the drive shaft 20, the dust cover 23 is fixed to the outer periphery of the intermediate portion 20b.

  As shown in FIG. 4, the snap ring 22 is attached to the groove 20d of the drive shaft 20 (step S1). Next, in a state where the diameter of the snap ring 22 is reduced, the small-diameter portion 20a of the drive shaft 20 is inserted into the cylinder inner portion of the differential side gear 194 of the differential gear 19 (step S2).

  As shown in the enlarged portion of FIG. 2, when the tip end portion of the drive shaft 20 reaches the portion where the groove portion is engraved in the differential side gear 194, the snap ring 22 that has been reduced in diameter expands, and the drive shaft 20 becomes differential. Coupled to the side gear 194.

  Next, in order to inspect the coupling state of the drive shaft 20 to the differential gear 19, an inspection tool is mounted on the end surface 20e of the large-diameter portion 20c of the drive shaft 20 (step S3). Specifically, as shown in FIG. 5, an inspection tool 50 having a substantially Y-shaped tip is inserted into a gap between the differential case 190 and the large-diameter portion 20c of the drive shaft 20, and the inspection tool is inserted. The inner edge 50a of the 50 is located at the inner side of the outer periphery of the end face 20e.

  As shown in FIG. 5, when the inspection tool 50 is intruded, a portion (engagement portion 50b) where the inspection tool 50 and the end surface 20e come into contact with each other is generated.

In addition, as shown in FIG. 6, when the front-end | tip part of the inspection tool 50 is made to penetrate | invade into a clearance area like the arrow C, the outer peripheral part 242a of the sealing member 24 bends by elastic deformation (part indicated by the arrow D). . Thereby, an opening into which the inspection tool 50 can be easily inserted is formed in the gap region, and the inspection tool 50 can be brought into contact with the end surface 20e of the large-diameter portion 20c of the drive shaft 20.

  Returning to FIG. 4, a force is applied in the Y direction to the inspection tool 50 brought into contact with the end face 20e. Thereby, the coupling | bonding state of the drive shaft 20 with respect to the differential side gear 194 can be test | inspected (step S4). Thereafter, the inspection tool 50 is removed, and the inspection of the coupling state between the differential gear 19 and the drive shaft 20 is completed.

4). Effect In the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, the outer peripheral portion 242a of the seal member 24 is made of rubber that is a flexible material. The outer peripheral portion 242a of the rubber portion 242 covers the outer periphery of the gap region (the outer periphery of the intermediate portion 20b of the drive shaft 20) in a state where no external force is received (the inspection tool 50 is not inserted). In a state in which a force is applied from the outside (a state in which the inspection tool 50 is inserted), it is elastically deformed as shown in FIG.

  Thus, in the state where the outer peripheral portion 242a of the seal member 24 is elastically deformed by inserting the inspection tool 50, the end surface 20e of the drive shaft 20 is exposed to the outside from the outer peripheral portion to a predetermined portion radially inward. The inspection tool 50 can be brought into contact with the portion.

  Therefore, in the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, the inspection tool 50 can be mounted on the end surface 20e of the drive shaft 20 without requiring a complicated operation. This makes it possible to inspect the coupling state between the differential gear 19 and the drive shaft 20. That is, in the coupling structure between the differential gear 19 and the drive shaft 20 according to the present embodiment, the coupling state between the differential gear 19 and the drive shaft 20 can be inspected without the need to provide the bracket 94 as in the prior art. The manufacturing cost can be reduced.

  Therefore, in the coupling structure between the differential gear 19 and the drive shaft 20 according to the present embodiment, it is possible to inspect the coupling state of the differential side gear 194 and the drive shaft 20 in the differential gear 19 and reduce the manufacturing cost. it can.

  Further, in the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, the inner peripheral portion 242b of the seal member 24 is disposed radially inward from the outer peripheral portion of the dust cover 23, and the inner peripheral portion 242b The tip portion is in contact with the outer peripheral portion of the dust cover 23. Therefore, in this embodiment, the sealing member 24 having the outer peripheral portion 242a and the inner peripheral portion 242b functions as a labyrinth portion, which is advantageous for ensuring high sealing performance at the joint portion between the differential gear 19 and the drive shaft 20. is there.

  Further, in the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, the seal member 24 includes the metal part 241 and the rubber part 242. This is advantageous in ensuring high sealing performance while suppressing an increase in manufacturing cost.

  Further, in the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, the snap ring 22 is used to couple the differential side gear 194 of the differential gear 19 and the small-diameter portion 20a of the drive shaft 20. It is possible to achieve a reliable coupling between the differential gear 19 and the drive shaft 20 while avoiding complicated operations during manufacturing.

  Moreover, in the manufacturing method of the vehicle 1 according to the present embodiment, a member in which the outer peripheral portion 242a is made of rubber that is a flexible material is employed as the seal member 24 that is fixed to the differential case 190 in advance. As shown in FIG. 6, when the tip portion of the inspection tool 50 is inserted into the gap region between the differential case 190 and the end surface 20 e of the drive shaft 20, the outer peripheral portion 242 a of the seal member 24 is elastically deformed. For this reason, it is possible to make the inspection tool 50 and the 20e end surface of the drive shaft 20 directly contact each other without requiring a complicated operation, and even without providing the bracket 94 as shown in FIG. The coupling state between the differential gear 19 and the drive shaft 20 can be easily inspected, and the manufacturing cost can be reduced.

  Therefore, in the manufacturing supplement method for the vehicle 1 according to the present embodiment, it is possible to check the coupling state between the differential side gear 194 and the drive shaft 20 in the differential gear 19 and reduce the manufacturing cost.

[Second Embodiment]
A coupling structure of the differential gear 19 and the drive shaft 20 in the vehicle according to the second embodiment will be described with reference to FIG. In the following, the structure of the seal member 34, which is a difference from the first embodiment, will be described, and the other description will be omitted.

  FIG. 7 is a schematic cross-sectional view showing the configuration of the seal member 34.

  As shown in FIG. 7, also in the present embodiment, the dust cover 23 and the seal member 34 are provided in the gap region between the differential case 190 and the end surface 20 e of the drive shaft 20 in the Y direction. Yes. The configuration of the dust cover 23 is the same as that in the first embodiment.

  The seal member 34 according to the present embodiment also includes a metal part 341, a rubber part 342, and a pressing spring 343. In FIG. 7, the rubber portion 342 of the seal member 34 has a reduced diameter at the tip of the outer peripheral portion 342a (portion indicated by an arrow E in FIG. 7). Therefore, the outer peripheral portion 342a has a tip portion bent toward the −X side in the cross section shown in FIG.

  In addition, also in the rubber part 342 of the seal member 34, the tip part of the inner peripheral part 342b comes into contact with a bent outer peripheral part of the dust cover 23. Also in this embodiment, the rubber part 342 has the structure as a labyrinth part as a whole by having the outer peripheral part 342a and the inner peripheral part 342b.

  In the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, since the tip end portion of the outer peripheral portion 342a of the seal member 34 is reduced in diameter, mud or dirt is formed at the coupling portion of the differential gear 19 and the drive shaft 20. Dust is harder to enter. Therefore, in this embodiment, it is advantageous to ensure high sealing performance at the joint portion between the differential gear 19 and the drive shaft 20.

  The coupling structure between the differential gear 19 and the drive shaft 20 according to the present embodiment has the same configuration as the coupling structure between the differential gear 19 and the drive shaft 20 according to the first embodiment. The same effect can be obtained.

[Third Embodiment]
A coupling structure between the differential gear 19 and the drive shaft 20 in the vehicle according to the third embodiment will be described with reference to FIGS. 8 and 9. In the following, the structure of the seal member 44 that is different from the first embodiment will be mainly described.

  8A and 8B are schematic cross-sectional views showing the configuration of the seal member 44, in which FIG. 8A shows a configuration in a part in the circumferential direction, and FIG. 8B shows a configuration in another portion in the circumferential direction. FIG. 9 is a schematic diagram illustrating a state in which the inspection tool 51 is engaged with the end surface 20 e of the drive shaft 20.

  As shown in FIGS. 8A and 8B, also in the present embodiment, the gap region between the differential case 190 and the end surface 20e of the drive shaft 20 in the Y direction includes the dust cover 23 and A seal member 44 is provided. The configuration of the dust cover 23 is the same as that in the first embodiment.

  The seal member 44 according to the present embodiment also includes a metal portion 441, a rubber portion 442, and a pressing spring 443. The seal member 44 has a different cross-sectional structure in the circumferential direction.

  Specifically, as shown in FIG. 8A, the seal member 44 has an outer peripheral portion 441a in which a part of the metal portion 441 extends in a partial region in the circumferential direction (portion indicated by an arrow F). . In this region, the rubber portion 442 does not have an outer peripheral portion.

  On the other hand, as shown in FIG. 8B, the seal member 44 has an outer peripheral portion 442a in which a part of the rubber portion 442 is extended in the other region in the circumferential direction (portion indicated by an arrow G). In this region, the metal portion 441 does not have an outer peripheral portion.

  It is to be noted that the rubber part 442 of the seal member 44 constitutes the inner peripheral part 442b over the entire circumference.

  In the sealing member 44, each region of the region in which the metal portion 441 forms the outer peripheral portion 441a and the region in which the rubber portion 442 forms the outer peripheral portion 442a is defined as follows.

As shown in FIG. 9, when an inspection tool 51 having a substantially Y-shaped tip is inserted into the gap region and the arm portions 51a and 51b are brought into contact with the end surface 20e of the drive shaft 20, the arm portion 51a, The portions where 51b engages are referred to as engagement portions 51c and 51d. At this time, in the circumferential direction, a region corresponding to the engaging portions 51c and 51d is defined as a region Ar ₂ , and other regions are defined as a region Ar ₁ .

In the above provision, the region corresponding to the region where Ar ₁ is a region where the metal portion 441 constituting the outer peripheral portion 441a, the region corresponding to the region Ar ₂ is, to be a region in which the rubber portion 442 constituting the outer peripheral portion 442a A seal member 44 is formed.

  In the coupling structure of the differential gear 19 and the drive shaft 20 according to the present embodiment, a part of the outer peripheral portion of the seal member 44 is made of a metal member (the metal portion 441 has an outer peripheral portion 441a). In comparison with the case where the outer peripheral portion is constituted only by the rubber material (only the rubber portion 442 has the outer peripheral portion 442a), it is possible to prevent mud and dust from entering from the outside more effectively. Therefore, in this embodiment, it is advantageous to ensure a higher sealing performance.

  In addition, about the part which inserts the arm parts 51a and 51b of the inspection tool 51, since the outer peripheral part 442a is comprised with the rubber material, the effect similar to the said 1st Embodiment can be acquired.

[Modification]
In the first to third embodiments, the coupling structure of the rear differential gear 19 and the rear drive shaft 20 (20L, 20R) in the vehicle 1 is taken as an example. However, the present invention is not limited to this. Not receive. For example, the same structure as that in the first to third embodiments can be adopted for the coupling structure between the front-side differential gear 13 and the front drive shafts 14L and 14R.

  Moreover, in the said 1st Embodiment to the said 3rd Embodiment, although the FF vehicle base four-wheel drive vehicle was made into an example as the vehicle 1, this invention is not limited to this. For example, it is possible to adopt a four-wheel drive vehicle based on an FR vehicle, an FF vehicle, an FR vehicle, an RR vehicle, an MR vehicle, or the like.

  Moreover, in the said 1st Embodiment to the said 3rd Embodiment, although it decided to employ | adopt the engine 11 as a motive power source in the vehicle 1, this invention is not limited to this. For example, it is possible to employ an electric motor as a power source.

  In the first to third embodiments, the dust cover 23 is provided together with the seal members 24, 34, and 44 in the gap region between the differential case 190 and the end surface 20 e of the drive shaft 20. In the present invention, the dust cover 23 is not an essential component.

  2, 3, 7, and 8 (b), the outer peripheral portions 242 a, 342 a, and 442 a of the seal members 24, 34, and 44 are located on the end surface 20 e of the drive shaft 20 for the convenience of illustration. However, the present invention is not limited to this. In a state where the outer peripheral portion of the seal member is not subjected to an external force, the distal end of the outer peripheral portion of the seal member may be in contact with the end surface of the drive shaft.

  Moreover, in the said 1st Embodiment to the said 3rd Embodiment, although it was set as the labyrinth part which has outer peripheral part 242a, 342a, 441a, 442a and inner peripheral part 242b, 342b, 442b about the sealing members 24,34,44. However, the present invention is not limited to this. For example, a seal member that does not have an inner peripheral portion can be employed.

  In the first to third embodiments, the flexible portions of the seal members 24, 34, and 44 are rubber portions 242, 342, and 442 made of a rubber material. You are not limited to this. As long as the material has flexibility, the material is not limited to rubber, and a resin material or the like can also be adopted.

  In the first to third embodiments, the rigid portions of the seal members 24, 34, and 44 are metal portions 241, 341, and 441 made of a metal material. However, the present invention is not limited to this. Not receive. For example, a ceramic material can be used.

  In the first to third embodiments, the drive shaft 20 is provided with the intermediate portion 20b between the small diameter portion 20a and the large diameter portion 20c. However, the present invention is not limited thereto. It is not something to receive. For example, it is possible to employ a drive shaft in which a small diameter portion and a large diameter portion are continuous without interposing an intermediate portion therebetween.

DESCRIPTION OF SYMBOLS 1 Vehicle 13, 19 Differential gear 14L, 14R, 20L, 20R Drive shaft 20a Small diameter part 20b Middle part 20c Large diameter part 20d Groove part 20e End surface 22 Snap ring 23 Dust cover 24, 34, 44 Seal member 50, 51 Inspection tool 190 Differential Case 193 Differential pinion gear 194 Differential side gear 241, 341, 441 Metal part 242, 342, 442 Rubber part (labyrinth part)

Claims (9)

In the coupling structure of the differential gear and the drive shaft,
The differential gear includes a differential case having an opening, and a differential pinion gear and a differential side gear that are housed in the differential case and mesh with each other,
The drive shaft has a small diameter portion and a large diameter portion in the axial direction, the small diameter portion is inserted into the differential case, and the large diameter portion is disposed outside the differential case,
The small-diameter portion of the drive shaft is coupled to the differential side gear, and an annular gap region is provided between the end surface on the small-diameter portion side of the large-diameter portion and the differential case,
An annular seal member fixed to a portion facing the opening in the differential case;
The seal member has an outer peripheral portion covering the outer periphery of the drive shaft in the gap region, and at least a partial region in the circumferential direction of the outer peripheral portion is made of a flexible material,
In a state where the portion made of the flexible material in the outer peripheral portion is elastically deformed by the addition of an external force, the end portion of the inspection tool is inserted by exposing the end surface of the large diameter portion to the outside. Configured to form possible openings ,
Combined structure of differential gear and drive shaft. A coupling structure between the differential gear and the drive shaft according to claim 1,
In the gap area, it is fixed to the outer peripheral surface of the drive shaft, further comprising a dust cover that suppresses intrusion of dust,
The dust cover is disposed radially inward of the outer peripheral portion of the seal member, and has an outer peripheral portion that covers the outer periphery of the drive shaft in the gap region,
The seal member is disposed radially inward from the outer peripheral portion of the dust cover, and further includes an inner peripheral portion that covers the outer periphery of the drive shaft in the gap region.
The inner peripheral portion of the seal member has a tip portion of the inner peripheral portion in contact with the outer peripheral portion of the dust cover.
Combined structure of differential gear and drive shaft. A structure for coupling a differential gear and a drive shaft according to claim 1 or 2,
The outer peripheral portion of the seal member is in a state in which the distal end portion of the outer peripheral portion is reduced in diameter.
Combined structure of differential gear and drive shaft. In the coupling structure of the differential gear and the drive shaft,
The differential gear includes a differential case having an opening, and a differential pinion gear and a differential side gear that are housed in the differential case and mesh with each other,
The drive shaft has a small diameter portion and a large diameter portion in the axial direction, the small diameter portion is inserted into the differential case, and the large diameter portion is disposed outside the differential case,
The small-diameter portion of the drive shaft is coupled to the differential side gear, and an annular gap region is provided between the end surface on the small-diameter portion side of the large-diameter portion and the differential case,
An annular seal member fixed to a portion facing the opening in the differential case;
The seal member has an outer peripheral portion covering the outer periphery of the drive shaft in the gap region, and at least a partial region in the circumferential direction of the outer peripheral portion is made of a flexible material,
In a state where the portion formed of the flexible material in the outer peripheral portion is elastically deformed by the addition of external force, the end surface of the large diameter portion is exposed to the outside,
In the outer peripheral portion of the seal member, a partial region in the circumferential direction is configured by the flexible material, and the remaining region is configured by a rigid material having higher rigidity than the flexible material.
Combined structure of differential gear and drive shaft. A differential gear and drive shaft coupling structure according to claim 4,
The flexible material is a rubber material, and the rigid material is a metal material.
Combined structure of differential gear and drive shaft. A coupling structure of the differential gear and the drive shaft according to any one of claims 1 to 5,
The differential side gear has a cylindrical shape in which a gear portion is formed on the outer peripheral portion, and a groove portion extending in the circumferential direction is formed on the inner peripheral surface of the cylinder,
The small-diameter portion of the drive shaft is engraved with a groove portion extending in the circumferential direction at the tip portion thereof,
The coupling between the differential gear and the drive shaft is made by a snap ring that is fitted over a groove formed in the differential gear and a groove formed in the drive shaft.
Combined structure of differential gear and drive shaft. A structure for coupling a differential gear and a drive shaft according to any one of claims 1 to 6,
The gap region is a region that accepts insertion of a tip portion of an inspection tool for inspecting a coupling state between the differential gear and the drive shaft,
The portion made of the flexible material in the outer peripheral portion of the seal member is elastically deformed by insertion of a tip portion of an inspection tool.
Combined structure of differential gear and drive shaft. Preparing a differential gear having a differential case having an opening, and a differential pinion gear and a differential side gear housed in the differential case and meshing with each other;
Fixing a seal member having an outer peripheral portion that is annular and extends in a cylindrical shape toward the outside of the differential case, with respect to a portion facing the opening of the differential case;
Providing a drive shaft having a small diameter portion and a large diameter portion in an axial direction;
A state where an annular gap region is formed between an end surface of the large diameter portion on the small diameter portion side and the differential case, with respect to the differential gear, by inserting the small diameter portion of the drive shaft from the opening. And connecting the small diameter portion of the drive shaft and the differential gear;
Inserting the tip portion of the inspection tool into at least a part of the gap region, bringing the tip portion of the inspection tool into contact with the end surface on the small diameter portion side of the large diameter portion of the drive shaft, in the state Inspecting the coupling state of the differential gear and the drive shaft by applying a force in the axial direction to the inspection tool;
Extracting the inspection tool from the gap area;
With
The outer peripheral portion of the seal member has at least a partial region in the circumferential direction made of a flexible material,
In the step of inspecting, by inserting a tip portion of the inspection tool, a portion made of the flexible material in the outer peripheral portion of the seal member is elastically deformed, and the elastic deformation of the partial region causes the The tip portion of the inspection tool and the end face of the large diameter portion are in direct contact with each other,
Vehicle manufacturing method. A method for manufacturing a vehicle according to claim 8,
In the outer peripheral portion of the seal member, a partial region in the circumferential direction is configured by the flexible material, and the remaining region is configured by a rigid material having higher rigidity than the flexible material,
In the step of inspecting, the tip portion of the inspection tool is inserted into a region whose outer periphery is covered with a portion made of the flexible material in the gap region.
Vehicle manufacturing method.

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