In addition to improving the efficiency of individual drive train components and making energy conversion more efficient, reducing the weight of a transmission is essential for saving fuel while improving driving dynamics. Considerable success in weight reduction has been achieved in the past by using more efficient materials, but no major improvements have been made in differential technology. The most common axle differential design continues to be a bevel gear differential. Due to the high component loads, this design does not allow weight reductions by replacing materials. Schaeffler's lightweight differential offers a solution that combines low weight and cost efficiency with remarkable design space reduction. This move away from conventional bevel gear differential designs toward spur gear differentials provides opportunities for integrating innovative design ideas and state-of-the-art manufacturing technology. This paper discusses of the possibilities of lightweight differentials, beginning with a description of the design and the function of these differentials. This is followed by a comparison with conventional bevel gear differentials, specifically with regard to weight and space reduction for various torque classes.


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