阅读说明：本技术 组装差速器组件的结构和方法 (Structure and method for assembling a differential assembly ) 是由 P·J·戴尔 R·R·斯科特三世 A·贝尔 M·M·马努斯扎克 于 2018-04-12 设计创作，主要内容包括：嵌套结构支撑差速器箱。嵌套结构包括支撑差速器箱的第一支撑结构。嵌套结构包括与第一支撑结构间隔开的第二支撑结构,以限定支撑开口。支撑开口接纳第一垫片并且在第一垫片与差速器箱之间建立第一取向,在第一取向中,第一垫片相对于差速器箱的第一轴承表面不平行。(The nested structure supports the differential case. The nested configuration includes a first support structure that supports the differential case. The nesting structure includes a second support structure spaced apart from the first support structure to define a support opening. The support opening receives the first shim and establishes a first orientation between the first shim and the differential case in which the first shim is non-parallel relative to the first bearing surface of the differential case.)

1. A nesting structure configured to support a differential case, the nesting structure comprising:

a first support structure configured to support the differential case; and

a second support structure spaced apart from the first support structure to define a support opening configured to receive a first shim and establish a first orientation between the first shim and the differential case in which the first shim is non-parallel relative to a first bearing surface of the differential case.

2. The nesting structure of claim 1, wherein the first support structure is attached to the second support structure to define the support opening.

3. The nesting structure of claim 1, wherein the second support structure includes a second support wall supporting the first spacer, the first spacer extending parallel to the second support wall when the spacer is in the first orientation.

4. The nesting structure of claim 3, wherein the second support wall is non-parallel with respect to the first bearing surface of the differential case when the first support structure supports the differential case.

5. The nesting structure of claim 1, including a third support structure configured to support the differential case.

6. The nesting structure of claim 5, including a fourth support structure spaced from said third support structure to define a second support opening configured to receive a second spacer and establish a first orientation between said second spacer and said differential case in which said second spacer is non-parallel relative to a second bearing surface of said differential case.

7. The nesting structure of claim 6, wherein the first spacer is non-parallel with respect to the second spacer when the first orientation between the first spacer and the differential case is established and the first orientation between the second spacer and the differential case is established.

8. The nesting structure of claim 7, wherein a first spacer axis of the first spacer is non-parallel with respect to a differential case axis of the differential case when the first orientation between the first spacer and the differential case is established.

9. The nesting structure of claim 8, wherein a second spacer axis of the second spacer is non-parallel with respect to the differential case axis of the differential case when the first orientation between the second spacer and the differential case is established.

10. The nesting structure of claim 9, wherein the first shim axis is non-parallel with respect to the second shim axis when the first orientation between the first shim and the differential case is established and the first orientation between the second shim and the differential case is established.

11. A method of assembling a differential assembly, the method comprising:

establishing a first orientation between a first shim and a differential case, in which the first shim is non-parallel relative to a first bearing surface of the differential case; and

inserting the first shim and the differential case into a differential opening defined by a differential carrier such that the first shim contacts the differential carrier and moves from the first orientation to a second orientation in which the first shim is parallel relative to the first bearing surface.

12. The method of claim 11, wherein, when establishing the first orientation, a first shim axis of the first shim is non-parallel with respect to a differential case axis of the differential case.

13. The method of claim 12, upon inserting the first shim and the differential case into the differential opening, the first shim contacts the differential carrier and moves from the first orientation to the second orientation in which the first shim axis of the first shim is parallel relative to the differential case axis of the differential case.

14. The method of claim 11, comprising:

establishing a first orientation between a second shim and the differential case in which the second shim is non-parallel relative to a second bearing surface of the differential case; and

inserting the second shim and the differential case into the differential opening defined by the differential carrier such that the second shim contacts the differential carrier and moves from the first orientation to a second orientation in which the second shim is parallel relative to the second bearing surface.

15. The method of claim 14, wherein the first shim is non-parallel relative to the second shim when the first orientation between the first shim and the differential case is established and the first orientation between the second shim and the differential case is established.

16. The method of claim 14, wherein the first spacer is parallel with respect to the second spacer when the second orientation of the first spacer is established and the second orientation of the second spacer is established.

17. The method of claim 14, wherein the first and second shims are inserted into the differential case simultaneously.

18. The method of claim 11, comprising:

moving the first shim and the differential case toward the differential carrier while maintaining the first orientation between the first shim and the differential case.

19. A method of assembling a differential assembly, the method comprising:

establishing a first orientation between a first shim and a differential case in which a first shim axis of the first shim is non-parallel with respect to a differential case axis of the differential case; and

inserting the first shim and the differential case into a differential opening defined by a differential carrier such that the first shim contacts the differential carrier and moves from the first orientation to a second orientation in which the first shim axis of the first shim is parallel with respect to the differential case axis of the differential case.

20. The method of claim 19, comprising:

after inserting the first shim and the differential case into the differential opening, moving the first shim relative to the differential case such that the first shim axis of the first shim is collinear with respect to the differential case axis of the differential case.

21. The method of claim 19, comprising:

moving the first shim and the differential case toward the differential carrier while maintaining the first orientation between the first shim and the differential case.

22. A robot configured to move a differential case between a nested configuration and a differential carrier, the robot comprising:

a support structure;

first and second inner clamp arms attached to the support structure, the first and second inner clamp arms movable relative to the support structure between an open position in which the first and second inner clamp arms are configured to removably receive a first bearing structure of the differential case and a closed position in which the first and second inner clamp arms are configured to contact and clamp the first bearing structure of the differential case; and

a first outer clamp arm attached to the first inner clamp arm and a second outer clamp arm attached to the second inner clamp arm, the first outer clamp arm movable relative to the first inner clamp arm between an open position in which the first and second outer clamp arms are configured to removably receive a first gasket and a closed position in which the first and second outer clamp arms are configured to contact and clamp the first gasket.

23. The robot of claim 22, wherein the first and second inner clamp arms are configured to move along a translation axis between the open and closed positions.

24. The robot of claim 23, wherein the first and second outer gripper arms are configured to: pivot relative to the first and second inner clamp arms between the open and closed positions.

25. The robot of claim 22, comprising a force applicator configured to: applying a force to the differential case when the first and second inner clamp arms are in the open position and when the first and second outer clamp arms are in the open position.

26. A method of assembling a differential assembly, the method comprising:

simultaneously inserting a first shim, a second shim, and a differential case into a differential opening defined by a differential carrier such that when the first shim, the second shim, and the differential case are fully seated within the differential carrier:

the first shim contacts the differential carrier and is parallel with respect to a first bearing surface of the differential case; and

the second shim contacts the differential carrier and is parallel with respect to a second bearing surface of the differential case.

27. The method of claim 26, wherein no force is applied to the differential carrier in a direction perpendicular to a differential case axis when the first shim, the second shim, and the differential case are simultaneously inserted into the differential opening.

28. A method of assembling a differential assembly, the method comprising:

inserting a first shim and a differential case into a differential opening defined by a differential carrier such that the first shim and the differential case are in a first position that is not fully disposed within the differential carrier;

applying an insertion force to at least one of the first shim or the differential case to transition the first shim and the differential case from the first position to a second position disposed entirely within the differential carrier;

measuring the insertion force applied to at least one of the first shim or the differential case; and

determining, from the insertion force, an axial force applied by the differential carrier to the differential case.

29. The method of claim 28, comprising: inserting a second shim into the differential opening with the first shim and the differential case such that the first shim, the second shim, and the differential case are in the first position not fully disposed within the differential carrier.

30. The method of claim 29, comprising: applying the insertion force to at least one of the first shim, the second shim, or the differential case to transition the first shim, the second shim, and the differential case from the first position to the second position fully disposed within the differential carrier.

31. The method of claim 28, wherein in the first position, the first spacer is non-parallel relative to a first bearing surface of the differential case.

32. The method of claim 31, wherein in the second position, the first spacer is parallel relative to the first bearing surface of the differential case.

Background

The differential case may be inserted into the differential carrier.

Disclosure of Invention

This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key factors or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

According to one aspect, the nesting structure is configured to support a differential case. The nested configuration includes a first support structure configured to support the differential case. The second support structure is spaced apart from the first support structure to define a support opening configured to receive the first shim and establish a first orientation between the first shim and the differential case in which the first shim is non-parallel relative to the first bearing surface of the differential case.

According to one aspect, a method of assembling a differential assembly is provided. The method includes establishing a first orientation between a first shim and a differential case, wherein the first shim is non-parallel relative to a first bearing surface of the differential case. The method includes inserting a first shim and a differential case into a differential opening defined by a differential carrier such that the first shim contacts the differential carrier and moves from a first orientation to a second orientation in which the first shim is parallel relative to a first bearing surface.

According to one aspect, a method of assembling a differential assembly is provided. The method includes establishing a first orientation between the first shim and the differential case in which a first shim axis of the first shim is non-parallel with respect to a differential case axis of the differential case. The method includes inserting a first shim and a differential case into a differential opening defined by a differential carrier such that the first shim contacts the differential carrier and moves from a first orientation to a second orientation in which a first shim axis of the first shim is parallel with respect to a differential case axis of the differential case.

According to one aspect, a robot is configured to move a differential case between a nested configuration and a differential carrier. The robot includes a support structure and first and second inner clamp arms attached to the support structure. The first and second inner clamp arms are movable relative to the support structure between an open position in which the first and second inner clamp arms are configured to removably receive the first bearing structure of the differential case and a closed position in which the first and second inner clamp arms are configured to contact and clamp the first bearing structure of the differential case. The robot includes a first outer clamp arm attached to the first inner clamp arm and a second outer clamp arm attached to the second inner clamp arm. The first outer clamp arm is movable relative to the first inner clamp arm between an open position in which the first and second outer clamp arms are configured to removably receive the first gasket and a closed position in which the first and second outer clamp arms are configured to contact and clamp the first gasket.

According to one aspect, a method of assembling a differential assembly includes: the first spacer, the second spacer, and the differential case are simultaneously inserted into a differential opening defined by the differential carrier such that when the first spacer, the second spacer, and the differential case are fully seated within the differential carrier, the first spacer contacts the differential carrier and is parallel with respect to a first bearing surface of the differential case, and the second spacer contacts the differential carrier and is parallel with respect to a second bearing surface of the differential case.

According to one aspect, a method of assembling a differential assembly includes: the first spacer and the differential case are inserted into a differential opening defined by the differential carrier such that the first spacer and the differential case are in a first position that is not fully seated within the differential carrier. The method comprises the following steps: an insertion force is applied to at least one of the first shim or the differential case to transition the first shim and the differential case from a first position to a second position disposed entirely within the differential carrier. The method includes measuring an insertion force applied to at least one of the first shim or the differential case. The method includes determining an axial force applied by the differential carrier to the differential case from the insertion force.

To the accomplishment of the foregoing and related ends, the following description and annexed drawings set forth certain illustrative aspects and implementations. These are indicative of but a few of the various ways in which one or more aspects may be employed. Other aspects, advantages and novel features of the disclosure will become apparent from the following detailed description when considered in conjunction with the drawings.

Drawings

The present application is illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which like reference numerals generally indicate similar elements and in which:

FIG. 1 illustrates an example nesting arrangement for supporting a differential case and spacers;

FIG. 2 illustrates an example nesting arrangement for supporting a differential case and spacers;

FIG. 3 shows an example differential case and shim lifted by a robot;

FIG. 4 shows an example differential case and shim lifted by a robot;

FIG. 5 illustrates an example portion of an example differential carrier;

FIG. 6 illustrates an example differential case and shim inserted into an example differential carrier;

FIG. 7 illustrates an example robot inserting an example differential case and shim into an example differential carrier;

FIG. 8 illustrates an example robot inserting an example differential case and shim into an example differential carrier;

FIG. 9 illustrates an example robot inserting an example differential case and shim into an example differential carrier;

FIG. 10 illustrates an example robot inserting an example differential case and shim into an example differential carrier;

FIG. 11 illustrates an example robot inserting an example differential case and shim into an example differential carrier;

FIG. 12 illustrates an example differential case and shim supported within an example differential carrier;

FIG. 13 illustrates an example method of assembling a differential assembly;

FIG. 14 illustrates an example method of assembling a differential assembly;

FIG. 15 illustrates an example method of assembling a differential assembly;

FIG. 16 illustrates an example method of assembling a differential assembly; and

fig. 17 shows a graphical representation of the insertion force versus time when the differential case is inserted into the differential carrier.

Detailed Description

The claimed subject matter is now described with reference to the drawings, wherein like reference numerals are generally used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced without these specific details. In other instances, structures and devices are shown in block diagram form in order to facilitate describing the claimed subject matter.

Referring to fig. 1, a nesting arrangement 100 for supporting components is shown. In an example, the component may include a differential case 102. The differential case 102 may include a differential having a gear train with one or more shafts that allow for different rotational speeds.

The nested configuration 100 may include a first support 104 and a second support 106 for supporting a differential case 102. In an example, the first support 104 and the second support 106 can be attached to each other (e.g., indirectly attached in the example shown), such as to the base 108. The first support 104 and the second support 106 may be spaced apart from each other to define a tank opening 110. The first support 104 and the second support 106 may be attached to the base 108 with the bin opening 110 defined by the first support 104 along one side, by the second support 106 along a second side, and by the base 108 along a third side. In an example, the differential case 102 may be selectively inserted into and removed from a case opening 110, the case opening 110 being opposite the base 108.

The first support 104 includes a first support structure 112 extending from the base 108 along a first support structure axis 113. In an example, the first support structure 112 may support a portion of the differential case 102. The first support structure 112 may be attached to the base 108 at one end and may support the differential case 102 at an opposite end.

The first support structure 112 includes a support wall 114 having a first surface 116 and a second surface 118. The first surface 116 may face inwardly toward the tank opening 110, while the second surface 118 may face in the opposite direction, i.e., outwardly away from the tank opening 110. In an example, the first surface 116 may extend non-parallel relative to the first support structure axis 113, such as by defining an angle relative to the first support structure axis 113. In an example, an angle defined between the first surface 116 and the first support structure axis 113 may be between about 10 degrees and about 80 degrees. Although not limited to being non-parallel with respect to the first support structure axis 113, the first surface 116 may be angled to accommodate the size and shape of the differential case 102. In an example, the second surface 118 may extend substantially parallel to the first support structure axis 113. The differential case 102 may be supported on a surface of the first support structure 112 extending between a first surface 116 and a second surface 118, opposite the base 108.

The first support 104 includes a second support structure 120 extending along a second support structure axis 122. In an example, the second support structure axis 122 may be substantially parallel to the first support structure axis 113. The second support structure 120 may be attached to the first support structure 112 and spaced apart from the first support structure 112 to define a support opening 124.

The second support structure 120 includes a second support wall 126 attached to the support wall 114 of the first support structure 112. In an example, the second support structure 120 may not be directly attached to the base 108. Conversely, the second support structure 120 may be attached to the first support structure 112, with the first support structure 112 attached to the base. In the example, the second support wall 126 includes a first wall portion 128 and a second wall portion 130. The first wall portion 128 may be attached to the second surface 118 of the support wall 114. In an example, the first wall portion 128 may be attached to the support wall 114 at an intermediate location of the support wall 114 between a first end of the support wall 114 (e.g., the end attached to the base 108) and a second end of the support wall 114 (e.g., the end supporting the differential case 102).

The second wall portion 130 can be attached to (e.g., separately connected together, formed together, etc.) the first wall portion 128. In an example, the second wall portion 130 can be spaced apart from the second surface 118 of the support wall 114 to define the support opening 124. In the example, the second wall portion 130 includes a third surface 132 that faces inwardly toward the tank opening 110. In an example, the third surface 132 may extend non-parallel to the first and second support structure axes 113, 122. Conversely, in an example, the third surface 132 may define an angle relative to the second support structure axis 122 that is between about 10 degrees and about 80 degrees. In an example, the third surface 132 extends non-parallel relative to the second surface 118.

The third surface 132 of the second wall portion 130 may engage the fourth surface 134 of the first wall portion 128. In an example, the fourth surface 134 may not extend perpendicularly relative to the first and second support structure axes 113, 122. For example, the fourth surface 134 may define an angle relative to the second support structure axis 122 that is between about 10 degrees and about 80 degrees. In an example, the fourth surface 134 can be substantially perpendicular relative to the third surface 132.

The second support 106 includes a third support structure 142 extending from the base 108 along a third support structure axis 143. In an example, the third support structure 142 may support a portion of the differential case 102. The third support structure 142 may be attached to the base 108 at one end and may support the differential case 102 at an opposite end.

The third support structure 142 includes a third support wall 144 having a fifth surface 146 and a sixth surface 148. The fifth surface 146 may face inwardly toward the tank opening 110, while the sixth surface 148 may face in the opposite direction, i.e., outwardly away from the tank opening 110. In an example, the fifth surface 146 may extend non-parallel with respect to the third support structure axis 143, such as by defining an angle with respect to the third support structure axis 143. In an example, an angle defined between the fifth surface 146 and the third support structure axis 143 may be between about 10 degrees and about 80 degrees. While not limited to being non-parallel with respect to the third support structure axis 143, the fifth surface 146 may be angled to accommodate the size and shape of the differential case 102. In an example, sixth surface 148 may extend substantially parallel to third support structure axis 143. The differential case 102 may be supported on a surface of the third support structure 142 that extends between the fifth surface 146 and the sixth surface 148.

The second support 106 includes a fourth support structure 150 extending along a fourth support structure axis 152. In an example, the fourth support structure axis 152 may be substantially parallel to the third support structure axis 143. The fourth support structure 150 may be attached to the third support structure 142 and spaced apart from the third support structure 142 to define a second support opening 165.

The fourth support structure 150 includes a fourth support wall 156 attached to the third support wall 144 of the third support structure 142. In an example, the fourth support structure 150 may not be directly attached to the base 108. Conversely, the fourth support structure 150 may be attached to the third support structure 142, with the third support structure 142 being attached to the base 108. In the example, the fourth support wall 156 includes a third wall portion 158 and a fourth wall portion 160. The third wall portion 158 may be attached to the sixth surface 148 of the third support wall 144. In an example, the third wall portion 158 can be attached to the third support wall 144 at an intermediate position of the third support wall 144 between a first end of the third support wall 144 (e.g., the end attached to the base 108) and a second end of the third support wall 144 (e.g., the end supporting the differential case 102).

The fourth wall portion 160 may be attached to (e.g., separately connected together, formed together, etc.) the third wall portion 158. In an example, the fourth wall portion 160 may be spaced apart from the sixth surface 148 of the third support wall 144 to define the second support opening 165. In the example, the fourth wall portion 160 includes a seventh surface 162 that faces inwardly toward the tank opening 110. In an example, the seventh surface 162 may extend non-parallel to the third support structure axis 143 and the fourth support structure axis 152. Conversely, in an example, the seventh surface 162 may define an angle relative to the fourth support structure axis 152 that is between about 10 degrees and about 80 degrees. In an example, seventh surface 162 extends non-parallel with respect to sixth surface 148.

The seventh surface 162 of the fourth wall portion 160 may be engaged with the eighth surface 164 of the third wall portion 158. In an example, the eighth surface 164 may not extend perpendicularly relative to the third support structure axis 143 and the fourth support structure axis 152. For example, the eighth surface 164 may define an angle relative to the fourth support structure axis 152 that is between about 10 degrees and about 80 degrees. In an example, the eighth surface 164 may be substantially perpendicular with respect to the seventh surface 162.

In an example, the first support 104 and the second support 106 may be mirror images relative to each other. For example, the first support 104 and the second support 106 may be symmetrical with respect to each other about an axis intersecting a midpoint of the base 108.

Referring to the differential case 102, the differential case 102 includes a differential 170. The differential 170 may be used to align engine power to the wheels of the vehicle and as a final gear reduction in the vehicle. In addition, the differential 170 may transmit power to the wheels of the vehicle while allowing them to rotate at different speeds.

In the example, the differential 170 includes a first bearing structure 171 having a first bearing surface 172 and a second bearing structure 173 having a second bearing surface 174. First and second bearing surfaces 172, 174 may be provided at opposite ends of differential 170. In an example, the differential case axis 176 may extend through the first and second bearing surfaces 172, 174 such that the first and second bearing surfaces 172, 174 may extend coaxially about the differential case axis 176.

The first bearing surface 172 may define a first circumferential opening 180, the first circumferential opening 180 extending at least partially circumferentially around the first bearing surface 172. In an example, the first circumferential opening 180 may be defined between opposing walls of the differential 170. In an example, the second bearing surface 174 may define a second circumferential opening 182, the second circumferential opening 182 extending at least partially circumferentially around the second bearing surface 174. In an example, a second circumferential opening 182 may be defined between opposing walls of the differential 170.

The first and second shims 190, 192 may be positioned adjacent the differential case 102. In an example, the first shim 190 may be positioned adjacent the first bearing surface 172 and the second shim 192 may be positioned adjacent the second bearing surface 174. In an example, the first and second shims 190 and 192 may define a generally circular configuration that matches the size and/or shape of the first and second bearing surfaces 172 and 174.

The differential case 102, the first shim 190, and the second shim 192 may be moved in a first direction 194 toward the nested configuration 100. As will be explained herein, the differential case 102, the first shim 190, and the second shim 192 may be supported by the nesting structure 100 by moving in the first direction 194.

Referring to fig. 2, the nesting structure 100 may support a differential case 102, a first shim 190, and a second shim 192. In an example, at least one of the first shim 190 or the second shim 192 may be supported in a first orientation relative to the differential case 102.

In the first orientation, the first gasket 190 may be received within the support opening 124. In this manner, the support opening 124 may receive the first shim 190 and establish the first orientation between the first shim 190 and the differential case 102. In an example, the first shim 190 is non-parallel with respect to the first bearing surface 172 of the differential case 102. The second support wall 126 of the second support structure 120 may support the first gasket 190 when the first gasket 190 is received within the support opening 124. In an example, in the first orientation, the first shim axis 200 of the first shim 190 may be non-parallel with respect to the differential case axis 176 of the differential case 102. The first shim axis 200 may extend substantially perpendicular relative to a plane along which the first shim 190 extends.

In an example, one side of the first gasket 190 may be adjacent to the third surface 132 of the second support wall 126 and/or in contact with the third surface 132 of the second support wall 126. The outer radial side of the first shim 190 may be adjacent to the fourth surface 134 of the second support wall 126 and/or in contact with the fourth surface 134 of the second support wall 126. Thus, due to the angle defined by the third surface 132 and the fourth surface 134, the first shim 190 may be supported in a first orientation in which the first shim 190 is non-parallel with respect to the first bearing surface 172. In an example, the first bearing surface 172 may extend substantially parallel to the first bearing structure axis 113 and the second bearing structure axis 122.

In the first orientation, second shim 192 may be received within second support opening 165. In this manner, the second support opening 165 may receive the second shim 192 and establish the first orientation between the second shim 192 and the differential case 102. In the example, the second spacer 192 is non-parallel with respect to the second bearing surface 174 of the differential case 102. Fourth support wall 156 of fourth support structure 150 may support second shim 192 when second shim 192 is received within second support opening 165. In an example, in the first orientation, the second pad axis 202 of the second pad 192 may be non-parallel with respect to the differential case axis 176 of the differential case 102. Second shim axis 202 may extend substantially perpendicularly with respect to a plane along which second shim 192 extends.

In an example, one side of the second spacer 192 may be adjacent to the seventh surface 162 of the fourth support wall 156 and/or in contact with the seventh surface 162 of the fourth support wall 156. The outer radial side of the second spacer 192 may be adjacent to and/or in contact with the eighth surface 164 of the fourth support wall 156. Accordingly, due to the angle defined by seventh surface 162 and eighth surface 164, second shim 192 may be supported in a first orientation in which second shim 192 is non-parallel with respect to second bearing surface 174. In an example, the second bearing surface 174 may extend substantially parallel to the third bearing structure axis 143 and the fourth bearing structure axis 152.

The differential case 102 may be supported by a first support 104 and a second support 106 of the nested configuration 100. For example, the first support structure 112 may be received within the first circumferential opening 180 of the differential case 102. The third support structure 142 may be received within the second circumferential opening 182 of the differential case 102. In this manner, the differential case 102 may rest on the first and third support structures 112, 142 with the differential case 102 extending into the case opening 110. When the differential case 102 is supported by the nested structure 100, the differential case axis 176 may extend substantially perpendicularly with respect to the first support structure axis 113, the second support structure axis 122, the third support structure axis 143, and/or the fourth support structure axis 152.

In an example, when first shim 190 and second shim 192 are in the first orientation, first shim 190 is not parallel with respect to second shim 192. For example, in the first orientation, the first shim axis 200 is non-parallel with respect to the second shim axis 202. In the first orientation, the bottom of first shim 190 and second shim 192 may be in closer contact than the top of first shim 190 and second shim 192. In this manner, first and second shims 190 and 192 may define a funnel shape. In this manner, the nesting arrangement 100 may establish a first orientation between the first shim 190 and the differential case 102 in which the first shim 190 is non-parallel relative to the first bearing surface 172. Likewise, the nested configuration 100 may establish a first orientation between the second spacer 192 and the differential case 102 in which the second spacer 192 is non-parallel relative to the second bearing surface 174.

Referring to fig. 3, an end view of the nested structure 100 supporting the differential case 102, the first shim 190, and the second shim 192 is shown from the perspective indicated at 3-3 of fig. 2. In an example, the robot 300 may be used to remove the differential case 102, the first shim 190, and the second shim 192 (obscured in fig. 3, but shown in fig. 2 and 4) from the nested configuration 100. The differential case 102, the first shim 190, and the second shim 192 may be removed from the nested configuration 100 simultaneously by the robot 300. It should be understood that although reference is made throughout this application to a "robot," this application, including the scope of the claims, is not meant to be unduly limited thereby. For example, any one or more structure(s), mechanism(s), etc. capable of performing the action(s), operation(s), etc. of one or more of lifting, clamping, inserting, etc. mentioned in this application are contemplated. This includes where manual/human intervention is implemented (e.g., the spacer is placed in an angled or non-parallel orientation relative to the bearing surface of the differential case when the differential case and bearing are inserted into the opening defined by the differential carrier). For example, the pulley(s) and/or lever system may be used to lift the differential case and allow a human to maneuver the differential case over and into an opening defined by the differential carrier, where the human may insert the shim in an angled or non-parallel orientation relative to the bearing surface during insertion of the differential case into the differential carrier.

In an example, the robot 300 includes a gripping structure 302 for removing the first shim 190. The clamp structure 302 includes a first clamp arm 304 and a second clamp arm 306. The first clamp arm 304 and the second clamp arm 306 may define rounded surfaces that substantially match the outer surface of the first shim 190. The first clamp arm 304 and the second clamp arm 306 define a space therebetween within which the first shim 190 is received. In an example, the first clamp arm 304 and the second clamp arm 306 may move along a first clamp direction 308 (e.g., toward each other) to clamp the first shim 190. It should be appreciated that while a first shim 190 is shown in fig. 3, a second shim 192 may be clamped in a similar manner using an additional clamping structure having a third clamping arm and a fourth clamping arm (e.g., the third clamping structure shown in fig. 4). The third clamp structure, third clamp arm, and fourth clamp arm may be substantially similar to clamp structure 302, first clamp arm 304, and second clamp arm 306 of fig. 3.

Referring to fig. 4, the differential case 102, the first shim 190, and the second shim 192 may be removed from the nested configuration 100 by the robot 300. In an example, the robot 300 includes one or more second clamp structures 400 configured to clamp the differential case 102. Robot 300 may also include a third gripping structure 402 capable of gripping second pad 192. In an example, the third clamp structure 402 is substantially similar in structure to the clamp structure 302 (e.g., shown in fig. 3 and 4).

The robot 300 may maintain the first shim 190 and the second shim 192 in a first orientation relative to the differential case 102. For example, when the clamping structure 302 initially clamps the first shim 190 while the first shim 190 is supported by the nesting structure 100, the clamping structure 302 may hold the first shim 190 in the first orientation. Likewise, when the third clamping structure 402 initially clamps the second shim 192 when the second shim 192 is supported by the nesting structure 100, the third clamping structure 402 may hold the second shim 192 in the first orientation. In this manner, the robot 300 may grip/lift the differential case 102, the first shim 190, and the second shim 192, thereby causing the differential case 102, the first shim 190, and the second shim 192 to be removed from the nested configuration 100. As the robot 300 removes the differential case 102, the first shim 190, and the second shim 192 from the nested configuration 100, the relative positions of the first shim 190 and the second shim 192 with respect to the differential case 102 may remain in the first orientation.

Referring to fig. 5, an example of a differential carrier 500 is shown. After the differential case 102, the first shim 190, and the second shim 192 are removed from the nested structure 100, the robot 300 may insert the differential case 102, the first shim 190, and the second shim 192 into the differential carrier 500. It should be appreciated that the differential carrier 500 includes any number of different sizes, shapes, configurations, and constructions. Indeed, the differential carrier 500 shown in fig. 5 is merely an example of a possible differential carrier into which the differential case 102, the first shim 190, and the second shim 192 may be inserted.

The differential carrier 500 includes a carrier wall 502. In the example, the pedestal wall 502 defines a differential opening 504 into which the differential case 102, the first shim 190, and the second shim 192 may be inserted. In an example, the differential opening 504 may have a quadrilateral shape with rounded corners, but any number of sides may be envisioned. The pedestal wall 502 may define one or more wall openings 506 that may be aligned relative to the first bearing surface 172 and the second bearing surface 174.

Referring to fig. 6, the robot 300 may insert the differential case 102, the first shim 190, and the second shim 192 simultaneously into the differential carrier 500. For example, the robot 300 may move in a first direction 600 (e.g., downward) toward the differential carrier 500. When the robot 300 moves in the first direction 600, the differential case 102, the first shim 190, and the second shim 192 may be inserted into the differential opening 504 defined by the differential carrier 500. The clamp structure 302 may release the first shim 190 by moving the first clamp arm 304 and the second clamp arm 306 (shown, for example, in fig. 3) in an outward direction. Likewise, the third clamp structure 402 may release the second shim 192 by moving the clamp arms of the third clamp structure 402 in an outward direction. As such, first shim 190 and second shim 192 may no longer be held in the first orientation. The robot 300 may similarly release the differential case 102, allowing the differential case 102 to move downward into the differential carrier 500. In an example, when the robot 300 releases the differential case 102, the first shim 190, and the second shim 192, the differential case 102, the first shim 190, and the second shim 192 may fall under the influence of gravity into the differential opening 504 of the differential carrier 500.

After the clamping structure 302 releases the first shim 190, the first shim 190 may contact the carrier wall 502 of the differential carrier 500 and may move from the first orientation to the second orientation. In the second orientation, the first shim 190 is parallel with respect to the first bearing surface 172. Similarly, after the third clamp structure 402 releases the second shim 192, the second shim 192 may contact the carrier wall 502 of the differential carrier 500 and may move from the first orientation to the second orientation. In the second orientation, the second shim 192 is parallel with respect to the second bearing surface 174. In an example, due to the first orientation of at least one of the first shim 190 or the second shim 192, a force may not be applied to the differential carrier 500 in a direction perpendicular to the differential case axis 176 to cause the first shim 190, the second shim 192, and the differential case 102 to deform and/or lengthen the size of the differential opening defined by the differential carrier when inserted simultaneously into the differential opening 504. In other words, forces (e.g., compressive forces, tensile forces, etc.) may not be applied to the one or more load bearing walls 502 of the differential carrier 500 to cause a change in the size of the differential opening (e.g., by narrowing the differential opening in a direction perpendicular to the differential case axis 176 to lengthen the differential opening in a direction along the differential case axis 176) when the first shim 190, the second shim 192, and the differential case 102 are simultaneously inserted into the differential opening 504 of the differential carrier 500.

Fig. 7 shows an example of the robot 300 moving the differential case 102 from the nested configuration 100 to the differential carrier 500. The robot 300 includes a support structure 700. When the robot 300 picks up the differential case 102, the support structure 700 may be positioned vertically above the differential case 102. As shown in fig. 6 and 7, the robot 300 may insert the first shim 190, the second shim 192, and the differential case 102 into a differential opening 504 defined by the differential carrier 500. In this manner, the first shim 190, the second shim 192, and the differential case 102 may be in the first position not fully seated within the differential carrier 500. In the first position, the first shim 190, the second shim 192, and/or the bottom surface(s) of the differential case 102, for example, may not contact the differential carrier 500. In the first position, the first shim 190 may be non-parallel (e.g., have a non-parallel orientation as shown in fig. 2) with respect to the first bearing surface 172 of the differential case 102. In the first position, the second spacer 192 may be non-parallel (e.g., having a non-parallel orientation as shown in fig. 2) with respect to the second bearing surface 174 of the differential case 102.

The robot 300 includes one or more translating arms. For example, the robot 300 may include a first translation arm 702 and a second translation arm 704. The first translation arm 702 and the second translation arm 704 may be attached to the support structure 700. In an example, the first translation arm 702 and the second translation arm 704 are movable relative to the support structure 700 along a translation axis 706. In this manner, the first translation arm 702 and the second translation arm 704 may move along the movement direction 708. In an example, the translation axis 706 may be substantially parallel to a surface (e.g., ground, floor, etc.) on which the differential carrier 500 rests.

The robot 300 includes one or more inner gripper arms. For example, the robot 300 may include a first inner gripping arm 720 and a second inner gripping arm 722. In an example, the first and second inner clamp arms 720, 722 may be spaced apart to define a gap, space, opening, or the like therebetween. The first and second inner clamp arms 720, 722 may be attached to the support structure 700 via the first and second translation arms 702, 704. For example, a first inner clamp arm 720 may be attached to a first translation arm 702, the first translation arm 702 being movably attached to the support structure 700. Likewise, a second inner clamp arm 722 may be attached to the second translating arm 704, the second translating arm 704 being movably attached to the support structure 700.

In this manner, the first and second inner clamp arms 720, 722 are movable relative to the support structure 700 between an open position (shown, for example, in fig. 11) and a closed position (shown, for example, in fig. 7). In the open position, the first and second inner clamp arms 720, 722 are configured to removably receive the first bearing structure 171 of the differential case 102. In the closed position, the first and second inner clamping arms 720 and 722 are configured to contact and clamp the first bearing structure 171 of the differential case 102.

The robot 300 includes one or more outer gripper arms. For example, robot 300 may include a first outer clamp arm 730 and a second outer clamp arm 732. In one example, the first outer clamp arm 730 and the second outer clamp arm 732 may be positioned farther from the center of the differential case 102 than the first inner clamp arm 720 and the second inner clamp arm 722. In an example, the first outer clamp arm 730 and the second outer clamp arm 732 can be spaced apart to define a gap, space, opening, etc. therebetween. A first outer clamp arm 730 may be attached to the first inner clamp arm 720 and a second outer clamp arm 732 may be attached to the second inner clamp arm 722. As such, when the first inner clamp arm 720 and the second inner clamp arm 722 move (e.g., along the translation axis 706), the first outer clamp arm 730 and the second outer clamp arm 732 may likewise move along the translation axis 706.

The first outer clamp arm 730 may be attached to the first inner clamp arm 720 using a first attachment structure 740. The second outer clamp arm 732 may be attached to the second inner clamp arm 722 using a second attachment structure 742. In an example, the first attachment structure 740 and the second attachment structure 742 may include screws, bolts, nuts, and the like. In this manner, the first and second attachment structures 740, 742 may allow pivotal movement of the first and second outer clamp arms 730, 732 relative to the first and second inner clamp arms 720, 722, respectively.

In an example, the robot 300 includes one or more biasing devices. For example, the robot 300 may include a first biasing device 750 and a second biasing device 752. The first biasing device 750 may be attached to and/or in contact with the first translating arm 702 and the first outer clamp arm 730. The first biasing device 750 may apply a force to the first outer clamp arm 730 to bias the first outer clamp arm 730 to pivot away from the first translating arm 702. In an example, the second biasing device 752 may be attached to and/or in contact with the second translating arm 704 and the second outer clamp arm 732. The second biasing device 752 may apply a force to the second outer clamp arm 732 to bias the second outer clamp arm 732 to pivot away from the second translation arm 704. In an example, the first attachment structure 740 and the first biasing apparatus 750 may allow pivotal movement of the first outer clamp arm 730 in the first movement direction 760. Likewise, in an example, the second attachment structure 742 and the second biasing device 752 can allow pivotal movement of the second outer clamp arm 732 in the second movement direction 762.

In an example, the first and second outer clamp arms 730, 732 can be movable between an open position (e.g., shown in fig. 11) and a closed position (e.g., shown in fig. 7) relative to the first and second inner clamp arms 720, 722, respectively. In the open position, the first outer clamp arm 730 and the second outer clamp arm 732 are configured to removably receive the first gasket 190. In the closed position, the first outer clamp arm 730 and the second outer clamp arm 732 are configured to contact and clamp the first gasket 190.

In an example, the robot 300 includes a force applicator 770. The force applicator 770 may apply a force to the differential case 102 during insertion of the differential case 102 into the differential carrier 500. In an example, the force applicator 770 may apply a force in a substantially vertical direction perpendicular to the translation axis 706.

In fig. 7, the first bearing structure 171 may be supported by a first inner clamp arm 720 and a second inner clamp arm 722. For example, the first and second inner clamp arms 720 and 722 may clamp the first bearing structure 171 therebetween and retain the first bearing structure 171. Likewise, the first shim 190 may be supported by the first outer clamp arm 730 and the second outer clamp arm 732. For example, the first outer clamp arm 730 and the second outer clamp arm 732 may clamp the first shim 190 therein and hold the first shim 190. In this manner, the robot 300 may lift and move the differential case 102 while maintaining the relative position of the first spacer 190 with respect to the first bearing structure 171 of the differential case 102.

Referring to fig. 8, the first translation arm 702 and the second translation arm 704 may be moved away from the closed position (e.g., shown in fig. 7) to an open position (e.g., shown in fig. 8). For example, the first translation arm 702 and the second translation arm 704 may move away from each other along the movement direction 708. This movement may move the first and second inner clamp arms 720, 722 from the closed position to the open position, thereby releasing the first bearing structure 171. Likewise, the first outer clamp arm 730 and the second outer clamp arm 732 can be moved from a closed position and pivoted to an open position, thereby releasing the first gasket 190.

In an example, because the first and second outer clamp arms 730, 732 are spring loaded (e.g., by the first and second biasing devices 750, 752), the first and second outer clamp arms 730, 732 may remain in contact with the first spacer 190 for a period of time after the first and second inner clamp arms 720, 722 have released the first bearing structure 171. Also, in one example, the first and second outer clamp arms 730, 732 may contact the first spacer 190 before the first and second inner clamp arms 720, 722 contact the first bearing structure 171 when the first and second inner clamp arms 720, 722 move from the open position to the closed position.

Referring to fig. 8 and 9, with the first bearing structure 171 and the first shim 190 released, the differential case 102 may fall into the differential carrier 500 (e.g., the first shim 190, the second shim 192, and/or the differential case 102 may be inserted into the differential opening 504 defined by the differential carrier 500 such that the first shim 190, the second shim 192, and/or the differential case 102 are in a first position that is not fully seated within the differential carrier 500). In an example, the force applicator 770 may apply a downward force (e.g., an insertion force 850) to the differential case 102 to move the differential case 102 into the differential carrier 500. As the differential case 102 is moved further into the differential carrier 500, the first shim 190 may begin to align with the first bearing structure 171 (e.g., become more parallel with the first bearing structure 171) and/or the second shim 192 may begin to align with the second bearing structure 173 (e.g., become more parallel with the second bearing structure 173).

In an example, the force applicator 770 may apply an insertion force 850 to at least one of the first shim 190, the second shim 192, and/or the differential case 102. As a result of this insertion force 850, the first shim 190, the second shim 192, and the differential case 102 may transition from a first position (shown in fig. 6 and 7, for example) to a second position (shown in fig. 11, for example) that is disposed entirely within the differential carrier 500. In the second position, the first shim 190, the second shim 192, and/or the bottom surface(s) of the differential case 102 may, for example, contact the differential carrier 500 (e.g., the inner surface(s) of the differential carrier 500). As shown in fig. 12, in the fully seated position, the first shim 190 may be parallel, or at least substantially parallel, with respect to the first bearing surface 172 of the differential case 102. The second spacer 192 may be parallel, or at least substantially parallel, with respect to the second bearing surface 174 of the differential case 102.

Referring to fig. 10 and 11, with respect to effecting the transition from the first (unset) position to the second (seated) position, the force applicator 770 may continue to apply a downward force (e.g., insertion force 850) to the differential case 102. In addition to the insertion force 850, the influence of gravity may cause the first bearing structure 171 and the first shim 190 to be received within a seat 1100 defined within the differential carrier 500. In an example, when the first shim 190 is released and moved toward the seat 1100, the first end 1102 of the first outer clamp arm 730 and the second end 1104 of the second outer clamp arm 732 may remain in contact with the first shim 190.

It should be understood that while fig. 7-11 focus on one side of the differential case 102 and the robot 300, the opposite side may be substantially similar or identical. For example, the side shown in fig. 7-11 includes a first bearing structure 171, a first spacer 190, a first translating arm 702, a second translating arm 704, a first inner clamp arm 720, a second inner clamp arm 722, a first outer clamp arm 730, a second outer clamp arm 732, and so forth. However, the other side of the robot 300 may include similar or identical structures for supporting the second bearing structure 173 and the second spacer 192. In practice, the robot 300 may include another pair of translation arms (e.g., similar or identical to the first and second translation arms 702, 704), another pair of inner clamp arms (e.g., similar or identical to the first and second inner clamp arms 720, 722), another pair of outer clamp arms (e.g., similar or identical to the first and second outer clamp arms 730, 732), and so forth.

Further, it should be understood that the robot 300 shown in fig. 7-11 includes only one example of a robot for supporting and moving the differential case 102 and the shims 190, 192. For example, the outer clamp arms 730, 732 are not limited to the illustrated attachment with the inner clamp arms 720, 722. In contrast, in an example, the outer clamp arms 730, 732 may not pivot relative to the inner clamp arms 720, 722. Rather, in an example, the outer clamp arms 730, 732 can slide and/or translate relative to the inner clamp arms 720, 722. In such an example, the outer clamp arms 730, 732 are movable along the translation axis 706 so as to be movable in the movable direction 708 relative to the outer clamp arms 730, 732.

Fig. 12 shows an example of a differential assembly 1200 in which the differential case 102, the first shim 190, and the second shim 192 are received within the differential opening 504 of the differential carrier 500. It should be appreciated that for purposes of illustration, only a portion of the differential carrier 500 is shown in fig. 12, and the corresponding location of the structure received within the differential opening 504 of the differential carrier 500 is more clearly shown. However, in an example, the differential opening 504 may be surrounded on multiple sides by the carrier wall 502 of the differential carrier 500.

In the example of fig. 12, first shim 190 and second shim 192 are shown in a second orientation. When the first shim 190 is in the second orientation, the first shim axis 200 of the first shim 190 is parallel with respect to the differential case axis 176 of the differential case 102. In the example, when the second shim 192 is in the second orientation, the second shim axis 202 of the second shim 192 is parallel with respect to the differential case axis 176 and the first shim axis 200 of the differential case 102. In an example, in the second orientation, the first shim 190, the second shim 192, and the differential case 102 may extend coaxially with respect to one another such that the differential case axis 176, the first shim axis 200, and the second shim axis 202 are collinear. In the second orientation, first shim 190 may extend substantially parallel to second shim 192.

In this manner, the first and second shims 190, 192 may be aligned relative to the differential case 102. In an example, after the robot releases the differential case 102, the first shim 190, and the second shim 192 into the differential carrier 500, the first shim 190 and the second shim 192 may be parallel to the first bearing surface 172 and the second bearing surface 174, but not coaxial with respect to the differential case axis 176 of the differential case 102. In such an example, the position of the first and second shims 190, 192 may be moved and adjusted after the first and second shims 190, 192 and the differential case 102 are inserted into the differential opening 504. In an example, the first and second shims 190, 192 may be moved (e.g., by a user using a tool such as a hammer or the like) such that a first shim axis 200 of the first shim 190 and a second shim axis 202 of the second shim 192 are collinear with respect to the differential case axis 176 of the differential case 102, as shown in fig. 12.

In an example, the insertion force 850 applied by the force applicator 770 to at least one of the first shim 190, the second shim 192, and/or the differential case 102 may be measured (e.g., the pneumatic force associated with the force applicator 770 may be monitored, measured, etc.). By measuring the insertion force 850, an axial force (e.g., bearing preload) applied by the differential carrier 500 to the first shim 190, the first bearing surface 172, the second shim 192, and/or the second bearing surface 174 in a direction parallel to the differential case axis 176 shown in fig. 12 may be determined. In an example, the differential carrier 500 may apply a first axial force 1250 to the first shim 190 and the first bearing surface 172. Differential carrier 500 may apply a second axial force 1252 to second shim 192 and second bearing surface 174.

Insertion force 850 may be measured in any number of ways, such as with a sensor (e.g., a pressure sensor, etc.), a force sensing resistor, a force gauge, and so forth. The insertion force 850 may be represented by the variable f. In an example, the coefficient of friction of the first shim 190, the second shim 192, the differential case 102, and/or the differential carrier 500 may be known based on the material of the first shim 190, the second shim 192, the differential case 102, and/or the differential carrier 500. The coefficient of friction may be represented by the variable μ. In this manner, axial force(s) 1250 and/or 1252 may be determined based on insertion force 850 (e.g., f) and a coefficient of friction (e.g., μ), where axial forces 1250, 1252 are represented by variable N. For example, the axial forces 1250, 1252 may be represented by equation (1):

in this manner, the axial forces 1250, 1252 (e.g., N) applied to the first and second bearing surfaces 172, 174 by the differential carrier 500 may be determined as a function of the insertion force (e.g., f). With the axial forces 1250, 1252 known, one or more features of the differential assembly 1200 may be adjusted. For example, if one or more axial forces do not fall within the threshold ranges of acceptable, expected, etc., the thickness and/or material composition of the first shim 190, the thickness and/or material composition of the second shim 192, the dimensions and/or material composition of the differential case 102 (e.g., along the differential case axis 176), the dimensions and/or material composition of the differential carrier 500, the dimensions, size, etc. of the differential opening 504 defined by the differential carrier 500 may be adjusted in a feed-forward and/or feedback manner with respect to the currently assembled differential assembly 1200 and/or one or more differential assemblies to be assembled (e.g., on an assembly line).

Referring to fig. 13, an example method 1300 of assembling a differential assembly 1200 is provided. At 1302, the method 1300 includes establishing a first orientation between the first shim 190 and the differential case 102 in which the first shim 190 is non-parallel relative to the first bearing surface 172 of the differential case 102. At 1304, the method 1300 includes inserting the first shim 190 and the differential case 102 into the differential opening 504 defined by the differential carrier 500 such that the first shim 190 contacts the differential carrier 500 and moves from a first orientation to a second orientation in which the first shim 190 is parallel relative to the first bearing surface 172.

Referring to fig. 14, an example method 1400 of assembling the differential assembly 1200 is provided. At 1402, the method 1400 includes establishing a first orientation between the first shim 190 and the differential case 102 in which the first shim axis 200 of the first shim 190 is non-parallel with respect to the differential case axis 176 of the differential case 102. At 1404, the method 1400 includes inserting the first shim 190 and the differential case 102 into the differential opening 504 defined by the differential carrier 500 such that the first shim 190 contacts the differential carrier 500 and moves from a first orientation to a second orientation in which the first shim axis 200 of the first shim 190 is parallel with respect to the differential case axis 176 of the differential case 102.

Referring to fig. 15, an example method 1500 of assembling the differential assembly 1200 is provided. At 1502, method 1500 includes simultaneously inserting first shim 190, second shim 192, and differential case 102 into a differential opening 504 defined by differential carrier 500. Thus, when the first, second, and differential case 190, 192 and the differential case 102 are fully seated within the differential carrier 500, the first shim 190 contacts the differential carrier 500 and is parallel with respect to the first bearing surface 172 of the differential case 102, and the second shim 192 contacts the differential carrier 500 and is parallel with respect to the second bearing surface 174 of the differential case 102. As shown in fig. 11 and 12, when the first, second, and differential case 190, 192 and 102 are fully seated, the differential case axis 176, the first, and second shim axes 200, 202 are coaxial with one another. In such a fully seated position, the first shim 190 may be substantially parallel to the first bearing surface 172, while the second shim 192 may be substantially parallel to the second bearing surface 174.

When the first, second, and differential case 190, 192 and the differential case 102 are simultaneously inserted into the differential opening 504, but before the first, second, and differential case 190, 192 and 102 are fully seated within the differential carrier 500, at least one of the first or second shims 190, 192 may be in a first orientation but need not be in the first orientation (e.g., the first shim axis 200 of the first shim 190 is not parallel with respect to the differential case axis 176, the first shim 190 is not parallel with respect to the first bearing surface 172, the second shim axis 202 of the second shim 192 is not parallel with respect to the differential case axis 176, and/or the second shim 192 is not parallel with respect to the second bearing surface 174, etc.).

Referring to fig. 16, an example method 1600 of assembling the differential assembly 1200 is provided. At 1602, the method 1600 includes inserting the first shim 190 and the differential case 102 into a differential opening 504 defined by the differential carrier 500. Thus, the first shim 190 and the differential case 102 may be in a first position that is not fully seated within the differential carrier 500. In the example, the second shim 192 is also (simultaneously) inserted into the differential opening 504 in the first (unseated) position. At 1604, the method 1600 includes applying an insertion force 850 to at least one of the first shim 190 or the differential case 102 to transition the first shim 190 and the differential case 102 from a first position to a second position fully disposed within the differential carrier 500. In the example, second shim 192 also transitions to the second (seated) position (simultaneously).

At 1606, method 1600 includes measuring an insertion force 850 applied to at least one of first shim 190 or differential case 102 (e.g., and/or second shim 192). At 1608, method 1600 includes determining an axial force 1250 applied by differential carrier 500 to first bearing surface 172 from insertion force 850. In the example, the axial force 1252 applied to the second bearing surface 174 is also determined (simultaneously).

Referring to fig. 17, a graph 1700 is shown depicting an insertion force 850 (applied to at least one of the first shim 190, the second shim 192, and/or the differential case 102) versus time. The x-axis 1702 represents time and the y-axis 1704 represents insertion force 850. Line 1706 represents the change in insertion force 850 over time.

At 1710, the first shim 190 may be non-parallel with respect to the first bearing surface 172 and the second shim 192 may be non-parallel with respect to the second bearing surface 174. When the first shim 190 may transition from non-parallel to parallel with respect to the first bearing surface 172 and/or the second shim 192 may transition from non-parallel to parallel with respect to the second bearing surface 174 (e.g., the first shim 190, the second shim 192, and the differential case 102 may be in the first position so as not to be fully seated within the differential carrier 500), the insertion force 850 may increase up to 1712. At 1714, the insertion force 850 may be reduced when the first shim 190 and/or the second shim 192 have transitioned from being non-parallel with respect to the bearing surfaces 172, 174 to being parallel with respect to the bearing surfaces 172, 174 (e.g., but still not in the second (fully seated) position). With first shim 190 and/or second shim 192 parallel, insertion force 850 may again increase at 1716. At 1718, the insertion force 850 has transitioned the shims 190, 192 and the differential case 102 from the first (incompletely seated) position to the second (fully seated) position within the differential carrier 500.

The insertion force 850 may be measured at any number of points along the line 1706 to determine the axial forces 1250, 1252 applied to the bearing surfaces 172, 174 of the differential case 102. In an example, the insertion force 850 may be measured at 1716, where 1716 represents the time between when the pads 190, 192 are parallel to the bearing surfaces 172, 174 but when the pads 190, 192 and the differential case 102 are fully seated (e.g., as shown in fig. 11 and 12) within the differential carrier 500.

It will be appreciated that the nested configuration 100 provides a number of benefits. For example, the nesting structure 100 may support the differential case 102 while allowing the first and second shims 190, 192 to remain in a first orientation prior to insertion into the differential carrier 500. With the first and second shims 190, 192 in the first orientation, the robot 300 may lift and insert the differential case 102, the first and second shims 190, 192 into the differential carrier 500. This orientation of first and second shims 190, 192 may reduce friction and wear on first and second shims 190, 192, first and second bearing surfaces 172, 174.

The foregoing process may also reduce the need for compression and/or tension of the differential carrier 500 to install the differential case 102 and the shims 190, 192. Thereby, the possibility of deformation and elastic deformation of the differential carrier 500 caused by the pressing and/or stretching can be reduced.

As used in this application, "exemplary" is used herein to mean serving as an example, instance, illustration, or the like, and is not necessarily advantageous. As used in this application, "or" is intended to mean an inclusive "or" rather than an exclusive "or". In addition, the use of "a" and "an" in this application is to be construed generally to mean "one or more" unless specified otherwise or clear from context to be directed to a singular form. Also, at least one of A and B and/or the like generally means A, or B, and/or both A and B. Furthermore, to the extent that the terms "includes," has, "" with, "or variants thereof are used, such terms are intended to be inclusive in a manner similar to the term" comprising.

Many modifications may be made to the present disclosure without departing from the scope or spirit of the claimed subject matter. Unless otherwise stated, "first," "second," or the like are not intended to imply temporal aspects, spatial aspects, order, or the like. Rather, such terms are merely used as identifiers, names, etc. of features, elements, items, etc. For example, a first component and a second component may generally correspond to component a and component B, or two different components or two identical components, or the same component.

Further, although the disclosure has been shown and described with respect to one or more implementations, equivalent alterations and modifications will occur to others skilled in the art based upon a reading and understanding of this specification and the annexed drawings. The present disclosure includes all such modifications and alterations, and is limited only by the scope of the appended claims. In particular regard to the various functions performed by the above described components (e.g., elements, resources, etc.), the terms used to describe such components are intended to correspond, unless otherwise indicated, to any component which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure. In addition, while a particular feature of the disclosure may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application.