High-integration electric drive system gear shifting mechanism

Abstract

The invention belongs to the technical field of vehicle electric driving, and particularly relates to a high-integration electric driving system gear shifting mechanism which comprises an actuating mechanism and an executing mechanism. The actuating mechanism comprises a permanent magnet synchronous motor, a reduction gear set, a worm and gear mechanism and an angle sensor. The executing mechanism comprises a rotating shaft, a shifting fork, a sliding block, a left side combination gear sleeve, a right side combination gear sleeve, a middle hub and a combination sleeve. According to the working principle, the actuating mechanism forms a swing angle, the synchronizer is driven to work through the worm gear and the rotating shaft, and a first gear, a neutral gear and a second gear can be achieved. Specifically, a permanent magnet synchronous motor is decelerated through a reduction gear set and transmitted to a worm, a worm gear is fixed to a rotating shaft, the rotating shaft is driven to rotate within a certain angle, the rotating shaft rotates to drive a shifting fork to swing left and right, and at the moment, a sliding block on the shifting fork pushes a joint sleeve of a synchronizer; and the synchronizer combination sleeve is connected with the left side combination gear sleeve and the right side combination gear sleeve by moving left and right, so that the gear engaging operation of a first gear, a neutral gear and a second gear is realized.

Description

Technical Field

[0001] The present invention belongs to the technical field of vehicle electric drive, and particularly relates to a high-integration electric drive system shifting mechanism. Background Art

[0002] The power source of new energy vehicles is required to output large torque at low speed and constant power at high speed. If the electric drive system of new energy vehicles adopts a drive motor and a fixed-ratio reducer, the requirements for the torque and speed of the drive motor are relatively high, the drive motor has a large volume, difficult control, low efficiency, and high cost. By adopting a drive motor and a transmission with several gears, the volume and cost of the drive motor can be significantly reduced, and the efficiency of the working area of the drive motor can be improved. However, the transmission with several gears increases the design difficulty of the mechanical system, and the design of the high-integration electric drive system shifting mechanism is particularly crucial. Summary of the Invention

[0003] (1) Technical Problems to be Solved

[0004] The technical problem to be solved by the present invention is: how to provide a high-integration electric drive system shifting mechanism. The electric drive system of new energy vehicles consists of a drive motor and a transmission, and requires high power density and wide-speed-range torque output. The high integration of the shifting mechanism with the drive motor and the transmission can significantly improve the power density of the electric drive system.

[0005] (2) Technical Solutions

[0006] To solve the above technical problems, the present invention provides a high-integration electric drive system shifting mechanism, which includes: an actuating mechanism 1 and an executing mechanism 2;

[0007] The actuating mechanism 1 includes: a permanent magnet synchronous motor 3, a reduction gear set 4, a worm 5, a worm gear 6, an angle sensor 7, and a support 8;

[0008] The executing mechanism 2 includes: a rotating shaft 9, a fork 10, a slider 11, a left engaging sleeve 12, a right engaging sleeve 13, an intermediate hub 14, and a coupling sleeve 15. Among them, the left engaging sleeve 12, the right engaging sleeve 13, the intermediate hub 14, and the coupling sleeve 15 are collectively referred to as a synchronizer;

[0009] The actuating mechanism 1 forms a swing angle, and drives the synchronizer to work through the worm gear 6 and the rotating shaft 9, so as to realize three positions: first gear, neutral gear, and second gear;

[0010] The specific process is as follows: The output power of the permanent magnet synchronous motor 3 is transmitted to the worm 5 through the reduction gear set 4. The worm 5 corresponds to the worm gear 6, and the worm gear 6 is fixed to the rotating shaft 9, thereby driving the rotating shaft 9 to rotate within a certain angle. The rotation of the rotating shaft 9 drives the fork 10 to swing left and right. At this time, the slider 11 on the fork 10 pushes the engaging sleeve 15 of the synchronizer, causing it to move left and right to complete the connection between the engaging sleeve 15 of the synchronizer and the left engaging gear sleeve 12 or the right engaging gear sleeve 13, thereby realizing the gear shifting operations of the first gear, neutral gear, and second gear.

[0011] The gear shifting mechanism of the highly integrated electric drive system realizes the locking of gears by using the self-locking principle of the worm and worm gear.

[0012] The fork 10 together with the slider 11 drives the left movement of the engaging sleeve 15 to connect with the left engaging gear sleeve 12, forming the first gear, which is defined as the low gear. The fork 10 together with the slider 11 drives the engaging sleeve 15 to move to the right to connect with the right engaging gear sleeve 13, forming the second gear, which is defined as the high gear. When the engaging sleeve 15 is in the middle position, it is in neutral gear.

[0013] The rotation angle of the rotating shaft 9 is identified by the angle sensor 7 to obtain the position information of the engaging sleeve 15 of the synchronizer, and the start-stop and rotation speed of the permanent magnet synchronous motor 3 are controlled.

[0014] The gear shifting mechanism of the highly integrated electric drive system combines the shifting motor with the synchronizer and realizes gear shifting through the rotation of the worm gear. It has a high structural integration degree and smooth gear shifting.

[0015] (III) Beneficial effects

[0016] The present invention combines the shifting motor with the synchronizer, which can be highly integrated with the electric drive system body, making the gear shifting process smoother and having significant application prospects.

[0017] Compared with the prior art, the present invention adopts the combination of the shifting motor and the synchronizer. Through the reduction gear set, worm and worm gear, and rotating shaft as the transmission components of the shifting motor and the synchronizer, the actuating mechanism such as the shifting motor is placed outside the synchronizer, without occupying the axial space of the drive motor and the transmission, facilitating the realization of the compact structure of the electric drive system and reducing the volume and weight of the electric drive system. Description of the drawings

[0018] Figure 1 is a schematic diagram of the composition of a gear shifting mechanism of a highly integrated electric drive system of the present invention.

[0019] Figure 2 is a schematic diagram of the composition of the actuating mechanism of the present invention.

[0020] Figure 3 is a schematic diagram of the composition of the execution mechanism of the present invention. Specific embodiments

[0021] To make the objectives, content, and advantages of the present invention clearer, the following further describes in detail the specific implementation manners of the present invention in conjunction with the accompanying drawings and embodiments.

[0022] To solve the above technical problems, the present invention provides a shifting mechanism for a highly integrated electric drive system, which includes: an actuating mechanism 1 and an executing mechanism 2;

[0023] The actuating mechanism 1 includes: a permanent magnet synchronous motor 3, a reduction gear set 4, a worm 5, a worm gear 6, an angle sensor 7, and a support 8;

[0024] The executing mechanism 2 includes: a rotating shaft 9, a fork 10, a slider 11, a left coupling sleeve 12, a right coupling sleeve 13, an intermediate hub 14, and a coupling sleeve 15. Among them, the left coupling sleeve 12, the right coupling sleeve 13, the intermediate hub 14, and the coupling sleeve 15 are collectively referred to as a synchronizer;

[0025] The actuating mechanism 1 forms a swinging angle, and drives the synchronizer to work through the worm gear 6 and the rotating shaft 9, for realizing three positions: first gear, neutral gear, and second gear;

[0026] Specifically as follows: The output power of the permanent magnet synchronous motor 3 is decelerated and transmitted to the worm 5 through the reduction gear set 4. The worm 5 corresponds to the worm gear 6, and the worm gear 6 is fixed to the rotating shaft 9, thereby driving the rotating shaft 9 to rotate within a certain angle. The rotation of the rotating shaft 9 drives the fork 10 to swing left and right. At this time, the slider 11 on the fork 10 pushes the engaging sleeve 15 of the synchronizer, so that it moves left and right to complete the connection between the engaging sleeve 15 of the synchronizer and the left coupling sleeve 12 or the right coupling sleeve 13, thereby realizing the gear shifting operations of first gear, neutral gear, and second gear.

[0027] The shifting mechanism of the highly integrated electric drive system realizes the locking of gears by using the self-locking principle of the worm and worm gear.

[0028] The fork 10 together with the slider 11 drives the engaging sleeve 15 to move leftward and connect with the left coupling sleeve 12 to form first gear, which is defined as low gear. The fork 10 together with the slider 11 drives the engaging sleeve 15 to move rightward and connect with the right coupling sleeve 13 to form second gear, which is defined as high gear. When the engaging sleeve 15 is in the middle position, it is in neutral gear.

[0029] The angle sensor 7 identifies the rotation angle of the rotating shaft 9, obtains the position information of the engaging sleeve 15 of the synchronizer, and controls the start-stop and rotation speed of the permanent magnet synchronous motor 3.

[0030] The shifting mechanism of the highly integrated electric drive system combines the shifting motor with the synchronizer, and realizes gear shifting through the rotation of the worm gear, with high structural integration and smooth gear shifting.

[0031] The following further describes the present invention in detail with specific embodiments.

[0032] Embodiment

[0033] This embodiment provides a high-integration electric drive system shift mechanism. As Figure 1 shown, if the required static shift force is 150 N, according to the characteristics of the selected synchronizer, the effective force arm length of the shift fork is 70 mm, the unilateral stroke is 10 mm, and the torque required for the rotating shaft during shifting is 10.5 N·m. The designed reduction ratio of the reduction gear set is 2, and the reduction ratio of the worm and worm gear is 64. Then the motor output torque needs to be 0.164 N·m. The rated speed of the motor can be selected as 5366 rpm, and the output torque is 443.7 mN·m. Assuming the transmission efficiency of the worm and worm gear is 50%, and the transmission efficiency of the gears and bearings is 80%, the actual torque of the rotating shaft is 22.72 N·m, which meets the requirements.

[0034] The above is only the preferred embodiment of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the technical principle of the present invention, several improvements and deformations can be made, and these improvements and deformations should also be regarded as the protection scope of the present invention.

Claims

1. A highly integrated electric drive system shift mechanism, characterized in that: It comprises: an actuating mechanism (1) and an executing mechanism (2); The actuating mechanism (1) comprises: a permanent magnet synchronous motor (3), a reduction gear set (4), a worm (5), a worm wheel (6), and an angle sensor (7); The actuator (2) comprises: a rotating shaft (9), a shift fork (10), a slider (11), a left-side combined gear sleeve (12), a right-side combined gear sleeve (13), an intermediate hub (14) and a combined sleeve (15), wherein the left-side combined gear sleeve (12), the right-side combined gear sleeve (13), the intermediate hub (14) and the combined sleeve (15) are collectively referred to as a synchronizer; The actuating mechanism (1) forms a swing angle, and drives the synchronizer to work through the worm gear (6) and the rotating shaft (9), so as to realize three positions: gear position 1, neutral gear, and gear position 2; Specifically, the output power of the permanent magnet synchronous motor (3) is transmitted to the worm (5) through the reduction gear set (4), the worm (5) corresponds to the worm wheel (6), and the worm wheel (6) is fixed to the rotating shaft (9), thereby driving the rotating shaft (9) to rotate within a certain angle, and the rotation of the rotating shaft (9) drives the shift fork (10) to swing left and right. At this time, the slider (11) on the shift fork (10) pushes the synchronizer coupling sleeve (15) to move left and right to complete the connection between the synchronizer coupling sleeve (15) and the left coupling gear sleeve (12) or the right coupling gear sleeve (13), thereby realizing the gear operation of the first gear, the neutral gear, and the second gear.

2. The highly integrated electric drive system shift mechanism according to claim 1, characterized in that: The highly integrated electric drive system shift mechanism utilizes the worm gear self-locking principle to achieve gear locking.

3. The highly integrated electric drive system shift mechanism according to claim 1, characterized in that: The shift fork (10) together with the slider (11) drives the coupling sleeve (15) to move to the left side and connects with the left coupling gear sleeve (12) to form a gear position 1, which is defined as a low gear.

4. The highly integrated electric drive system shift mechanism according to claim 3, characterized in that: The shift fork (10) together with the slider (11) drives the coupling sleeve (15) to move to the right side and connects with the right coupling gear sleeve (13) to form a second gear position, which is defined as a high gear.

5. The highly integrated electric drive system shift mechanism according to claim 4, characterized in that: When the coupling sleeve (15) is in the middle position, it is in neutral.

6. The highly integrated electric drive system shift mechanism according to claim 4, characterized in that: The rotation angle of the rotating shaft (9) is identified by an angle sensor (7), the position information of the synchronizer coupling sleeve (15) is obtained, and the start and stop and rotation speed of the permanent magnet synchronous motor (3) are controlled.

7. The highly integrated electric drive system shift mechanism according to claim 6, characterized in that: The highly integrated electric drive system shift mechanism combines the shift motor with the synchronizer, realizes gear switching through the rotation of the worm gear, has high structural integration and smooth shifting.

8. The highly integrated electric drive system shift mechanism according to claim 6, characterized in that: The mechanism adopts a combination of a shift motor and a synchronizer, and uses a reduction gear set, a worm gear and a rotating shaft as transmission parts of the shift motor and the synchronizer. The shift motor is placed on the outside of the synchronizer as an actuating mechanism, does not occupy the axial space of the drive motor and the transmission, and is convenient for realizing a compact structure of the electric drive system and reducing the volume and weight of the electric drive system.

9. The highly integrated electric drive system shift mechanism according to claim 6, characterized in that: The mechanism belongs to the technical field of vehicle electric drive.

10. The highly integrated electric drive system shift mechanism according to claim 6, characterized in that: The mechanism has high power density and torque output over a wide speed range, and the high degree of integration of the shift mechanism with the drive motor and the transmission can significantly improve the power density of the electric drive system.

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