Seamless variable speed variator gear box

Abstract

The invention relates to a speed changer gear box between the motor (2) output and the wheel drive connection in electric vehicles. The invention relates to controllable four-wheel drive output and external power output in electric vehicles.

Description

[0001] SEAMLESS VARIABLE SPEED VARIATOR GEAR BOX

[0002] Technical Field

[0003] The invention relates to a speed changer gear box between the motor output and the wheel drive connection in electric vehicles. The invention relates to controllable four-wheel drive output and external power output in electric vehicles.

[0004] Prior art

[0005] Nowadays, electric vehicles using low-capacity electric motors have low efficiency under load. In addition, there is no controllable all-wheel drive output and no power output for external equipment such as compressors / pumps.

[0006] Vehicles in the current state of the art use a larger motor to provide the same torque. In addition, as an alternative to external output, equipment such as electronic compressors and pumps that use 24V, 12V or high voltage are used and efficiency is low.

[0007] Known applications of the technique include the use of mechanical compressors and pumps in internal combustion engine vehicles where power is transferred by belt and pulley method such as serpentine. This practice also results in low efficiency.

[0008] Electric vehicles in the current state of the art offer uncontrolled permanent four- wheel drive connections or electromagnetically controlled four-wheel drive connections. These technical solutions result in high costs.

[0009] Aim of the Invention

[0010] The main purpose of the invention is to create a wheel drive output (2 continuous outputs) with a bevel differential gear set by coupling the electric motor (1 input), reducing the speed with a seamless variable bond ratio and increasing the torque at low speeds. Multiplexing from the gear set where the speed is reduced, a four- wheel drive output is provided by a milling gear set driven by a linear actuator and an external power output (2nd controllable output) is provided by a milling gear set also driven by a linear actuator. By multiplexing from the gear set where the speed is reduced, a four-wheel drive output is provided by the milling gear set driven by a linear actuator and a controllable, speed-compensated output 1. With the milling gear set driven by linear actuator, 2nd controllable output is obtained with external power output.

[0011] Detailed Description of the Invention

[0012] Figures of the seamless variable speed variator gear box suitable for the purposes of the subject matter of the invention are as follows;

[0013] Figure 1 - General view of the seamless variable speed variator gearbox according to the invention

[0014] Figure 2 - Top view of the body

[0015] Figure 3 - Bottom view of the body

[0016] Figure 4 - Side view of the body

[0017] Figure 5 - Front view of the planetary gear set

[0018] Figure 6 - Side view of the planetary gear set

[0019] Figure 7 - View of the differential group

[0020] Figure 8 - View of the differential group

[0021] Figure 9 - View of the differential group

[0022] Figure 10 - View of the shafts transmitting motion in the seamless variable speed variator gear box according to the invention

[0023] The items in the figures above are numbered as follows and will be used throughout the rest of the description:

[0024] 1. Body

[0025] 1.1. Machined body

[0026] 1.2. Bearing

[0027] 1.3. Felt

[0028] 2. Motor

[0029] 3. Planetary Gear Group

[0030] 3.1. Ring Gear

[0031] 3.2. Planetary Gear

[0032] 3.3. Sun Gear

[0033] 3.4. Planetary Front Carrier Flange

[0034] 3.5. Planetary Rear Carrier Flange 3.6. Bearing

[0035] 3.7. Fixing Pin

[0036] 3.8. Circlip

[0037] 3.9. Flanged Nut

[0038] 3.10. Flanged Bolt

[0039] 4. Differential Group

[0040] 4.1. Ring Gear

[0041] 4.2. 1. Bevel Gear

[0042] 4.3. 2. Bevel Gear

[0043] 4.4. 1st Axle Shaft

[0044] 4.5. 2nd Axle Shaft

[0045] 4.6. Bearing

[0046] 4.7. Differential Hub

[0047] 4.8. 4x4 Output Gear

[0048] 4.9. Synchronization Shift Lever

[0049] 4.10. 4x4 Output Shaft

[0050] 4.11. 4x4 Transmission Shaft

[0051] 4.12. Auxilary Transfer Shaft

[0052] 4.13. Auxilary Output Shaft

[0053] 4.14. Auxilary Transmission Gear

[0054] 4.15. Auxilary Drive Gear

[0055] 4.16. Star Pinion

[0056] 5. DC Motor

[0057] 6. DC Drive Gear

[0058] 7. DC Drive Shaft

[0059] 8. Oil

[0060] 9. Actuator

[0061] The body(l) shown in Figure - 2, Figure - 3 and Figure - 4 can be produced as welded or cast. The body(l) is mainly composed of machined body(l.l), bearing(1.2) and felf(1.3). The machined body(l.l) contains the machining details and tolerances of the welded or cast body(l). In the body(l) the bearing(1.2) is used for bearing the input and output shafts and the fixed shafts. In the body(l) felt(1.3) is used for sealing the input and output shafts. The body(l) is a mechanical component where the bearings are made, the oil(8) inside provides convectional cooling through the walls of the body(l) and the system is connected to the vehicle. The oil (8) inside the body(l) is the automatic transmission oil used for cooling the system. The body(l) made of aluminum is the carrier of the system. The fact that the body(l) is made of aluminum reduces the weight on the axle and provides ease of production. Since it is thought that this system will be used especially in electric vehicles, aluminum body(l) is preferred to provide range advantage.

[0062] The motor(2) connected to the body(l) shown in Figure - 1 is the system that drives the wheels by converting electrical energy into mechanical motion. It is possible to use different motors by changing the connection flange and the milled input shaft.

[0063] The planetary gear group(3) shown in Figure - 5 is mainly composed of ring gear(3.1), planetary gear(3.2), sun gear(3.3), planetary front carrier flange(3.4), planetary rear carrier flange(3.5), bearing(3.6), fixing pin(3.7), circlip(3.8), flanged nut(3.9) and flanged bolt(3.10).

[0064] Planetary gears(3.2) shown in Figure - 6 are connected between the sun gear(3.3) and ring gear(3.1) to which the input shaft is connected. The input power from the motor(2) is first transferred to the sun gear(3.3). The sun gear(3.3) gives the planetary gear(3.2), of which there is at least one in the planetary gear group(3), a rotational movement in the opposite direction of its own rotation. Bearing(3.6) is used for the bearing of the planetary gears(3.2) to the sun gear(3.3). The joint connection of the planetary gears(3.2) to the sun gear(3.3) and ring gear(3.1) is provided by the planetary front carrier flange(3.4). The input power of the motor(2) is transferred from the sun gear(3.3) to the ring gear(3.1) via the planetary gears(3.2) in the opposite direction. The ring gear(3.1) affects the output speed and is connected to the DC motor(5) outside the planetary gear group(3). Since the rotational motion of the DC motor(5), which is another source of motion, and the rotational motion transmitted through the planetary gears(3.2) are opposite to each other, a relative motion occurs in the ring gear(3.1). As a result, the input power to the sun gear(3.3) and the output power from the ring gear(3.1) are not equal. Thanks to the DC motor(5), the speed of the ring gear(3.1) is changed and affects the output speed. The speed of the DC motor(5) is transferred to the ring gear(3.1) by means of DC drive gear(6). The connection of DC Motor(5) to the system is provided by DC drive shaft(7). The ring gear(3.1), which controls the speed by creating the relative speed of the planetary gears(3.2) and DC motor(5), transfers the said relative speed to the 2nd bevel gear(4.3) via the planetary rear carrier flange(3.5). The speed change is provided with the relative speed obtained in the ring gear(3.1). Planetary back carrier flange(3.5) is the common connection flange of the output shaft. Fixing pin(3.7) is used to fix the planetary gears(3.2) to the planetary back carrier flange(3.5). Circlips(3.8) are used for fixing the fixing pins(3.7). The connection of planetary front carrier flange(3.4) and planetary rear carrier flange(3.5) is provided with flanged nut(3.9) and flanged bolt(3.10).

[0065] The motion transmitted through the planetary rear carrier flange(3.5) is taken by the 2nd bevel gear(4.3) on the differential group(4). The 2nd bevel gear(4.3) acts as the input gear and provides 90° angular transmission with its bevel gear. The movement coming to the 2nd bevel gear(4.3) is transferred to the star pinion(4.16). Two outputs of the star pinion(4.16) are connected to the axles and two outputs of the star pinion(4.16) are mounted to the differential hub(4.7). Star pinion(4.16) provides 90° bevel gear transmission. The star pinion(4.16) transfers motion to the differential hub(4.7) and ring gear(4.1) in which it is mounted. The differential hub(4.7) collects and holds together the set of ring gear(4.16) and is connected to the ring gear(4.1). The ring gear(4.1) shown in Figure - 7 is a bevel gear working with the 1st and 2nd bevel gears(4.2, 4.3). The ring gear(4.1) provides transmission to the axle link. The movement is finally output to the 1st and 2nd axle shaft(4.4, 4.5) where they are connected to the ring gear(4.1) by balancing the speed. Bearing(4.6) is used for the bearing of 1st and 2nd axle shaft(4.4, 4.5). At the same time, for external power output, it takes the movement from the 2nd bevel gear(4.3) with which it shares the same shaft. This motion is then transmitted to the auxiliary drive gear(4.15) and the auxiliary transmission gear(4.14) with which it is in contact. The auxiliary drive gear(4.15) shown in Figure - 9 acts as the gear that transmits the main motion working with the 2nd bevel gear(4.3). The auxiliary transmission gear(4.14) working with the auxiliary drive gear(4.15) is located on the auxiliary transfer shaft(4.12). Finally, the motion is transmitted to the auxiliary transfer shaft(4.12). The synchronization shift lever(4.9) on the auxiliary transfer shaft(4.12) and auxiliary output shaft(4.13) is controlled by actuator(9) and the auxiliary output is activated and / or deactivated. Auxiliary output shaft(4.13) provides external power output. The synchronization shift lever(4.9) is connected to both the auxiliary transfer shaft(4.12) and the auxiliary output shaft(4.13) when the auxiliary output is active, and to the auxiliary transmission shaft(4.12) when it is passive. The synchronization shift lever(4.9) moves the 4x4 transmission shaft(4.11) and the auxiliary transfer shaft (4.12) to transmit motion to the respective output.

[0066] When the driver wants to activate and / or deactivate the auxiliary output; that is, when he wants to operate the auxiliary equipment from the control screen from inside the cabin; the given command can trigger the actuator(9) from the control screen. Thus, the linear actuator(9) slides the synchronization shift lever(4.9) on the spline tooth and causes the 4x4 output gear(4.8) to rotate. In this way, power is transferred to the 4x4 output gear(4.8). There is a 4x4 output gear(4.8) which transmits the main motion working with the 1st bevel gear(4.2) (Figure - 8).

[0067] To activate and / or deactivate the 4x4 output, the 1st bevel gear(4.2) is connected to the 4x4 output shaft(4.10) on the same shaft. The 4x4 output shaft(4.10) is in contact with the 4x4 transmission shaft(4.11). The 4x4 transmission shaft(4.11) and the 4x4 output shaft(4.10) transmit motion through the actuator(9) to control the synchronous toggle lever(4.9) on the 4x4 output shaft(4.10). In this way, the 4x4 output is activated and / or deactivated by the control of the synchronization shift lever(4.9). When active, the synchronization shift lever(4.9) is connected to both the 4x4 transmission shaft(4.11) and the 4x4 output shaft(4.10). In deactive state, the synchronization shift lever(4.9) is connected to the 4x4 transmission shaft(4.11).

[0068] Except for the motor(2), DC motor(5) and actuator(9), the remaining elements are designed according to input power, speed, number of outputs and control features. For electric vehicles, there is a gearbox that can change speed, has a differential set, has four outputs, two of which are main axles, two of which are continuous and two of which are controllable, one of the controllable outputs can be used for 4x4 connection with speed compensation and the other can be used for external component connection such as pumps and compressors.

[0069] The drive from the motor(2) is controlled by changing the speed of the DC motor(5). The motor(2) is selected according to the driving values of the vehicle in which the system will be used and the DC motor(5) is selected according to the torque value corresponding to the zero acceleration state of the ring gear(3.1) in the transmission line designed according to the power of the said motor(2). The 1st and 2nd axle shafts(4.4, 4.5) are regulated and continuous power output is provided by balancing the speed between the two wheels. Apart from this, if the actuator(9) for 4x4 is activated, power output is provided with 4x4 output shaft(4.1O). If the actuator(9) for external power output is activated, power output is provided by the auxiliary output shaft(4.13). (Figure - 10) The controls of the motor(2), DC Motor(5) and actuators(9) are made through the main controller on the vehicle and algorithms are created by considering the torque requirement of the vehicle.

Claims

CLAIMS1. A seamless variable speed gearbox for use in electric vehicles, comprising a planetary gear group(3) located within a body(l) and positioned between a sun gear(3.3) connected to the input shaft and a ring gear(3.1), said planetary gear set(3) includes planetary gears(3.2) transmitting motion sequentially through the 2nd bevel gear(4.3), a star pinion(4.16), a differential hub(4.7), a mirror gear(4.1), and a differential group(4) with 1st and 2nd axle shafts(4.4, 4.5) said gear box has one input and two controllable continuous outputs, characterized in that;- A DC motor(5), which controls the drive speed from the motor(2) by changing, is used according to the torque value corresponding to the zero acceleration state of the ring gear(3.1) in the transmission line designed based on the power of said motor(2), and through the rotational motion transmitted via the planetary gears(3.2) connected to said ring gear(3.1), creates opposite directional movements to change the speed of the ring gear(3.1) and affects the output speed,- An actuator(9), which is activated and / or deactivated by the control of the synchronization shift lever(4.9) on the 4x4 transmission shaft(4.11) and 4x4 output shaft(4.10) in contact with each other, which provides power output with the mentioned 4x4 output shaft(4.10) to activate the 4x4 output, and An actuator (9) that is controlled using the synchronous transition arm (4.9) located on the auxiliary transfer shaft (4.12) and the auxiliary output shaft (4.13), wherein the auxiliary output is activated and / or deactivated, and when activated, it provides external power output with the mentioned auxiliary output shaft (4.13).

2. A seamless variable speed gear box in accordance with Claim 1, characterized in that; the body(l) is made of aluminum by welding or casting method in order to provide range advantage in electric vehicles by reducing the weight on the axle.

3. A seamless variable speed gear box in accordance with Claim 1, characterized in that; the synchronization shift lever(4.9) is connected to both the auxiliary transfer shaft(4.12) and the auxiliary output shaft(4.13) when the auxiliary output is active.

4. A seamless variable speed gear box in accordance with Claim 1, characterized in that; the synchronization shift lever(4.9) is only connected to the auxiliary transfer shaft(4.12) when the auxiliary output is deactivated.

5. A seamless variable speed gear box in accordance with Claim 1, characterized in that; in the active state of the 4x4 power output, the synchronization shift lever(4.9) is connected to both the 4x4 transmission shaft(4.11) and the 4x4 output shaft(4.10).

6. A seamless variable speed gear box in accordance with Claim 1, characterized in that; when the 4x4 power output is deactive, the synchronization shift lever(4.9) is only connected to the 4x4 transmission shaft(4.11).

7. A seamless variable speed gear box in accordance with Claim 1, characterized in that; comprises bearings(3.6) for housing planetary gears(3.2) to sun gears(3.3).

8. A seamless variable speed gear box in accordance with Claim 1, characterized in that; the fixing pins(3.7) used for positioning the planetary gear(3.2) to the planetary rear carrier flange(3.5) include a circlip(3.8) which fixes said planetary gears(3.2) to said planetary rear carrier flange(3.5).

9. A seamless variable speed gear box in accordance with Claim 1, characterized in that; comprises bearings(4.6) used for housing the 1st and 2nd axle shaft(4.4, 4.5).

10. A seamless variable speed gear box in accordance with Claim 1, characterized in that; comprises a DC drive gear(6) which transfers the speed of the DC motor(5) to the ring gear(3.1).

11. A seamless variable speed gear box in accordance with Claim 1, characterized in that; comprises a DC drive shaft(7) for connecting the DC motor(5) to the system.

12. A seamless variable speed gear box in accordance with Claim 1, characterized in that; the body(l) contains oil(8) of the type of automatic transmission oil used for cooling the system, which provides convectional cooling through the walls of said body(l).

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