Vehicle Axle Gearbox Assembly With Modular Multi-Speed Packaging

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Solution Overview

Problem

Modern electric vehicle axles face challenges in packaging components such as high voltage cables, brake lines, pneumatics, and cooling hoses within the limited space of vehicles, necessitating improved design for efficient installation and flexibility.

Innovation Solution

A gearbox assembly with a planetary gear system, differential, free wheeling gear, and multiple countershaft assemblies, along with a clutch, is designed to create a compact and modular powertrain assembly that can be used in both heavy-duty and medium-duty vehicles, allowing for flexible configuration and reduced need for bearings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a conventional E-axle design is used, then the vehicle can be equipped with basic propulsion components, but there is insufficient space for routing high voltage cables, brake lines, pneumatics, cooling hoses, and harnesses

Engineering Contradiction:

Improveavailable space for component routingVSAvoidcomplexity of component routing

Core Design Contradiction:

Area of stationary objectVSDevice complexity

Solution Approach 1:

The gearbox assembly is divided into modular components including planetary gear system, countershaft assemblies, differential, and clutch mechanisms. This segmentation allows each component to be independently positioned and routed, creating dedicated pathways for high voltage cables, brake lines, and cooling hoses within the limited space

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent utilizes three-dimensional spatial arrangement by positioning the planetary gear system concentrically around the rotation axis, with countershafts arranged in multiple radial positions. This dimensional approach creates vertical and radial pathways for routing various lines and cables that would be impossible in a two-dimensional layout

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If a compact gearbox assembly is designed, then packaging efficiency is improved, but the design complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvevolume of gearbox assemblyVSAvoidease of assembly and installation

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The clutch mechanism serves multiple functions: it couples the planet carrier with either the differential or the free wheeling gear depending on operating conditions. This multi-functionality reduces the number of separate components needed, simplifying the overall assembly process while maintaining compact dimensions

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines the differential and gearbox functions into a single integrated assembly, with the differential positioned adjacent to the planetary gear system and connected through shared components. This merging eliminates the need for separate housings and mounting structures, reducing volume while facilitating standardized manufacturing

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If multiple speed ratios are enabled, then the vehicle has improved performance flexibility, but the gearbox structure becomes more complex requiring additional bearings and support structures

Engineering Contradiction:

Improvespeed ratio optionsVSAvoidcomplexity of bearing layout

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The clutch mechanism dynamically reconfigures the power transmission path by engaging or disengaging different gear sets based on the required speed ratio. This dynamic switching capability provides multiple gear ratios without requiring all gears to be simultaneously present, thereby reducing the number of bearings and support structures needed compared to a traditional multi-gear design

Inventive Principle:

Principle #15Dynamics

4Adaptability or versatility

If a modular powertrain assembly is created for both heavy-duty and medium-duty vehicles, then versatility across vehicle types is improved, but the design must accommodate varying space and load requirements

Engineering Contradiction:

Improveapplicability to different vehicle typesVSAvoidconfiguration flexibility

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20240416746A1Gearbox assembly and power train assembly for a vehicle axle, and related vehicle

Publication Date: 2024.12.19 VOLVO TRUCK CORP

AI summary

A gearbox assembly for a vehicle axle which extends along a rotation axis is disclosed herein and includes:a planetary gear system positioned along the vehicle axle and receiving power from a motor, the planetary gear system comprising a ring gear, a sun gear, a planet, and a planet carrier including an output member;a differential including a shaft which includes an output gear positioned concentrically to the rotation axis along the shaft;a freewheeling gear located concentrically to the output member;a plurality of countershaft assemblies each including:a countershaft rotating about an axis parallel to the rotation axis; andtwo countershaft gears; anda clutch configured to be operated between a first position where it couples the output member with the freewheeling gear and a second position where it couples the output member with the differential.