Common Transmission Housing for Flexible Multi-Stage Gear Ratios
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Solution Overview
Problem
Existing vehicle powertrain designs face increased manufacturing complexity and costs due to the need for varied gear ratio designs, which can lead to component degradation and power delays, especially when pairing electric motors with shiftable transmissions.
Innovation Solution
A vehicle product line featuring a common housing that accommodates multiple gear train assemblies with different ratios, utilizing a combination of single and multiple layshafts, common bearings, and shared components to achieve flexible gear ratios while reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the housing is redesigned to accommodate different gearbox layouts for varied gear ratio targets, then different gear ratio design goals can be met, but manufacturing complexity and production costs increase
Solution Approach 1:
The patent applies universality by designing a single housing that can accommodate multiple gearbox layouts and serve different gear ratio requirements. The housing is configured with adaptable mounting positions and structural features that allow it to function across various gear train configurations, eliminating the need for separate housing designs for each gear ratio target.
Solution Approach 2:
The patent applies segmentation by dividing the gearbox into modular components (gear trains, differentials, axles) that can be independently configured within the unified housing. This allows different gear ratio assemblies to be assembled and disassembled within the same housing structure, providing design flexibility without requiring housing redesign.
2Speed
If shiftable transmission is paired with electric motors to achieve wide variance in output speed range, then speed flexibility is improved, but complexity and potential gearbox degradation modes increase
Solution Approach 1:
The patent applies dynamics by incorporating a shiftable transmission system that allows the gearbox to change gear ratios dynamically during operation. This enables the electric motor to operate across a wide speed range by selecting appropriate gear ratios, achieving speed flexibility while managing the complexity through controlled dynamic adjustment rather than static multi-gearbox configurations.
3Adaptability or versatility
If shiftable transmission is used in gearbox, then gear ratio flexibility is improved, but component degradation and power delays occur during shifting
Solution Approach 1:
The patent applies preliminary action by designing the shiftable transmission system with pre-positioned synchronizers and gear engagement mechanisms that are prepared in advance for smooth shifting operations. The synchronizers are pre-configured to match speeds before engagement, and the gear train layout is designed to minimize shock loads during ratio changes, thereby reducing degradation and power delays.
Data Source
AI summary
A line of vehicle transmissions is provided. The vehicle line includes a first multi-stage gear train assembly with at least two stages, a second multi-stage gear train assembly with at least three stages, and a housing including a first section removably attached to a second section. The second housing section is configured to receive the first and second multi-stage gear train assemblies in different product arrangements.