Double Reduction Wheel Assembly Brake Service
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Solution Overview
Problem
The existing configuration of electric drive axles in mass transit vehicles requires disassembly of the double reduction gear assembly and wheel bearings to service brake components, leading to increased maintenance time and costs.
Innovation Solution
A vehicle wheel assembly with a double reduction gear set where the brake component can be removed without disassembling the gear sets, utilizing an adapter to secure the wheel rim and brake component to the output shaft, allowing only the adapter and wheel rim to be removed for service, while keeping the planetary and input gear sets in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the brake component is integrated with the wheel hub in a traditional configuration, then the brake component can be securely mounted, but servicing the brake component requires disassembly of the wheel hub, planetary gear set, and wheel bearings which is time consuming and increases maintenance costs
Solution Approach 1:
The wheel hub assembly is segmented into distinct functional modules: the planetary gear set remains integrated with the wheel hub, while the brake component is separated and mounted on the output shaft through an adapter. This segmentation allows the brake component to be serviced independently without disassembling the planetary gear set or wheel bearings, directly resolving the maintenance complexity issue while preserving structural integrity.
2Length of moving object
If a rigid drive axle configuration is used, then the driveline can be simplified, but the vehicle floor cannot be lowered to desired levels
Solution Approach 1:
The patent transitions from a rigid drive axle configuration to a dynamic independent wheel drive system where each wheel is independently driven by an electric motor with integrated double reduction gear assembly. This dynamic configuration allows the floor to be lowered closer to ground level while maintaining drivetrain functionality through flexible, independent wheel drives rather than a fixed rigid axle structure.
3Power
If the planetary gear set is directly incorporated into the wheel hub, then the double reduction gear assembly can achieve desired output torque and speed, but the wheel hub must be disassembled to service brake components
Solution Approach 1:
The brake component is extracted from the traditional wheel hub integration and relocated to mount on the output shaft through a separate adapter. This extraction allows the planetary gear set to remain fully integrated in the wheel hub for optimal power transmission, while the brake component becomes independently accessible for servicing without requiring wheel hub disassembly, thus preserving both power transmission efficiency and maintenance ease.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces maintenance downtime and costs by allowing quick and efficient service of brake components without disassembling the gear sets, facilitating a lower vehicle floor for easier passenger access.
Implementation Method 1
a first reduction gear set that is coupled to the electric motor and a second reduction gear set that is incorporated into the wheel. The second reduction gear set is typically a planetary gear set
Implementation Method 2
The input gear set includes a pinion gear that is directly driven by an electric motor output shaft and an annular gear that is directly driven by the pinion gear
Data Source
AI summary
A drive unit for a vehicle wheel assembly includes an input gear set driven by an electric motor, a planetary gear set driven by the input gear set, and an output shaft driven by the planetary gear set. An adapter is used to attach a wheel rim and a brake component for rotation with the output shaft, which is rotatably supported by a wheel bearing. The input gear set and the planetary gear set are positioned outboard of the electric motor and inboard of the brake component. The brake component can be easily removed without requiring removal of the planetary gear set or any wheel bearings. Only the wheel rim and the adapter have to be removed in order to remove the brake component.