Integrated EDM Winch Gearbox for Selective Torque Routing

Solution Overview

Problem

Existing winch implementations on electrified vehicles are not optimized for efficient torque delivery and often require additional components like supplemental electric motors and enhanced bumpers, which increase complexity and cost.

Innovation Solution

A gearbox assembly for an electric drive module that includes a differential and a planetary gear set, allowing the electric motor to selectively provide drive torque to either the vehicle's drive axles or a winch spool, thereby eliminating the need for additional components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a dedicated accessory assembly with supplemental electric motor is used for the winch, then the winch can be independently operated, but the device complexity and cost increase

Engineering Contradiction:

Improvewinch operation independenceVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the winch function with the existing electric motor of the electrified vehicle by routing torque from the motor through a planetary gear set to drive the winch spool. This eliminates the need for a supplemental electric motor and dedicated accessory assembly, reducing system complexity while maintaining winch operational capability through the vehicle's existing powertrain

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electric motor of the vehicle is designed to serve multiple functions: propelling the vehicle and operating the winch. By using the same motor for both purposes and controlling torque distribution through the planetary gear set, the system achieves multi-functionality without requiring additional motors or complex control systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If a dedicated accessory assembly with supplemental electric motor is used for the winch, then the winch can be independently operated, but the cost increases

Engineering Contradiction:

Improvewinch operation independenceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges the winch function with the existing electric motor of the electrified vehicle by routing torque from the motor through a planetary gear set to drive the winch spool. This eliminates the need for a supplemental electric motor and dedicated accessory assembly, reducing system complexity while maintaining winch operational capability through the vehicle's existing powertrain

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The electric motor of the vehicle is designed to serve multiple functions: propelling the vehicle and operating the winch. By using the same motor for both purposes and controlling torque distribution through the planetary gear set, the system achieves multi-functionality without requiring additional motors or complex control systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Power

If torque is routed through the planetary gear set to the winch, then efficient torque delivery is achieved, but the drive axles cannot receive torque simultaneously

Engineering Contradiction:

Improvetorque delivery efficiencyVSAvoiddrive mode flexibility

Core Design Contradiction:

PowerVSAdaptability or versatility

Solution Approach 1:

The planetary gear set is designed with dynamic, selectable connections that can route torque to different outputs based on operational requirements. The system can selectively engage the winch mode or drive mode by controlling which elements of the planetary gear set are connected, allowing efficient torque delivery to either the winch or drive axles as needed

Inventive Principle:

Principle #15Dynamics

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 solution enables efficient torque delivery to the winch, enhancing the vehicle's off-road capabilities without the need for additional motors or hardware, thus simplifying the system and reducing costs.

Implementation Method 1

a planetary gear set configured to selectively connect to an output of an electric motor through the differential, the planetary gear set including a sun gear, a ring gear and a planetary carrier

Methodology Applied

Scientific EffectGear: Gear

Data Source

PatentUS12203534B1Electric drive motor with integrated winch

Publication Date: 2025.01.21 FCA US LLC

AI summary

A gearbox assembly for an electric drive module (EDM) having an electric motor that selectively provides drive torque for an electrified vehicle is provided. A differential is driven by the electric motor and is configured to selectively drive first and second drive axles. A planetary gear set is configured to selectively connect to an output of an electric motor through the differential, the planetary gear set including a sun gear, a ring gear and a planetary carrier. A winch includes a spool and is selectively driven by the planetary gear set. The gearbox assembly is switchable between (i) a first drive mode where the drive torque is routed from the electric motor, through the differential and to the first and second drive axles; and (ii) a second winch mode where the drive torque is routed from the electric motor, through the differential and to the spool.