E-Drive Transmission Layout With Axial Load Support for Compact Packaging
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Solution Overview
Problem
Existing electric vehicles face challenges in energy efficiency and transmission complexity due to high power consumption and complex controller configurations when vehicle speed is controlled by the driving motor, and conventional transmissions are not well-suited for electric vehicles.
Innovation Solution
A transmission system with a housing, first, second, and third helical gears, supported by bearings and a bearing support frame, which includes a roller bearing to support the axial load of the third gear, reducing the size and cost of the E-drive system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional transmissions with 4 or more gear ratios are used in electric vehicles, then the transmission can provide multiple gear ratios for efficient power transmission, but the transmission system becomes complex and occupies large space
Solution Approach 1:
The transmission system is segmented into three distinct gear ratios (first, second, and third gears) that are selectively engaged through a simplified shifting mechanism. Each gear serves a specific function in the power transmission chain, allowing the system to provide multiple gear ratios without the complexity of conventional 4+ gear transmissions.
Solution Approach 2:
The patent combines the functions of multiple gear ratios into a compact three-gear configuration. The first gear (drive gear), second gear (intermediate gear), and third gear (output gear) are integrated into a single transmission housing with a unified shifting mechanism, merging what would traditionally require separate gear sets into one cohesive unit.
2Ease of operation
If synchronized manual transmission is used to match circumferential speeds of gears, then gear engagement becomes easier, but the transmission structure becomes more complex with additional synchronization mechanisms
Solution Approach 1:
The transmission system employs self-synchronizing gear engagement through the natural meshing of helical gears. The helical tooth geometry inherently guides the gears into proper alignment during engagement, eliminating the need for separate synchronization mechanisms. The gears self-adjust to match circumferential speeds through their inclined tooth surfaces.
3Device complexity
If the third gear is directly supported without additional support structures, then the transmission structure remains simple, but the axial load of the third gear cannot be properly supported
Solution Approach 1:
The output shaft serves multiple functions: it transmits rotational motion from the second gear to the third gear, supports the axial load of the third gear through its bearing arrangement, and provides the mounting structure for the third gear itself. This multi-functional design supports axial loads without adding separate support structures.
4Device complexity
If electric vehicles control vehicle speed by adjusting driving motor parameters, then transmission control becomes simpler, but power consumption increases and travel distance per charge decreases
Solution Approach 1:
The transmission system provides dynamic gear ratio selection with three distinct gear ratios that can be switched based on driving conditions. This allows the electric motor to operate in different efficiency ranges, optimizing power consumption by matching the gear ratio to the required output torque and speed, thereby improving travel distance per charge.
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
The solution provides efficient power transmission with reduced packaging size and cost, while enabling a parking function without additional structural changes, enhancing energy efficiency and simplifying the transmission system.
Implementation Method 1
a bearing which is interposed between the differential case and the bearing support frame, the bearing support frame serves as an outer wheel of the bearing, and the third gear serves as an inner wheel. The bearing may be a roller bearing.
Data Source
AI summary
A transmission, which is accommodated in a housing in which a space is formed and includes a first gear rotated by a driving force provided by an electric motor, a rotary shaft to which the first gear is coupled, a second gear formed on an outer circumferential surface of the rotary shaft and having a diameter smaller than a diameter of the first gear, and a third gear engaged with the second gear and having a diameter greater than the diameter of the second gear, wherein the rotary shaft includes a support configured to support an axial load of the third gear, can be provided.