Electric AWD Two-Speed Split Double Reduction Planetary Gearbox
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Solution Overview
Problem
Current vehicle powertrain systems lack efficient mechanisms for shifting between high, low, and neutral modes, particularly in electric all-wheel drive systems, which affects torque distribution and rotational speed, leading to suboptimal performance and packaging challenges.
Innovation Solution
A driveline module incorporating an electrical machine connected to a gear train, a first planetary gear set with multiple ratios, a second planetary gear set with a fixed ratio, and a synchronizer that shifts the ring gear between the gear sets to achieve high, low, and neutral modes, allowing selective power transmission to the differential.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single planetary gear set is used, then the device complexity is reduced, but the adaptability for multiple driving modes (high, low, neutral) is insufficient
Solution Approach 1:
The patent combines two planetary gear sets with different fixed gear ratios into a single driveline module, allowing the system to achieve multiple driving modes (high range, low range, neutral) through the interaction of these gear sets and a synchronizer mechanism, thereby improving adaptability without proportionally increasing complexity
Solution Approach 2:
The driveline module is designed to perform multiple functions through a single integrated structure: it can operate in high range mode, low range mode, and neutral mode, with the synchronizer enabling seamless transitions between these modes by selectively engaging different gear paths
2Power
If multiple planetary gear sets with different fixed gear ratios are used, then the torque management capability is improved, but the packaging space increases
Solution Approach 1:
The patent employs a nested arrangement where the first and second planetary gear sets are positioned concentrically or in close proximity, with the synchronizer mechanism integrated between them, allowing compact packaging of multiple gear sets with different fixed gear ratios to achieve superior torque management in a limited space
3Ease of operation
If a synchronizer mechanism is added to enable mode shifting, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The synchronizer acts as an intermediary mechanism between the two planetary gear sets, enabling smooth transitions between high range and low range modes by selectively engaging or disengaging the connection between the gear sets, thereby improving ease of operation with a relatively simple added component
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
Enables efficient torque management and improved vehicle dynamics by allowing seamless shifting between modes, enhancing traction and reducing packaging space while maintaining high-speed lubrication ease.
Implementation Method 1
a gear train having a fixed gear ratio, a first planetary gear set having multiple gear ratios operatively connected to the gear train, a second planetary gear set having a fixed gear ratio
Implementation Method 2
a helical gear train, a first helical planetary gear set operatively connected to the helical gear train
Data Source
AI summary
A number of variations may include a product comprising an electrical machine operatively connected to a driveline module comprising a gear train having a fixed gear ratio, a first planetary gear set having multiple gear ratios operatively connected to the gear train, a second planetary gear set having a fixed gear ratio operatively connected to the first planetary gear set, and a synchronizer operatively connected to the first planetary gear set and which is positioned between the first and second planetary gear set; a differential operatively connected to the second planetary gear set; wherein the electrical machine selectively transmits power to the differential through the gear train, first planetary gear set, synchronizer, and second planetary gear set, and wherein the synchronizer is constructed and arranged to shift the driveline module into a high, low, and a neutral mode through placement of a ring gear of the first planetary gear set.