Electric Axle Gearset Layout for Selectable Torque and Speed
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Solution Overview
Problem
There is a need for an axle assembly that optimizes efficiency and performance by integrating one or more electric drive units into vehicles, particularly in propulsion systems that replace traditional internal combustion engines.
Innovation Solution
The electric axle assembly includes a housing with a drive assembly that comprises an input gearset, an output gearset, and a differential, allowing for selectable gear ratios and motive force transfer to axle shafts, enabling efficient torque and speed adjustments for enhanced vehicle performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single gear ratio is used in the axle assembly, then the device complexity is reduced, but the vehicle performance and efficiency are compromised due to inability to optimize for different driving conditions
Solution Approach 1:
The patent implements a shiftable input gearset that can dynamically change between first and second configurations, allowing the gear ratio to be adjusted based on driving conditions. This dynamic reconfiguration enables the system to optimize vehicle performance for different operational requirements while maintaining a relatively simple overall structure.
2Productivity
If multiple gear ratios are provided through shiftable input gearset, then the vehicle acceleration and velocity are improved, but the device complexity increases due to additional clutch arrangements and configurations
Solution Approach 1:
The patent combines the input gearset and clutch arrangement into an integrated shiftable mechanism where the clutch is directly coupled to the input gearset. This merging of components allows for multiple gear ratios to be achieved while reducing the overall complexity compared to having separate clutch and gearset systems.
Solution Approach 2:
The input gearset serves multiple functions by being capable of operating in both first and second configurations, effectively acting as both a single-speed and multi-speed mechanism. This multi-functionality allows the same component to provide different gear ratios without requiring entirely separate mechanisms for each function.
3Force
If the drive input is offset from the axis, then the torque distribution and vehicle propulsion are improved, but the manufacturing precision requirements increase due to the offset configuration
Solution Approach 1:
The patent deliberately employs an asymmetric configuration by offsetting the drive input from the central axis. This asymmetric positioning is designed to optimize torque distribution and vehicle propulsion characteristics. The offset arrangement creates a mechanical advantage that improves force transmission while the patent provides specific guidelines for maintaining the required precision in this asymmetric configuration.
Data Source
AI summary
An electric axle assembly includes a drive housing and a drive assembly. The drive assembly is housed in the drive housing and engages with wheels of a vehicle for rotating the wheels to move the vehicle along a ground surface. The drive assembly includes a drive input, one or more gearsets, and axle shafts. The one or more gearsets transfer motive force from the drive input to the axle shafts.