Electric Axle Gear Switching with Spring-Loaded Independent Shift Paths
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Solution Overview
Problem
Existing motor vehicle designs face challenges in efficiently utilizing actuators for switching multiple gear mechanisms due to space and cost constraints, leading to inefficient actuator use and complex constructions.
Innovation Solution
A device comprising an actuator connected to a rotatable component with two independent switching devices, each having a sleeve, shift gate, guide element, shift fork, and elastic storage arrangement, allowing simultaneous blocking-free switching of two partial gear mechanisms by storing energy until synchronization is achieved.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single actuator is used to switch multiple partial gear mechanisms, then cost and construction complexity are reduced, but the actuator must operate efficiently under space constraints and asynchronous switching conditions
Solution Approach 1:
The single actuator is segmented into two independent switching devices, each with its own sleeve, shift gate, guide element, shift fork, and elastic storage arrangement. This segmentation allows each switching device to independently control a partial gear mechanism while sharing the common actuator, reducing construction complexity while maintaining switching reliability through decentralized control elements.
Solution Approach 2:
The elastic storage arrangement (springs) is pre-loaded to store energy before switching is required. This preliminary action allows the switching devices to accumulate the necessary force for gear engagement, ensuring reliable switching even when the actuator operates asynchronously or under varying load conditions.
2Productivity
If switching occurs only for short periods, then actuator usage is intensive, but this leads to inefficient actuator utilization
Solution Approach 1:
The elastic storage arrangement continuously stores energy from the actuator's rotation, converting rotational motion into pre-loaded spring energy. This continuous energy accumulation ensures that the switching action is always ready to execute, transforming intermittent switching operations into a continuous useful action that maximizes actuator utilization efficiency.
3Reliability
If blocking-free switching is achieved in asynchronous conditions, then gear changes are seamless, but this requires storing energy until synchronization is achieved
Solution Approach 1:
The elastic storage arrangement pre-loads springs to accumulate energy before switching is needed. This preliminary energy storage ensures that when synchronization is achieved, the stored energy can immediately drive the shift fork to engage the gear smoothly without blockages, achieving reliable seamless switching while managing energy storage requirements.
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, compact, and simple mechanical switching of two partial gear mechanisms, ensuring seamless gear changes without blockages, even in asynchronous conditions.
Implementation Method 1
an elastic storage arrangement (13, 13') which can be loaded by the sleeve (8, 8') via a first carrier element (14, 14') arranged fixedly on the sleeve (8, 8') in order to transmit a load to the shift fork (11, 11')
Data Source
AI summary
A device for switching at least two partial gear mechanisms, namely a first partial gear mechanism and a second partial gear mechanism, each having at least two gear stages. The device comprising an actuator connected for drive purposes to a rotatable component, a first switching device for switching the first partial gear mechanism and a second switching device for switching the second partial gear mechanism both of which are arranged on the rotatable component, and an electric drive axle for a motor vehicle comprising a first drive wheel, a second drive wheel and such a device.