Electric Drive Unit Clutch Pack for Hybrid Axle
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Solution Overview
Problem
Existing drive trains for all-wheel drive motor vehicles face challenges in efficiently utilizing electric machines over a wide operating range and optimizing installation space and weight distribution, particularly in hybrid systems where mechanical and hydraulic actuation of shifting clutches is complex and inefficient.
Innovation Solution
A drive train design that integrates a clutch pack with two clutches for setting different gear ratios within the electric drive unit, allowing the electric motor to operate over a wide range, and includes a friction clutch for power transmission to the second axle, eliminating the need for a cardan shaft and simplifying the structure by using a planetary gear set and electromagnetic actuators for clutch actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a clutch pack with multiple clutches is integrated into the electric drive unit, then the electric motor can operate over a wide speed range, but the device complexity increases
Solution Approach 1:
The clutch pack is integrated directly into the electric drive unit, merging the clutch mechanism with the motor assembly. This allows multiple gear ratios to be achieved within a single compact unit, expanding the operating range without proportionally increasing overall system complexity
Solution Approach 2:
The electric drive unit is designed to perform multiple functions: it serves as both the motor assembly and the transmission system with multiple gear ratios. The clutch pack enables the same drive unit to operate efficiently across a wide speed range by switching between different gear ratios, making the system universally adaptable to various operating conditions
2Reliability
If hydraulic units and separate electric motors are used for clutch actuation, then reliable clutch operation is achieved, but the installation space and weight increase
Solution Approach 1:
The actuation mechanism is integrated directly into the clutch pack assembly, merging the actuator with the clutch mechanism. This eliminates the need for separate hydraulic units and distant electric motors, reducing installation space while maintaining reliable actuation through direct coupling
Solution Approach 2:
The invention extracts and eliminates unnecessary intermediate components (separate hydraulic units and distant actuation motors) by implementing direct actuation within the clutch pack. This simplifies the system architecture and reduces the overall installation space required for the drive train
3Length of stationary object
If a cardan shaft is used for power transmission to the second axle, then power can be transmitted over longer distances, but the structure becomes more complex
Solution Approach 1:
The invention extracts and eliminates the cardan shaft from the power transmission path by positioning the electric drive unit directly at the second axle. This removes the intermediate transmission component, simplifying the overall structure while maintaining effective power transmission to the second axle
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 design enables efficient use of the electric drive unit over a large speed range, optimizes installation space and weight distribution, and simplifies the drive train structure by eliminating the need for hydraulic units and separate electric motors, while ensuring accurate clutch actuation and power transmission.
Implementation Method 1
electromagnetic actuators for clutch actuation
Data Source
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AI summary
The invention relates to a drive train (20) for a motor vehicle (10) comprising a first and a second axle (12, 14), said drive train having a first drive unit (22) for permanently driving the first axle (12) and an electric drive unit (30) arranged in the region of the second axle (14) and comprising an electric motor (32) and a clutch group (36) containing a first clutch (64) for setting up a first transmission and a second clutch (70) for setting up a second transmission between the electric motor and an output (38) of the electric drive unit (30). The electric drive unit (30) is arranged parallel to an input shaft (52) of a transverse differential (50) of the second axle (14).