Electric Vehicle Gear Shifting System with Axial Synchronizing Gear
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Solution Overview
Problem
Current automatic transmission systems for electric vehicles are complex and expensive due to their structure, which increases the production and maintenance costs, and they often require a second speed system to enhance motor performance, but they lack a simple and cost-effective solution for gear shifting.
Innovation Solution
A gear shifting system with a simplified structure that includes an input shaft, a synchronizing gear, first and second gears, and insert units that allow for axial movement to engage with engagement apertures, enabling efficient torque transfer and gear shifting between first and second speeds using a spline and shaft bearing configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a synchronizing device and actuator are used in automatic transmission systems, then gear shifting function is achieved, but device complexity and production cost increase
Solution Approach 1:
The patent extracts and eliminates the complex synchronizing device and actuator from the automatic transmission system. Instead, it uses a simplified structure where the shift fork directly engages with the synchronizing gear through insert units, removing the need for separate synchronizing mechanisms and actuators while maintaining the gear shifting function.
Solution Approach 2:
The synchronizing gear is designed to perform both synchronization and shifting functions simultaneously. The insert units on the shift fork directly engage with engagement apertures on the synchronizing gear, allowing the system to self-regulate the shifting process without external actuators or complex control mechanisms.
2Ease of operation
If a synchronizing device and actuator are used in automatic transmission systems, then gear shifting function is achieved, but production cost increases
Solution Approach 1:
The patent removes the expensive synchronizing device and actuator components from the transmission system. By using a direct engagement mechanism between the shift fork and synchronizing gear, it significantly reduces the bill of materials and manufacturing complexity, leading to lower production costs.
Solution Approach 2:
The patent combines multiple functions into fewer components. The synchronizing gear serves both as the synchronization mechanism and the shifting target, while the shift fork integrates both the shifting lever and engagement features. This consolidation reduces part count and assembly complexity, lowering production costs.
3Use of energy by moving object
If a second speed system is used to enhance motor performance, then power efficiency is improved, but device complexity increases
Solution Approach 1:
The patent merges the first and second speed gears into a single transmission system that shares common components. Both gears rotate on the same input shaft and use the same synchronizing gear and shift fork mechanism, allowing the system to achieve multiple speed ratios without duplicating entire transmission subsystems.
Solution Approach 2:
The synchronizing gear and shift fork are designed as universal components that can engage with both the first and second speed gears. The engagement apertures on the synchronizing gear are positioned to accommodate insert units for selecting different gear ratios, allowing a single mechanism to perform multiple shifting functions.
Data Source
AI summary
A gear shifting system is described that includes an first shaft that is connected to a motor to be rotated thereby, a synchronizing gear, a first insert unit and a second insert unit protrude at both sides thereof, a first gear and a second gear configured to rotate around the first shaft, a first plate and a second plate, a first engagement aperture and a second engagement aperture, and a second shaft. The second shaft is configured to move the synchronizing gear in an axial direction so that the first insert unit is inserted into the first engagement aperture or the second insert unit is inserted into the second engagement aperture to transfer a torque of the synchronizing gear to the first gear or the second gear.