EV Transmission Clutch Actuator with Mechanical Lock
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Solution Overview
Problem
Electrical vehicle (EV) transmissions face inefficiencies due to the continuous need for high-pressure fluid circulation to maintain clutch engagement, leading to energy loss and reduced vehicle range.
Innovation Solution
A torque transmitting device with a secondary clutch actuator independent of fluid actuation, allowing high pressure only during shifts, and a mechanical lock to hold the indexer in the engaged state, eliminating the need for continuous pump operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wet friction clutch with high-pressure hydraulic pump is used to maintain clutch engagement, then full-power shifts are enabled, but energy consumption increases and vehicle range decreases
Solution Approach 1:
The hydraulic pump operates periodically only during shift events rather than continuously. The system uses a mechanical lock (parking pawl) to maintain clutch engagement after the shift is complete, allowing the pump to be deactivated and eliminating continuous energy consumption while preserving full-power shift capability when needed.
Solution Approach 2:
The patent extracts the continuous hydraulic pressure maintenance function from the shift actuation system. By separating the shift actuation (requiring hydraulic pressure) from the engagement maintenance (achieved through mechanical lock), the system eliminates the need for continuous pump operation while retaining full-power shift capability.
2Stability of the object's composition
If a hydraulic pump continuously provides high pressure to maintain clutch engagement, then the clutch remains engaged, but pump losses increase and efficiency decreases
Solution Approach 1:
The patent replaces the hydraulic pressure-based engagement maintenance with a mechanical locking system. The parking pawl mechanically locks the clutch in the engaged position, eliminating the need for continuous hydraulic pressure and associated pump losses while maintaining stable engagement.
Solution Approach 2:
The mechanical lock system is self-sustaining once engaged, requiring no continuous energy input to maintain the clutch engagement state. The system serves itself by using the mechanical lock to hold the clutch engaged without external hydraulic pressure, eliminating pump losses.
3Adaptability or versatility
If multiple friction clutches are used to achieve dynamic speed and torque ratio shifts, then shift capability is improved, but device complexity increases
Solution Approach 1:
The patent extracts the continuous hydraulic control function from the multi-clutch system and replaces it with a mechanical locking mechanism. This reduces the complexity of the hydraulic control system while maintaining the ability to achieve dynamic speed and torque ratio shifts through the friction clutches during transient events.
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 solution enhances EV transmission efficiency by reducing energy consumption and extending vehicle range by eliminating the need for continuous high-pressure fluid circulation during regular operation.
Implementation Method 1
a hydraulic pump and piston operatively connected to the hydraulic pump, the hydraulic pump being configured to selectively apply a hydraulic pressure to a first side of the piston
Implementation Method 2
a biasing element positioned configured to provide a biasing force to the indexer into the engaged state, such that the biasing element is operable to mechanically hold the indexer in the engaged state absent the hydraulic pressure
Data Source
AI summary
A transmission system efficiently performs efficiently and also provides the ability to perform full-power shifts. For example, a secondary clutch actuator, independent of fluid actuation, may eliminate the need for a pump to continuously provide high pressure during regular vehicle operation such that high pressures are only required during a shift event. This eliminates the need for energy at the pump to maintain application of the clutch, thereby allowing such energy to be used of other systems in the EV or to facilitate increased vehicle range.