EV Transmission Layout With Selective Dual Torque Paths
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Solution Overview
Problem
Current transmission systems for electric vehicles are not optimized for compactness and efficiency, leading to increased mechanical losses and reduced driving performance.
Innovation Solution
A transmission system comprising a first gear assembly, a second gear assembly, and an intermediate unit with a coupling element, allowing for selective torque transfer through two pathways, reducing the number of components and mechanical losses, and enabling efficient torque delivery based on drive needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multiple-speed gearbox is provided, then driving efficiency is optimized and smaller electric machines can be used, but the device complexity and size increase
Solution Approach 1:
The transmission system is divided into two independent single-speed gearboxes (first and second gear assemblies), each handling a specific torque range. This segmentation allows each unit to be optimized for its specific function while maintaining overall system efficiency, avoiding the complexity of a single multi-speed gearbox
Solution Approach 2:
The system dynamically switches between two different torque pathways using selectable coupling elements. The output gear assembly can selectively engage with either the first or second gear assembly based on the required torque characteristics, enabling adaptive efficiency optimization without permanent mechanical complexity
2Power
If a multiple-speed gearbox is provided, then smaller electric machines can be used, but the transmission system size increases
Solution Approach 1:
Two single-speed gear assemblies are merged into a single transmission system with shared components (housing, output gear assembly, input shaft). This combining approach achieves the functional benefits of multiple gear ratios while maintaining a compact footprint comparable to a single-speed transmission
Solution Approach 2:
The output gear assembly serves multiple functions by being able to engage with either the first or second gear assembly. This multi-functionality allows the system to provide different torque multiplication ratios using a single universal output interface, reducing overall system size
3Adaptability or versatility
If more transfer elements are added to switch between gear assemblies, then torque conversion flexibility is improved, but mechanical losses increase
Solution Approach 1:
The intermediate conversion elements are extracted and replaced by a direct selective coupling mechanism. The output gear assembly can directly engage with either the first or second gear assembly through selectable coupling elements, eliminating unnecessary intermediate transfer components and reducing mechanical losses
Solution Approach 2:
The selectable coupling elements act as intelligent intermediaries that directly connect the input shaft to the appropriate gear assembly without requiring multiple intermediate transfer elements. This mediator approach provides flexible torque delivery while minimizing the number of mechanical interfaces and associated losses
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
The system achieves a compact design with improved efficiency by minimizing torque transfer components and allowing for adaptable torque delivery, enhancing driving performance and reducing mechanical losses.
Implementation Method 1
The first sprocket element (31) is connectable to an input shaft (5) of a traction motor of the vehicle in an axial direction of the first sprocket element (31) to receive an input torque
Implementation Method 2
The second sprocket element (32) is arranged radially to the first sprocket element (31) and in communication with the first sprocket element (31) through the coupling element (33) to receive the input torque
Implementation Method 3
The first gear assembly (1) is connectable to the second sprocket element (32) coaxially to convert the input torque to a first output torque. The second gear assembly (2) is connectable to the first sprocket element (31) coaxially to convert the input torque to a second output torque
Data Source
AI summary
The disclosure relates to a transmission system for a vehicle comprising a first gear assembly, a second gear assembly, an intermediate unit comprising a first sprocket element, a second sprocket element, a coupling element, and an output gear assembly with an output shaft. The first sprocket element is connectable to an input shaft of a traction motor of the vehicle in an axial direction of the first sprocket element to receive an input torque and the first gear assembly is connectable to the second sprocket element coaxially to convert the input torque to a first output torque. The second sprocket element is arranged radially to the first sprocket element and in communication with the first sprocket element through the coupling element to receive the input torque and the second gear assembly is connectable to the first sprocket element coaxially to convert the input torque to a second output torque.