Gear-Change Device Third Shaft Electrical Machine Integration
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Solution Overview
Problem
Existing gear-change devices for motor vehicles are complex and occupy significant space, making them less efficient in terms of construction simplicity and space utilization.
Innovation Solution
A gear-change device with a third shaft carrying a reverse gear and output pinion connected to an electrical machine via a gear reducer, allowing for a simple and non-cumbersome integration of the electrical machine, which operates as both a motor and generator, while maintaining a compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an electrical machine is integrated into the gear-change device, then torque compensation and energy recovery functions are improved, but the device complexity and space occupation increase
Solution Approach 1:
The electrical machine is integrated directly into the third shaft assembly, merging the electrical machine housing with the gear-change device casing. The third shaft serves dual purposes: supporting the reverse gear and serving as the electrical machine shaft, eliminating the need for separate mounting structures and reducing overall complexity.
Solution Approach 2:
The third shaft is designed to perform multiple functions simultaneously: it supports the reverse gear, serves as the rotor shaft for the electrical machine, and transmits power to the differential through the output pinion. This multi-functionality reduces the number of separate components needed in the system.
2Adaptability or versatility
If an electrical machine is integrated into the gear-change device, then torque compensation and energy recovery functions are improved, but the space occupied by the device increases
Solution Approach 1:
The electrical machine housing is merged with the gear-change device casing, allowing the electrical machine to occupy space that would otherwise be unused or require separate enclosure. This integration significantly reduces the total volume required for both components.
Solution Approach 2:
The electrical machine is nested within the existing gear-change device structure, with the third shaft and electrical machine assembly fitting within the confines of the differential and gear housing. This nesting approach minimizes the overall envelope of the transmission system.
3Adaptability or versatility
If a reverse gear selection device is added to connect the reverse gear to the third shaft, then the reversibility function is improved, but the device complexity increases
Solution Approach 1:
The reverse gear selection device is integrated into the existing third shaft assembly, merging the reverse gear mechanism with the electrical machine mounting structure. This consolidation reduces the number of separate selection mechanisms needed in the system.
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 solution enables a compact and simplified gear-change device structure, allowing for efficient torque compensation during gear changes and energy recovery, while reducing the overall complexity and space requirements.
Implementation Method 1
the electrical machine is used as electric motor designed to deliver a torque to the gears of the vehicle for example in the phases of gearchange
Implementation Method 2
the electrical machine is used as generator to recover energy in all the phases in which the transmission is entrained by the gears of the vehicle
Implementation Method 3
an output pinion (U2) meshing with the ring gear of the differential
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A gear-change device comprises a primary shaft (3), a secondary shaft (6), and a third shaft (9), which bears both a gear (RM) of the reverse and an output pinion (U2) meshing with a gear (D1) of a differential (D). The third shaft (9) is connected via a gear reducer (R) to the shaft (11) of an electrical machine (E), the casing of which is rigidly connected to the casing (2) of the gear-change device.