Gear Coupling Synchronizer for Electric Drive Modules
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Solution Overview
Problem
Conventional coupling and synchronizing devices for hybrid vehicles face challenges in efficiently and reliably connecting and disconnecting electric motors from wheel axles, leading to mechanical stress, wear, and inefficiency due to friction losses and complex mechanical coupling processes.
Innovation Solution
A coupling device with a synchronizing mechanism that adjusts the angular velocity of input and output gears to minimize differences before mechanical or frictional engagement, using a synchronizing sleeve and cone-shaped or beveled friction surfaces to reduce mechanical stress and wear, and allowing for fast and reliable coupling and decoupling of the electric drive to the wheel axle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional friction clutch is used for coupling the electric motor with a rotating vehicle wheel, then the coupling mechanism can be simple in structure, but the clutch mechanism will be subject to extreme stress and mechanical wear and may require intensive maintenance
Solution Approach 1:
The synchronizing means minimizes the difference of angular velocity between the input gear and output gear before the synchronizing member frictionally engages them. This preliminary synchronization action reduces the speed differential that would otherwise cause extreme stress and mechanical wear on the clutch mechanism, thereby improving reliability without complicating the overall structure.
2Device complexity
If the electric motor is permanently coupled to the wheels, then the coupling structure is simple, but the electric motor acts as a brake at high velocities and mechanical stress increases
Solution Approach 1:
The coupling device enables dynamic switching between coupled and decoupled states. The synchronizing member allows frictional engagement when coupling is needed, while the ability to disengage permits the electric motor to be decoupled at high velocities, eliminating the braking effect and reducing mechanical stress on the coupling structure.
3Loss of energy
If the electric motor is decoupled from the wheels at high velocity, then friction losses and mechanical stress are reduced, but the coupling process becomes elaborate and complex when reconnecting at lower velocities
Solution Approach 1:
The synchronizing means performs preliminary synchronization by minimizing the angular velocity difference between input and output gears before the synchronizing member establishes frictional engagement. This preliminary action simplifies the overall coupling process by ensuring that when engagement occurs, the speed differential is already reduced, preventing complex multi-step synchronization procedures.
4Loss of time
If the angular velocity difference between input gear and output gear is large during coupling, then the coupling time is short, but mechanical stress and wear increase
Solution Approach 1:
The synchronizing means minimizes the angular velocity difference between input and output gears before the synchronizing member frictionally engages them. This preliminary synchronization reduces the speed differential that would cause mechanical stress and wear during engagement, while still maintaining a relatively short coupling time by preparing the gears in advance for smooth engagement.
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 effectively reduces mechanical stress and wear during coupling, optimizes coupling time and mechanical stress, and enhances the efficiency of the electric drive by minimizing friction losses, allowing for efficient operation in both low and high-speed driving conditions.
Implementation Method 1
a synchronizing means, which is adapted to contactlessly minimize a difference of the input gear's and the output gear's angular velocity below a predefined threshold
Implementation Method 2
a synchronizing member, which is adapted to frictionally engage with the input gear and/or with the output gear, when the difference in angular velocity of the input gear and the output gear is below the predefined threshold
Data Source
AI summary
A coupling device and a coupling mechanism is provided for selectively coupling of an electric drive to a wheel axle of a vehicle. The coupling device includes, but is not limited to an output gear connected to the wheel axle, an input gear connected to the electric motor. A synchronizer is adapted to contactlessly minimize a difference of the input gear's and the output gear's angular velocity below a predefined threshold, and a synchronizing member is adapted to frictionally engage with the input gear and/or with the output gear when the difference in angular velocity of input gear and output gear is below the predefined threshold.