Hybrid Drive Planetary Gear Layout for Compact Torque Delivery
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Solution Overview
Problem
Existing hybrid drive systems for motor vehicles are not optimized for space-saving and cost-effective designs, leading to increased installation space, weight, and costs.
Innovation Solution
A hybrid drive system incorporating a four-shaft planetary set with a second planetary set and three shifting elements, where the first output shaft is rotationally fixed to the first shaft, and the rotor shaft is fixed to the second shaft, allowing for a compact design with low installation space and weight, and integrating a high-voltage electric machine for efficient torque delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional hybrid drive system with separate planetary sets is used, then the system provides sufficient torque and power, but the installation space and weight increase
Solution Approach 1:
The patent merges the first and second planetary sets into a single integrated planetary gear unit where both sets share common shafts (first shaft, second shaft, third shaft) and planetary gears. This consolidation eliminates the need for completely separate planetary mechanisms while maintaining the ability to provide multiple torque paths and gear ratios, thereby reducing installation space without compromising torque delivery capability.
Solution Approach 2:
The integrated planetary gear unit serves multiple functions simultaneously: it provides gear reduction for the internal combustion engine, enables electric machine torque multiplication, facilitates torque mixing between engine and electric motor, and supports multiple operating modes (electric-only, hybrid, engine-only). This multi-functionality replaces what would traditionally require separate dedicated mechanisms, reducing overall system volume.
2Adaptability or versatility
If a conventional hybrid drive system with more planetary sets is used, then the system provides versatile torque management, but the cost increases
Solution Approach 1:
The patent combines multiple planetary sets into a single integrated unit that shares common components (shafts, planetary gears, carriers). This merger reduces the total number of discrete parts that need to be manufactured and assembled, thereby lowering manufacturing costs while preserving the versatile torque management capabilities through the integrated design.
Solution Approach 2:
The integrated planetary gear unit is designed to handle multiple torque management functions within a single mechanism, replacing what would traditionally require multiple separate planetary sets. This universal design reduces component count and assembly complexity, leading to cost savings while maintaining adaptability in torque distribution and gear ratio selection.
3Power
If a conventional hybrid drive system with four-shaft planetary set and separate second planetary set is used, then the system achieves high torque output, but the weight increases
Solution Approach 1:
The patent merges the first and second planetary sets into a single integrated mechanism that shares common shafts (first shaft, second shaft, third shaft) and planetary gears. This consolidation eliminates duplicate heavy components while maintaining the ability to generate high torque through multiple torque paths and gear reduction stages, thereby reducing overall system weight without compromising torque output capability.
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, lightweight, and cost-effective hybrid drive system that efficiently powers vehicles by combining internal combustion and electric machine torques, reducing installation space and operational costs while maintaining high performance.
Implementation Method 1
The planetary set (40) has a first shaft (42a), a second shaft (42b), a third shaft (42c), and a fourth shaft (42d), which can be rotated relative to one another, in particular about a planetary set rotation axis
Implementation Method 2
The rotor can rotate about a machine rotation axis relative to the stator. The rotor shaft is a second output shaft
Data Source
AI summary
A hybrid drive system includes an internal combustion engine having a first output shaft, an electric machine having a rotor with a rotor shaft as second output shaft, and a transmission having a four-shaft, first planetary set, a second planetary set, a first shifting element, a second shifting element, a third shifting element, and a third output shaft. The four-shaft, first planetary set has a first shaft, a second shaft, a third shaft, and a fourth shaft, the second planetary set has a first element, a second element, and a third element. The first shaft, the second shaft, the third shaft, and the fourth shaft are rotatable relative to one another and connectable to one another in a rotationally fixed manner by a blocking shifting element. The first output shaft is coupled or is couplable to the first shaft in a rotationally fixed manner.