Hybrid Drive Subassembly With Switchable Motor-to-Shaft Coupling
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Solution Overview
Problem
Existing powertrain assemblies in vehicles limit the operating modes of electric machines due to constant connection to an intermediate or countershaft, restricting flexibility and efficiency.
Innovation Solution
A hybrid subassembly with a reversible electric machine and a coupling device that allows kinematic connection to both an intermediate and secondary shaft independently, enabling various operating modes including direct power transmission, regenerative braking, and transient synchronization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric machine is permanently connected to the intermediate shaft, then the transmission box can be synchronized during gear changes, but the operating modes are limited and flexibility is reduced
Solution Approach 1:
The coupling device is designed with dynamic reconfigurability, allowing it to switch between different coupling configurations. The electric machine can be dynamically connected to either the intermediate shaft or the secondary shaft based on operating conditions, enabling transient coupling modes that adapt to different driving scenarios while maintaining operational flexibility.
Solution Approach 2:
The coupling device is designed to perform multiple functions: it can couple the electric machine to the intermediate shaft for traditional operation modes, couple it directly to the secondary shaft for enhanced performance modes, and provide transient synchronization during gear changes. This multi-functional design allows a single device to support diverse operating modes without requiring separate dedicated mechanisms.
2Power
If the electric machine is directly connected to the secondary shaft without passing through the intermediate shaft, then power transmission efficiency is improved, but the intermediate shaft may experience increased stress
Solution Approach 1:
The coupling device acts as an intermediary mechanism that manages the transition of power flow between the electric machine and the transmission system. When directly coupling the electric machine to the secondary shaft, the coupling device controls the engagement and disengagement timing, allowing the intermediate shaft to be bypassed during high-power modes while still providing mechanical support and alignment functions when needed.
Solution Approach 2:
The system dynamically switches between different power transmission paths based on operating conditions. During high-power demand modes, the electric machine connects directly to the secondary shaft for efficient power transmission. During gear changes or low-power modes, the system routes power through the intermediate shaft, dynamically adjusting the stress distribution based on real-time requirements.
3Adaptability or versatility
If the coupling device allows multiple coupling positions, then operational flexibility is enhanced, but the control complexity increases
Solution Approach 1:
The control system incorporates feedback mechanisms that monitor the operating state of the transmission system, including gear position, rotational speed, and torque demands. Based on this feedback, the controller automatically selects the appropriate coupling configuration, managing the complexity of multiple coupling positions through intelligent decision-making rather than manual intervention.
Solution Approach 2:
The coupling device is designed with self-actuating capabilities where the coupling and decoupling actions are automatically triggered by system conditions. The device can autonomously transition between different coupling positions based on pre-programmed logic and real-time sensor data, reducing the operational burden on the operator while managing the complexity of multiple coupling states.
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
Enhances operational flexibility and efficiency by allowing multiple operating modes, such as direct electric drive, regenerative braking, and transient synchronization, while reducing inertia and extending component lifespan.
Implementation Method 1
an electromotive group (56, 58) comprising at least one reversible electric machine (56)
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A hybrid sub-assembly (10) of a vehicle drive system comprises at least one primary shaft (12), at least one secondary shaft (16), a transmission (18) comprising at least one intermediate shaft (26) separate from the primary shaft (12) and the secondary shaft (16), and an electric motor unit comprising at least one reversible electric machine (56), and a coupling device (58) capable of assuming at least one intermediate coupling position in which an output shaft (57) of the reversible electric machine (56) is kinematically linked to the intermediate shaft (26), and a secondary coupling position in which the output shaft (57) of the reversible electric machine (56) is kinematically linked to the secondary shaft (16) without passing through the intermediate shaft (26).