Hybrid Drivetrain Universal Mounting Flange Design

Solution Overview

Problem

Conventional drivetrains for hybrid electric vehicles require multiple transmission configurations and additional components to accommodate both two wheel and four wheel drive configurations, increasing complexity and cost.

Innovation Solution

A drivetrain design that uses a single transmission with a shared output mounting flange for both configurations, along with an electric drive unit that can mount directly to the transmission in two wheel drive and to the transfer case in four wheel drive, reducing component variability and packaging issues.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple transmission configurations are used to accommodate both two wheel drive and four wheel drive configurations, then both drive configurations can be supported, but device complexity and manufacturing cost increase

Engineering Contradiction:

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The electric drive unit is designed with a universal mounting flange that can interface with both the transmission output shaft (for two wheel drive) and the transfer case output shaft (for four wheel drive). This allows a single electric drive unit design to serve multiple drive configurations, eliminating the need for different transmission configurations and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If multiple transmission configurations are used, then both drive configurations can be supported, but manufacturing cost increases

Engineering Contradiction:

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

By designing the electric drive unit with a universal mounting interface that works with both transmission and transfer case outputs, the manufacturer produces only one type of electric drive unit for both two wheel drive and four wheel drive vehicle versions. This eliminates the need to manufacture multiple transmission configurations and reduces inventory complexity, directly lowering manufacturing costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If the electric drive unit is added to the drivetrain, then hybrid electric capability is achieved, but packaging space and underbody design are affected

Engineering Contradiction:

Core Design Contradiction:

Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The electric drive unit is positioned as an intermediary component between the power source (transmission or transfer case) and the drive shafts. By mounting the electric drive unit to existing output shafts through standardized flanges, the design leverages existing packaging space and avoids the need for extensive underbody re-design, minimizing interference with other vehicle systems.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS7665560B2Drivetrain for hybrid electric vehicle

Publication Date: 2010.02.23

AI summary

A drivetrain for a hybrid electric vehicle having a rear wheel drive configuration and a four wheel drive configuration is disclosed. Certain of the mounting flanges and input/output couplings are replicated between a transmission, a transfer case and an electric drive unit.