Hybrid Vehicle Gearbox Integrating Battery Pack
Solution Overview
Problem
In hybrid road vehicles, the placement of the electric accumulating system is complex due to space constraints, leading to suboptimal positioning that limits energy storage and electric machine usage, as it must be close to the electric machine, protected from impacts and heat, and balanced within the vehicle.
Innovation Solution
A hybrid propulsion road vehicle design with a rear-mounted gearbox and centrally placed accumulating system beside the gear case, which is protected by the gear case during impacts and ventilated, allowing for reduced cable length and balanced mass distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the accumulating system is placed close to the electric machine, then the length of connecting electric cables is reduced and power losses are decreased, but the available space for placement is severely limited and the system must be positioned in suboptimal locations
Solution Approach 1:
The patent merges the accumulating system with the gearbox by integrating the battery pack into the gearbox housing. This combination allows the accumulating system to be positioned close to the electric machine (reducing cable length and power losses) while utilizing the existing gearbox space, thereby avoiding the need for separate dedicated space and simplifying the overall placement complexity.
Solution Approach 2:
The gearbox housing serves multiple functions: it houses the gear mechanism and simultaneously accommodates the accumulating system. This multi-functionality resolves the space constraint issue by allowing the accumulating system to be placed in a location that would otherwise be occupied solely by mechanical components, thereby reducing cable length without requiring additional space.
2Length of stationary object
If the accumulating system is placed in proximity to the electric machine, then cable length is reduced, but the system must be protected from impacts and heat sources which further constrains placement options
Solution Approach 1:
By integrating the accumulating system into the gearbox housing, the system benefits from the gearbox's inherent protective structure. The housing provides mechanical protection against impacts and thermal insulation from heat sources, allowing the accumulating system to be positioned close to the electric machine without being directly exposed to harmful factors.
Solution Approach 2:
The gearbox housing acts as an intermediary protective barrier between the accumulating system and harmful external factors such as impacts and heat. This mediator allows the accumulating system to be positioned in a location that would otherwise be vulnerable, while the housing structure provides the necessary protection.
3Reliability
If the accumulating system is positioned to be protected from impacts and heat, then safety is improved, but the useful space for energy storage is severely limited
Solution Approach 1:
The integration of the accumulating system into the gearbox housing utilizes otherwise wasted space within the gearbox structure. By combining the protective housing function with the energy storage function, the design achieves both protection and adequate storage capacity without requiring additional external space that would compromise safety.
Solution Approach 2:
The accumulating system is arranged in a specific configuration within the gearbox housing, utilizing three-dimensional space efficiently. The batteries are positioned to optimize both protection and storage capacity by distributing them throughout the available volume of the housing, thereby maximizing energy storage while maintaining safety requirements.
4Stability of the object's composition
If the accumulating system is placed to achieve good dynamic behavior by positioning near the centre of gravity, then vehicle balance is improved, but the placement options are severely constrained by available space
Solution Approach 1:
By integrating the accumulating system into the gearbox housing, the design allows flexible positioning of the mass within the vehicle. The gearbox location can be selected to optimize the center of gravity and dynamic balance, while the accumulating system occupies space within the gearbox housing, thereby achieving both good dynamic behavior and simplified placement without conflicting with other components.
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
This design optimizes the positioning of the electric system, reducing power losses, enhancing protection, and improving energy storage and usage efficiency while maintaining a cost-effective and simple implementation.
Implementation Method 1
at least one electric machine which is mechanically connected to the driving wheels
Implementation Method 2
the electric machine may be used as a generator for achieving a regenerative deceleration in which the kinetic energy of the road vehicle is partially converted into electric power
Implementation Method 3
an electric accumulating system typically made of a pack of chemical batteries
Implementation Method 4
chemical batteries possibly connected in parallel to one or more super-capacitors
Implementation Method 5
an internal combustion engine which transmits the driving torque to the driving wheels
Implementation Method 6
a transmission provided with a gearbox
Data Source
AI summary
A hybrid propulsion road vehicle (1) having: a couple of rear driving wheels (3); a thermal internal combustion engine (5); a gearbox (10), which is arranged in rear position, receives motion from the thermal internal combustion engine (5) and transmits motion to the rear driving wheels (3), and comprises a gear case (16) housing all the moving parts; a reversible electric machine (8) mechanically connectable to the rear driving wheels (3); an electric drive (13) controlling the electric machine (8); and an accumulating system (14), which is able to store electric energy, is connected to the electric drive (13) and is placed beside the gear case (16) and on the opposite sides of the gear case (16) so as not to longitudinally exceed the extension of the gear case (16) itself.