Hybrid Multi-Speed Gearbox Layout for Cross-Platform Modularity
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Solution Overview
Problem
Existing transmission systems in hybrid and ICE vehicles face challenges with modularity and cross-platform flexibility due to incompatible architectures, leading to separate development and manufacturing processes, and an inability to share common component layouts.
Innovation Solution
A multi-speed gearbox with an electric drive interface gear positioned coaxially to a primary shaft, allowing for selective coupling with an electric machine, and an electric drive clutch to bypass or engage the primary shaft, enabling operation in various modes, including hybrid, EV, and kinetic energy recovery modes, with adaptable gear combinations and increased modularity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a three axis layout is used in dual-clutch transmission, then geartrain functionality is achieved, but adaptability to other vehicle platforms (AMT, MT) is reduced
Solution Approach 1:
The transmission system is designed with a universal architecture that can function as dual-clutch transmission, automated manual transmission, or manual transmission by selectively engaging different clutches. The housing contains multiple clutch mechanisms (first and second clutches for dual-clutch mode, single clutch for AMT/MT mode) that allow the same physical structure to serve multiple transmission types, enabling one design to fit multiple vehicle platforms.
Solution Approach 2:
The transmission system is divided into modular functional segments: dual-clutch assembly, single clutch assembly, geartrain, and housing. These segmented components can be independently configured or engaged based on the desired transmission mode, allowing the system to adapt between different transmission types without requiring complete redesign.
2Adaptability or versatility
If Jouve's transmission architecture is used, then hybrid vehicle operation is enabled, but adaptability to dual-clutch transmission platforms is reduced
Solution Approach 1:
The transmission system incorporates both Jouve-style opposing ends driving capability and dual-clutch architecture. The housing receives both the dual-clutch assembly and the engine, with the electric machine positioned to drive the input shaft from the opposite end, enabling the system to operate in both hybrid mode (with opposing ends driving) and dual-clutch mode (with single-end driving), thus achieving universality across different operational requirements.
3Productivity
If separate development and manufacturing processes are used for different transmission types, then platform-specific optimization is achieved, but development time and manufacturing duration are increased
Solution Approach 1:
By designing a universal transmission system that can function as dual-clutch, automated manual, or manual transmission through selective clutch engagement, the patent eliminates the need for separate development and manufacturing processes for different transmission types. The same housing, geartrain, and component layout serve multiple transmission functions, significantly reducing development time and manufacturing duration while maintaining platform-specific optimization capabilities.
4Adaptability or versatility
If common component layouts are not shared across platforms, then platform-specific performance is optimized, but design rigidity increases
Solution Approach 1:
The patent implements a universal component layout where the same housing, geartrain, clutch mechanisms, and bearing supports are used across dual-clutch, automated manual, and manual transmission platforms. The design achieves cross-platform component sharing by incorporating multiple clutch assemblies that can be selectively engaged, allowing common components to serve different transmission functions without compromising platform-specific performance optimization.
Data Source
AI summary
A transmission system that includes a multi-speed gearbox. The multi-speed gearbox, in one example, includes a primary shaft with a first set of gears positioned thereon, a secondary shaft with a second set of gears positioned thereon, an internal combustion engine (ICE) clutch configured to selectively couple an ICE to the primary shaft, and an electric drive interface gear that is positioned axially between two gears in the first set of gears, configured to couple to an electric machine, and coupled to a gear in the second set of gears.