Hybrid Vehicle Power Distributor and Differential Case Integration
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Solution Overview
Problem
Existing layouts of industrial vehicles, particularly electric and hybrid models, face inefficiencies in weight distribution and space utilization, as well as limitations in integrating standard car motors and torque management during full-load starting.
Innovation Solution
A power distributor layout where a portion of the case encloses inner components, including shafts and gear trains, is directly connected to the differential gear, allowing for up to three electric motors and incorporating speed reducers in wheel hubs to enhance torque, while retaining rods prevent differential gear rotation, and a tubular case design allows access without interfering with the differential gear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the power distributor is spaced apart from the driving axle connected by an intermediate shaft, then the power transmission function is achieved, but the weight distribution and space utilization are suboptimal
Solution Approach 1:
The patent merges the power distributor case with the differential gear case by providing a portion of the power distributor case that is shared by the differential gear case. This integration eliminates the need for separate housings and intermediate shafts, optimizing weight distribution and space utilization while maintaining power transmission functionality.
Solution Approach 2:
The shared case structure serves multiple functions: it houses both the power distributor components and the differential gear, acts as a structural support element, and provides mounting surfaces for other axle components. This multi-functionality reduces the overall number of parts and improves weight distribution.
2Adaptability or versatility
If standard car motors are used in industrial vehicles, then the adaptability and availability of motors improve, but the torque management during full-load starting becomes challenging
Solution Approach 1:
The patent nests speed reducers within the wheel hubs, allowing torque multiplication at the point of wheel engagement. This nested configuration enables standard car motors to achieve the required torque levels for full-load starting by combining the motor's rotational output with the speed reducer's mechanical advantage, without requiring oversized motors.
Solution Approach 2:
The speed reducers change the rotational parameters (speed and torque) of the motor output. By reducing the rotational speed and increasing the torque through gear multiplication, the system adapts standard car motor characteristics to meet the high-torque requirements of industrial vehicle full-load starting conditions.
3Volume of moving object
If the case of the power distributor is fully integrated with the differential gear case, then the space utilization improves, but the accessibility for maintenance and assembly becomes difficult
Solution Approach 1:
The patent segments the shared case into distinct functional portions: a power distributor case portion and a differential gear case portion. This segmentation allows for separate access points and maintenance pathways for each subsystem while maintaining the integrated space-saving configuration. The case can be opened or accessed at specific locations without requiring complete disassembly of the entire assembly.
Data Source
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AI summary
A layout of a hybrid or electric industrial vehicle comprising a driving axle (RX) and a power distributor (TB) wherein said driving axle comprises a differential gear (D) wherein a crown wheel and pinion are housed and to which a left axle-shaft (SX) and a right axle-shaft (SD) are connected thereto, arranged for guiding respective wheels (RW) into rotation, wherein said differential gear comprises a first timing case (DF) comprising at least two parts and said power distributor (TB) comprises a second timing case (TBC) comprising at least two parts, and wherein a part of said second timing case is shared with said first timing case, defining a lid for said first timing case.