Integral Differential Gear Unit for Compact Vehicle Power Splitting
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Solution Overview
Problem
Existing gear units for vehicle powertrains are inefficient in terms of space usage and component weight, as they require separate assemblies for torque conversion and distribution, leading to increased complexity and weight.
Innovation Solution
A compact gear unit with an integral differential that combines torque conversion and distribution functions using a planetary gearset and epicyclic gear train, eliminating the need for separate components and achieving power splitting by connecting the input shaft to both output shafts in a defined ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If separate assemblies are used for torque conversion and distribution, then the functions are clearly separated, but the device complexity and weight increase
Solution Approach 1:
The patent combines torque conversion and torque distribution functions into a single integrated differential assembly. The planetary gearset performs both torque conversion (changing torque magnitude) and torque distribution (splitting torque to output shafts) simultaneously, eliminating the need for separate assemblies and reducing overall device complexity while maintaining functional reliability
2Device complexity
If an integral differential combining torque conversion and distribution is used, then device complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The integral differential is segmented into discrete planetary gearset elements (sun gear, planet gears, ring gear, planet carrier) that can be manufactured and assembled separately. This segmentation allows for standardized manufacturing processes and quality control while achieving the required precision through modular assembly, reducing the overall manufacturing precision burden compared to a monolithic design
Data Source
AI summary
Gear unit with an integral differential arranged between an input shaft and two output shafts, having a first and a second planetary gearset with gearset elements. One gearset element is connected to an epicyclic gear train input, an output of the epicyclic gear train and a stationary component of the gear unit. A first gearset element is connected to the input shaft, a second gearset element is connected to the first output shaft, and a third gearset element is connected to a first gearset element of the second planetary gearset. A second gearset element is connectible to a second gearset element of the epicyclic gear train. A third gearset element is connected to the second output shaft. A first gearset element of the epicyclic gear train is connected to the input shaft. A third gearset element of the epicyclic gear train is connected to the stationary structural component.