Integrated Drive Unit Assembly for Hybrid AWD Systems
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Solution Overview
Problem
Conventional hybrid vehicles require a secondary drive-line system to transmit power to the rear axle, adding weight and complexity, and occupying space that could be used for battery storage in all-wheel drive configurations.
Innovation Solution
A drive unit assembly that integrates a motor connected to a gear assembly, including a sun gear, planetary gears, and a differential, eliminating the need for a secondary drive-line by directly transmitting power from the motor to the rear axle through a planetary gear system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a secondary drive-line system is used to transmit power to the rear axle, then the vehicle can achieve all-wheel drive capability, but the weight and complexity of the drivetrain increases
Solution Approach 1:
The patent combines the rear axle drive unit with the motor assembly into a single integrated unit. The motor housing serves as the drive unit housing, the motor output shaft becomes the drive shaft, and the differential assembly is integrated within the same structure. This merging eliminates the need for separate secondary drive-line components while maintaining all-wheel drive capability.
Solution Approach 2:
The integrated drive unit performs multiple functions within a single assembly: the motor provides propulsion power, the planetary gear assembly provides gear reduction and torque multiplication, the differential distributes power to both rear wheels, and the entire assembly serves as both the power source and power transmission system. This multi-functionality eliminates the need for separate secondary drive-line systems.
2Adaptability or versatility
If a secondary drive-line system is used to transmit power to the rear axle, then the vehicle can achieve all-wheel drive capability, but the space required under the vehicle increases
Solution Approach 1:
The patent merges the motor assembly and rear axle drive unit into a single compact integrated unit that occupies minimal space under the vehicle. By combining the motor housing, gear assembly, differential, and drive shafts into one structure, the overall volume required is significantly reduced compared to separate secondary drive-line components.
3Adaptability or versatility
If a secondary drive-line system is used to transmit power to the rear axle, then the vehicle can achieve all-wheel drive capability, but the cost of the drivetrain increases
Solution Approach 1:
The integrated drive unit consolidates multiple components into a single manufacturable assembly, reducing the number of parts that need to be produced, inventory-managed, and assembled. This merging simplifies the manufacturing process and reduces overall production costs while maintaining all-wheel drive functionality.
4Adaptability or versatility
If conventional hybrid vehicle architecture with separate motor and rear axle systems is used, then power can be transmitted to both front and rear axles, but the overall vehicle weight increases
Solution Approach 1:
The patent integrates the motor assembly with the rear axle drive unit, eliminating redundant components and structural elements. The motor housing serves as the drive unit housing, the motor output shaft becomes the drive shaft, and the differential assembly is integrated within the same structure. This merging significantly reduces the overall weight of the drivetrain while maintaining the ability to transmit power to both front and rear axles.
Data Source
AI summary
A drive unit assembly. The drive unit includes a motor drivingly connected to a motor output shaft which in turn is drivingly connected to a sun gear of a gear assembly. The gear assembly further includes a gear assembly housing, one or more planetary gears and a pinion gear. At least a portion of the one or more planetary gears are drivingly connected to the sun gear, the gear assembly housing and a plurality of gear teeth circumferentially extending from an inner surface of a drive unit housing. The pinion gear has a first side and a second side, where the second side of the pinion gear is integrally connected to a first end portion of the gear assembly housing. Drivingly connected to the pinion gear is a differential ring gear of a differential assembly having a first side gear, a second side gear and one or more bevel gears.