Integrated Gear Assembly Axial Length Reduction
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Solution Overview
Problem
Existing torque transmission devices for ground vehicles face challenges in balancing performance, weight, packaging, and durability, particularly in efficiently transferring mechanical power while minimizing axial length and ensuring interference-free assembly.
Innovation Solution
An integrated gear assembly is designed, comprising a conjoined carrier assembly that couples a reducing gear set to a differential gear set, featuring coaxial sun gears and pinion gears with axial overlapping configurations to reduce axial length and prevent interference, allowing for efficient torque transfer and compact packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If traditional separate gear assemblies are used, then ease of manufacture and repair are improved, but axial length increases and packaging efficiency deteriorates
Solution Approach 1:
The patent combines the carrier assembly of the reducing gear set with the carrier assembly of the differential gear set into a single conjoined carrier assembly. This merging of two separate carrier assemblies into one integrated structure reduces the overall axial length of the gear assembly while maintaining all necessary functional components for both reducing and differential operations.
Solution Approach 2:
The patent positions the pinion gears of the differential gear set such that they axially overlap with the pinion gears of the reducing gear set. This nested arrangement allows the differential pinion gears to be positioned within the axial space already occupied by the reducing gear pinion gears, thereby minimizing the total axial length without causing interference between the gear sets.
2Volume of moving object
If gear elements are positioned closer together, then packaging efficiency is improved, but interference between gear elements increases
Solution Approach 1:
The patent applies different axial positioning strategies to different gear elements within the same assembly. Specifically, the differential pinion gears are positioned at different axial locations relative to the reducing gear pinion gears depending on their specific functional requirements. This localized differentiation allows optimal space utilization while preventing interference between specific gear pairs.
Solution Approach 2:
The patent resolves potential interference issues by utilizing the axial dimension strategically. By positioning the differential pinion gears to axially overlap with the reducing gear pinion gears in a controlled manner, the design transforms a potential conflict in the radial plane into a resolved arrangement in the axial dimension, achieving compact packaging without interference.
3Power
If coaxial sun gears are used, then torque transfer efficiency is improved, but manufacturing precision requirements increase
Solution Approach 1:
The conjoined carrier assembly serves multiple functions simultaneously: it supports both the reducing gear set and the differential gear set, provides coaxial alignment for all sun gears, and enables torque transfer from the input shaft through both gear sets to the output shafts. This multi-functionality consolidates what would otherwise require separate alignment systems into a single integrated structure.
Solution Approach 2:
The coaxial alignment of all sun gears is pre-established through the rigid conjoined carrier assembly structure during manufacturing. This preliminary establishment of precise coaxial relationships eliminates the need for complex field alignment procedures and ensures consistent torque transfer efficiency while maintaining manufacturability through standardized assembly processes.
Data Source
AI summary
An integrated gear assembly includes a conjoined carrier assembly coupling a reducing gear set to a differential gear set. This includes first, second and third coaxial sun gears. The first sun gear meshingly engages first gear elements of stepped pinion gears of the reducing gear set. The second sun gear meshingly engages third pinion gears of the differential gear set. The third sun gear meshingly engages fourth pinion gears of the differential gear set. The third pinion gears of the differential gear set axially overlap second gear elements of the stepped pinion gears of the reducing gear set. The fourth pinion gears of the differential gear set axially overlap the third pinion gears of the differential gear set.