Modular Drive Module with Chain Reduction for Electric Vehicle Axles
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Solution Overview
Problem
Existing drive unit assemblies for electrically-powered vehicle axles are costly and lack flexibility in motor placement and output axis alignment, as seen in epicycloid gear reductions and multi-chain transmissions.
Innovation Solution
A drive module design featuring a housing with interchangeable housing members, multiple sprockets, and chains providing adjustable reduction ratios, along with a differential and output shafts, to enhance flexibility and reduce costs by allowing for customizable motor placement and output axis alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epicycloid gear reduction is used, then power transmission efficiency is improved, but cost increases and flexibility in motor placement decreases
Solution Approach 1:
The drive unit is segmented into modular components: electric motor, chain-driven reduction gear, and hub assembly. These can be configured in different arrangements (in-line or offset) to provide flexibility in motor placement while maintaining power transmission efficiency through the chain-driven reduction mechanism.
Solution Approach 2:
The system allows dynamic configuration options where the electric motor can be positioned in-line with or offset from the output axis depending on application requirements. The chain-driven reduction gear adapts to different spatial arrangements while maintaining functional performance.
2Reliability
If epicycloid gear reduction is used, then power transmission efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive epicycloid gear reduction with a chain-driven reduction system using standard sprockets and chains. These components are simpler to manufacture, more readily available, and lower in cost while achieving the same power transmission function.
Solution Approach 2:
The complex epicycloid gear mechanical system is substituted with a simpler chain-driven reduction mechanism. This substitution maintains the power transmission efficiency function while dramatically reducing manufacturing complexity and cost.
3Adaptability or versatility
If three-chain transmission is used, then flexibility in output axis alignment is improved, but device complexity increases
Solution Approach 1:
The transmission system is segmented into two independent chain-driven reduction stages instead of a single complex three-chain transmission. Each stage uses simple sprocket-and-chain pairs, reducing overall system complexity while maintaining flexibility in output axis alignment through the two-stage configuration.
Solution Approach 2:
The system provides dynamic alignment flexibility through its two-stage chain-driven reduction, allowing the output axis to be aligned in different configurations (in-line or offset) without requiring a complex three-chain transmission system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The drive module offers a cost-effective and flexible solution for electric vehicle axles by providing adjustable reduction ratios and improved motor placement options, enhancing the efficiency and adaptability of the driveline system.
Implementation Method 1
The first chain is disposed about and engages the first and second sprockets. The first sprocket, the second sprocket and the first chain provide a first reduction ratio.
Implementation Method 2
The second chain is disposed about and engages the third and fourth sprockets. The third sprocket, the fourth sprocket and the second chain provide a second reduction ratio.
Implementation Method 3
a first bearing is received in the first annular bearing pocket and supports the input shaft for rotation about the third axis
Data Source
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AI summary
A drive module for driving a pair of vehicle wheels. The drive module can be driven by an electric motor and includes two reductions between the electric motor and the vehicle wheels. At least one of the reductions is provided by a chain and a pair of sprockets.