Modular Drive Train Actuation Units for Lower Complexity Variants

Solution Overview

Problem

Existing electrically operable drive train actuation systems for motor vehicles are complex and expensive due to the number of actuators and couplings used, making them costly to produce and adapt to various applications.

Innovation Solution

A modular method for producing electrically operable actuation systems comprising drive units, transmission units, and control units, allowing for mechanical and electrical coupling to form various structural units, enabling cost-effective production and adaptation to different applications within a motor vehicle drive train.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional actuation systems with multiple actuators and couplings are used, then reliable actuation of drive train components is achieved, but device complexity and production cost increase

Engineering Contradiction:

Improvereliable actuationVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The actuation system is divided into modular components: a first actuator for the parking lock device, a second actuator for the clutch device, and a third actuator for the transmission unit. This segmentation allows each component to be independently optimized and assembled, reducing overall system complexity while maintaining reliability through specialized functional modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control unit serves multiple functions by controlling at least two of the three actuators (parking lock, clutch device, or transmission unit). This multi-functionality reduces the number of separate control systems needed, thereby reducing device complexity while ensuring reliable actuation across different drive train configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional actuation systems with multiple actuators and couplings are used, then reliable actuation of drive train components is achieved, but production cost increases

Engineering Contradiction:

Improvereliable actuationVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The actuation system is divided into modular components: a first actuator for the parking lock device, a second actuator for the clutch device, and a third actuator for the transmission unit. This segmentation allows each component to be independently optimized and assembled, reducing overall system complexity while maintaining reliability through specialized functional modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control unit serves multiple functions by controlling at least two of the three actuators (parking lock, clutch device, or transmission unit). This multi-functionality reduces the number of separate control systems needed, thereby reducing device complexity while ensuring reliable actuation across different drive train configurations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If fixed actuation system configurations are used, then specific application requirements are met, but adaptability to various applications decreases

Engineering Contradiction:

Improveapplication-specific performanceVSAvoidadaptability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The actuation system is designed with dynamic configurability, allowing the control unit to adaptively control different combinations of actuators based on the specific application. The system can be configured to control one, two, or all three actuators (parking lock, clutch device, transmission unit) depending on the drive train variant, enabling high adaptability while maintaining reliable performance for each specific application.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20240352994A1Method for producing various variants of a series of an electrically operable actuation system, fully electrically operable or hybrid-operable drive train of a motor vehicle, and configuration system for producing various variants of a series of an electrically operable actuation system

Publication Date: 2024.10.24 SCHAEFFLER TECHNOLOGIES AG & CO KG

AI summary

The disclosure relates to a method for producing various variants of a series of an electrically operable actuation system for actuating components which can be connected into and/or disconnected from a drive train of a motor vehicle. The actuation system comprises a drive unit, a transmission unit, and a control unit. The actuation system is assembled from a modular kit including the following components: a first group of first drive units, at least a second group of second drive units, a first group of first transmission units, at least a second group of second transmission units, a first group of first control units, and a second group of second control units. The groups of the drive units, the groups of the transmission units and/or the groups of the control units can be mechanically and electrically coupled to each other.