Modular Power Train Assembly with Hydraulic Quill Insert
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Solution Overview
Problem
The complexity and cost associated with manufacturing various power train designs for vehicles, due to the need for multiple parts and assembly processes, increase as the number of power train configurations increases, leading to manufacturing inefficiencies.
Innovation Solution
A modular power train assembly with a housing that includes interconnected cavities and a hydraulic quill insert, allowing for interchangeable countershafts and clutch devices, which are controlled by a hydraulic control system, enabling various gear ratios and configurations without significant modification of the housing or additional parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple power train designs are provided for different vehicle configurations, then consumer options and adaptability are enhanced, but manufacturing complexity and cost increase due to requiring large numbers of parts and assembly lines
Solution Approach 1:
The housing is designed with a universal inter-cavity passage structure that can accommodate multiple different countershaft assemblies through a single standardized interface. The hydraulic quill insert provides multi-functional hydraulic routing capability, directing control signals to various clutch devices depending on which countershaft assembly is installed. This allows one housing design to support multiple power train configurations without requiring separate dedicated housings for each variant.
Solution Approach 2:
The power train assembly is segmented into modular components: a common housing with input/output shafts and clutch devices, interchangeable countershaft assemblies with specific gear ratios, and a standardized hydraulic control system. This segmentation allows different countershaft assemblies to be swapped without modifying the housing or other components, enabling flexible configuration changes while maintaining manufacturing efficiency through standardized parts.
2Adaptability or versatility
If multiple power train designs are provided for different vehicle configurations, then consumer options are enhanced, but the number of parts and manufacturing processes increase leading to higher costs
Solution Approach 1:
The housing serves multiple functions: it contains the input and output shafts, houses the clutch devices, and provides a standardized inter-cavity passage for hydraulic routing. The hydraulic quill insert similarly provides multi-functionality by routing hydraulic control signals to various clutch devices depending on the installed countershaft configuration. This reduces the need for separate housing designs and associated parts for each power train variant.
Solution Approach 2:
Multiple functional elements are merged into the housing structure: the inter-cavity passage is integrated directly into the housing body, the hydraulic quill insert is received within the housing, and various clutch devices are mounted within the housing cavities. This consolidation reduces the total number of separate components compared to having dedicated housings for each power train configuration.
3Adaptability or versatility
If multiple power train designs are provided for different vehicle configurations, then consumer options are enhanced, but assembly line complexity and manufacturing processes increase
Solution Approach 1:
The power train is segmented into a common assembly (housing with input/output shafts and clutch devices) and interchangeable modules (countershaft assemblies with specific gear ratios). This segmentation simplifies manufacturing by allowing the common assembly to be produced once and reused across multiple configurations, while only the countershaft assemblies need to be varied for different power train options.
Solution Approach 2:
The housing and hydraulic control system are designed as universal platforms that work with multiple countershaft assembly variants. The inter-cavity passage geometry and hydraulic routing capability are standardized to accommodate different configurations without requiring modification to the housing or control system, thereby simplifying the manufacturing and assembly processes.
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
This modular design simplifies the assembly of vehicles with different power train configurations, reduces manufacturing complexity and cost, and allows for flexible power transmission options by using a common base platform with interchangeable components.
Implementation Method 1
A hydraulic control device provides hydraulic control signals to control, at least in part, the first clutch device. A hydraulic routing system receives hydraulic control signals from the hydraulic control device and directs the signals to control power flow from the input shaft to the output shaft.
Data Source
AI summary
A modular assembly is described for a power train. An assembly housing includes first and second cavities connected by an inter-cavity passage. An input shaft and an output shaft linked by a first clutch are disposed, at least in part, in the first cavity. A hydraulic control assembly provides hydraulic control signals to control, at least in part, the first clutch device. A hydraulic quill insert disposed, at least in part, in the inter-cavity passage, includes a plurality of control passages. The hydraulic quill insert receives the hydraulic control signals and directs the signals to control power flow from the input shaft to the output shaft.