Modular Electric Shift Actuator With Three-Stage Gear Reduction
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Solution Overview
Problem
Existing electric shift actuators for motor vehicles face inefficiencies due to worm gear structures that reduce transmission efficiency and output power, and they lack modular design, leading to complex assembly processes and low production efficiency.
Innovation Solution
The electric shift actuator employs a modular design with a three-stage gear reduction mechanism using spur gears for high efficiency, and a face gear set for improved stability and reduced noise, allowing for independent assembly of components and enhanced space utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If worm gear structure is used for power direction conversion, then 90° power direction conversion is achieved, but transmission efficiency is reduced and output power is affected
Solution Approach 1:
The patent replaces the worm gear mechanical transmission system with a direct parallel axis gear transmission system. The motor output shaft is directly connected to the input shaft of the gear reduction mechanism through parallel alignment, eliminating the 90° direction conversion requirement. This substitution of mechanical system architecture resolves the inherent efficiency losses of worm gears while maintaining the necessary power transmission function.
Solution Approach 2:
Instead of converting power direction by 90° as in conventional designs, the patent inverts the approach by maintaining parallel power flow direction throughout the transmission system. The gear reduction mechanism is designed with parallel input and output shafts, and the parking mechanism is accordingly oriented to receive power in the same direction as motor rotation, thereby eliminating unnecessary directional conversion and associated efficiency losses.
2Productivity
If scattered parts are assembled in an interspersed manner without modular design, then assembly flexibility is maintained, but assembly process becomes complex and production efficiency is low
Solution Approach 1:
The patent divides the electric shift actuator into distinct modular assemblies: motor assembly, gear reduction mechanism assembly, and parking mechanism assembly. Each module is designed as an independent functional unit with standardized interfaces, allowing them to be manufactured, tested, and assembled separately. This segmentation enables parallel production of modules and simplifies the final assembly process, directly improving production efficiency while reducing overall system complexity.
Solution Approach 2:
The patent designs the gear reduction mechanism as a universal module that can be integrated with different motor types and parking mechanism configurations. The standardized gear reduction assembly serves multiple functions: speed reduction, torque multiplication, and power transmission to the parking mechanism. This multi-functional universal module reduces the number of specialized parts needed and simplifies the assembly process across different vehicle applications.
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 solution achieves higher transmission efficiency, compact structure, and improved production efficiency by utilizing modular design and three-stage spur gear transmission, while also providing an emergency parking function for enhanced safety.
Implementation Method 1
An electric shift actuator includes a case body assembly, a case cover assembly covering the case body assembly, and a gear reduction mechanism assembly arranged in the case body assembly, where the gear reduction mechanism assembly includes a motor subassembly
Implementation Method 2
an output of the motor subassembly meshes with an input of the first-stage gear reduction subassembly in parallel to form first-stage gear reduction transmission
Implementation Method 3
an output of the first-stage gear reduction subassembly vertically meshes with an input of the face gear set to form second-stage gear reduction transmission
Data Source
AI summary
An electric shift actuator includes a case body assembly, a case cover assembly covering the case body assembly, and a gear reduction mechanism assembly arranged in the case body assembly. The gear reduction mechanism assembly includes a motor subassembly, a face gear set, a first-stage gear reduction subassembly, and an output gear assembly configured to be connected to a parking mechanism. An output of the motor subassembly meshes with an input of the first-stage gear reduction subassembly in parallel to form first-stage gear reduction transmission, an output of the first-stage gear reduction subassembly vertically meshes with an input of the face gear set to form second-stage gear reduction transmission, and an output of the face gear set meshes with an input of the output gear assembly in parallel to form third-stage gear reduction transmission. The actuator has functions of emergency parking and manual unlocking with improved safety and redundancy.