Pinion Holder Integrated with Differential Casing for Compact Transmission
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Solution Overview
Problem
Existing power systems in electric motor vehicles lack efficient support for gears in the transmission system, leading to inefficiencies in power transmission and size minimization.
Innovation Solution
A power system design that includes a pinion holder supporting the pinion gear on the differential gear casing, with a second gear having an inner diameter equal to or smaller than the pinion holder's outer diameter, allowing for appropriate power transmission and size reduction, and a method of assembling the pinion gear, second gear, pinion holder, and differential gear system in a specific order to enhance layout flexibility and reduce component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the pinion gear is supported by a conventional support structure, then the gear can be supported, but the system size increases and layout flexibility decreases
Solution Approach 1:
The pinion holder is merged with the differential gear casing by providing a through-hole that passes through the casing. This integration eliminates the need for separate support structures, reduces system size, and improves layout flexibility while maintaining proper gear support functionality.
Solution Approach 2:
The differential gear casing is given multiple functions: it not only houses the differential gears but also provides support for the pinion gear through the integrated pinion holder with through-hole. This multi-functionality reduces the number of components and optimizes space utilization.
2Reliability
If multiple separate components are used for gear support, then the gear support function is achieved, but the number of components increases
Solution Approach 1:
The pinion holder and differential gear casing are combined into a single integrated structure. The through-hole in the pinion holder passes through the differential gear casing, creating a unified component that maintains reliable gear support while reducing the total number of parts.
3Ease of manufacture
If the second gear inner diameter is made larger, then assembly is easier, but the system size increases
Solution Approach 1:
The inner diameter of the second gear is optimized to a specific dimension that balances assembly ease with compactness. This parameter is carefully selected to allow proper assembly while maintaining minimal system size.
Solution Approach 2:
The second gear is designed with different local dimensions: a smaller inner diameter in the meshing portion to reduce overall size, and appropriate clearances in other areas to facilitate assembly. This localized optimization resolves the contradiction between compactness and ease of assembly.
Data Source
AI summary
A power system includes an electric motor, a transmission, and a differential gear system. The transmission includes a first gear that is mechanically connected to the electric motor, a second gear that has a rotation axis in common with the first gear and is mechanically connected to a differential gear casing of the differential gear system, a pinion gear that meshes with the first gear and the second gear, and a pinion holder that rotatably supports the pinion gear. The pinion holder has a pinion gear supporting portion which is disposed on a side of the differential gear casing of the differential gear system to support the pinion gear, relative to a meshing portion between the second gear and the pinion gear. An inner diameter of the second gear at the meshing portion is equal to or smaller than an outer diameter of the pinion holder.