Planetary E-Drive Layout for Compact Multi-Gear Shifting

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Solution Overview

Problem

Existing electric drive devices for motor vehicles face challenges in achieving a low-loss and compact structure while maintaining efficient drivability and multi-gear capability.

Innovation Solution

The electric drive device incorporates a planetary transmission with two gear sets, a differential, and switch elements, including a form-fit claw coupling and freewheel coupling, to enable conjoint rotation and blocking of gear sets, optimizing the structure for low loss and compactness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a planetary transmission with two gear sets is used to achieve multi-gear capability, then the drivability and power shifting efficiency are improved, but the device complexity and installation space increase

Engineering Contradiction:
Improvemulti-gear capabilityVSAvoidtransmission structure complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines two planetary gear sets (first and second planetary gear sets) into a single integrated transmission unit sharing common components such as the housing, input shaft, and output shaft. This merging approach enables multi-gear capability while reducing the overall number of separate components compared to using two independent gear sets, thereby improving adaptability while controlling device complexity.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The second planetary gear set is nested within the same housing as the first planetary gear set, with both gear sets sharing the same input and output shafts. This nested arrangement allows the transmission to achieve multiple gear ratios through different combinations of planetary gears and switch elements without requiring separate transmission units, thus improving multi-gear capability while minimizing installation space and reducing structural complexity.

Inventive Principle:
Principle #7Nested doll (Nesting)

2Ease of operation

If switch elements (claw coupling and freewheel coupling) are added to enable gear switching, then the ease of operation and power shifting capability are improved, but the device complexity increases

Engineering Contradiction:
Improvegear switching capabilityVSAvoidswitch element complexity
Core Design Contradiction:
Ease of operationVSDevice complexity

Solution Approach 1:

The patent employs switch elements (claw coupling and freewheel coupling) that can dynamically change their engagement state based on rotational direction and torque requirements. These switch elements automatically engage or disengage depending on the operating conditions, enabling seamless gear switching without requiring complex control mechanisms, thus improving ease of operation while keeping the control system relatively simple.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The claw coupling and freewheel coupling are designed to automatically engage and disengage based on the direction of rotation and torque application. The switch elements self-regulate their engagement state without requiring external control signals, enabling automatic gear switching that improves ease of operation while minimizing the complexity of control systems.

Inventive Principle:
Principle #25Self-service

3Volume of moving object

If the second planetary gear set is arranged axially overlapping the differential, then the installation space and compactness are improved, but the manufacturing precision requirements increase

Engineering Contradiction:
Improveinstallation spaceVSAvoidaxial alignment precision
Core Design Contradiction:
Volume of moving objectVSManufacturing precision

Solution Approach 1:

The second planetary gear set is arranged to axially overlap with the differential housing, with both components sharing the same radial space. This nested arrangement allows the transmission to achieve a compact axial profile by utilizing the radial space already occupied by the differential, thereby reducing installation space requirements while maintaining functional independence of both components.

Inventive Principle:
Principle #7Nested doll (Nesting)

Data Source

PatentUS12352340B2Electric drive device for a motor vehicle, in particular for a motor car, and motor vehicle
Publication Date: 2025.07.08 MERCEDES BENZ GROUP AG
  • US12352340B2 patent drawing
  • US12352340B2 patent drawing

AI summary

An electric drive device for a motor vehicle includes a housing, an electric engine having a rotor, a planetary transmission at least partially arranged in the housing, a first planetary gear set having a first sun gear connected to the rotor for conjoint rotation, a first planetary carrier, and a first annular gear, and a second planetary gear set having a second planetary carrier connected to the first planetary carrier for conjoint rotation and a second annular gear; at least two switch elements for switching at least two gears, and a differential having a differential input shaft and two output drive shafts. The second planetary gear set has a second sun gear which is connected to the differential input shaft for conjoint rotation.