Compact Planetary Gear Reducer for High-Speed EV Motors
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Solution Overview
Problem
Conventional gearboxes for electric vehicles are unable to adequately reduce the speed from smaller, high-speed electric motors, which are used to decrease the size and cost of electric motors.
Innovation Solution
A compact gear speed reducer is designed to operate between the high-speed electric motor and the existing gearbox, utilizing a gear ratio to reduce the motor's high speed to a level compatible with conventional gearboxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a smaller electric motor is used to decrease size and cost, then the motor size and cost are reduced, but the motor operates at a higher speed that cannot be adequately reduced by conventional gearboxes
Solution Approach 1:
The speed reduction function is divided into two separate stages: the first speed reducer (with ratio 1.5:1 to 3:1) reduces speed from the high-speed motor output, and the second speed reducer (with ratio 3:1 to 10:1) further reduces speed to the final output. This segmentation allows each stage to be optimized for its specific speed range, enabling the use of smaller, higher-speed motors while achieving the required final speed reduction.
2Device complexity
If a conventional gearbox is used with smaller high-speed motors, then the existing gearbox design can be maintained, but the speed reduction is inadequate
Solution Approach 1:
The first speed reducer acts as an intermediary device between the high-speed motor and the conventional second speed reducer. It pre-reduces the motor speed before it enters the conventional gearbox, allowing the existing gearbox design to be maintained while achieving adequate overall speed reduction. The intermediary first speed reducer bridges the gap between high-speed motor output and conventional gearbox input requirements.
3Speed
If a single-stage high ratio speed reducer is used, then the speed reduction ratio is achieved, but the device size and complexity increase
Solution Approach 1:
The overall speed reduction ratio is segmented into two separate stages with manageable ratios. The first speed reducer handles a portion of the reduction (1.5:1 to 3:1), and the second speed reducer handles the remaining reduction (3:1 to 10:1). This segmentation avoids the need for a single complex high-ratio reducer, reducing overall device complexity while achieving the required total speed reduction ratio.
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 compact gear speed reducer effectively reduces the speed of smaller, high-speed electric motors to a level that existing gearboxes can handle, allowing for the use of lighter, smaller, and less expensive electric motors without the need for redesigning the gearbox.
Implementation Method 1
a plurality of planet gears intermeshed with the ring gear, wherein the plurality of planet gears are connected to each other by a planet carrier; and a sun gear intermeshed with the plurality of planet gears
Data Source
AI summary
A compact design of a gear speed reducer for an electric vehicle is disclosed that operates to reduce speed from a high-speed electric motor to a lower speed appropriate for a gearbox designed to accept the lower speed. In an example, the compact gear speed reducer may be installed between the high-speed electric motor and the gearbox. In an example, the compact gear speed reducer may be installed within an enclosure of the electric motor. The compact gear speed reducer may include a ring gear, a sun gear, and a plurality of planet gears operatively connected by a planet carrier.