Planetary Torque Transfer Unit for Integrated Axle Split and Range Shift
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Solution Overview
Problem
Existing torque transfer devices in vehicles with multiple axles often separate torque splitting and range gear selection into distinct functions, leading to separate hardware requirements and inefficiencies, particularly in heavy-duty vehicles.
Innovation Solution
A torque transfer device incorporating a planetary gear system with a shifting device that allows for multiple drive modes, including four-wheel drive and two-wheel drive, by selectively distributing torque between axles through various gear configurations, thereby integrating torque splitting and range gear selection into a single compact unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If torque splitting and range gear selection are separated into distinct functions, then each function can be optimized independently, but the device complexity and hardware requirements increase
Solution Approach 1:
The patent combines torque splitting and range gear selection into a single integrated torque transfer device. The planetary gear system provides multiple gear ratios (range selection) while simultaneously distributing torque between front and rear axles (torque splitting). This merging of functions reduces the number of separate components needed and simplifies the overall drivetrain architecture.
Solution Approach 2:
The torque transfer device is designed to perform multiple functions: it acts as both a differential for torque distribution and a range selector for gear ratio changes. The single device can operate in multiple modes (2WD high range, 2WD low range, 4WD high range, 4WD low range), making it a universal component that replaces what would traditionally require separate torque splitter and range selector units.
2Adaptability or versatility
If separate hardware is used for torque splitting and range gear selection, then each component can be optimized for its specific function, but the overall device size and weight increase
Solution Approach 1:
The patent merges torque splitting and range gear selection into a single integrated unit, eliminating the need for separate hardware components. This consolidation reduces the total weight of the powertrain while maintaining all necessary drive modes and torque distribution capabilities.
Solution Approach 2:
The torque transfer device is designed as a multi-functional universal component that performs both torque distribution and range selection. By making the device universal rather than specialized, the patent avoids the weight penalty of having multiple separate components, each optimized for a single function.
3Adaptability or versatility
If multiple separate components are used for torque management, then functional requirements can be met, but friction losses and energy efficiency decrease
Solution Approach 1:
The patent combines multiple torque management functions into a single integrated device, reducing the number of mechanical interfaces and gear meshes required. Fewer separate components mean fewer points of friction and energy loss, improving overall drivetrain efficiency while maintaining torque distribution capability.
4Adaptability or versatility
If traditional separate systems are used for torque splitting and range selection, then each system can be independently controlled, but the overall system complexity and control requirements increase
Solution Approach 1:
The patent merges torque splitting and range selection control into a single integrated system. The control unit manages both functions through one device rather than coordinating multiple separate components, simplifying the control architecture while maintaining the ability to select between multiple drive modes and torque distribution strategies.
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 provides enhanced torque distribution flexibility, enabling improved traction in challenging conditions and efficient gear ratio selection, reducing hardware complexity and friction losses, and offering a compact powertrain design.
Implementation Method 1
a planetary gear system comprising a sun gear, a ring gear, and a planet gear carrier carrying a plurality of planet gears
Data Source
AI summary
A torque transfer device for distributing torque from an input shaft to a first and a second output shaft driving a first and a second axle of a vehicle, respectively, is disclosed. The torque transfer device comprises a planetary gear system and a first shifting device selectively settable to one of a first position, a second position, and a third position, wherein in the first position, it provides increased output torque via the planetary gear system to the first and second output shafts, in the second position, it provides increased output torque only to the first output shaft, and in the third position, it provides output torque only to the first output shaft, at a direct gear ratio, or at a gear ratio which is lower than in the second position.