Power Split Hybrid Powertrain Multi-Step Gearset Torque
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Solution Overview
Problem
Hybrid-electric vehicle powertrains face challenges in providing sufficient torque, particularly in reverse, for applications like light- or medium-duty trucks, due to the limitations of existing power split architectures.
Innovation Solution
A power split hybrid-electric powertrain integrated with a multi-step gearset housed in a single transmission housing, featuring a power split gearset positioned adjacent to the electric machines and supported by internal walls for enhanced structural rigidity and precision, along with a multi-step transmission assembly and a brake clutch for efficient torque management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a multi-speed gearset is mated to the power split configuration to provide greater torque, then torque capability is improved, but device complexity increases
Solution Approach 1:
The patent combines the power split gearset and multi-step transmission assembly into a single integrated housing, merging two separate mechanical systems into one unified structure. This integration maintains the enhanced torque capability of the multi-speed configuration while reducing overall system complexity by eliminating the need for separate housings and alignment interfaces.
Solution Approach 2:
The integrated housing serves multiple functions: it contains both the power split gearset components and the multi-step transmission assembly, provides structural support for both systems, and facilitates torque transmission pathways between the engine, electric machines, and drivetrain. This multi-functionality reduces the number of separate components needed.
2Manufacturing precision
If the power split gearset is positioned adjacent to the electric machines, then mechanical precision is improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the housing structure, including precision-machined mounting surfaces and定位 features that pre-align the power split gearset with the electric machines before final assembly. This preliminary action ensures high mechanical precision while simplifying the manufacturing process by eliminating the need for complex post-assembly alignment procedures.
3Strength
If internal walls are added for structural support, then rigidity is improved, but device complexity increases
Solution Approach 1:
The housing is segmented into multiple sections by internal walls that are strategically positioned to provide structural support and define separate compartments for the power split gearset and multi-step transmission assembly. These segmented structures enhance rigidity while maintaining manufacturing simplicity through modular construction techniques.
4Length of moving object
If the transmission housing is designed as a single integrated housing, then overall length is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The single integrated housing incorporates preliminary alignment features and modular mounting interfaces that facilitate precise positioning of the power split gearset and multi-step transmission assembly during assembly. These pre-built alignment features reduce the need for high-precision machining throughout the entire housing, allowing standard manufacturing tolerances to achieve the required overall precision.
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
This configuration enables greater torque delivery and improved mechanical precision, adapting the powertrain for a wider range of vehicle types while simplifying manufacturing and reducing overall length, thus enhancing efficiency and adaptability.
Implementation Method 1
a planetary gearset, a concentric shaft and a traction motor, establish a mechanical torque flow path
Implementation Method 2
the electric motor draws power from the battery and drives the vehicle independently of the engine
Implementation Method 3
the generator can draw power from the battery and drive against a one-way clutch on the engine power output shaft
Data Source
AI summary
A power split powertrain for a hybrid-electric vehicle powertrain has first and second electric machines disposed on opposite sides of a central support wall having a peripheral edge anchored to a transmission housing and a center region rotatably supporting rotors of the two electric machines on opposite sides of the support wall. A power split gearset is disposed adjacent to the first electric machine such that the first electric machine is between the first support wall and the power split gearset. A brake clutch associated with the second electric machine is mounted to the support wall and the support has a hydraulic feed channel supplying the brake clutch. Resolvers associated with the electric machines are mounted to the support wall and electrical connections with the resolvers are integrated with the support wall. A multi-step transmission assembly receiving torque from the power split gearset is also enclosed by the transmission housing.