Pedal Vehicle Power Unit With One-Way Clutch for Reverse Torque Blocking

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Solution Overview

Problem

In pedal vehicle power units, the rotation direction change of the control gear at lower transmission ratios leads to torque being transmitted from the control gear to the control motor, causing the control motor to heat up and reducing efficiency.

Innovation Solution

Incorporating a one-way clutch in the control assembly to prevent rotation of the control motor's rotor in the second rotation direction, ensuring torque is only transmitted in the first rotation direction, thereby preventing torque transmission from the control gear to the control motor and allowing for a smaller, more efficient control motor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the control gear rotates in the second rotation direction at lower transmission ratios, then the transmission ratio is adjusted, but torque is transmitted from the control gear to the control motor causing the control motor to heat up and reducing efficiency

Engineering Contradiction:
Improvetransmission ratio adjustmentVSAvoidcontrol motor efficiency
Core Design Contradiction:
Adaptability or versatilityVSLoss of energy

Solution Approach 1:

A one-way clutch is introduced as an intermediary component between the control gear and the control motor. This clutch allows torque transmission only in the first rotation direction, blocking torque transmission in the second rotation direction. The one-way clutch acts as a mediator that permits the control gear to rotate bidirectionally for transmission ratio adjustment while preventing harmful reverse torque from reaching the control motor, thus resolving the contradiction between adaptability and energy loss.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the control motor is designed to handle bidirectional torque transmission, then the transmission ratio can be adjusted at all ratios, but the control motor size increases and compactness is reduced

Engineering Contradiction:
Improvetransmission ratio control rangeVSAvoidcontrol motor volume
Core Design Contradiction:
Adaptability or versatilityVSVolume of moving object

Solution Approach 1:

The one-way clutch serves as a mechanical intermediary that enables the control gear to rotate in both directions for full transmission ratio control while preventing reverse torque from being transmitted to the control motor. This allows the use of a smaller, more compact control motor designed for unidirectional operation, resolving the contradiction between adaptability and motor volume.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The one-way clutch extracts or separates the bidirectional rotation requirement from the control motor's functional requirements. By placing the one-way clutch in the torque transmission path, the system removes the need for the control motor to handle reverse torque, allowing the motor to be optimized for unidirectional operation with reduced size and volume.

Inventive Principle:
Principle #2Taking out (Extraction)

3Adaptability or versatility

If torque is transmitted from the control gear to the control motor in the second rotation direction, then the transmission ratio is adjusted, but the control motor heats up decreasing its lifespan

Engineering Contradiction:
Improvetransmission ratio adjustment capabilityVSAvoidcontrol motor lifespan
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The one-way clutch is positioned as an intermediary component that blocks harmful reverse torque transmission from the control gear to the control motor during second rotation direction operation. This protective intermediary prevents thermal damage and excessive heating, thereby extending the control motor's operational lifespan while maintaining the ability to adjust transmission ratios across the full range.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The one-way clutch converts the potentially harmful reverse rotation into a beneficial protective action. By allowing the control gear to rotate in the second direction for transmission ratio adjustment while simultaneously blocking harmful torque transmission, the system transforms what would be a damaging condition into a safe operating mode, preserving motor reliability while maintaining adaptability.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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 enhances power unit efficiency, prevents excessive heating of the control motor, and allows for a more compact design by ensuring torque is only transmitted in the intended direction, thus maintaining high efficiency and extending the motor's lifespan.

Implementation Method 1

a one-way clutch provided to the control assembly of the power unit and arranged to transmit rotation in only a first rotation direction

Methodology Applied
Scientific EffectOne-way clutch mechanism: Ratchet

Data Source

PatentUS11932349B2Power unit and method
Publication Date: 2024.03.19 THE GATES CORP
  • US11932349B2 patent drawing
  • US11932349B2 patent drawing
  • US11932349B2 patent drawing

AI summary

A power unit for a pedal vehicle includes a pedal shaft, an output shaft arranged to transfer torque to a vehicle wheel, a main epicyclic gear set arranged to control transmission ratio between the pedal shaft and the output shaft, an assist motor connected to an assist gear of the main epicyclic gear set, and a control motor connected to a control gear of the main epicyclic gear set. The control motor and the control gear form a control assembly of the power unit. The power unit includes a one-way clutch provided to the control assembly of the power unit and arranged to transmit rotation in only a first rotation direction.