Ring Gear-Clutch Basket Coupling for Gear Mesh Load Durability
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Solution Overview
Problem
Existing electric drive modules in electrified vehicles face challenges in achieving a robust weld design that can withstand tangential, radial, and axial gear mesh loads between the ring gear and clutch basket, leading to potential premature damage or failure of the electric drive gearbox assembly.
Innovation Solution
A mechanical coupling system using bolts or rivets circumferentially connecting the ring gear and clutch basket, with the clutch basket featuring outwardly extending tabs that nest into complementary insets on the ring gear, supplemented by inset sidewalls to inhibit rotation and absorb gear mesh loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to join the ring gear and clutch basket, then the connection is achieved, but the robustness against tangential, radial and axial gear mesh loads is insufficient
Solution Approach 1:
The connection between ring gear and clutch basket is segmented into multiple discrete mechanical joining members (bolts or rivets) distributed around the circumference, rather than relying on a continuous weld. This segmentation allows each joining member to specifically handle different load components (tangential, radial, axial) and provides redundancy, improving overall reliability under gear mesh loads.
Solution Approach 2:
The solution combines different joining methods (mechanical fasteners through passages) to create a composite connection system that leverages the strengths of each method. The mechanical joining members work together with the gear mesh interface to create a multi-mode load-bearing system that is more robust than welding alone.
2Ease of manufacture
If a weld design is used to connect ring gear and clutch basket, then the assembly is simplified, but the ability to withstand tangential, radial and axial loads is compromised
Solution Approach 1:
The connection is divided into multiple discrete mechanical joining members positioned at specific locations around the ring gear-clutch basket interface. This segmentation enables better distribution of tangential, radial and axial loads across multiple load paths, significantly improving load bearing capacity compared to a single continuous weld.
Solution Approach 2:
Passages are created at specific locations in the ring gear and clutch basket to accommodate mechanical joining members. This local modification approach concentrates the load-bearing capability exactly where needed to handle gear mesh loads, while maintaining simplicity elsewhere in the design.
3Force
If mechanical joining members are used to connect ring gear and clutch basket, then load bearing capacity is improved, but device complexity increases
Solution Approach 1:
The mechanical joining members serve multiple functions simultaneously: they provide structural connection, bear tangential and radial loads, position the clutch basket relative to the ring gear, and allow for assembly/disassembly. This multi-functionality reduces the need for additional separate components, thereby limiting the increase in device complexity.
Solution Approach 2:
Passages are strategically positioned at specific locations in the ring gear and clutch basket to accommodate mechanical joining members. This localized approach concentrates the complexity only where load bearing is needed, rather than throughout the entire assembly, thereby minimizing overall device complexity.
Data Source
AI summary
An electric drive module that generates and transfers drive torque to a driveline of an electrified vehicle is provided. The electric drive module includes an electric drive gearbox assembly having a ring gear, a clutch assembly and a plurality of mechanical joining members. The ring gear receives a rotational input from an electric motor of the electric drive module and defines a first plurality of passages therein. The clutch assembly includes a clutch basket that receives a plurality of clutch plates therein, the clutch basket having a second plurality of passages therein. The plurality of mechanical joining members extend through the first plurality of passages of the ring gear and the second plurality of passages in the clutch basket, the plurality of mechanical joining members mitigating loads experienced between the ring gear and the clutch basket.