Sealed eCVT Clutch Layout for Compact Utility Vehicles
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Solution Overview
Problem
Positioning all components needed for an electronically controlled continuously variable transmission (CVT) on a compact off-road vehicle is challenging due to space constraints and the need for accommodating electrical components and cooling, which affects the vehicle's size and powertrain life.
Innovation Solution
A utility vehicle design with a powertrain assembly including a continuously variable transmission (CVT) positioned rearward of the operator area, featuring a sealed enclosure for the drive clutch with a moveable sheave and lead screw nut, and a support structure within the housing to increase strength, along with an electric motor and actuation assembly that operates within a sealed housing to minimize wear and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an electronically controlled CVT is implemented on a compact off-road vehicle, then the powertrain life and functionality are improved, but the vehicle size increases due to space requirements for electrical components and cooling
Solution Approach 1:
The patent combines the electric motor, actuation assembly, and cooling components into an integrated unit that operates within the sealed housing of the drive clutch. This merging of components eliminates the need for separate mounting spaces, allowing the electronically controlled CVT to be installed on compact off-road vehicles without significantly increasing vehicle size, while still providing improved powertrain life through electronic control and enhanced cooling
Solution Approach 2:
The electric motor and actuation assembly are positioned within the sealed housing of the drive clutch, nesting these components inside the existing CVT structure. This nesting approach allows the electrical components to occupy space that would otherwise be unused or require separate mounting locations, thereby avoiding an increase in overall vehicle dimensions while enabling electronically controlled CVT functionality
2Reliability
If a sealed enclosure is used for the drive clutch, then wear and contamination are reduced, but manufacturing complexity increases
Solution Approach 1:
The sealed enclosure of the drive clutch is designed to also house the electric motor and actuation assembly, combining multiple functions into a single integrated component. This approach maintains the protective benefits of the sealed enclosure against wear and contamination while simplifying manufacturing by reducing the number of separate sealed housings needed for different components
Data Source
AI summary
A utility vehicle includes a frame assembly, a plurality of ground-engaging members supporting the frame assembly, and a powertrain assembly operably coupled to the ground-engaging members and including a prime mover and a continuously variable transmission. Additionally, the utility vehicle includes an operator defined by a portion of the frame assembly and including seating for at least an operator. The utility vehicle also includes an electrical assembly comprising an electric motor operably coupled to the continuously variable transmission. The electric motor is positioned rearward of the operator area.