Single-Chain Idler Drive Layout for Narrower 4WD Drivetrains
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Solution Overview
Problem
Four-wheel drive vehicles with double-chain per side configurations require significant space and larger motor bearings due to the need for small drive sprockets, leading to increased chain loading on the drive motor.
Innovation Solution
A single-chain per side configuration utilizing a drive sprocket, idler sprockets, and a single chain, with a floating lantern gear design that reduces the width requirement and chain loading, allowing for smaller motor bearings and an integrated parking brake.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a double-chain per side configuration is used, then the desired speed-reduction/torque-multiplication is achieved, but the vehicle width increases and motor bearing size increases
Solution Approach 1:
The patent merges the function of two separate chains into a single chain that drives both the front and rear axles. The single chain wraps around the drive sprocket, idler sprocket, front axle sprocket, and rear axle sprocket, consolidating what would traditionally require two separate chain drives into one integrated system, thereby reducing vehicle width while maintaining torque multiplication
Solution Approach 2:
The patent uses a lantern gear drive sprocket with pins extending between front and back covers, creating a three-dimensional engagement structure. The idler sprocket teeth mesh with these pins in a multi-dimensional arrangement, allowing the single chain to effectively engage multiple drive points without requiring increased lateral space, thus achieving torque multiplication without increasing vehicle width
2Power
If a double-chain per side configuration is used, then the desired speed-reduction/torque-multiplication is achieved, but chain loading on the drive motor increases
Solution Approach 1:
The patent segments the chain drive path into distinct engagement zones with the lantern gear's pins. The single chain engages multiple pin locations along its length, distributing the drive force across several contact points rather than concentrating it at a single location, thereby reducing peak chain loading on the drive motor while maintaining overall torque multiplication
Solution Approach 2:
The idler sprocket acts as an intermediary between the drive sprocket and the front/rear axle sprockets. It receives force from the drive sprocket through the single chain and redistributes it to both axle sprockets, mediating the force transmission and reducing the direct loading burden on the drive motor and chain segments
3Power
If a small drive sprocket is used in a double-chain configuration, then the desired speed-reduction/torque-multiplication is achieved, but motor support bearing size increases
Solution Approach 1:
The lantern gear drive sprocket utilizes a three-dimensional pin structure with front and back covers, allowing the drive mechanism to achieve torque multiplication without requiring a small-diameter sprocket. The pins extend radially between covers, creating a multi-dimensional engagement that distributes mechanical loads more effectively, enabling the use of smaller motor support bearings while maintaining the desired power transmission characteristics
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 single-chain configuration reduces the overall vehicle width, decreases chain loading, and allows for smaller motor bearings, enhancing efficiency and assembly ease while maintaining desired speed-reduction/torque-multiplication.
Implementation Method 1
When the parking brake is engaged, the engagement member can activate to compress the brake disc against the stationary reactionary member to prevent rotation of the drive shaft
Implementation Method 2
The drive motor rotates the drive sprocket, which rotates the first idler sprocket, which rotates the single chain, which rotates the front and rear axle sprockets
Data Source
AI summary
A single chain drive is disclosed that includes a drive sprocket, a drive motor, idler sprockets, front and rear axle sprockets, and a single chain. The drive motor rotates the drive sprocket, which rotates the idler sprockets, which rotate the single chain, which rotates the front and rear axle sprockets. The drive sprocket can be a lantern gear with covers, and pins that connect the cover, and the idler sprockets can have teeth that mesh with the pins between the covers of the drive sprocket. A drive shaft can couple the drive motor and drive sprocket, and an integrated parking brake can prevent rotation of the drive shaft when engaged. A chain case with lubricant can enclose the drive sprocket, idler sprockets, chain, and axle sprockets. The drive sprocket, idler sprockets and axle sprockets can be sized to provide a desired gear reduction.