Split Gearbox Reverse Mechanism Using Coupling Sleeves
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Solution Overview
Problem
Current range gearboxes in vehicles face challenges in achieving a balance between compact dimensions, efficient torque transmission, and low energy consumption, particularly in reverse gear operations, which affects driveability and increases manufacturing and repair costs due to the limitations in gear ratio and component size.
Innovation Solution
A gearbox design incorporating a split configuration with a main gearbox, range gearbox, and a crawler gear that allows for a reverse gear mechanism, utilizing axially movable coupling sleeves and a planetary gear with a specific gear ratio range to enable efficient torque transfer and compact dimensions, while minimizing the diameter of the sun gear wheel to maintain torque capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the reverse gear is integrated into the main gearbox, then the reverse gear function is achieved, but the main gearbox length and vehicle weight increase
Solution Approach 1:
The transmission system is divided into two independent gearboxes: main gearbox and range gearbox. The reverse gear function is segregated into the range gearbox rather than being integrated into the main gearbox, thereby preventing the main gearbox from elongating while still providing reverse gear capability through the coupled range gearbox system.
Solution Approach 2:
Instead of extending the main gearbox in the longitudinal direction to accommodate reverse gear components, the patent uses the range gearbox positioned at the output end to provide reverse gear function. This shifts the solution from one dimension (lengthening main gearbox) to another dimension (adding a compact range gearbox module).
2Strength
If the planetary gear diameter is increased, then torque transmission capacity is improved, but the gearbox dimensions and vehicle weight increase
Solution Approach 1:
The planetary gear components are designed with optimized tooth profiles and meshing characteristics that dynamically distribute torque loads more efficiently. This allows the planetary gear to transmit high torque without requiring an increased diameter, as the dynamic load distribution maximizes the torque capacity of the existing component sizes.
Solution Approach 2:
The patent optimizes critical parameters of the planetary gear including tooth width, tooth profile shape, and meshing angle to enhance torque transmission efficiency. By changing these parameters rather than simply increasing the overall diameter, the system achieves higher torque capacity within compact dimensions.
Data Source
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AI summary
A gearbox for vehicles, comprising a split gearbox (15C), a main gearbox (15A) and a range gearbox (15B), which is shiftable into a low range gear position and a high range gear position; the range gearbox (15B) comprises a planetary gear (14) with a ring gear wheel (22), a sun gear wheel (18) and a planet carrier (20), on which at least one planet gear wheel (24) is rotatable mounted, which ring gear wheel (22) and sun gear wheel (18) engage with the at least one planet gear wheel (24); a gear- box housing (12) surrounding the planetary gear (14); a first axially movable coupling sleeve (42) arranged to engage the planet carrier (20) with the gearbox housing (12); and a second axially movable coupling sleeve (43) arranged to engage the ring gear wheel (22) with an output shaft (28) for achieving a reverse gear in the gearbox (2). A crawler gear (211) in the main gearbox (15A) is arranged to transfer torque through the gearbox (2) when the range gearbox (15B) is shifted into the reverse gear. The invention also relates to a vehicle (1), which comprises such a gearbox (2).