Vehicle Drive Device with Shiftable Gears and Decoupling

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Solution Overview

Problem

Existing drive devices for motor vehicles that use electric machines to drive axles without gearboxes face inefficiencies due to fixed gear reductions, leading to unfavorable operating points for electric motors and limited spread in rear axle drives.

Innovation Solution

A drive device with a differential preceded by shiftable gears via a synchronizer clutch or claw clutch, actuated electrically, allowing for efficient gear ratio changes and decoupling, utilizing electromagnetic actuators to move a sliding sleeve for gear engagement and disengagement, enabling optimal operating range for electric machines.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If a fixed gear reduction is used in the axle drive, then the structure is simple, but the electric machine operates at unfavorable operating points and the working range is limited

Engineering Contradiction:
Improvestructure simplicityVSAvoidworking range of electric machine
Core Design Contradiction:
Device complexityVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the gear ratio changeable through shiftable gears (first and second gears) that can be selectively engaged or disengaged. The gear set transitions from a fixed reduction to a dynamic system where the gear ratio can be adapted to different operating conditions, allowing the electric machine to operate across a wider range of speeds and torques while maintaining structural simplicity through the use of a compact gear arrangement with a common pinion gear.

Inventive Principle:
Principle #15Dynamics

2Adaptability or versatility

If a gearbox with multiple gear ratios is provided, then the working range is extended, but the device complexity and installation space increase

Engineering Contradiction:
Improveworking range of electric machineVSAvoidgearbox structure
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple gear functions into a compact gear set where a first gear and second gear share a common pinion gear (32). This combining of gear elements allows the system to achieve multiple gear ratios without requiring separate, bulky gearbox structures. The merged gear arrangement reduces device complexity and installation space while maintaining the ability to extend the working range through selective gear engagement controlled by the shift sleeve.

Inventive Principle:
Principle #5Merging (Combining)

3Reliability

If electromagnetic actuators are used to shift gears, then the shifting is precise and reliable, but the device complexity increases

Engineering Contradiction:
Improvegear shifting reliabilityVSAvoidactuating mechanism
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the shifting control function from complex mechanical linkages and implements it through dedicated electromagnetic actuators (first and second electromagnetic actuators). Each actuator is independently responsible for controlling the shift sleeve position, which simplifies the overall control architecture while ensuring reliable gear shifting. The actuators are integrated into the gear set structure, minimizing additional complexity while providing precise and reliable gear ratio changes.

Inventive Principle:
Principle #2Taking out (Extraction)

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 solution provides a structurally simple and efficient gear shifting mechanism that extends the working range of electric machines, maintains low effort, and allows for decoupling, thereby optimizing transmission efficiency and reducing weight and installation space requirements.

Implementation Method 1

the armature of the actuating device which interacts with the shift sleeve can preferably be pretensioned by at least one spring in the neutral position of the synchronous clutch. This means that the gears are shifted electromagnetically

Methodology Applied
Scientific EffectElectromagnetic actuation: Electromagnetic Induction

Implementation Method 2

the armature of the actuating device which interacts with the shift sleeve can preferably be pretensioned by at least one spring in the neutral position of the synchronous clutch

Methodology Applied
Scientific EffectSpring force: Spring

Data Source

PatentEP2870012B1Driving device for vehicle, which can be in particular decoupled
Publication Date: 2016.09.14 AUDI AG
  • EP2870012B1 patent drawingFigure 1
  • EP2870012B1 patent drawingFigure 2
  • EP2870012B1 patent drawingFigure 3

AI summary

The invention relates to a drive device for motor vehicles or decouplable vehicle drive systems, wherein an electric machine outputs drive to a differential of a drive axle in transmission ratio stages. According to the invention, at least two gear stages (I, II), which can be switched between by means of a switching clutch (28) and which are formed by gearwheel sets (22, 24, 26, 28), and a decoupling means (neutral) are connected upstream of the differential (16), wherein, in particular, the switching device (42) of the switching clutch (28) can be actuated into the gear position (I, II) and into a neutral position (N) electrically.