Vehicle Gearbox Segmented Right Angle and Parallel Shaft Design

Solution Overview

Problem

Existing gearboxes for vehicles face challenges in fitting within limited motor assembly spaces while effectively connecting rotating components mounted at different angles and heights, as conventional right angle gear drives and universal joints are insufficient due to space constraints.

Innovation Solution

A gearbox design featuring a housing with an input shaft, a right angle gear set, an intermediate shaft, and a parallel shaft gear set, which facilitates a 90-degree rotational motion transfer and accounts for vertical height differences between components, allowing for the connection of components at varying angles and heights within the motor assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional right angle gear drives and universal joints are used to connect components at different angles and heights, then the rotational motion transfer is achieved, but the space requirements exceed the available motor assembly space

Engineering Contradiction:

Improverotational motion transfer capabilityVSAvoidspace occupied by gearbox

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The gearbox is segmented into two separate gear sets: a first right angle gear set for angular motion transfer and a second parallel shaft gear set for height differential accommodation. This segmentation allows each gear set to be optimized for its specific function, reducing the overall volume required compared to a single complex mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

An intermediate shaft is introduced as a mediator between the input and output shafts. The intermediate shaft receives rotational motion from the first gear set and transmits it to the second gear set, enabling the decoupling of angular and vertical motion transfer functions into two separate stages.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If a compact gearbox design is implemented to fit limited motor assembly space, then space constraints are satisfied, but the ability to connect components at different angles and heights is compromised

Engineering Contradiction:

Improvespace occupied by gearboxVSAvoidcomponent connection flexibility

Core Design Contradiction:

Volume of moving objectVSAdaptability or versatility

Solution Approach 1:

The gearbox is segmented into two separate gear sets: a first right angle gear set for angular motion transfer and a second parallel shaft gear set for height differential accommodation. This segmentation allows each gear set to be optimized for its specific function, reducing the overall volume required compared to a single complex mechanism.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gearbox achieves multi-functionality by integrating two distinct gear sets within a single housing: the first gear set handles angular orientation changes while the second gear set manages vertical height differences. This universal design allows the gearbox to accommodate various component configurations without requiring multiple separate mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If multiple gear sets and intermediate shafts are added to accommodate different angles and heights, then component connection flexibility is improved, but the device complexity increases

Engineering Contradiction:

Improvecomponent connection flexibilityVSAvoidgearbox structural complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Two separate functional requirements (angular motion transfer and height differential accommodation) are merged into a single integrated gearbox housing. By combining the first right angle gear set, second parallel shaft gear set, and intermediate shaft within one compact unit, the design reduces assembly complexity and simplifies installation compared to using separate mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The gearbox achieves multi-functionality by integrating two distinct gear sets within a single housing: the first gear set handles angular orientation changes while the second gear set manages vertical height differences. This universal design allows the gearbox to accommodate various component configurations without requiring multiple separate mechanisms.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS10378618B2Mechanical gearbox for use with a vehicle and methods of assembling the same

Publication Date: 2019.08.13 HUB CITY

AI summary

A gearbox for use in a vehicle having a motor assembly includes a housing and an input shaft coupled to the housing. The input shaft is configured to be coupled to a first component of the motor assembly. The gearbox also includes a first gear set positioned within the housing and coupled to the input shaft. An intermediate shaft is positioned within the housing and is coupled to the first gear set. The gearbox further includes a second gear set positioned within the housing and coupled to the intermediate shaft and an output shaft coupled to the second gear set and to the housing. The output shaft is configured to be coupled to a second component of the motor assembly.