Wheel Hub Torque Multiplier Using Pinion-Annular Gear Nesting
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Solution Overview
Problem
Existing gear reduction and multiplication systems, such as portals, are prone to failure due to weak design and add significant weight and width to vehicles, while also subjecting upstream drivetrain components to excessive torque and stress, particularly in high-torque applications like rock crawling.
Innovation Solution
A torque vector multiplier system that replaces standardized components like unitary bearing hubs or carrier bearings with a pinion and annular gear configuration, providing efficient gear reduction or multiplication by ensuring a large number of teeth are in constant communication, reducing the weight and width added to the vehicle and distributing torque more evenly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If portals are used to achieve gear reduction at the wheel hub, then gear reduction is attained close to the driven wheel, but the system adds significant width (eight inches) and weight (40 pounds per wheel hub) to the vehicle
Solution Approach 1:
The patent combines the pinion gear and annular gear into a single integrated assembly that replaces the traditional portal structure. This merging eliminates the need for separate idler gears and multiple stacked components, achieving gear reduction in a compact configuration that significantly reduces both width and weight while maintaining the gear reduction function at the wheel hub
Solution Approach 2:
The patent employs a nested configuration where the pinion gear is positioned inside the annular gear, with the pinion teeth meshing with the annular gear teeth. This nesting arrangement allows the gear reduction mechanism to be contained within a much smaller volume compared to external portal configurations, reducing the eight-inch width addition to a compact radial arrangement
2Speed
If portals are used to achieve gear reduction at the wheel hub, then gear reduction is attained close to the driven wheel, but the system adds significant width (eight inches) to the vehicle
Solution Approach 1:
The patent combines the pinion gear and annular gear into a single integrated assembly that replaces the traditional portal structure. This merging eliminates the need for separate idler gears and multiple stacked components, achieving gear reduction in a compact configuration that significantly reduces width
Solution Approach 2:
The patent transitions from a linear/stacked gear arrangement (portal) to a radial/concentric arrangement (pinion inside annular gear). This dimensional change from axial stacking to radial nesting reduces the width requirement from eight inches to a compact diameter, as the gear teeth engage in a circular pattern rather than a linear stack
3Speed
If gear reduction is configured at the transmission, then all downstream drivetrain components enjoy less rotational speed and sustain higher torque, but this makes them more susceptible to material fatigue and failure
Solution Approach 1:
The patent applies gear reduction at the wheel hub, which is the earliest possible point in the drivetrain where torque can be increased before it reaches downstream components. This preliminary gear reduction action ensures that axles, CV joints, and other downstream components receive reduced torque loads, preventing material fatigue and failure before it occurs
Solution Approach 2:
The patent extracts the gear reduction function from the transmission and relocates it to the wheel hub. This extraction allows the transmission to operate at its original design specifications while the wheel hub performs the torque multiplication, isolating downstream components from excessive torque loads
4Speed
If portals are used to achieve gear reduction, then gear reduction is attained at the wheel hub, but the gear stack configuration offers only a few teeth between the idler gear and each respective input or output gear, leading to tooth chipping or breaking
Solution Approach 1:
The patent eliminates the idler gear intermediary that causes reliability issues in portal systems. Instead, the pinion gear directly meshes with the annular gear, creating a simpler two-gear system where both gears have numerous teeth in constant engagement, removing the weak point of few-teeth engagement found in idler gear configurations
Solution Approach 2:
The patent changes the gear engagement parameters by using a pinion-annular gear configuration where a large number of teeth are in constant communication compared to the few teeth in portal idler gear engagements. This parameter change from few-teeth to many-teeth engagement significantly increases tooth durability and resistance to chipping and breaking
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 torque vector multiplier system enhances reliability and reduces material fatigue by distributing torque more evenly, offering significant weight and space savings while maintaining original drivetrain specifications, and can be easily swapped for gear multiplication or reduction applications.
Implementation Method 1
a pinion gear comprising a plurality of pinion teeth facing outward; an annular gear comprising a plurality of annular teeth facing inward. The plurality of teeth of the annular gear exceeds in number the plurality of teeth of the pinion gear, and the plurality of pinion teeth and the plurality of annular teeth are approximately mated to each other providing for rotational communication between the pinion gear and the annular gear
Data Source
AI summary
A torque vector multiplier for gear reduction or gear multiplication of vehicle driveline, machinery or any rotating structure, such as an automobile or offroad vehicle. Said embodiments comprise an input structure such as an axle or driveline, an output structure such as wheel studs or a driven driveshaft, with a pinion gear and an annular or ring gear. In preferred embodiments replacement of a standardized component such as a unitary bearing hub or a carrier bearing results in gearing down or gearing up the final output speed and corresponding torque. In some applications the orientation can be swapped resulting in switching gear reduction with multiplication, and vice versa. A pinion gear with automatic lubrication channels. Apparatus and method claims are provided.