Optimal Design of Non-contact Overrunning Clutch for Two-speed Electric Vehicle Transmissions

doi:10.3901/JME.2022.16.270

Abstract

Abstract: Compared with the fixed speed ratio reducer, the two-speed transmission can effectively improve the power performance and economy of electric vehicles. The hydraulic automatic transmission technology and dual clutch automatic transmission technology developed for fuel vehicles can realize smooth shift, but it requires a series of complex structures such as two sets of friction clutches and actuators, and there is always the drag loss of multiple clutches when cruising at medium and high speed. Electronic mechanical transmission has a simplified structure and high efficiency, but it has the problem of shifting power interruption, which affects the driving quality and the safety of the ramps. Therefore, a ratchet type controllable overrunning clutch is proposed, which has no contact between the wedge element and the rotating element in the overrunning state, and can realize three working states of bidirectional locking, one-way overrunning and bidirectional overrunning. Through the cooperative control of the mechanism and a power-assisted friction clutch, the problem of shifting power interruption of mechanical transmission is solved, and unnecessary friction energy consumption and noise during operation are avoided. Taking the two-speed transmission of an electric light truck as an example, the structure of the proposed ratchet non-contact controllable overrunning clutch is designed. The performance of shifting without power interruption of this type of automatic transmission is verified through the dynamic simulation. The idling angle of the overrunning clutch is further optimized to 3.18 °, which effectively reduces the shift impact. Finally, the strength analysis shows that the life of the designed controllable overrunning clutch meets the requirements of use.

Key words: controllable overrunning clutch, shift mechanism, electric vehicle, two-speed transmission, shift without torque interruption

CLC Number:

U463

CAI Wenqi, HAN Yudong, YUE Hanqi, GAO Bingzhao. Optimal Design of Non-contact Overrunning Clutch for Two-speed Electric Vehicle Transmissions[J]. Journal of Mechanical Engineering, 2022, 58(16): 270-279.

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