Alternating Electric Machine Roles for Serial Driving

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Solution Overview

Problem

Existing motor vehicle transmissions with dual electrical machines face thermal overload issues during serial driving at slow speeds with high resistance, limiting the duration of serial driving mode due to overheating of the electric machine in motor operation.

Innovation Solution

Alternating the functions of the two electrical machines by switching the first electrical machine from motor to generator operation and the second from generator to motor operation based on temperature thresholds, ensuring both machines are used alternately to prevent overheating and maintain even loading, thus extending serial driving duration without interruption.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Duration of action of moving object

If the first electric machine operates continuously in motor mode to propel the vehicle during serial driving, then the vehicle can maintain motion under high resistance, but the electric machine overheats and serial operation can only be maintained for a limited time

Engineering Contradiction:
Improveserial driving durationVSAvoidelectric machine temperature
Core Design Contradiction:
Duration of action of moving objectVSTemperature

Solution Approach 1:

The patent implements periodic switching between two electric machines, alternating their roles as motor and generator. The control unit monitors temperatures and switches functions periodically to prevent continuous operation of one machine, thereby distributing thermal load and extending overall serial driving duration while maintaining vehicle propulsion.

Inventive Principle:
Principle #19Periodic action

2Power

If the first electric machine operates in motor mode to drive the vehicle, then propulsion is maintained, but the machine is subjected to high thermal stress and cannot operate indefinitely

Engineering Contradiction:
Improvepropulsion powerVSAvoidelectric machine reliability
Core Design Contradiction:
PowerVSReliability

Solution Approach 1:

The patent implements a functional switching mechanism where the first electric machine can be discarded from motor operation and recovered later. When the first machine overheats, it is switched to generator mode (discarded as motor), and the second machine takes over propulsion. Once the first machine cools down, its functions can be recovered by switching back, ensuring continuous reliability while maintaining propulsion power.

Inventive Principle:
Principle #34Discarding and recovering

3Productivity

If one electric machine is used continuously for propulsion, then the vehicle can maintain serial operation, but that machine becomes thermally overloaded while the other remains underutilized

Engineering Contradiction:
Improveserial operation continuityVSAvoidthermal overload
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent segments the propulsion function between two electric machines rather than relying on one machine continuously. By dividing the workload and alternating their roles, the system maintains serial operation continuity while preventing thermal overload on any single machine, as each machine operates intermittently rather than continuously.

Inventive Principle:
Principle #1Segmentation

4Force

If the electric machine in motor mode operates at high power to overcome high resistance, then the vehicle can maintain motion, but the machine overheats quickly

Engineering Contradiction:
Improvedriving forceVSAvoidoperation duration
Core Design Contradiction:
ForceVSDuration of action of moving object

Solution Approach 1:

The patent ensures continuity of useful propulsion action by having two electric machines ready to alternate. When one machine reaches thermal limits during high-power operation, the system seamlessly transitions to the other machine, maintaining continuous driving force without interruption. This continuity principle ensures that high force can be sustained indefinitely by rotating between machines rather than being limited by single-machine thermal capacity.

Inventive Principle:
Principle #20Continuity of useful action

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 method allows for prolonged serial driving with high driving resistance by preventing overheating and evenly loading the electrical machines, enhancing their service life and maintaining continuous operation without traction interruption.

Implementation Method 1

The electric machine consists of at least a stator and a rotatably mounted rotor and is designed in motor mode to convert electrical energy into mechanical energy in the form of rotational speed and torque, and in generator mode to convert mechanical energy into electrical energy

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

The electric machine consists of at least a stator and a rotatably mounted rotor and is designed in motor mode to convert electrical energy into mechanical energy in the form of rotational speed and torque, and in generator mode to convert mechanical energy into electrical energy

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentEP3727919B1Method for a serial driving mode of a motor vehicle
Publication Date: 2023.05.03 ZF FRIEDRICHSHAFEN AG
  • EP3727919B1 patent drawingFigure 1

AI summary

The invention relates to a method for a serial driving mode of a motor vehicle comprising a transmission that has a first electric machine, which is driven in a motor mode for driving the motor vehicle, and a second electric machine, which is operated in a generator mode. The method is characterized in that after a switchover signal is generated, the first electric machine is switched over from the motor mode to the generator mode and the second electric machine is switched over from the generator mode to the motor mode in order to drive the motor vehicle.