Integrated Axle Retarder Layout for Compact EV Braking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of retarders on powertrains in vehicles is space-consuming, and the transition to electro-mobility in vehicles requires compact powertrains to accommodate batteries and other components, while existing regenerative braking systems in electric vehicles are limited when the battery is full.
Innovation Solution
An axle design that incorporates a retarder configured to generate braking force, integrated within the axle connecting two wheels, allowing for supplementary braking without occupying additional space on the powertrain, featuring a transmission unit with an electric motor, gearbox, and differential assembly, with the retarder connected to either the output or intermediate shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a retarder is integrated on the powertrain to provide auxiliary braking, then braking efficiency is improved, but space consumption increases
Solution Approach 1:
The patent combines the retarder with the existing axle assembly, integrating the braking function into the wheel mounting structure. The retarder is positioned at the wheel hub, merging two separate systems (axle and braking) into a unified compact assembly, thereby providing auxiliary braking without increasing overall powertrain space consumption.
Solution Approach 2:
The retarder is arranged in a radial direction at the wheel hub, utilizing the radial space dimension rather than adding length to the powertrain assembly. This dimensional repositioning allows the braking mechanism to occupy space that would otherwise be unused, maintaining a compact powertrain footprint while enabling effective braking.
2Reliability
If the battery system is full of energy, then regenerative braking cannot accept electrical energy, but the vehicle still needs braking capability
Solution Approach 1:
The retarder acts as an intermediary braking mechanism that operates independently of the regenerative braking system's electrical state. When the battery is full and regenerative braking cannot accept energy, the retarder provides the necessary braking force through mechanical or electromagnetic means, ensuring continuous braking availability regardless of battery charge level.
Solution Approach 2:
The system dynamically switches between regenerative braking and retarder operation based on battery charge state. When battery acceptance capacity is sufficient, regenerative braking is used; when full, the retarder takes over. This parameter-based switching maintains braking versatility and adaptability across different operational conditions.
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 supplementary braking without consuming powertrain space, enhancing braking efficiency and supporting regenerative braking systems by allowing energy capture even when the battery is full, thus optimizing space for batteries and other components in electric vehicles.
Implementation Method 1
a retarder configured to generate a braking force
Data Source
AI summary
An axle for connecting two wheels of a vehicle is provided, The axle includes a retarder configured to generate a braking force.