Bypass Power Shaft for EV Torque Continuity
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Solution Overview
Problem
Traditional powertrain transmissions in electric vehicles (EVs) experience significant energy waste due to hydraulic and friction-based mechanisms, limiting their range and commercial viability compared to internal combustion engine vehicles.
Innovation Solution
A powertrain assembly featuring two electric motors, a summing subassembly, and a gearset with a bypass power shaft that selectively routes torque to minimize interruptions during mode changes, ensuring continuous power delivery and reducing energy waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional hydraulic and friction-based transmissions are used in EVs, then power transfer is achieved, but extreme energy waste occurs
Solution Approach 1:
The patent replaces traditional hydraulic and friction-based mechanical transmissions with an electric motor-driven powertrain system. Two electric motors (first and second motors) directly drive the wheels through a summing subassembly and gearset, eliminating hydraulic fluids and friction-based clutch/transmission mechanisms that cause extreme energy waste in conventional EVs.
Solution Approach 2:
The powertrain is segmented into multiple independent electric motors (first motor and second motor) that can operate independently or in combination. This segmentation allows flexible power distribution and enables the system to maintain efficient operation across different driving conditions, thereby extending vehicle range without energy-wasting mechanical transmissions.
2Power
If summing subassembly is used to combine torque from multiple motors, then power output is increased, but torque interruptions occur during mode changes
Solution Approach 1:
The bypass power shaft is pre-configured to provide an alternative torque transmission path from the second motor to the output. During mode changes in the summing subassembly, the bypass power shaft is already in position to immediately pick up torque transmission, preventing any interruption in power delivery to the wheels.
Solution Approach 2:
The bypass power shaft acts as an intermediary torque transmission element between the second motor and the output. When the summing subassembly is transitioning between different torque combining modes, the bypass power shaft mediates the torque flow, ensuring continuous power delivery without interruptions.
3Reliability
If bypass power shaft is added to reduce torque interruptions, then torque consistency is improved, but device complexity increases
Solution Approach 1:
The bypass power shaft serves multiple functions: it provides an alternative torque path during summing subassembly mode changes, enables direct torque transmission from the second motor, and works in conjunction with the clutch assembly for seamless power delivery. This multi-functionality justifies the additional component by providing significant reliability benefits across multiple operating scenarios.
Data Source
AI summary
A powertrain assembly for a vehicle includes a first motor and a second motor. A power split assembly, having an output power shaft, is connected to both the first and second motors to the power output shaft. The power split assembly selectively receives power output from the first and second motors, wherein the power split assembly defines a plurality of modes of operation to provide torque to the output power shaft. The powertrain assembly also includes a bypass power shaft operatively connected between the second motor and the output power shaft, such that the second motor provides torque to the output power shaft using the bypass power shaft to reduce torque interruptions created by the power split assembly during changes in the plurality of modes of operation.