Vehicle Corner Module Layout for Efficient Power Transfer and Steering
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Solution Overview
Problem
Existing electric vehicles with in-wheel motors face challenges in integrating driving, braking, steering, and suspension systems efficiently, leading to complexity and inefficiencies in power transfer and shock absorption.
Innovation Solution
A corner module apparatus that integrates a knuckle, drive motor, transfer module, suspension, and steering system, utilizing angle-adjustable joints and expandable boots for airtight connections, allowing independent operation of each wheel for driving, braking, and steering, with shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If in-wheel motors are installed directly inside wheels to eliminate intermediate power transfer units, then weight is reduced and energy loss is minimized, but integration of driving, braking, steering, and suspension systems becomes complex and inefficient
Solution Approach 1:
The system is divided into independent corner module units, each handling one wheel's driving, braking, steering, and suspension functions separately. This segmentation allows each module to be optimized independently while maintaining overall system efficiency and reducing integration complexity through modular architecture.
Solution Approach 2:
Each corner module integrates multiple functions (driving motor, braking system, steering mechanism, and suspension) into a single multi-functional unit. This universal design reduces the number of separate components and simplifies system integration while maintaining all necessary vehicle functions.
2Weight of moving object
If intermediate power transfer units are eliminated by installing motors directly in wheels, then weight is reduced, but power transfer efficiency and system integration become challenging
Solution Approach 1:
The vehicle chassis is divided into multiple corner modules, each independently housing a complete set of driving, braking, steering, and suspension systems for one wheel. This segmentation eliminates the need for heavy intermediate power transfer units while maintaining manageable system complexity through modular design.
Solution Approach 2:
Multiple subsystems (driving motor, braking mechanism, steering linkage, and suspension components) are merged into integrated corner module units. This combination reduces overall system weight by eliminating redundant structures and intermediate power transfer components while organizing complexity within standardized modules.
3Ease of operation
If driving, braking, steering, and suspension systems are integrated into corner modules, then vehicle handling and independent wheel control are improved, but manufacturing and assembly complexity increases
Solution Approach 1:
The integrated system is segmented into standardized corner module units that can be manufactured independently and then assembled onto the vehicle chassis. This segmentation enables specialized manufacturing of each module while simplifying final assembly through modular attachment points and standardized interfaces.
Solution Approach 2:
The design employs adjustable parameters in the joint mechanisms (such as angle-adjustable connections and expandable boots) that allow for tolerance compensation and assembly flexibility. This enables easier manufacturing and assembly while maintaining the sophisticated independent control capabilities of each wheel.
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
Enhances power transfer efficiency, reduces weight and energy loss, and improves vehicle handling by allowing independent control of each wheel's operation, enhancing driving, braking, and steering performance.
Implementation Method 1
a plurality of rollers rotatably supported on the plurality of journals, respectively, and brought into contact with the plurality of tracks, respectively, in a rolling manner
Implementation Method 2
a plurality of balls rotatably supported on the cage, circumferences of both sides of each thereof being brought into contact with the first groove and the second groove, respectively, in a rolling manner
Implementation Method 3
a suspension connected to the knuckle and configured to absorb shock transferred from a road surface
Data Source
AI summary
Disclosed is a corner module apparatus for a vehicle. The corner module includes a knuckle coupled to a wheel bearing rotatably supporting a wheel, a drive motor, configured to generate a drive power, spaced a distance away from the wheel, a transfer shaft, disposed between the wheel and the drive motor, configured to transfer the drive power generated from the drive motor, a suspension connected to the knuckle and configured to absorb shock transferred from a road surface, and a steering system configured to support the drive motor and the suspension and to adjust a steering wheel of the wheel.