Dual-Motor Output Gearing With Downstream Planetaries for Low Noise
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Solution Overview
Problem
Current electric motors in consumer vehicles are unable to produce sufficient torque for large commercial vehicles, requiring larger and heavier motors that increase energy consumption.
Innovation Solution
A powertrain system utilizing two electric motors, where one motor has an uninterrupted connection to the output drive shaft and the other has an intermittently connected motor with a clutch arrangement, including planetary gears and various clutch types, to efficiently provide torque and reduce noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If larger and heavier electric motors are used to produce sufficient torque for large commercial vehicles, then torque output is improved, but energy consumption increases
Solution Approach 1:
The powertrain is divided into two separate electric motors: a first electric motor continuously connected to the output shaft, and a second electric motor intermittently connected via a clutch. This segmentation allows each motor to be optimized for specific operating conditions, enabling the use of smaller motors that consume less energy while collectively delivering the required torque for commercial vehicles.
2Force
If gearing and clutches are located upstream in the powertrain, then torque multiplication is achieved, but noise inside the cabin increases
Solution Approach 1:
The gearing system is repositioned from an upstream location to a downstream location, closer to the output shaft. This spatial reconfiguration allows torque multiplication to occur after the noise-generating components are positioned away from the cabin, effectively decoupling the torque multiplication function from the noise source location and reducing cabin noise while maintaining torque multiplication benefits.
3Device complexity
If a single electric motor is used to provide continuous power, then system complexity is reduced, but the motor must be larger and heavier to meet torque requirements
Solution Approach 1:
The single motor system is segmented into two smaller electric motors with different connection strategies. The first motor provides continuous power through an uninterrupted connection, while the second motor provides intermittent power through a clutch mechanism. This segmentation reduces the weight of individual motors while maintaining the capability to meet overall torque requirements through coordinated operation.
4Use of energy by moving object
If the second electric motor is intermittently connected via clutch, then energy efficiency is improved, but reliability of power delivery may be compromised
Solution Approach 1:
A clutch mechanism serves as an intermediary between the second electric motor and the output shaft, enabling controlled intermittent connection. This intermediary component allows the system to optimize energy efficiency by engaging the second motor only when needed, while maintaining reliability through the first motor's continuous connection that ensures uninterrupted power delivery to the output shaft.
Data Source
AI summary
An electric powertrain includes a first electric motor that has an uninterrupted connection with a drive shaft of a vehicle. The electric powertrain further includes a second electric motor that has an interruptible connection with the drive shaft. In one form, this interruptible connection includes a clutch. The electric powertrain further includes a first gear train in the form of a first planetary gear and a second gear train in the form of a second planetary gear. The first gear train, second gear train, and clutch are arranged downstream from the first electric motor and second electric motor.