Dual-Mode Electric Drive Axle for Torque Vectoring and Coupling
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Solution Overview
Problem
Current electric vehicle (EV) torque vectoring technologies face limitations in power density, unsprung mass, mechanical efficiency, reliability, cost, and complexity, particularly in dual-motor drive axles, which hinder efficient energy use and handling stability.
Innovation Solution
A dual-mode electric drive axle with torque parallel coupling and torque vectoring, utilizing two sets of clutches and three planetary gear sets, allows switching between main motor independent drive, dual-motor torque coupling, and torque vectoring modes, enabling efficient energy use and improved handling stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional mechanical torque vectoring distribution mechanism (multi-disc clutch) is used, then torque vectoring function is achieved, but structure complexity increases and reliability decreases
Solution Approach 1:
The patent replaces the traditional mechanical multi-disc clutch torque vectoring mechanism with an electric motor-based torque vectoring system. The electric motor (second motor) directly generates torque vectoring force without requiring complex mechanical friction-based clutch packs, thereby achieving the same torque distribution function with significantly reduced mechanical complexity and improved reliability.
Solution Approach 2:
The patent introduces a planetary gear set as an intermediary mechanism between the electric motor and the drive shafts. This planetary mechanism efficiently transmits and distributes the electric motor's torque to both drive wheels, providing a compact and reliable torque vectoring solution that avoids the complexity of direct mechanical clutch systems.
2Power
If dual-motor torque coupling mode is implemented, then dynamic performance under large torque demand is improved, but system complexity and control difficulty increase
Solution Approach 1:
The patent implements a dual-mode drive system that can dynamically switch between single-motor mode and dual-motor torque coupling mode based on real-time power demand. The first motor (main drive motor) and second motor (torque vectoring motor) can be selectively engaged or disengaged, allowing the system to adapt its complexity level to the operational requirements, thereby managing system complexity while maintaining high dynamic performance when needed.
Solution Approach 2:
The second motor serves multiple functions: it acts as a torque vectoring motor during normal operation and as an auxiliary drive motor during high-power demand conditions. This multi-functionality allows the system to achieve dual-motor torque coupling capability without adding a completely separate auxiliary motor system, thereby reducing overall system complexity while maintaining the ability to deliver high torque when required.
3Power
If high-power motors are used to meet extreme power requirements, then power demand is satisfied, but motor utilization rate decreases
Solution Approach 1:
The patent employs a dual-motor configuration where the second motor provides partial torque contribution during high-power demand conditions rather than requiring the first motor to operate at full capacity continuously. This allows the primary high-power motor to operate at lower utilization rates during normal conditions while still meeting peak power requirements when both motors contribute, thereby improving overall motor utilization efficiency.
Solution Approach 2:
The system dynamically adjusts motor operation modes based on power demand: during low-to-moderate power conditions, only the first motor operates; during high-power demand, the second motor is engaged to provide additional torque. This dynamic operation allows the high-power first motor to spend more time in its efficient operating range, improving its utilization rate and efficiency while still satisfying extreme power requirements when needed.
Data Source
AI summary
A dual-mode electric drive axle with torque parallel coupling and torque vectoring, including: a main motor, an auxiliary motor, a spur gear differential, a first half shaft, a second half shaft, a primary reducer, a secondary reducer, a dual-planetary gear set mechanism, a first clutch, a second clutch and a primary housing. The main motor and the auxiliary motor are respectively connected to input ends of the primary reducer and the secondary reducer. Output ends of the primary reducer and the secondary reducer are respectively connected to a housing of the spur gear differential and a gear ring of the dual-planetary gear set mechanism. A planet carrier of the dual-planetary gear set mechanism is connected to a sun gear through a first clutch, and a gear ring through a second clutch. A characteristic parameter of the dual-planetary gear set mechanism is 2.