Dual Motor Powertrain Segmentation for Heavy Duty Torque
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Solution Overview
Problem
Commercial heavy-duty vehicles have been slow to transition from fossil fuels to electricity due to high torque requirements and vehicle range concerns, making it challenging to retrofit electric powertrains in existing designs without increasing energy consumption.
Innovation Solution
A system utilizing two electric motors, where one motor provides continuous power and the other supplies additional torque intermittently through a clutch arrangement, allowing smaller, more efficient motors to be used, such as consumer-grade motors, to power larger vehicles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If larger electric motors are used to meet high torque requirements of commercial heavy-duty vehicles, then torque capability is improved, but motor weight and energy consumption increase
Solution Approach 1:
The power transmission system is segmented into multiple independent electric motors (first motor, second motor, third motor) that can operate independently or in combination. This allows the vehicle to use smaller motors that consume less energy individually, while still achieving the required total torque output when motors work together, thereby resolving the contradiction between torque capability and energy consumption.
2Force
If larger electric motors are used to meet high torque requirements, then torque capability is improved, but motor size and vehicle weight increase
Solution Approach 1:
Instead of using one or two large heavy motors, the system employs multiple smaller motors whose combined torque output meets the vehicle's requirements. Each motor can be lighter in weight, but collectively they provide the necessary force, thus reducing overall motor weight while maintaining torque capability.
Solution Approach 2:
Multiple motor outputs are merged through a power transmission system that combines their torque contributions. The first motor is connected to the drive shaft, while the second and third motors connect through a clutch mechanism, allowing their combined output to achieve the required torque level without any single motor being excessively large or heavy.
3Use of energy by moving object
If consumer-grade electric motors are used to power heavy-duty vehicles, then cost and energy efficiency are improved, but torque and power capability are insufficient
Solution Approach 1:
The system divides the torque production task across multiple consumer-grade motors rather than relying on a single high-performance motor. Each motor operates within its efficient range, and their combined output through the power transmission system achieves the total torque capability needed for heavy-duty vehicles, maintaining both energy efficiency and force requirements.
Solution Approach 2:
The power transmission system is designed to handle multiple motor inputs and combine them effectively. The clutch mechanism and gear train can accommodate different motor configurations, allowing consumer-grade motors to be used in various combinations to meet different torque and power requirements, thus achieving multi-functionality and versatility.
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 configuration enables the use of smaller, less expensive motors to power heavy-duty vehicles, improving energy efficiency and extending the driving range while maintaining performance and torque requirements.
Implementation Method 1
the first electric motor (A) is connected to the output via a planetary gear arrangement so as to reduce speed and increase output torque
Implementation Method 2
The clutch engages and disengages the second electric motor (B) with the output shaft
Implementation Method 3
The dog clutch along with gearing is used to transmit torque from the second electric motor (B) 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. To provide a compact configuration, the first electric motor and second electric motor are arranged in a centerline orientation with the drive shaft.