Dual-Motor Gearbox Spool Lock for Single-Wheel Torque Combining
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Solution Overview
Problem
Existing electric vehicle drivetrains with dual electric motors face challenges in maintaining traction and mobility during off-road conditions or high-performance driving when one wheel is not in contact with the driving surface or is slipping, as the torque output is limited by the maximum output of individual motors.
Innovation Solution
A spool lock mechanism is introduced to couple the gear trains of dual electric motors, allowing the torque outputs from both motors to be combined and directed to the wheel in contact with the driving surface, enhancing traction and mobility by increasing torque beyond the capacity of a single motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dual electric motors are used with separate gear trains, then torque vectoring capability is improved, but maximum torque output to a single wheel is limited by individual motor capacity
Solution Approach 1:
The spool lock mechanism merges the two separate gear trains by mechanically coupling them together. When engaged, the spool lock connects the first gear train and second gear train through a common carrier, allowing both motors to contribute torque to the same wheel. This combining of previously separate power paths enables torque output to exceed the capacity of a single motor while maintaining the dual-motor architecture's adaptability.
2Reliability
If spool lock is engaged to combine torque from both motors, then traction and mobility are improved, but device complexity increases
Solution Approach 1:
The spool lock mechanism serves multiple functions within a single component structure. It can engage and disengage to switch between independent and combined torque delivery modes, it provides mechanical coupling between gear trains, and it enables the system to adapt to different driving conditions. This multi-functionality reduces the need for separate mechanisms for each function, thereby limiting the increase in overall device complexity despite the added capability.
3Adaptability or versatility
If separate gear trains are used for each motor, then wheel independence is improved, but torque combination capability deteriorates
Solution Approach 1:
The spool lock mechanism introduces dynamic reconfigurability to the gear train system. Rather than being fixed in a single configuration, the system can dynamically switch between two states: independent operation mode (spool lock disengaged) where each wheel receives torque from its dedicated motor, and combined torque mode (spool lock engaged) where both motors contribute to a single wheel. This dynamic capability allows the system to optimize for either wheel independence or torque combination depending on driving conditions.
Data Source
AI summary
Methods and systems are provided for a vehicle including a first motor coupled to a first gear train, a second motor coupled to a second gear train, and a spool lock configured to variably couple the first gear train and the second gear train, allowing a first torque output by the first motor and a second torque output by the second motor to be combined and output to a first wheel coupled to the first gear train or a second wheel coupled to the second gear train.