Electric Differential Torque Vectoring for Turning Maneuverability
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Solution Overview
Problem
Traditional electric vehicle differentials lack the ability to regulate and vector torque unequally to the left and right wheels, leading to instability and reduced turning maneuverability due to equal torque distribution, which is not effectively addressed in existing technologies.
Innovation Solution
An electric differential with a torque vectoring function is designed, incorporating a main drive mechanism and a torque vectoring control drive mechanism, utilizing a series of planetary gear trains to allow for unequal torque distribution between wheels, including a TV control motor and main drive motor arrangement for compactness and reduced unsprung mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a traditional differential is used to transfer power to the drive wheels, then the structure is simple and easy to manufacture, but the torque is equally vectored to both left and right wheels which reduces turning maneuverability and causes wheel slippage under non-uniform ground adhesion
Solution Approach 1:
The differential system is segmented into two independent torque transmission paths: a main drive mechanism for longitudinal torque transmission and a torque vectoring mechanism for lateral torque distribution. This segmentation allows equal torque distribution for straight-line driving while enabling differential torque vectoring during turning operations, resolving the contradiction between structural simplicity and turning maneuverability
Solution Approach 2:
The patent introduces a torque vectoring mechanism that adds a lateral dimension to the traditional longitudinal torque transmission. By incorporating planetary gear trains that can independently adjust torque distribution between left and right wheels, the system transitions from single-dimensional equal torque distribution to multi-dimensional adaptive torque vectoring, significantly improving turning maneuverability
2Device complexity
If a traditional differential is used, then the device complexity is low, but the torque distribution cannot be regulated which causes wheel slippage and reduces driving stability
Solution Approach 1:
A torque vectoring mechanism acts as an intermediary between the main drive mechanism and the drive wheels. This intermediary component, composed of planetary gear trains, actively regulates and adjusts torque distribution between left and right wheels based on driving conditions, preventing wheel slippage and improving driving stability without excessively increasing overall system complexity
Solution Approach 2:
The differential system transitions from a static equal torque distribution mechanism to a dynamic adaptive torque vectoring system. The torque vectoring mechanism can continuously adjust torque distribution ratios in real-time based on wheel speed differences, ground adhesion conditions, and steering requirements, thereby maintaining optimal driving stability across varying operating conditions
3Speed
If hub motors are used to drive the electric automobile, then the acceleration performance is improved due to rapid response and large torque, but the unsprung mass increases and heat dissipation becomes poor
Solution Approach 1:
The motor is extracted from the wheel hub location and relocated to the vehicle chassis. This separation removes the heavy motor mass from the unsprung mass, allowing for better suspension performance and heat dissipation while maintaining the motor's rapid response and large torque characteristics for superior acceleration performance
4Adaptability or versatility
If a torque vectoring differential is introduced to improve turning maneuverability, then the turning capability is enhanced, but the device complexity increases
Solution Approach 1:
The torque vectoring mechanism is merged with the existing differential structure, sharing common components such as the differential housing and planetary gear elements. This integration allows the system to achieve advanced torque vectoring functionality for enhanced turning capability while minimizing the increase in overall device complexity through component sharing and space-efficient arrangement
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 solution enables unequal torque vectoring to the wheels, enhancing turning maneuverability and driving pleasure while maintaining total longitudinal drive torque, and reducing unsprung mass for smoother vehicle operation.
Implementation Method 1
a first single-row planetary gear train including a first sun gear, a first planetary gear, a first planet carrier and a first gear ring, wherein the first sun gear is coaxially and fixedly connected with a first half shaft, and the first gear ring is connected with an output end of the TV control drive mechanism
Data Source
AI summary
Disclosed is an electric differential with a torque vectoring function. The electric differential includes: a main drive mechanism; a bevel gear differential; a TV control drive mechanism used for outputting control power; a first single-row planetary gear train, of which a first sun gear is coaxially and fixedly connected with a first half shaft and a first gear ring is connected with a control output end; a second single-row planetary gear train, of which a second gear ring is fixed to a drive axle housing, a second planet carrier is fixedly connected with a first planet carrier and a second sun gear is supported on the first half shaft through a bearing.