Multi-Axle Gear Combination Control for EV Torque and Efficiency

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Solution Overview

Problem

Vehicles with single electric motors face inefficiencies in acceleration due to high power demands, overheating, and insufficient power at full loading, while multiple drive systems with electric motors can provide sufficient torque but require optimal gear combinations to enhance performance.

Innovation Solution

A method for determining a target gear combination in vehicles with multiple drive systems, which includes determining the target gear combination using a method for determining a target gear combination for vehicles with multiple drive systems, each driving a vehicle axle, and utilizing electric motors with transmissions to optimize torque and resistance forces based on vehicle requirements and route profiles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a single electric motor with very high maximum power is used to ensure sufficient acceleration, then the vehicle can accelerate adequately, but the motor operates very inefficiently at low acceleration and may overheat

Engineering Contradiction:
Improveacceleration capabilityVSAvoidmotor efficiency
Core Design Contradiction:
SpeedVSUse of energy by moving object

Solution Approach 1:

The vehicle is divided into multiple drive systems, each with its own electric motor and transmission. Instead of using one large motor, the total drive torque is distributed across multiple smaller motors that can operate efficiently at lower power levels while collectively providing sufficient acceleration power.

Inventive Principle:
Principle #1Segmentation

2Device complexity

If a single electric motor is used, then the system is simpler, but it cannot provide sufficient power at full vehicle loading

Engineering Contradiction:
Improvenumber of drive systemsVSAvoidtotal drive torque
Core Design Contradiction:
Device complexityVSPower

Solution Approach 1:

Multiple drive systems are combined in parallel, with each system contributing to the total drive torque. The transmissions of multiple drive systems are merged through the differential to provide cumulative power output that exceeds what a single motor could deliver.

Inventive Principle:
Principle #5Merging (Combining)

3Adaptability or versatility

If multiple drive systems with different torque characteristic curves are used to adapt to different vehicle requirements, then the system can be optimized for different loadings, but the device complexity increases

Engineering Contradiction:
Improveadaptation to different loadingsVSAvoidtransmission configuration
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The system dynamically selects optimal gear combinations from multiple transmissions based on real-time driving conditions, vehicle loading, and route profile. The control system continuously adapts the gear configuration to match current power requirements, enabling versatility without requiring permanent physical reconfiguration.

Inventive Principle:
Principle #15Dynamics

Data Source

PatentUS20250340131A1Force-based determination of a target gear combination for a plurality of drive systems
Publication Date: 2025.11.06 MAN TRUCK & BUS SE
  • US20250340131A1 patent drawing
  • US20250340131A1 patent drawing
  • US20250340131A1 patent drawing

AI summary

The invention relates to a method for determining a target gear combination for a vehicle having at least two drive systems, wherein each drive system drives a vehicle axle and each of the two drive systems has at least one electric motor and at least one transmission with in each case at least two gears; wherein the method comprises the following step: determining the target gear combination on the basis of a route profile lying ahead and/or a speed and/or an acceleration of at least one vehicle driving ahead and/or driving behind and/or on the basis of a distance from at least one vehicle driving ahead and/or driving behind.