Dual-Axle EV Motor Clutch Control for Variable Load Efficiency
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Solution Overview
Problem
Electric vehicles with multiple motors in a drive axle exhibit inefficiencies during certain operating conditions, particularly when payload varies widely, leading to reduced powertrain efficiency.
Innovation Solution
An EV system with motor coupling clutches that selectively couple electric motors in each drive axle, controlled by a controller based on vehicle load and steering angle, allowing one motor to be shut down when not needed, thereby increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple motors are used in a drive axle, then tractive performance is improved, but powertrain efficiency deteriorates during certain operating conditions
Solution Approach 1:
The system dynamically adjusts the number of operating motors based on real-time vehicle conditions. The controller monitors vehicle load and steering angle, then selectively engages or disengages motors and couples them together using clutches to optimize efficiency for current operating conditions while maintaining tractive performance when needed.
Solution Approach 2:
The patent combines multiple motors into a single operational unit through motor coupling clutches when dual-motor operation is not required. This merging allows the system to function as a single motor during low-load conditions, reducing energy consumption while maintaining the capability for multi-motor operation when high tractive performance is needed.
2Reliability
If dual-motor operation is maintained, then vehicle reliability is improved, but energy consumption increases
Solution Approach 1:
The system dynamically switches between single-motor and dual-motor configurations based on operational requirements. During low-load straight-line travel, one motor is shut down to conserve energy. When steering or higher load is detected, the system transitions to dual-motor operation to maintain reliability and performance.
Solution Approach 2:
The control system applies different operational states to different motors based on local conditions. One motor can be actively driving while another is shut down or coupled, allowing the system to optimize energy usage by keeping only the necessary number of motors operational at any given time.
3Loss of energy
If motor coupling clutch is engaged, then powertrain efficiency is improved, but device complexity increases
Solution Approach 1:
Motor coupling clutches serve as intermediary components that selectively connect or disconnect motors from each other and from the drivetrain. These clutches enable the system to merge or separate motor outputs as needed, providing the flexibility to optimize efficiency without requiring a complete redesign of the powertrain architecture.
Data Source
AI summary
Methods and systems for an electric vehicle (EV). The EV system, in one example, includes a first electric drive axle and a second electric drive axle that each include a pair of electric motors and a motor coupling clutch. The EV system further includes a controller configured to selectively engage one or both of the motor coupling clutches based on vehicle load.