EV Powertrain Assembly with Planetary Gearset for Torque and Space
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Solution Overview
Problem
Conventional electric vehicle powertrains are limited in providing rotational torque to wheels and occupy significant space, leading to increased cost and weight.
Innovation Solution
The assembly includes an input shaft, an electric motor, an intermediate input shaft, a planetary gearset, and a final drive, where the planetary gearset is co-axially aligned with the intermediate input shaft and output shaft to transmit rotational torque, and a transfer shaft to extend along a third axis, allowing for a wider range of torque without dependency on the electric motor design, reducing packaging space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional electric powertrain is used, then the structure is simple, but the range of rotational torque is limited and packaging space is large
Solution Approach 1:
The planetary gearset is nested within the housing that also contains the final drive components. The sun gear is positioned at the center, with planet gears surrounding it, all contained within a compact cylindrical housing. This nesting arrangement allows multiple torque-modifying mechanisms to occupy overlapping spatial volumes, achieving a wide torque range without proportionally increasing packaging space
Solution Approach 2:
The patent transitions from a single-axis torque transmission (conventional direct drive) to a multi-axis planetary gear system. The planetary gearset introduces radial and axial dimensions for torque modification, allowing the system to provide variable torque multiplication ratios without increasing the longitudinal packaging length. The final drive differential components are arranged in a compact configuration that utilizes three-dimensional space efficiently
2Adaptability or versatility
If the electric motor size is increased to provide wider torque range, then the torque range improves, but the packaging space and cost increase
Solution Approach 1:
The planetary gearset acts as an intermediary mechanism between the electric motor and the final drive. Instead of increasing motor size to achieve wider torque range, the planetary gearset provides torque multiplication and variation while the motor maintains a compact size. The gearset mediates the torque transmission, allowing a single motor size to serve multiple torque requirements
Solution Approach 2:
The planetary gearset enables continuous variation of torque multiplication ratio through its gear geometry and configuration. By changing the effective gear ratio parameter within the planetary system, the same motor can deliver different torque levels to the wheels, eliminating the need for multiple motors or a large motor designed for maximum torque
3Adaptability or versatility
If more components are added to the assembly, then the torque transmission capability improves, but the device complexity increases
Solution Approach 1:
The planetary gearset and final drive differential are merged into a single integrated housing and assembly. The planetary carrier, planet gears, sun gear, and differential components are arranged to share common mounting structures and lubrication systems. This merging reduces the number of separate assemblies, connection points, and maintenance interfaces, keeping device complexity manageable despite the enhanced torque transmission capability
Data Source
AI summary
An assembly for an electric vehicle includes an input shaft extending along a first axis and an electric motor rotatably coupled to the input shaft and co-axially aligned with the first axis. The assembly also includes an intermediate input shaft extending along a second axis and rotatably coupled to the input shaft. The assembly also includes an output shaft extending along the second axis and spaced from the intermediate input shaft along the second axis. The assembly further includes a planetary gearset rotatably coupled to the intermediate input shaft and to the output shaft, and co-axially aligned with the second axis. The assembly includes a final drive co-axially aligned with the first axis and rotatably coupled to the output shaft for providing rotational torque to at least one of a first and second set of wheels of the electric vehicle.