Electric Powertrain Torque Converter Layout for Compact EV Packaging
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Solution Overview
Problem
There is a need for improved electric powertrains in fully electric automotive vehicles that are lighter, less spacious, and less costly while maintaining or enhancing performance in terms of range, acceleration, and speed.
Innovation Solution
The development of a torque converter for electric powertrains comprising an impeller, turbine, and stator, with a monolithic output shaft, and a clutch system that allows for efficient torque transfer without mechanical gears, combined with an electric motor for direct torque conversion, and optional reduction gear sets for speed adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional electric powertrain designs are used, then performance requirements are met, but weight and space requirements increase
Solution Approach 1:
The patent combines the electric motor, torque converter, and transmission components into a single integrated powertrain unit. The motor housing serves as the torque converter housing, and the output shaft is directly coupled to the torque converter impeller, eliminating the need for separate mounting structures and reducing overall weight while maintaining performance
Solution Approach 2:
The powertrain components are designed to perform multiple functions: the motor housing also serves as the torque converter housing, the output shaft functions as both a mechanical connector and a structural support element, and the integrated design allows the same components to handle both torque transmission and structural loads, reducing the total number of parts needed
2Device complexity
If traditional electric powertrain designs are used, then performance requirements are met, but device complexity increases
Solution Approach 1:
The patent extracts and eliminates unnecessary mechanical components such as separate mounting brackets, intermediate shafts, and complex coupling mechanisms. By directly coupling the motor output shaft to the torque converter impeller and using the motor housing as the torque converter housing, the design removes redundant parts while maintaining all necessary functions
Solution Approach 2:
Multiple functional components are merged into single integrated structures: the motor housing and torque converter housing are unified, the output shaft serves dual purposes as both a mechanical connector and structural support, and the direct-drive configuration combines the motor and torque converter into a single operational unit, significantly reducing mechanical complexity
3Ease of manufacture
If traditional electric powertrain designs are used, then performance requirements are met, but manufacturing cost increases
Solution Approach 1:
The integrated design merges the motor housing and torque converter housing into a single stamped or cast component, reducing manufacturing steps and assembly operations. The direct coupling of the output shaft to the impeller eliminates the need for separate machining operations and assembly procedures, simplifying production and reducing costs
Solution Approach 2:
The design extracts and removes complex mechanical linkages, intermediate components, and multiple assembly steps that would increase manufacturing cost. By using a direct-drive configuration with integrated housings, the patent reduces the number of parts that need to be manufactured, inventoried, and assembled, thereby lowering overall manufacturing costs
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
The solution provides a compact, efficient, and cost-effective electric powertrain that enhances torque amplification and reduces mechanical complexity, resulting in improved performance and reduced weight and space requirements.
Implementation Method 1
The cover, impeller, turbine, and stator may be concentric with respect to the output shaft. It is understood that a torque converter can convert an input torque to an amplified, or greater, output torque. The cover, or the rear cover portion, may be configured to receive an input torque, or be driven by a prime mover, such as an electric motor.
Implementation Method 2
The impeller, turbine, and stator may be configured to convert the input torque to the output torque. The torque converter may be configured to receive an input torque at the rear end of the torque converter. The output shaft may be configured to deliver an output torque or do drive a load.
Data Source
AI summary
An electric powertrain (98) for an automotive road vehicle (300) is proposed, the powertrain (98) comprises: a drive assembly (350) comprising: an electric motor (108) and a torque converter (100). The torque converter (100) comprises an output shaft (106) and is configured to receive torque from the electric motor (108) and to deliver torque via the output shaft (106). The drive assembly (350) has a first side (356) and an opposite second side (358), the electric motor (108) and the torque converter (100) are centered on the output shaft (106), and the output shaft (106) extends through the drive assembly (350) and is accessible for delivering torque on both the first side (356) and the second side (358) of the drive assembly (350).