Heavy-Duty EV Powertrain Layout for Adaptive Torque Distribution
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Solution Overview
Problem
Current electric vehicles above 10,000 lbs gross vehicle weight rating lack effective torque control strategies, inadequate structural support for battery packs, and insufficient temperature monitoring, limiting their performance and adaptability for both on-road and off-road use.
Innovation Solution
An electric automotive vehicle design featuring a centralized electric powertrain with independent front and rear drive units, gear reduction at each wheel, adaptive torque control, and a hydraulic suspension system, along with advanced temperature regulation and power management modes, to enhance torque distribution, stability, and off-road capability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If electric vehicles are designed with gross vehicle weight rating above 10,000 lbs, then cargo capacity and payload capability are improved, but torque control capability deteriorates due to lack of adaptive torque distribution systems
Solution Approach 1:
The electric vehicle is divided into multiple independent drive units, with each wheel or axle having its own drive unit capable of independent torque control. This segmentation allows adaptive torque distribution to different wheels based on road conditions, vehicle load, and driving mode, resolving the torque control limitation in heavy-duty electric vehicles.
Solution Approach 2:
The vehicle implements dynamic torque adjustment through controllers that continuously monitor wheel speed, vehicle acceleration, and road conditions to adaptively distribute torque among drive units. This dynamic control enables the vehicle to maintain optimal torque distribution across varying operating conditions despite the heavy vehicle weight.
2Device complexity
If a single high voltage electrical connection is used to the battery pack, then device complexity is reduced, but reliability deteriorates due to insufficient power distribution and temperature monitoring
Solution Approach 1:
The electrical connection system is segmented into multiple high voltage connections distributed to different battery modules and drive units. This segmentation provides redundant power pathways, improves current distribution across the battery pack, and enables localized temperature monitoring at multiple connection points, thereby enhancing system reliability without excessive complexity.
Solution Approach 2:
Power distribution units and temperature sensors are introduced as intermediary components between the battery pack and drive units. These intermediaries manage power flow efficiently and provide distributed temperature monitoring, improving reliability while maintaining manageable system complexity.
3Ease of manufacture
If battery modules are positioned without adequate structural support, then manufacturing ease is improved, but temperature monitoring capability deteriorates leading to thermal management issues
Solution Approach 1:
The structural support framework for battery modules is designed to serve multiple functions: providing mechanical support for easy assembly, enabling thermal conduction pathways for heat dissipation, and incorporating integrated temperature sensors for monitoring. This multi-functional design improves temperature management without complicating the manufacturing process.
Solution Approach 2:
Thermal interface materials and heat dissipation structures are introduced as intermediaries between battery modules and the structural framework. These intermediaries facilitate efficient heat transfer while maintaining easy assembly through standardized interfaces and modular design.
4Adaptability or versatility
If all wheel drive with independent drive units is implemented, then torque distribution capability is improved, but device complexity increases due to multiple drive units and control systems
Solution Approach 1:
Control functions for multiple drive units are merged into integrated control systems that coordinate torque distribution across all wheels. By combining control algorithms and sensors into unified modules, the system achieves sophisticated torque vectoring and adaptive distribution while managing overall system complexity through functional integration.
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 design enables improved handling, increased torque production, and enhanced off-road performance by balancing torque distribution and managing weight distribution, while ensuring efficient battery operation and temperature control, thus addressing the limitations of existing electric vehicles.
Implementation Method 1
The electric powertrain includes a plurality of batteries and is positioned at a base of the frame
Implementation Method 2
the vehicle includes a hydraulic pump configured to provide hydraulic fluid to the hydraulic cylinders and vary the height of the vehicle based on the pressure and hydraulic fluid input into the hydraulic cylinders
Data Source
AI summary
An electric automotive vehicle gross vehicle rating of greater than 10,000 pounds includes an electric powertrain connected to the frame and positioned at a base of the frame. The vehicle includes a first central axis, and the weight of the electric powertrain is centered about the first central axis. All drivetrain components of the vehicle other than the electric powertrain may be positioned above the base of the electric powertrain. The vehicle includes two electric drive units configured to drive the front and rear axles respectively. The electric drive units consist of an electric motor, motor controller, two speed electrically actuated gearbox, electrically actuated park lock, and electrically actuated locking differential. The drive units transmit power to inboard mounted brakes, which in turn are connected by constant velocity driveshaft to the wheel hubs where a further final gear reduction resides. Additionally, the suspension of the vehicle utilizes a dynamically adjustable hydraulic suspension that is capable of automatically leveling the vehicle and also provides capability to adjust nominal vehicle ride height. The vehicle is capable of multiple modes of operation, and in one mode the vehicle is able to export electrical power for usage outside of the vehicle. The vehicle body has been designed in multiple embodiments, including a sport utility model and pickup truck model. Additionally, each embodiment is designed with available two door and four door variants. All vehicle variants utilize the aforementioned common powertrain and chassis.