In-Wheel Electric Drive and Braking for Modular Utility Vehicles

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Solution Overview

Problem

Conventional powertrain devices and brake systems in land vehicles, particularly in utility and delivery vehicles, face limitations such as inefficiency and complexity, which are exacerbated by the use of gas-powered motors and traditional brake mechanisms.

Innovation Solution

The implementation of a land vehicle design featuring electric motors integrated directly into the wheels, a modular power cell assembly for electrical power supply, and a sophisticated brake system with multiple braking devices, including electronic parking brakes and parking pawl mechanisms, allowing for independent wheel operation and efficient energy management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If gas-powered motors are used in land vehicles, then power generation capability is achieved, but efficiency is reduced and harmful emissions are generated

Engineering Contradiction:

Improveenergy efficiencyVSAvoidemissions

Core Design Contradiction:

Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the gas-powered internal combustion engine with an electric motor system. The electric motors are integrated directly into the wheel hubs, eliminating the need for a traditional engine, transmission, and drivetrain. This substitution of mechanical systems resolves the contradiction by providing efficient electrical power conversion without combustion-related emissions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent extracts and removes the internal combustion engine from the vehicle powertrain system. By taking out the gas-powered motor and replacing it with electric motors integrated into the wheels, the harmful emissions are eliminated while maintaining the power generation capability needed for vehicle operation.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If traditional brake systems are used in land vehicles, then braking function is achieved, but device complexity and maintenance needs increase

Engineering Contradiction:

Improvebraking reliabilityVSAvoidbrake system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the braking function directly into the wheel hub assembly where the electric motor is integrated. The brake caliper and rotor are positioned within the wheel hub structure, combining multiple functions (motor mounting, braking, and wheel support) into a single integrated assembly. This reduces overall system complexity while maintaining reliable braking performance.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If modular power cell assembly is used, then adaptability and energy management are improved, but device complexity increases

Engineering Contradiction:

Improveenergy capacity adaptabilityVSAvoidpower train complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The power cell assembly is divided into modular battery packs that can be independently configured and replaced. Each module contains standardized electrical connections and mounting features, allowing flexible arrangement to match different energy requirements. This segmentation provides adaptability while keeping individual module complexity manageable through standardization.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The modular power cell assembly is designed with universal mounting interfaces and electrical connections that can accommodate different configurations and capacities. The same basic module design serves multiple functions and can be arranged in various combinations to meet different energy requirements, reducing the need for specialized components for each application.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This configuration enhances efficiency, reduces complexity, and enables the vehicle to operate effectively without internal combustion engines, offering improved performance and reduced maintenance needs while maintaining a gross vehicular weight rating between 10,001 and 14,000 pounds.

Implementation Method 1

a plurality of electric motors to generate rotational power

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a power cell assembly to supply electrical power to the plurality of electric motors

Methodology Applied

Scientific EffectElectrochemical energy conversion: Battery (electricity)

Data Source

PatentUS12077043B2Land vehicles incorporating electric motors and methods therefor

Publication Date: 2024.09.03 WORKHORSE GROUP INC

AI summary

Land vehicles and methods of operating land vehicles are disclosed. A land vehicle includes a frame structure, a plurality of wheels, and a plurality of electric motors. The frame structure includes a front cage that at least partially defines an operator cabin and a rear compartment positioned rearward of the front cage in a longitudinal direction. The plurality of wheels are supported by the frame structure. The plurality of wheels includes a pair of front wheels and a pair of rear wheels positioned rearward of the pair of front wheels in the longitudinal direction.