Magnetic-Fluid Multispeed Actuation for Low-Loss EV Gear Shifting
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Solution Overview
Problem
Conventional clutch systems in electrified vehicles result in power loss due to components like pumps, valves, and solenoids, leading to inefficiencies in the powertrain.
Innovation Solution
A multispeed actuation mechanism (MAM) using magnetic fluid, such as ferromagnetic nanoparticles, is employed to engage and disengage rotating members, allowing smooth shifts between gears without the need for conventional friction clutches, reducing weight and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional clutch systems are used for gear shifting, then gear shifting function is achieved, but power loss increases due to pump, valves, and solenoids
Solution Approach 1:
The patent extracts and removes the pump, valves, and solenoids from the clutch system, retaining only the essential clutch plates and friction material. This extraction eliminates the power-consuming components while preserving the gear shifting function through direct magnetic actuation of the clutch plates.
Solution Approach 2:
The patent replaces the conventional mechanical actuation system (pump, valves, solenoids) with a magnetic field-based actuation system. The magnetic field directly actuates the clutch plates without requiring mechanical fluid power components, thereby eliminating the associated power losses.
2Weight of moving object
If conventional friction clutches are used, then gear shifting is enabled, but weight of the drive module increases
Solution Approach 1:
The patent removes unnecessary heavy components (pump, valves, solenoids) from the clutch system, retaining only the essential lightweight elements needed for gear shifting. This extraction significantly reduces the overall weight of the drive module.
Solution Approach 2:
The patent replaces heavy mechanical actuation components with a lightweight magnetic field-based actuation system, thereby reducing the overall weight of the drive module while maintaining the gear shifting capability.
3Productivity
If conventional clutch systems are used, then gear shifting function is achieved, but system efficiency decreases
Solution Approach 1:
The patent extracts and removes the power-lossy components (pump, valves, solenoids) from the system, leaving only the essential clutch elements. This extraction directly improves system efficiency by eliminating the energy losses associated with these components.
Solution Approach 2:
The patent replaces the inefficient mechanical fluid power system with a direct magnetic field actuation system, which has significantly lower energy losses and thereby improves overall system efficiency.
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 MAM enhances the electric drive module's efficiency by eliminating components like pumps, valves, and solenoids, resulting in faster and smoother gear shifts, thereby improving the overall performance of the electrified powertrain.
Implementation Method 1
The MAM has magnetic fluid therein. Activation of the magnetic fluid causes a shift to occur within the transmission from the first gear set to the second gear set.
Data Source
AI summary
An electric drive module for an electrified vehicle includes an electric motor, a transmission and a multispeed actuation mechanism (MAM). The transmission is driven by a rotatable output of the electric motor and includes a first drive shaft and a second drive shaft. The transmission has a first gear set that selectively converts rotatable motion of the first drive shaft into rotatable motion of the second drive shaft in a first gear mode at a first drive ratio, and a second gear set that selectively converts rotatable motion of the first drive shaft into rotatable motion of the second drive shaft in a second gear mode at a second drive ratio, distinct from the first drive ratio. The MAM has magnetic fluid therein. Activation of the magnetic fluid causes a shift to occur within the transmission from the first gear set to the second gear set.