Modular E-Axle Powertrain With Multi-Speed Gearbox for Torque Efficiency
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Solution Overview
Problem
Conventional electric powertrains for vehicles require a high reduction ratio to meet torque demands, leading to inefficiencies, increased stress on components, noise, vibrations, and high production costs due to the need for multiple gear stages and adaptation for various vehicle types.
Innovation Solution
A modular and compact electric powertrain kit with a multi-speed gearbox configuration that includes primary and secondary gear modules, allowing for adaptable architecture to suit different vehicle needs, reducing production costs and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a high reduction ratio is used to meet torque demands, then torque delivery is improved, but motor efficiency deteriorates and component stress increases
Solution Approach 1:
The patent applies a multi-speed gearbox with variable speed ratios that can dynamically change during operation. The gearbox includes at least two different speed ratios allowing the system to adapt between high torque (low speed ratio) and high efficiency (high speed ratio) conditions based on real-time operational demands, resolving the contradiction between maintaining torque delivery and preserving motor efficiency.
Solution Approach 2:
The system changes the speed ratio parameter of the gearbox based on operating conditions. By having multiple pre-defined speed ratios (at least two), the system can select the optimal ratio for current conditions - using lower ratios for high torque requirements and higher ratios for efficiency-critical operations, thus resolving the efficiency-torque tradeoff.
2Force
If a high reduction ratio is used to meet torque demands, then torque delivery is improved, but component stress and durability deteriorate
Solution Approach 1:
The multi-speed gearbox dynamically adjusts speed ratios to prevent sustained high-speed operation of gears and bearings. By switching to appropriate lower speed ratios during high torque demands, the system reduces rotational speeds and associated stresses on transmission components, improving durability while maintaining torque delivery capability.
3Power
If high rotation speed is used to meet power demands, then power output is improved, but noise and vibrations increase
Solution Approach 1:
The system uses variable speed ratios to optimize the balance between power output and noise/vibration generation. By selecting appropriate gear ratios, the system can achieve required power levels at lower motor speeds when possible, or use higher ratios during transient high-power demands, thereby reducing continuous high-speed operation and associated noise and vibrations.
4Force
If multiple reduction stages are used to achieve high reduction ratio, then torque delivery is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent segments the torque multiplication function across multiple operating modes rather than using a single complex high-ratio gearbox. By dividing the operation into different speed ratio modes (at least two), each handling specific torque requirements, the system achieves high torque delivery without requiring an excessively complex single-stage reduction mechanism.
Solution Approach 2:
The multi-speed gearbox serves multiple functions: it provides both high torque multiplication and high efficiency operation, as well as noise reduction. This single multi-functional component replaces what would otherwise require multiple specialized components, reducing overall system complexity while maintaining torque delivery capability.
5Reliability
If conventional electric powertrains are designed for specific vehicle types, then performance is optimized, but manufacturing cost and adaptability deteriorate
Solution Approach 1:
The multi-speed gearbox design serves multiple vehicle types and application scenarios through its variable speed ratio capability. The same gearbox architecture can be adapted to different vehicle duties (low-duty, medium-duty, heavy-duty) by adjusting control strategies and selecting appropriate gear ratios, eliminating the need for completely different powertrain designs for each vehicle category and reducing manufacturing costs.
Data Source
AI summary
A kit of parts for configuring an electric powertrain for a vehicle, electric powertrains for a vehicle and a method for configuring an electric powertrain for a vehicle, the invention applies to an electric powertrain integrated into a vehicle axle. Such electric axle (or “E-axle”) is a front or rear axle that includes an axle body (or “housing”) adapted to receive a powertrain, which is arranged to provide torque to the wheels of the axle.