Modular Powertrain With Nested Motor-Planetary Gear Coupling
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Solution Overview
Problem
Existing vehicle powertrain systems lack flexibility and scalability to accommodate various drive concepts efficiently and cost-effectively.
Innovation Solution
A powertrain design incorporating a first electromotive drive module with an integrated electric motor and planetary gear, allowing for modular expansion with additional electromotive and internal combustion engines through couplings, enabling efficient and compact series connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a powertrain system is designed to accommodate various drive concepts (hybrid, electric, combustion), then adaptability and versatility are improved, but device complexity increases due to the need for multiple coupling interfaces and modular components
Solution Approach 1:
The planetary gear unit is designed with multiple coupling possibilities: the input shaft can be connected to either the electric motor or the internal combustion engine, and the output shaft connects to the wheels. This universal design allows the same mechanical structure to serve multiple drive concepts (electric-only, hybrid, combustion-only) without requiring separate transmission systems for each configuration.
Solution Approach 2:
The powertrain is divided into modular components: electric motor, internal combustion engine, planetary gear unit, and coupling mechanisms. Each module can be independently selected, assembled, and configured based on the desired drive concept. This segmentation enables flexible combination of components while maintaining manageable complexity through standardized interfaces.
2Power
If additional electromotive drive modules are added to expand powertrain capability, then power and versatility are improved, but device complexity and space requirements increase
Solution Approach 1:
The planetary gear unit is positioned within the housing of the electric motor, with the sun gear of the planetary gear unit surrounded by the rotor of the electric motor. This nested arrangement allows multiple functional components (motor, gear system, clutches) to occupy overlapping spatial volumes, thereby reducing the overall footprint and making it feasible to integrate additional drive modules without proportionally increasing space requirements.
Solution Approach 2:
The patent combines the electric motor and planetary gear unit into a single integrated assembly where the motor housing serves as the planetary gear housing. This merging of components reduces the number of separate parts and simplifies the overall structure, making it easier to add or remove drive modules while maintaining a compact and manageable system architecture.
3Volume of moving object
If the electric motor is designed with integrated planetary gear, then compactness and efficiency are improved, but manufacturing precision requirements increase
Solution Approach 1:
The electric motor and planetary gear unit are merged into a single integrated assembly where the motor housing doubles as the planetary gear housing. This consolidation reduces the total volume by eliminating separate housings and mounting structures, while the shared manufacturing tolerances between motor and gear components can be optimized together rather than separately.
Solution Approach 2:
The motor housing serves multiple functions: it contains the electric motor windings and magnets, provides structural support for the rotor, and simultaneously serves as the housing for the planetary gear unit. This multi-functionality reduces the number of parts and assembly steps, thereby reducing cumulative tolerance stacking and manufacturing complexity despite the integrated design.
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
Facilitates a flexible and scalable powertrain system that can adapt to different drive concepts, ensuring efficient operation and compact design.
Implementation Method 1
an electric motor (6) and a planetary gear (8) wherein the electric motor (6) is an inner rotor (10)
Implementation Method 2
the planetary gear (8) of the first electromotive drive module (4) can be coupled to a second electromotive drive module (36)
Data Source
AI summary
A powertrain for a motor vehicle includes a first electromotive drive module. The first electromotive drive module includes an electric motor and a planetary gear. The electric motor is an inner rotor comprising and internally attached rotor which is circumferentially enclosed by a stator. The inner rotor encloses circumferentially the planetary gear. The planetary gear of the first electromotive drive module can be coupled to a second electromotive drive module. The planetary gear of the first electromotive drive module can be coupled to an internal combustion engine.