Modular Powertrain Torque Distribution via Segmented Differentials
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Solution Overview
Problem
Conventional powertrains in vehicles lack modularity and flexibility in torque distribution, particularly in all-wheel drive configurations, limiting their ability to adapt to varying vehicle configurations and propulsion needs.
Innovation Solution
A modular powertrain design incorporating a gearbox, longitudinal differential, central tube module, axle differentials, and primary axle differential, allowing for the integration of additional axles and engines via coupling devices, enabling flexible torque distribution and configuration changes between front and rear axles, such as from 4×4 to 6×6 to 8×8 all-wheel drive systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional powertrain design is used, then the structure is simple and easy to manufacture, but the adaptability to different drive configurations (4x4, 6x6, 8x8) is limited
Solution Approach 1:
The powertrain is divided into modular components: gearbox unit, central tube module, axle modules, and coupling devices. Each module can be independently configured and assembled to create different drive configurations (4x4, 6x6, 8x8), enabling adaptability without requiring a completely different powertrain design for each configuration.
Solution Approach 2:
The central tube module and coupling devices are designed as universal components that can connect different numbers of axles (one, two, or three axles per side). The same basic module serves multiple functions across different vehicle configurations, reducing the need for configuration-specific components while maintaining adaptability.
2Adaptability or versatility
If additional axles are integrated to enable 6x6 or 8x8 configurations, then the versatility increases, but the device complexity and number of components increases
Solution Approach 1:
The powertrain uses segmented modular units (gearbox, central tubes, axle modules) that can be assembled in different quantities. Instead of one complex integrated system, multiple simple standardized modules are combined, which reduces individual component complexity while enabling configuration versatility through modular assembly.
Solution Approach 2:
The coupling devices and central tube modules are designed to nest and connect in a hierarchical manner, where standardized interface components repeat across configurations. The same coupling mechanism serves both 4x4 and multi-axle configurations, reducing the variety of unique components needed despite increased system complexity.
3Ease of operation
If a modular design with multiple differentials is used, then torque distribution flexibility improves, but the manufacturing complexity increases
Solution Approach 1:
The differential system is segmented into separate functional units: longitudinal differential in the gearbox, transverse differentials in central tube modules, and axle differentials in axle modules. Each differential unit is a standardized, independently manufacturable component that can be assembled into different configurations, simplifying manufacturing compared to a single complex integrated differential system.
Solution Approach 2:
The same differential module design (transverse differential in central tube, axle differential in axle module) serves multiple configurations. The universal modular differential units provide torque distribution flexibility across 4x4, 6x6, and 8x8 configurations without requiring configuration-specific differential designs, easing manufacturing standardization.
Data Source
AI summary
A vehicle is provided according to the disclosure. This vehicle comprises a gearbox, a longitudinal differential, a central tube module, at least one axle with an axle differential, wherein the axles are mounted on the central module and the longitudinal differential transmits the driving torque provided by the gearbox to the at least one axle, and a primary axle differential integrated into the powertrain between the longitudinal differential and the axle.