Modular Powertrain Module Layout for Compact Torque Vectoring

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Solution Overview

Problem

The challenge in the transport industry is to create a compact powertrain system for electric vehicles that fits within the limited transverse width of vehicles, especially trucks, while maintaining efficiency and mechanical strength, particularly in independent wheel suspension configurations and torque vectoring solutions.

Innovation Solution

The solution involves a set of two identical powertrain modules with a compact casing design, each equipped with its own transmission system, including epicyclic gear trains, that can be connected mechanically to form a compact and modular powertrain system. This design allows for independent wheel operation, improved torque vectoring, and enhanced mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a mechanical differential is used in a powertrain system, then the differential effect is achieved allowing outer drive wheel to rotate faster than inner drive wheel, but the transverse width of the vehicle increases

Engineering Contradiction:

Improvedifferential effectVSAvoidtransverse width

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The powertrain system is divided into two independent powertrain modules, each capable of independent torque control. This segmentation eliminates the need for a mechanical differential while maintaining the differential effect through electronic control, thereby reducing transverse width.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mechanical differential system is replaced with an electronic control system that independently controls the torque of each drive wheel. This substitution eliminates the mechanical components that increase transverse width while achieving the same functional effect.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If independent wheel suspension configuration is implemented, then wheel independence is achieved, but the transverse length increases to accommodate drive shafts

Engineering Contradiction:

Improvewheel independenceVSAvoidtransverse length

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The drive shaft connection is segmented and redirected through the vehicle纵轴方向 (longitudinal direction) rather than requiring transverse space. Each powertrain module connects to its respective wheel through independent drive shafts that route along the vehicle length, reducing transverse length requirements.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If torque vectoring solution is implemented without mechanical differential, then left and right wheels are independently driven, but packaging space is reduced

Engineering Contradiction:

Improveindependent wheel driveVSAvoidpackaging space

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The powertrain module merges the motor, transmission system, and control units into a single integrated assembly. This consolidation achieves independent wheel drive capability while minimizing packaging space through unified component layout and shared structural elements.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If a single body casing is used to house both left and right powertrain modules, then structural integrity is maintained, but modularity is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidmodularity

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The casing is segmented into separate left and right powertrain module casings, each capable of independent assembly and installation. This segmentation enables modularity and flexibility in configuration while maintaining structural integrity through standardized connection interfaces between modules.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The standardized connection interface on the casing serves multiple functions: structural connection, torque transmission, and alignment positioning. This multi-functionality maintains structural integrity while enabling modular assembly and disassembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3826869B1A powertrain module

Publication Date: 2025.05.28 VOLVO TRUCK CORP

Figure 1~3b
Figure 4~5c
Figure 6~8

AI summary

The invention relates to a powertrain module (10) comprising: - a powertrain system for driving at least one wheel of a vehicle, the powertrain system comprising: - a motor (5) having an output shaft; - and a transmission system between the motor (5) and a drive shaft (4) connected to said wheel; - and a casing (11) which houses the transmission system. The powertrain module (10) comprises connecting means (15) for cooperating with the connecting means (15) of an identical powertrain module (10) arranged in a facing relationship with said powertrain module (10), for mechanically connecting said two powertrain modules (10).