Non-Coaxial Electrical Axle Torque Vectoring
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Solution Overview
Problem
Current 12V electrical power systems in passenger cars result in high currents and losses, necessitating larger cables and inefficient high-power electronics, which can be mitigated by transitioning to a 48V system for hybrid drive applications.
Innovation Solution
An electrical axle designed for medium to high voltage (48V) operation, incorporating a torque vectoring device with a non-coaxial electrical motor, reduction gear, and gear shift mechanism to achieve efficient torque distribution and reduced motor torque requirements, allowing for hybrid drive configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a 12V electrical power system is used in passenger cars, then the system is simple and compatible with existing infrastructure, but high currents result in high losses and increased cable dimensions
Solution Approach 1:
The patent changes the voltage parameter from 12V to 48V in the electrical power system. This parameter change reduces electrical losses and allows for smaller cable dimensions while maintaining system functionality. The 48V system enables more efficient power transmission for hybrid drive applications without requiring completely new system architecture.
2Power
If high power electronics are used to compensate for 12V system limitations, then sufficient power can be delivered, but cable dimensions and system complexity increase
Solution Approach 1:
By increasing the voltage parameter to 48V, the patent enables higher power transmission through the same or smaller cable cross-sections. This eliminates the need for oversized cables that would be required in a 12V system to deliver the same power levels.
3Device complexity
If a coaxial electrical motor design is used, then the structure is simple, but torque vectoring capability is limited
Solution Approach 1:
The patent employs a non-coaxial motor design where the motor shaft is offset from the axle centerline. This asymmetric configuration enables torque vectoring capability by allowing differential torque application to left and right wheels, improving vehicle handling and stability without requiring completely complex multi-motor architectures.
4Device complexity
If direct electrical motor to wheel connection is used, then the system is simple, but torque control and speed range are limited
Solution Approach 1:
The patent merges the electrical motor with a reduction gear mechanism in a single integrated unit. This combination provides both speed reduction and torque multiplication while maintaining a relatively simple overall structure. The reduction gear enables the motor to operate at optimal speeds while delivering high torque to the wheels across a wider speed range.
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
Enables a more efficient and cost-effective hybrid drive system with reduced component complexity, enabling peak wheel torque of 1600-2000 Nm in low range speed while maintaining sufficient traction at low speeds, and minimizing losses in neutral mode.
Implementation Method 1
an electrical motor (40) arranged non-coaxial with respect to the two drive shafts (22, 24)
Data Source
Figure 1~2
AI summary
An electrical axle is provided. The electrical axle comprises an electrical motor (40) which is selectively connected to a differential (30) via a reduction gear (50) and a planetary gear set (60), said planetary gear set (60) having one input (66) and two outputs (64, 66), The electrical axle (20) further comprises a gear shift mechanism (70) configured to selectively connect a differential housing (32) to one of said outputs (66, 64).