Single Speed Direct Drive Electric Drivetrain Space Optimization

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Solution Overview

Problem

Existing electric drivetrain systems require significant architectural modifications to replace mechanical drivetrain systems due to increased space requirements, as they typically include a multispeed transmission and larger electrical components, making them less adaptable.

Innovation Solution

A series electric drivetrain system with a single speed ratio direct drive, utilizing a switched reluctance motor and power electronics, is positioned between the engine and gear reduction to match the space claim of a mechanical drivetrain system, eliminating the need for a multispeed transmission and allowing for direct replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If a multispeed transmission is used in an electric drivetrain system, then run out speed performance is improved, but space claim increases significantly

Engineering Contradiction:
Improverun out speedVSAvoidspace claim
Core Design Contradiction:
SpeedVSArea of stationary object

Solution Approach 1:

The patent replaces the mechanical multispeed transmission system with an electric motor controller system that uses electronic control to achieve multiple speed ratios. The motor controller adjusts motor parameters (such as winding connections, pole pairs, or switching patterns) to provide different effective gear ratios, eliminating the need for physical transmission gears and reducing space claim while maintaining run out speed performance.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operational parameters of the electric motor through power electronic control to achieve variable speed ratios. By modifying electrical parameters (voltage, current, frequency, switching patterns) rather than mechanical parameters (gear ratios), the system achieves multiple speed levels without requiring a physically large multispeed transmission, thus resolving the contradiction between speed performance and space occupation.

Inventive Principle:
Principle #35Parameter changes

2Use of energy by moving object

If electrical components are added to replace mechanical drivetrain components, then adaptability is reduced, but electrical energy conversion capability is improved

Engineering Contradiction:
Improveelectrical energy conversionVSAvoidadaptability
Core Design Contradiction:
Use of energy by moving objectVSAdaptability or versatility

Solution Approach 1:

The patent designs the electric drivetrain system with universal interfaces and modular architecture that can adapt to different machine applications. The electric motor and controller system serves multiple functions (propulsion, energy recovery, speed control) and can be configured for various power requirements, making the system versatile across different machine types while maintaining excellent electrical energy conversion capability.

Inventive Principle:
Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent implements a dynamic control system that can adapt operating parameters in real-time based on load conditions, speed requirements, and energy availability. The motor controller dynamically adjusts electrical parameters to optimize performance across different operating scenarios, providing both excellent energy conversion and adaptability to varying machine requirements.

Inventive Principle:
Principle #15Dynamics

3Speed

If a multispeed transmission is combined with electric motor and generator, then speed control is improved, but device complexity increases

Engineering Contradiction:
Improvespeed controlVSAvoiddevice complexity
Core Design Contradiction:
SpeedVSDevice complexity

Solution Approach 1:

The patent replaces the complex mechanical multispeed transmission system with an electronically controlled motor system. Instead of multiple physical transmissions with associated mechanical linkages, the system uses power electronic controllers to achieve speed variation, significantly reducing device complexity while maintaining or improving speed control capability through electronic regulation.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent achieves multiple speed ratios by changing electrical parameters (such as inverter switching patterns, motor winding configurations, or controller algorithms) rather than mechanical parameters. This parameter-based approach simplifies the physical structure by eliminating complex mechanical transmission components while providing flexible and precise speed control through electronic parameter adjustment.

Inventive Principle:
Principle #35Parameter changes

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

This configuration enables the electric drivetrain system to match the performance of mechanical systems while occupying a comparable space, reducing the need for architectural modifications and maintaining run out speed and stall torque performance.

Implementation Method 1

an electric generator to convert the mechanical energy received from the engine into electrical energy

Methodology Applied
Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a motor to receive the electrical energy and to produce a rotational output

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS20170267093A1Electric drivetrain system and method having a single speed ratio direct drive
Publication Date: 2017.09.21 CATERPILLAR INC
  • US20170267093A1 patent drawing
  • US20170267093A1 patent drawing
  • US20170267093A1 patent drawing

AI summary

A machine having a series electric drivetrain system includes an engine to provide mechanical energy to an electric generator, the electric generator able to convert the mechanical energy received from the engine into electrical energy, the electric generator including an input shaft extending through the electric generator, a rotor to rotate on the input shaft, and the input shaft is able to rotate an input gear, an idler gear, a pump drive gear, and a rotor gear, a motor to receive the electrical energy and to produce a rotational output, a single speed ratio direct drive to transfer the rotational output of the motor to a torque output to deliver to a drive shaft, and power electronics to control the electrical energy between the electric generator and the motor and to regulate the rotational output of the motor.