Split Drive Axle Torque Vectoring With Dry Clutch Backup

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Solution Overview

Problem

Existing torque-vectoring dual clutch (TVDC) systems in drive trains experience overheating and inefficiency due to the use of wet clutches, particularly during small changes in vehicle direction or tire pressure differences, leading to a need for improved functional safety and efficiency.

Innovation Solution

A drive train design incorporating a split drive axle with a differential gear unit, distribution gear box, and separate transmission units with dry clutches, allowing for torque distribution and vectoring functions while enabling separate lubrication and reducing drag torque.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If wet clutches are used in TVDC systems to prevent overheating, then thermal protection is improved, but drag torque increases and efficiency decreases

Engineering Contradiction:
Improveclutch overheating protectionVSAvoiddrag torque
Core Design Contradiction:
TemperatureVSLoss of energy

Solution Approach 1:

The patent segments the lubrication system by providing separate lubrication paths: wet clutches receive lubricant for cooling, while dry clutches operate without lubricant. This segmentation allows each clutch type to operate in its optimal thermal and friction conditions, resolving the contradiction between thermal protection and drag torque reduction.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies different lubrication qualities to different components: wet clutches are provided with lubricant in a lubricant-filled chamber for thermal management, while dry clutches operate in a lubricant-free environment. This local differentiation of lubrication quality allows each component to perform optimally without compromising the other.

Inventive Principle:
Principle #3Local quality

2Ease of operation

If wet clutches are used to balance torque during small direction changes, then torque distribution is improved, but functional safety decreases due to overheating risks

Engineering Contradiction:
Improvetorque balancing capabilityVSAvoidfunctional safety
Core Design Contradiction:
Ease of operationVSReliability

Solution Approach 1:

The patent segments the clutch system into wet and dry clutches with different functional roles. Wet clutches handle torque balancing during normal operation, while dry clutches provide backup torque transmission for safety-critical situations. This functional segmentation improves both ease of operation and reliability.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent prepares for potential clutch failure by having dry clutches ready as a backup system. The dry clutches are positioned to automatically engage if wet clutches fail due to overheating or other issues, providing beforehand cushioning against functional safety risks.

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

3Productivity

If clutches are pressurized and fully closed during straight driving, then torque transmission efficiency is improved, but clutch wear increases during small cornering maneuvers

Engineering Contradiction:
Improvetorque transmission efficiencyVSAvoidclutch service life
Core Design Contradiction:
ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent applies different clutch types to different torque transmission needs: wet clutches with lubrication for high-wear straight-line driving, and dry clutches for low-wear cornering maneuvers. This local differentiation of clutch quality extends overall system service life while maintaining torque transmission efficiency.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

The patent enables dynamic switching between wet and dry clutch engagement based on driving conditions. During straight driving, wet clutches are engaged for efficient torque transmission; during cornering, the system can switch to dry clutches to reduce wear, optimizing both productivity and service life.

Inventive Principle:
Principle #15Dynamics

4Adaptability or versatility

If separate lubrication systems are implemented for wet and dry clutches, then adaptability to different clutch types is improved, but device complexity increases

Engineering Contradiction:
Improveclutch type compatibilityVSAvoidlubrication system complexity
Core Design Contradiction:
Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent segments the lubrication system into separate chambers: a lubricant-filled chamber for wet clutches and a lubricant-free chamber for dry clutches. This segmentation provides adaptability to different clutch types while containing the complexity within modular, manageable sections.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The differential gear unit is designed with universal adaptability to accommodate both wet and dry clutch types through its standardized mounting interfaces and torque distribution mechanism. This universality allows the same differential unit to work with different clutch configurations without requiring complete system redesign.

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

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

Enhances driving performance, functional safety, and efficiency by maintaining torque transmission even in clutch failure scenarios, reducing power consumption, and allowing the use of dry clutches for improved adaptability to future lubricants.

Implementation Method 1

The distribution gear box is coupled to the input gear in a torque-transmitting manner and configured to distribute a first portion of the input torque evenly between the first drive shaft and the second drive shaft

Methodology Applied
Scientific EffectTorque distribution: Gear

Implementation Method 2

The first clutch is configured to transmit the second portion of the input torque to the second drive shaft, when being in an at least partly closed state

Methodology Applied
Scientific EffectFriction: Friction

Implementation Method 3

The second clutch is configured to transmit the third portion of the input torque to the second drive shaft, when being in an at least partly closed state

Methodology Applied
Scientific EffectFriction: Friction

Data Source

PatentEP4467844B1Drive train for vehicle and vehicle
Publication Date: 2025.07.09 VOLVO CAR CORP
  • EP4467844B1 patent drawingFigure 1~3
  • EP4467844B1 patent drawingFigure 2
  • EP4467844B1 patent drawingFigure 4A~4C

AI summary

The disclosure relates to a drive train (100) for a vehicle, comprising: a split drive axle (102) having a first drive shaft (104) and a second drive shaft (106), an input gear (108) being couplable to a drive unit of the vehicle for providing an input torque (Tin) to a differential gear unit (110), the differential gear unit (110) being configured to distribute the input torque (Tin) on the first drive shaft (104) and the second drive shaft (106), the differential gear unit (110) comprising: a distribution gear box (116) being coupled to the input gear (108) in a torque-transmitting manner and configured to distribute a first portion (T1) of the input torque (Tin) evenly between the first drive shaft (104) and the second drive shaft (106), an internal gear (118) being coupled to the input gear (108) in a torque-transmitting manner for providing a second portion (T2) of the input torque (Tin), and an external gear (120) being coupled to the input gear (108) in a torque-transmitting manner for providing a third portion (T3) of the input torque (Tin), a first transmission gear assembly (124) and a first clutch (126), the first transmission gear assembly (124) being configured to connect the internal gear (118) of the differential gear unit (110) and the first clutch (126) in a torque-transmitting manner, and the first clutch (126) being configured to transmit the second portion (T2) of the input torque (Tin) to the second drive shaft (106), when being in an at least partly closed state, a second transmission gear assembly (128) and a second clutch (130), the second transmission gear assembly (128) being configured to connect the external gear (120) of the differential gear unit (110) and the second clutch (130) in a torque-transmitting manner, and the second clutch (130) being configured to transmit the third portion (T3) of the input torque (Tin) to the second drive shaft (106), when being in an at least partly closed state, wherein the input torque (Tin) corresponds to a sum of the first portion (T1) of the input torque (Tin) and the second portion (T2) of the input torque (Tin) or a sum of the first portion (T1) of the input torque (Tin) and the third portion (T3) of the input torque (Tin).