Torque Converter in Electric Drive Unit for Wide Torque Range
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Solution Overview
Problem
Existing electrical drive units for motor vehicles face challenges in providing a wide range of torque applications with optimal driving performance while minimizing installation space, weight, and investment costs, as they often require large and complex designs or suffer from torque limitations and efficiency losses due to transmission units and decoupling mechanisms.
Innovation Solution
The electrical drive unit incorporates a torque converter with a slip mode operation and a clutch in the torque transmission path, allowing for adjustable torque matching and increased torque at various rotation speeds, along with a step-up transmission and a cooling circuit to optimize performance and reduce complexity and space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electrical drive machine is designed to be very large to extend the torque range, then the torque range is extended, but the installation space requirements increase, weight increases, and investment increases
Solution Approach 1:
A torque converter is introduced as an intermediary component between the electrical drive machine and the driven wheels. This torque converter multiplies and adapts the torque output, allowing a compact electrical drive machine to deliver a wide torque range suitable for various driving conditions without requiring a large machine design
2Adaptability or versatility
If a transmission unit with multiple transmission stages is connected to the electrical drive machine to implement various output torques, then the torque requirements are met, but losses in convenience for the driver occur and the design becomes relatively complicated due to disconnection of the torque transmission path during shifting
Solution Approach 1:
The patent replaces the traditional mechanical transmission system with multiple stages and shifting mechanisms by using an electrically driven pump system. This allows continuous and seamless adjustment of torque output without mechanical disconnection or shifting operations, thereby maintaining driving convenience while achieving versatile torque requirements
3Adaptability or versatility
If continuously variable transmission units are used to implement various torques, then the torque requirements are met, but the design becomes relatively complex and a large amount of installation space is required
Solution Approach 1:
The patent replaces complex mechanical continuously variable transmission units with an electrically driven pump system that uses electrical control to adjust torque output. This substitution dramatically reduces mechanical complexity and component count while maintaining the ability to continuously vary torque across a wide range
4Speed
If the electrical drive machine is decoupled when its rotation speed range no longer meets the rotation speed requirements in a hybrid drive unit, then the rotation speed requirements can be met by the internal combustion engine, but the use of the torque provided by the electrical machine is restricted
Solution Approach 1:
The torque converter acts as an intermediary that allows the electrical drive machine to operate effectively across a broader range of vehicle speeds. By multiplying torque at lower speeds and adapting the torque-speed characteristics, the system enables the electrical machine to contribute torque even when its direct rotation speed range does not match the vehicle speed requirements
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 electrical drive unit to cover a broader torque range than the drive machine alone, ensuring efficient and flexible torque delivery across different speed conditions with reduced installation space and operational complexity, thereby enhancing the versatility and efficiency of motor vehicle operations.
Implementation Method 1
Owing to the arrangement of the torque converter, it is possible to operate said torque converter in a so-called slip mode, where the rotation speed of the pump side is higher than the rotation speed of the turbine side. This renders it possible to relatively easily increase the rotation speed on the pump side and to provide a correspondingly increased torque on the turbine side.
Implementation Method 2
the electrical drive unit furthermore comprises a cooling circuit which is designed to dissipate heat from the electrical drive machine and also from the torque converter
Data Source
AI summary
An electrical drive unit for an electrically at least partially driveable motor vehicle and also to a drive arrangement for an electrically at least partially driveable motor vehicle, comprising an electrical drive unit according to the disclosure. An electrical drive unit for an electrically at least partially driveable motor vehicle comprises an electrical drive machine and also an output device for transmitting a torque, which is provided by the electrical drive machine, to driven vehicle wheels of a motor vehicle, and also comprising a torque converter, which is arranged in the torque transmission path between a rotor of the electrical drive machine and the output device, for the purpose of matching the torque which is provided by the electrical drive machine to a respective torque requirement.