Torque Vectoring Axle Layout With Parallel Torque Paths

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Solution Overview

Problem

Existing torque vectoring devices for vehicles increase the size, weight, and cost of drive axles, while also requiring complex mechanical systems.

Innovation Solution

A torque vectoring device comprising an electric torque vectoring motor, a planetary gear, and a layshaft, which are configured to be coupled with a differential gear, allowing for compact mounting and flexible design to achieve torque vectoring without mechanically switchable couplings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional torque vectoring devices are used to freely distribute traction torque to different wheels, then vehicle driving dynamics are enhanced, but the size, weight, and costs of the drive axle increase

Engineering Contradiction:

Improvetorque distribution capabilityVSAvoiddrive axle weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent merges the torque vectoring function with the existing differential gear by integrating a torque vectoring motor and planetary gear set directly into the differential assembly. This combination allows torque distribution control without requiring separate torque vectoring devices for each wheel, thereby reducing overall system weight while maintaining adaptive torque distribution capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The differential gear cage is designed to serve multiple functions: it acts as both the differential mechanism carrier and the output shaft for the torque vectoring motor. This multi-functionality eliminates the need for additional dedicated torque vectoring components, reducing drive axle weight while preserving the ability to freely distribute traction torque to different wheels.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If conventional torque vectoring devices are used to freely distribute traction torque to different wheels, then vehicle driving dynamics are enhanced, but the device complexity increases

Engineering Contradiction:

Improvetorque distribution capabilityVSAvoidmechanical system complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanically switchable couplings with an electric torque vectoring motor that directly controls torque distribution. This substitution simplifies the mechanical system by eliminating the need for complex clutches, brakes, and switching mechanisms, while maintaining the ability to freely distribute traction torque through electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The torque vectoring function is segmented into a dedicated torque vectoring motor and planetary gear set that works in conjunction with the differential. This segmentation allows for modular design and control, simplifying the overall system architecture compared to integrated mechanical switching systems, while preserving adaptive torque distribution capability.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If conventional torque vectoring devices are used to freely distribute traction torque to different wheels, then vehicle driving dynamics are enhanced, but the assembly space requirements increase

Engineering Contradiction:

Improvetorque distribution capabilityVSAvoidassembly space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The planetary gear set is nested within the differential gear assembly, with the torque vectoring motor positioned to drive the planetary gear carrier. This nested arrangement allows the torque vectoring components to occupy the same spatial envelope as the differential, eliminating the need for additional assembly space while maintaining the capability to freely distribute traction torque.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The patent utilizes the axial dimension of the differential assembly to position the torque vectoring motor and planetary gear set, rather than requiring additional lateral space. By arranging components along the axial direction and using the existing differential housing as the mounting structure, the design achieves torque vectoring functionality without increasing the overall footprint of the drive axle assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS12264731B2Torque vectoring device, and a drive axle for a vehicle with a torque vectoring device

Publication Date: 2025.04.01 BORGWARNER SWEDEN AB

AI summary

A torque vectoring device for a drive axle of a vehicle including an electric torque vectoring motor, a planetary gear and a layshaft being configured to be coupled to a cage of a differential gear, the planetary gear including a first output being configured to be coupled to one of a left or right wheel drive shaft and a second output being coupled to the layshaft. The torque vectoring motor is forming a first torque flow path with the planetary gear and the layshaft and a second torque flow path with the first output of the planetary gear, wherein the first torque flow path and the second torque flow path are kinematically arranged in parallel. The layshaft is arranged eccentric with the first output of the planetary gear.