Electric Truck Drivetrain Gearbox Segmentation and Motor Merging
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Solution Overview
Problem
Current drive train systems for electric trucks face inefficiencies and limitations in power distribution, noise reduction, and reliability, particularly in handling strong load changes and four-wheel drive operations.
Innovation Solution
A drive train system comprising a multi-part gearbox housing with a double helical ring gear and a team of electric motors, including synchronous and asynchronous types, which are torque-controlled and arranged to provide efficient power transmission and redundancy, along with a center differential for four-wheel drive capability and noise reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single large ring gear is used, then the structure is simpler, but the noise increases and axial forces are not effectively managed under strong load changes
Solution Approach 1:
The single large ring gear is divided into multiple smaller ring gears (first ring gear and second ring gear) that are arranged back-to-back. This segmentation reduces the noise generated by each individual gear while effectively managing axial forces through the opposing arrangement, resolving the contradiction between structural simplicity and noise reduction.
2Reliability
If multiple electric motors are used, then the reliability and redundancy improve, but the device complexity increases
Solution Approach 1:
Multiple electric motors are combined into a single integrated drive unit with a common gearbox housing. The motors are arranged around a central output shaft, sharing common structural elements and lubrication systems. This merging approach maintains the reliability and redundancy benefits of multiple motors while reducing overall system complexity compared to separate motor assemblies.
3Ease of manufacture
If a multi-part gearbox housing is used, then the ease of manufacture and assembly improve, but the number of connection parts increases
Solution Approach 1:
The gearbox housing is divided into multiple standardized parts that can be manufactured independently and then assembled. Each housing part serves multiple functions: structural support, motor mounting, and lubrication containment. The standardized design of these parts reduces the overall complexity by using reusable, multi-functional components rather than custom-designed single-purpose parts.
Data Source
AI summary
A drive train for an electric truck includes a gearbox and a gear box housing. The drive train further includes an output shaft extending in an axial direction across a wall of the gear box housing and powering a cardan shaft arranged outside of the gear box housing. At least one output gear is arranged inside of the gear box housing on the output shaft. At least a first and a second electric motor attached to the housing of the gearbox form a team of electric motors, wherein each electric motor includes a drive shaft extending parallel to the axial direction and being interconnected via an input gear to an output gear.