Twin System Electric AWD Supplementary Drive Axle

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Solution Overview

Problem

Current vehicle powertrain systems face inefficiencies in energy consumption and vehicle dynamics, particularly in traction and performance, due to the limitations of larger electrical machines and lack of compact, high-efficiency solutions for driving multiple wheels.

Innovation Solution

A twin system transmission utilizing two electrical machines connected to a gearbox, which drives an axle assembly, allowing for improved traction, efficiency, and regenerative braking capabilities, with the option for all-wheel drive through a conventional power plant.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If larger electrical machines are used to drive multiple wheels, then power and traction are improved, but energy consumption increases and device complexity increases

Engineering Contradiction:
ImprovepowerVSAvoidenergy consumption
Core Design Contradiction:
PowerVSUse of energy by moving object

Solution Approach 1:

The patent divides the powertrain into two separate electrical machines: a first electrical machine coupled to the transmission for driving the vehicle, and a second electrical machine coupled to the wheels for providing traction. This segmentation allows each machine to be optimized for its specific function, with the second machine being smaller and more efficient since it only needs to provide auxiliary traction rather than full driving power.

Inventive Principle:
Principle #1Segmentation

2Power

If larger electrical machines are used to drive multiple wheels, then power and traction are improved, but device complexity increases

Engineering Contradiction:
ImprovepowerVSAvoiddevice complexity
Core Design Contradiction:
PowerVSDevice complexity

Solution Approach 1:

The patent combines the functions of two electrical machines into a single integrated powertrain system. The first electrical machine drives the transmission, while the second electrical machine provides direct wheel traction. Their outputs are merged to drive the vehicle, eliminating the need for a single large complex machine while maintaining simplified system architecture.

Inventive Principle:
Principle #5Merging (Combining)

3Adaptability or versatility

If conventional power plants are used for all-wheel drive, then all-wheel drive functionality is achieved, but energy consumption and emissions increase

Engineering Contradiction:
Improveall-wheel drive functionalityVSAvoidenergy consumption
Core Design Contradiction:
Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The patent replaces the conventional mechanical power plant with an electrical system for all-wheel drive functionality. The second electrical machine, being electrically driven, can independently drive the wheels to provide all-wheel drive capability without requiring a separate combustion engine or mechanical power transmission system, thereby reducing energy consumption and emissions.

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

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

The twin system transmission enhances vehicle performance by reducing energy consumption, improving traction and dynamics, and enabling compact high or low voltage electrical machines, while supporting regenerative braking and all-wheel drive functionality.

Implementation Method 1

a first electrical machine and a second electrical machine operatively connected to a gearbox; wherein the first electrical machine and the second electrical machine are constructed and arranged to drive the gearbox

Methodology Applied
Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Data Source

PatentUS11186162B2Twin system electric all-wheel drive supplementary drive axle
Publication Date: 2021.11.30 BORGWARNER INC
  • US11186162B2 patent drawing
  • US11186162B2 patent drawing
  • US11186162B2 patent drawing

AI summary

A number of variations may include a product comprising a first electrical machine and a second electrical machine operatively connected to a gearbox; at least one axle assembly operably attached to the gearbox; wherein the first electrical machine and the second electrical machine are constructed and arranged to drive the gearbox; and wherein the gearbox is constructed and arranged to drive the axle assembly.