Variable Torque Distribution System with Off-Axis Main Drive
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Solution Overview
Problem
Current systems for torque distribution in motor vehicle axles lack a modular structure with high power density, limiting their efficiency and space utilization.
Innovation Solution
A system featuring a main drive, arranged off-axis relative to the axle, transmitting torque to a differential via an upstream gear stage, which can be either a hypoid gear or a single-stage spur gear, coupled with a torque vectoring motor that uses power-split planetary gears and a load-balancing gear stage for dynamic torque distribution to individual wheels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional torque distribution systems are used, then torque can be transmitted to drive shafts, but the systems lack modular structure and high power density
Solution Approach 1:
The system is divided into modular components: a main drive unit with upstream gear stage, a differential unit with power-split planetary gears, and a torque vectoring motor unit. Each module can be independently designed, manufactured, and maintained, achieving modular structure while maintaining high power density through optimized component integration.
Solution Approach 2:
The torque vectoring motor is integrated within the differential unit, with the motor shaft directly connected to the planetary gear mechanism. This nested arrangement allows the smaller motor to be housed within the larger differential structure, achieving compact modular design with high power density.
2Area of stationary object
If the main drive is arranged on-axis with the axle, then torque transmission is straightforward, but axial installation space is increased
Solution Approach 1:
The main drive is positioned off-axis relative to the axle, utilizing the radial dimension rather than the axial dimension for torque transmission. The upstream gear stage (hypoid or spur gears) transmits torque from the off-axis main drive to the differential unit, reducing axial installation space while maintaining effective torque transmission through three-dimensional gear engagement.
3Volume of stationary object
If traditional differential designs are used, then torque distribution is simple, but the differential size is limited by available space
Solution Approach 1:
The differential unit combines traditional torque distribution functionality with power-split planetary gear mechanisms and integrated torque vectoring motor control. This merged design enables the differential to perform multiple functions (torque splitting, torque vectoring, and motor integration) within a compact volume, increasing differential size capability while managing complexity through functional integration.
4Ease of operation
If torque vectoring motor is continuously activated, then precise torque distribution is achieved, but energy consumption increases
Solution Approach 1:
The torque vectoring motor is activated only when torque redistribution is required (such as during cornering, acceleration, or deceleration), rather than continuous operation. The control system monitors driving conditions and engages the torque vectoring motor periodically when needed, achieving precise torque distribution while minimizing energy consumption during normal straight-line driving.
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 reduces axial installation space, allows for larger differentials, and enables efficient torque distribution for improved vehicle handling and energy savings by optimizing gear ratios and reducing unnecessary motor activation during straight driving.
Implementation Method 1
an upstream gear stage, which can be either a hypoid gear or a single-stage spur gear
Implementation Method 2
two power-split planetary gears, which are followed by a load-balancing gear stage in the form of a planetary gear
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a system (1) for variable torque distribution within at least one axle (3) of a motor vehicle that comprises a main drive (10) and a torque vectoring motor (20).