Combined electric motor beam axle assembly and steering actuator assembly

Abstract

An electric vehicle module assembly includes a steering actuator subassembly connected to a beam axle subassembly. The steering actuator subassembly provides a variety of functions including an intrinsic function of a steering actuator to improve the turning radius of an electric vehicle and positioning the center of gravity of the electric vehicle module assembly in a more desirable position such that NVH issues are reduced for the electric vehicle.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 403,467 filed on September 2, 2022 and U.S. Non-Provisional Patent Application No. 18 / 235,397 filed on August 18, 2023, the entire disclosures of the above U.S. patent applications are incorporated herein by reference. Technical Field

[0003] The present disclosure is directed to a combined assembly including a steering actuator subassembly and a beam axle subassembly for an electric vehicle. Background Art

[0004] Steering actuators and beam axle assemblies are well-known components that may be used in both internal combustion engine (ICE) vehicles and electric vehicles. As the demand for more power and greater range for electric vehicles increases, it has become desirable to install larger batteries in electric vehicles, which generally requires increasing the wheelbase of the vehicle. By moving the wheelbase further apart, the turning radius or circle for the vehicle is affected. With a beam axle assembly in an electric vehicle, the center of gravity is also undesirably positioned, which increases NVH issues.

[0005] It would be desirable to provide a configuration that addresses both the center of gravity problem and the turning radius problem in an electric vehicle. Summary of the invention

[0006] An electric vehicle module assembly is disclosed herein. The electric vehicle module assembly includes a beam axle subassembly and a steering actuator subassembly directly connected to the beam axle subassembly.

[0007] In one example, the beam axle subassembly and the steering actuator subassembly are connected via a common housing. The common housing may define a wall that defines an interior boundary between the beam axle subassembly and the steering actuator subassembly.

[0008] In another example, the steering actuator subassembly may be coupled to the beam axle subassembly via at least one fastening element.

[0009] The steering actuator subassembly may be coupled to a first side of the beam axle subassembly, and the beam axle subassembly may include an electric motor disposed on a second side opposite the first side.

[0010] The center of gravity of the electric vehicle module assembly may be defined closer to the wheel axis (X) of the beam axle subassembly than to the electric motor of the beam axle subassembly.

[0011] In another example, an electric vehicle module assembly is disclosed, the electric vehicle module assembly including: a beam axle subassembly including an electric motor and an axle assembly defining a wheel axis (X); and a steering actuator subassembly directly connected to the beam axle subassembly. The steering actuator subassembly can be arranged on a first side of the axle assembly and the electric motor can be arranged on a second side of the axle assembly opposite the first side.

[0012] In one example, the center of gravity of the electric vehicle module assembly can be located on the axle assembly. In one example, the center of gravity of the electric vehicle module assembly can be defined to be closer to the axle assembly than to the electric motor.

[0013] A method of reducing noise, vibration and harshness (NVH) in an electric vehicle is also disclosed herein. The method may include directly connecting a steering actuator subassembly to a beam axle subassembly to form an electric vehicle module assembly such that a center of gravity of the electric vehicle module assembly is shifted away from an electric motor of the beam axle subassembly and toward an axle assembly of the beam axle subassembly.

[0014] Additional implementations are disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The foregoing summary and the following detailed description will be better understood when read in conjunction with the accompanying drawings which illustrate preferred embodiments of the present disclosure. In the drawings:

[0016] Figure 1 is a schematic diagram showing a driving assembly according to a first example.

[0017] Figure 2 is a schematic diagram showing a driving assembly according to a second example.

[0018] Figure 3A is a side view of a beam axle assembly indicating associated forces or loads according to an example.

[0019] Figure 3B is a side view of another type of beam axle assembly indicating associated forces or loads according to one example.

[0020] Figure 3C is based on an example during increased force conditions Figure 3B A side view of a beam axle assembly.

[0021] Figure 4 is a side view of an electric vehicle module assembly according to one example.

[0022] Figure 5 is a perspective view of an electric vehicle module assembly according to one example.

[0023] Figure 6 is a perspective view of an electric vehicle module assembly according to another example.

[0024] Figure 7 is a graph showing the fore-aft acceleration for the two configurations.

[0025] Figure 8 is a graph showing the RMS fore-aft acceleration for the two configurations. DETAILED DESCRIPTION

[0026] Certain terms are used in the following description for convenience only and are not limiting. Reference to a list of items cited as "at least one of a, b, or c" (where a, b, and c represent the listed items) refers to any single one or combination of items a, b, or c. The terminology includes the words specifically noted above, their derivatives, and words of similar meaning.

[0027] Figure 1 1 shows a schematic diagram of a vehicle drive assembly 100, which generally includes a power electronics unit 105, an electric motor (e-motor) 110, a gearbox 115, and a housing 125. Figure 1 Also illustrated are various pathways for electrical signals and fluid flow paths. Figure 2 The diagram shows Figure 2 The vehicle drive assembly 200 is similar to the vehicle drive assembly 100 , but the vehicle drive assembly further includes a steering actuator 30 .

[0028] Figure 3A The beam axle assembly 120 is illustrated, for example, in a conventional internal combustion engine (ICE) configuration. Figure 3A As shown in FIG. 1 , the center of gravity (COG) is generally defined in the middle portion or mid-section of the beam axle assembly 120. When the vehicle is driven, due to the mass of the beam axle assembly 120, bumps or other road disruptions will generate a force or load (F2) at the wheel axis (X) that is generally opposite to the force (F1). It is desirable to position the center of gravity as close to the wheel axis (X) as possible to limit the amount of NVH, but this is more difficult to achieve in an electric motor configuration compared to an ICE due to battery weight and other considerations.

[0029] Figure 3B and Figure 3C One configuration for an electric vehicle including a beam axle subassembly 220 is shown. Figure 3B As shown in Figure 3A The center of gravity is defined as being further from the wheel axis (X) than a 3.5-inch vehicle. Therefore, forces or loads from road interruptions have a more destructive effect on the vehicle, such as Figure 3C As shown in .

[0030] Figure 4 An example of an electric vehicle module assembly 10 according to the present disclosure is illustrated in which the center of gravity is located in a more desirable position. Figure 4 As shown in FIG. 1 , the electric vehicle module assembly 10 includes a beam axle subassembly 20 and a steering actuator subassembly 30. Figure 4 and Figure 5 As shown in FIG, the beam axle subassembly 20 may generally include an electric motor 22 and an axle assembly 24, among other components. The axle assembly 24 may include wheel end assemblies 25a, 25b, including brakes and other components.

[0031] According to one aspect of the present disclosure, the steering actuator subassembly 30 can be connected to the beam axle subassembly 20. More specifically, the steering actuator subassembly 30 can be connected to the beam axle subassembly 20, such as via Figure 5 The common housing 40 shown in FIG. 1 is attached directly to the beam axle subassembly 20 or may be attached to the beam axle subassembly 20 via a Figure 6 The fastening elements 50 (i.e., bolts, fasteners, rivets, etc.) shown in FIG. 5 are attached to the beam axle subassembly. By attaching the steering actuator subassembly 30 to the beam axle subassembly 20, the center of gravity of the electric vehicle module assembly 10 is defined closer to the wheel axis (X) than an electric vehicle module assembly 10 lacking an integrated steering actuator.

[0032] According to one aspect of the present disclosure, positioning the steering actuator subassembly 30 achieves multiple advantages. According to one advantage, the steering actuator subassembly 30 solves problems associated with increased wheelbase dimensions for electric vehicles due to increased battery size. According to another advantage, the steering actuator subassembly 30 also solves center of gravity issues encountered by other electric vehicles in which the center of gravity is undesirably located away from the wheel axis (X). The present configuration provides a versatile solution to address both turning radius issues and NVH issues associated with electric vehicles by mounting a component (i.e., the steering actuator subassembly 30) directly to or in conjunction with the beam axle subassembly 20.

[0033] A method of reducing noise, vibration and harshness (NVH) in an electric vehicle is also disclosed herein. The method may include directly connecting a steering actuator subassembly 30 to a beam axle subassembly 20 to form an electric vehicle module assembly 10 such that a center of gravity of the electric vehicle module assembly 10 is shifted away from an electric motor 22 of the beam axle subassembly 20 and toward an axle assembly 24 of the beam axle subassembly 20. The method may include various other steps.

[0034] Figure 7Graph showing the velocity in m / s for (i) a standard electric vehicle (line P1) and (ii) an electric vehicle including an electric vehicle module assembly according to the present disclosure (line P2) 2 A graph of the front and rear acceleration in units of . Figure 8 Graph showing the velocity in m / s for (i) a standard electric vehicle (line P1) and (ii) an electric vehicle including an electric vehicle module assembly according to the present disclosure (line P2) 2 Another graph of the RMS of the forward and backward acceleration in units, and a threshold line (TL) indicating the limit of human perception capabilities.

[0035] Thus, having described the present disclosure in detail, it should be understood and will be apparent to those skilled in the art that many physical changes may be made without changing the inventive concepts and principles embodied herein, only some of which are exemplified in the detailed description of the present invention.

[0036] It should also be understood that various embodiments are possible that combine only a portion of the preferred embodiments without altering the inventive concepts and principles embodied herein with respect to those portions.

[0037] Therefore, the present embodiment and optional configurations are considered in all aspects to be exemplary and / or illustrative rather than restrictive, the scope of the embodiment is indicated by the appended claims rather than the foregoing description, and therefore, all alternative embodiments and changes of the embodiment that fall within the equivalent meaning and equivalent scope of the claims will be included in the scope of the embodiment.

[0038] Reference numerals list

[0039] 10 Electric vehicle module components

[0040] 20, 120, 220 beam axle subassembly

[0041] 20a First side portion of the beam axle subassembly

[0042] 20b Second side portion of beam axle subassembly

[0043] 22 Electric Motor

[0044] 24 Axle assembly

[0045] 25a, 25b Wheel end assembly

[0046] 30 Steering actuator subassembly

[0047] 40 shared housing

[0048] 42 wall

[0049] 50 Fastening elements

[0050] 100, 200 Vehicle drive components

[0051] 105 Power Electronics Unit

[0052] 110 Electric Motor

[0053] 115 Gear Box

[0054] 125 Housing

Claims

1. An electric vehicle module assembly, comprising: Beam axle subassemblies; as well as A steering actuator subassembly is directly connected to the beam axle subassembly.

2. The electric vehicle module assembly according to claim 1, wherein: The beam axle subassembly and the steering actuator subassembly are connected via a common housing.

3. The electric vehicle module assembly according to claim 2, wherein: The common housing includes a wall defining an interior boundary between the beam axle subassembly and the steering actuator subassembly.

4. The electric vehicle module assembly according to claim 1, wherein: The steering actuator subassembly is connected to the beam axle subassembly via at least one fastening element.

5. The electric vehicle module assembly according to claim 1, wherein: The steering actuator subassembly is connected to a first side of the beam axle subassembly, and the beam axle subassembly includes an electric motor disposed on a second side opposite the first side.

6. The electric vehicle module assembly according to claim 5, wherein: The center of gravity of the electric vehicle module assembly is defined closer to the wheel axis of the beam axle subassembly than to the electric motor of the beam axle subassembly.

7. An electric vehicle module assembly, comprising: a beam axle subassembly including an electric motor and an axle assembly defining a wheel axis; as well as a steering actuator subassembly directly connected to the beam axle subassembly; Wherein, the steering actuator subassembly is arranged on a first side of the wheel axle assembly and the electric motor is arranged on a second side of the wheel axle assembly opposite to the first side.

8. The electric vehicle module assembly according to claim 7, wherein: The center of gravity of the electric vehicle module assembly is located on the axle assembly.

9. The electric vehicle module assembly according to claim 7, wherein: The center of gravity of the electric vehicle module assembly is defined closer to the axle assembly than to the electric motor.

10. The electric vehicle module assembly according to claim 7, wherein: A common housing encloses at least a portion of the beam axle subassembly and at least a portion of the steering actuator subassembly.

11. The electric vehicle module assembly according to claim 7, wherein: The steering actuator subassembly is directly connected to the beam axle subassembly via at least one fastening element.

12. A method of reducing noise, vibration and harshness (NVH) in an electric vehicle, the method comprising: A steering actuator subassembly is directly connected to a beam axle subassembly to form an electric vehicle module assembly such that the center of gravity of the electric vehicle module assembly is shifted away from the electric motor of the beam axle subassembly and toward the axle assembly of the beam axle subassembly.

13. The method of claim 12, further comprising providing a common housing and using the common housing to enclose at least a portion of the beam axle subassembly and at least a portion of the steering actuator subassembly.

14. The method according to claim 12, wherein: The steering actuator subassembly is fastened to the beam axle subassembly via at least one fastening element.

15. The method according to claim 12, wherein: The center of gravity of the electric vehicle module assembly is located on the axle assembly.

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