Horn arm and electronic axle

Abstract

Horn arms and electronic axles are described herein. In one embodiment, the horn arm includes a housing (412, 141) having an arm portion (1422, 422), the arm portion (1422, 422) extending out of an arm length (1432, 432), the arm portion (1422, 422) having an outlet (1420, 420) at a first end (444, 1444), a flange (414, 141) of a plane (1428, 428) at a second end (1442, 442) opposite the first end; and an inner support (1408, 408) disposed within an interior (1410, 410) of the housing (412, 141) and extending through at least a first portion (1708) of a flange length (608) of the flange, a flange / arm transition (406, 1406) where the flange transitions to the arm portion, and at least a portion (612) of the arm length.

Description

[0001] Application Comparison Table

[0002] This application claims priority to U.S. Provisional Application No. 63 / 582,182, filed September 12, 2023, entitled "Trunk Arm with Internal Support". The entire contents of the above application are incorporated herein by reference. Technical Field

[0003] This instruction generally pertains to the flared arms of electric vehicle (EV) axles. Background Technology

[0004] The axle assembly is used to transmit rotational power from the vehicle's rotational power source to the wheels. Typically, an axle assembly includes a differential assembly that is rotatably supported within a non-rotatable housing (such as a bracket). The differential connects an input drive shaft extending from the rotational power source / transmission and a pair of output shafts extending to the wheels. The shafts are mounted in their respective non-rotating crossbeam housings and fixed to a central housing. Therefore, rotation of the differential by the drive shafts causes a corresponding rotation of the axle shafts. The central housing and crossbeam housing portions of these drivetrain components of the axle assembly form an axle housing in which the differential and axle shafts are supported for rotation.

[0005] One type of axle housing includes a modular central housing structure, commonly referred to as a Salisbury axle assembly. In this structure, the central housing (which houses the differential assembly) is directly connected to two beam tube sections (which house the rotatable axle). Another type of axle housing includes a central housing structure connected to two control arm sections, each forming a smooth, progressively flared connection with the central housing. The central section is typically a hollow cylinder with a large circular opening. The overall shape of this axle box roughly resembles a banjo. Therefore, this type of axle box is often referred to as a banjo-style axle box.

[0006] As electric vehicles evolve towards using electric axles, traditional Banjo and Salisbury axles with streamlined housings may not provide sufficient space to enclose all the components required for an electric axle, such as one or more motors, gears, shafts, bearings, transmission actuators, differentials, pumps, heat exchangers, filters, sensors, etc. For example, the long, gradual transition from the arm section to the bowl section in a Banjo axle can distribute road loads in the Yz plane (e.g., perpendicular to the drive surface) and reduce stress on the Banjo axle. Some Banjo axles may include a reinforcing ring within the bowl axle to further strengthen it in the Yz plane. However, regardless of whether a reinforcing ring is present or absent, the shape of the bowl plate may provide less space than required to enclose the electric axle assembly. Similarly, the geometry of a Salisbury axle may restrict the space for enclosing the electric axle assembly to a smaller-than-ideal bending space. Therefore, an axle that provides the ideal amount and shape space to enclose the electric axle assembly is needed. For example, packaging electric vehicle axle components may require a rectangular packaging envelope, but the rectangular shape may affect the structural reinforcement of Banjo axles and / or Salisbury axles (such as reinforcing rings, long gradient transitions).

[0007] One possible solution is an axle with a gearbox housing featuring relatively flat sides and two flared arms extending along the output shaft axis. This could help achieve the packing space required to mount the electric axle assembly. However, challenges arise when the flared arm engages with the flared arm flange (e.g., at the flange / arm transition), which is used to fasten the flared arm to the gearbox housing. The flange / arm transition is a high-stress area. However, reducing the arm length is undesirable, as the full-length arm can be used to integrate multiple different suspension mounting components. Maintaining the ideal arm length while providing the desired packing space may prevent the flared arm from employing a gradient transition, long chamfers, or external trusses to help reinforce and strengthen the flange / arm transition. Utility Model Content

[0008] This document describes an axle housing configured as a flared arm, featuring internal support to help reinforce and strengthen the flange / arm transition while maintaining the desired arm length. For example, the flared arm includes a housing with an arm segment extending the arm length, a first end of the arm segment having an outlet, and a second end opposite the first end having a flat flange. The flared arm also includes at least a first portion of the flange length disposed within the housing and extending through the flange, a flange / arm transition where the flange transitions to the arm, and internal support for at least a portion of the arm length. In some embodiments, the flared arm further includes an outer support (truss, stringer) extending at least a second portion of the flange length, with the endpoints of the inner and outer supports offset from each other. The flange may include a curved or inclined extension from the plane to the flange / arm transition. In this way, the flange / arm transition element effectively prevents the flared arm from degrading due to deformation when used on a vehicle axle. In addition, the plane of the flange provides a rectangular envelope within which the components of the electric vehicle axle can be positioned, thereby enabling the horn arm to be used in the electric vehicle axle of electric vehicles (e.g., electric cars, hybrid electric vehicles, and / or plug-in electric vehicles).

[0009] It should be understood that the above summary is intended to present some concepts further described in the detailed description in a simplified form. It is not intended to identify the key or essential features of the claimed subject matter, the scope of which is uniquely determined by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to embodiments that address any of the shortcomings pointed out in the foregoing or any part of this disclosure. Attached Figure Description

[0010] Figure 1 A schematic diagram of an electric drive system with a horn arm is shown.

[0011] Figure 2 A perspective view of an electric drive system is shown, which, according to one example, includes two horn arms.

[0012] Figure 3 A cross-sectional view of an electric drive system, drawn based on an example, is shown.

[0013] Figure 4 A perspective view of the horn arm is shown.

[0014] Figure 5 Showing Figure 4 Cross-sectional view of the middle horn arm.

[0015] Figure 6 A cross-sectional view of the horn arm is shown.

[0016] Figure 7 The first perspective view of the horn arm with the main shaft is shown.

[0017] Figure 8 Showing with Figure 7 The second perspective view of the horn arm of the main shaft.

[0018] Figure 9 A cross-sectional view of the horn arm with the main shaft is shown.

[0019] Figure 10 A perspective view of the horn arm with the main shaft and differential lock / bridge disconnect assembly is shown.

[0020] Figure 11 Showing with Figure 10 A cross-sectional view of the horn arm of the main shaft and differential lock / bridge disconnect assembly.

[0021] Figure 12 A schematic diagram of the load distribution within the horn arm's internal support is shown.

[0022] Figure 13 An example of the orientation of the internal bracket and the cross-section of the horn arm are shown.

[0023] Figure 14A and 14B A perspective view of a flared arm with an arcuate flange is shown.

[0024] Figure 15 Showing with Figure 14A and 14B The first set of sectional views of the flared arm with an arc-shaped flange.

[0025] Figure 16 The second set of sectional views shows the flared arm with an arcuate flange.

[0026] Figure 17 A cross-sectional view of the flared arm with an arcuate flange is shown.

[0027] Figure 18 A perspective view of the horn arm with an arcuate flange and a main shaft is shown.

[0028] Figure 19 Showing with Figure 18 A cross-sectional view of the arc-shaped flange and the flared arm of the spindle.

[0029] Figure 20 A cross-sectional view of the horn arm with an arcuate flange and a main shaft is shown. Detailed Implementation

[0030] The following description relates to an electric vehicle axle system, specifically a flared arm, including a housing with an arm segment extending the arm length. A first end of the arm segment has an outlet, and a second end opposite the first end has a flat flange. The flared arm also includes at least a first portion of the flange length disposed within the housing and extending through the flange, a flange / arm transition point where the flange transitions to the arm, and an inner support for at least a portion of the arm length. The inner support provides strength and stiffness to the flared arm. The flat flanges can form a rectangular space between two flared arms, in which an electric vehicle axle assembly can be mounted, as described herein. Furthermore, the configuration of the arm cross-sectional length allows for the mounting of suspension assemblies of different sizes and shapes. The configuration of the flared arms allows the electric vehicle axle assembly to be incorporated into an electrically driven axle (such as an electric vehicle axle) while achieving the required stiffness and strength of the flared arm.

[0031] The flared arm can be implemented in various ways, as further described herein, and these implementations are configured to provide ideal space, stiffness, and degradation resistance to systems incorporating the flared arm. For example, in some embodiments, the body of the flange may be inclined and include external supports (trusses, stringers), while in other embodiments, the body of the flange may be curved, with the convex or concave surface of the flange body connecting to the arm. The internal supports can be configured in various ways, consisting of two or more legs (e.g., "X" configuration, "Y" configuration, etc.), and different configurations can be used for different vehicle applications. Furthermore, the cross-section of the arm portion (e.g., rectangular, circular, etc.) may also differ for different vehicle applications. The flared arm embodiments described herein can be used in electric vehicle axles, where a first flared arm and a second flared arm are connected to the motor via the flange of each flared arm. Furthermore, the dimensions of the arm portions (e.g., arm length, cross-section of the arm portion) allow for the mounting of different suspension assemblies on the flared arms. Electric vehicles may also include a differential lock / axle disconnect assembly in one or more flared arms, which is connected to a differential for controlling the rotational power output from the motor to the electric vehicle wheels. As further described herein, adding reinforcing supports (such as internal and external supports) at the pivot points (e.g., stress points) of the horn arm can provide stiffness. Thus, the horn arm described herein provides a geometry that allows for the mounting of motor components and suspension assemblies on the electric axle, while also providing strength and stiffness to prevent degradation of the horn arm due to yaw stress.

[0032] Figure 1 An electric drive system in a vehicle is schematically described, in which at least one horn arm serves as the electronic axle of the electric drive system, wherein the horn arm is configured as described herein and acts as a non-rotating beam housing portion containing a rotatable shaft. Figure 2 and Figure 3 The electric drive system (such as) is shown Figure 1The view shows a first horn arm and a second horn arm positioned to form a rectangular space in which the main gearbox housing can be positioned and coupled to each of the first horn arm and the second horn arm. Figure 4-11 It shows that it can be included in Figure 1-3 Different cross-sectional views, perspective views, and cross-sectional views of the horn arm in the system, including embodiments of the horn arm, including additional components such as the spindle and differential lock / bridge disconnect assembly. Figure 12 The horn arm (as shown) is displayed Figure 4-11 A schematic diagram of the load reaction force of the internal support of the trumpet arm in the diagram. Figure 13 Different embodiments of the horn arm cross-section and different orientations of the internal support of the horn arm are shown. Figure 14A-20 Different cross-sectional views, perspective views and cross-sectional views of a second embodiment of the horn arm are shown, wherein the flange of the horn arm has a curved geometry. Figure 14A-20 The second embodiment of the horn arm may include in Figure 1-3 In the system. Figure 14A-16 Perspective and sectional views of a second embodiment of the horn arm are shown. Figure 17 A cross-sectional view of a second embodiment of the horn arm is shown. Figure 18-20 A perspective view and a cross-sectional view of a second embodiment of a horn arm with a main shaft are shown. Figure 2-11 It is drawn approximately to scale with 14A-20. However, other relative component dimensions may be used in other embodiments.

[0033] Figure 1 An electric vehicle 100 is schematically illustrated, which has an electric drive system 102 that powers and / or is integrated with the axle assembly 104 of the vehicle 100. In different examples, the vehicle 100 can take various forms, such as light, medium, or heavy-duty vehicles. Furthermore, the electric drive system 102 can also be used on the front and / or rear axles, as well as steerable and non-steerable axles. To generate power, the electric drive system 102 may include a motor 106. In some examples, the motor 106 may be an electric motor generator, and therefore may include conventional components such as a rotor and stator, mounted within a motor housing 107, for generating mechanical power and electricity in regenerative mode under certain conditions. Furthermore, in other examples, the vehicle 100 may include an additional power source, such as an internal combustion engine (ICE) (e.g., a spark and / or compression ignition engine), to power another axle. Therefore, the electric drive system 102 can be used for electric vehicles (EVs), such as hybrid electric vehicles (HEVs) or battery electric vehicles (BEVs).

[0034] In some examples, the motor housing 107 may be (e.g., bolted) connected to the gearbox housing 109 of the gearbox 108. Furthermore, the motor 106 can provide mechanical power to the differential 110 via the gearbox 108. This mechanical power can be transmitted from the differential 110 to the drive wheels 112 and 114 (e.g., first wheel 112, second wheel 114) via the axle shafts 117 and 115 of the axle assembly 104, respectively. Therefore, under certain operating conditions, the differential 110 can distribute the torque received from the motor 106 via the gearbox 108 to the drive wheels 112 and 114 of the axles 117 and 115, respectively. In some examples, the differential 110 may be a locking differential, an active or passive limited-slip differential, or a torque vectoring differential.

[0035] One or both shafts 117, 115 may be mounted in the horn arm, as further described herein. For example, shaft 117 is mounted in a first horn arm 118, and shaft 115 is mounted in a second horn arm 116. Each of the first horn arm 118 and the second horn arm 116 has the same horn arm construction, including: a housing with an arm portion 162 extending the arm length, the arm portion having an outlet at a first end and a flat flange 164 at a second end opposite the first end; and an inner support disposed within the housing and extending through the flange length, a flange / arm transition point where the flange transitions to the arm portion, and at least a portion of the arm length. Each of the first horn arm 118 and the second horn arm 116 may be connected to a differential 110 on the respective plane of the flange.

[0036] In some embodiments, the axle assembly 104 includes additional elements coupled, mounted, or otherwise connected to at least one of the first horn arm 118 and the second horn arm 116. For example, a suspension assembly 152 may be mounted along the respective arm 162 on the first horn arm 118 and the second horn arm 116. In some embodiments, a spindle 154 may be connected to the outlets of the first horn arm 118 and the second horn arm 116, respectively. For example, a first spindle end of the spindle 154 may be coupled to the respective horn arm, and a drive wheel (e.g., a first wheel 112 or a second wheel 114) may be coupled to each of the first and second spindles at a second spindle end opposite to the first spindle end of the spindle.

[0037] As further described herein, one or more of the first horn arm 118 and the second horn arm 116 may also include a differential lock / bridge disconnect assembly located in the body of flange 164. The differential lock / bridge disconnect assembly may be configured to selectively engage with the mating clutches of differential 110 and / or transmission 108, respectively.

[0038] The gearbox 108 can be a single-speed gearbox, meaning it operates at one gear ratio. However, other gearbox arrangements are also envisioned, such as multi-speed gearboxes that can operate at multiple different gear ratios. Furthermore, in one example, the motor 106, gearbox 108, and differential 110 can be integrated into the axle 104, forming an electric axle (electronic axle) in the vehicle 100. Among other functions, the electric axle can also power the wheels 112, 114 during operation. Specifically, in an electric axle embodiment, the motor 106 and gearbox 108 can be connected to and / or supported by the first horn arm 118 and the second horn arm 116. The electronic axle can provide a compact arrangement that delivers power directly to the axle 104. For example, the first horn arm 118 can be coupled to a first side of the gearbox housing 109, and the second horn arm 116 can be coupled to a second side of the motor housing 107, opposite the first side, as shown below. Figure 2-3 As stated above.

[0039] The electric drive system 102 may also include an oil passage 120 for circulating oil (e.g., natural and / or synthetic oil) through the transmission housing 109 to lubricate and / or cool various system components. The oil passage 120 may include a filter 123 and an oil pump 124, which draws oil from an oil reservoir 111 (e.g., oil pan) in the transmission housing 109 through an outlet 122 and drives pressurized oil through a delivery line 126 to an inlet 128 of the transmission housing 109. In some examples, the oil pump 124 may be located externally to the transmission housing 109. However, in other examples, the oil pump may be included within the transmission housing 109. Various distribution components and arrangements of the oil passage 120 (e.g., nozzles, valves, injectors, oil passages, etc.) may be included in the electric drive system 102 to facilitate the path of oil within the transmission housing 109; in a particular example, oil may be delivered to a portion of the motor housing 107. In some cases, oil passage 120 can be used to deliver oil to various gearbox bearings and gears, as well as the rotor shaft bearings of the motor stator, motor rotor, and motor 106, thereby providing an efficient system for effectively utilizing the gearbox oil to cool the system. In some embodiments, oil passage 120 may further include a heat exchanger (such as a radiator) for removing heat from the oil flowing out of the gearbox housing 109 through outlet 122.

[0040] The electric drive system 102 may further include a coolant circuit 130 that circulates coolant (e.g., water, glycol, and / or oil) through a coolant passage 131 formed in the motor 106 or motor housing 107. The coolant circuit 130 may include a coolant inlet 138 and a coolant outlet 132, respectively located on (or within) the motor housing 107. The coolant circuit 130 may further include a filter 133 and a pump 134 that circulates coolant from the coolant outlet 132 to the coolant inlet 138 via a coolant delivery line 136. Coolant enters from the coolant inlet 138 into the coolant passage 131 formed in the motor 106 or motor housing 107, thereby removing heat from the components of the motor 106. In some examples, the coolant circuit 130 may further include a heat exchanger (e.g., a radiator) for removing heat from the coolant flowing out of the motor housing 107 through the coolant outlet 132.

[0041] Vehicle 100 may also include a control system 140 with a controller 141. Controller 141 may include a processor 142 and a memory 144. Instructions may be stored in the memory, which, when executed by the processor, cause controller 141 to perform various methods, control techniques, etc., as described herein. Processor 142 may include a microprocessor unit and / or other types of circuitry. Memory 144 may include known data storage media such as random access memory, read-only memory, keep-alive memory, combinations thereof, etc. Controller 141 may receive various signals from sensors 146 located at different locations in vehicle 100 and electric drive system 102. Controller 141 may also send control signals to various actuators 148 located at different locations in vehicle 100 and electric drive system 102. For example, controller 141 may send command signals to oil pump 124 and / or pump 134, in response to which actuators in the pumps may be adjusted to change the flow rate of oil and / or coolant delivered therefrom. In other examples, the controller may send control signals to motor 106, and upon receiving a command signal, adjust the motor to change its rotor speed or torque. Other controllable components in the system can operate on sensor signals and actuator adjustments in a similar manner.

[0042] Figure 1 as well as Figure 2-20 A system of axes 150 is provided for reference. In one example, the Z-axis may be a vertical axis (e.g., parallel to the gravity axis), the X-axis may be a longitudinal axis (e.g., a horizontal axis), and / or the Y-axis may be a transverse axis. However, in other examples, the axes may have other orientations.

[0043] Figure 2An example of an electric drive system 200 is described, which includes an electric axle assembly 202 for powering an axle assembly 204. The electric axle assembly 202 of the electric drive system 200 may include a motor 206 coupled to a transmission 208 and may be included in a vehicle, such as... Figure 1 The vehicle 100 described herein. Therefore, the electric drive system 200 can be similar to the electric drive system 102. For example, Figure 1 At least a portion of the components discussed in the illustrated drive system 102 may be included in Figure 2 In the electric drive system 200 shown, the reverse is also true.

[0044] The axle assembly 204 includes a first horn arm 216 and a second horn arm 218, both examples of horn arms. Each horn arm includes a housing 212 having an arm portion 222 extending the arm length. The arm portion 222 has an outlet at a first end and a flange 214 with a flat surface 228 at a second end opposite the first end. It also includes an internal bracket. Figure 2 (Not shown in the image). 2) It is disposed inside the housing 212 and extends through at least a first portion of the flange length of the flange 214, the flange / arm transition point where the flange transitions to the arm 222, and at least a portion of the arm length. The plane of the flange 214 allows the electric vehicle axle assembly 202 (such as motor 206, gearbox 208, and / or differential) to pass through. Figure 2 (Not shown in the text) can be positioned in the axle assembly 204, while achieving the strength and stiffness required for the axle assembly 204 to distribute road loads and reduce stress on the horn arm, as further described herein.

[0045] Motor 206 may include motor housing 207, which is connected to gearbox housing 209 of gearbox 208. In some cases, motor housing 207 may be connected to gearbox housing 209 by any suitable connection mechanism (e.g., bolts, brackets, welding, and / or combinations thereof) (e.g., bolt 211). As further described herein, flanges 214 of the first horn arm 216 and the second horn arm 218 include a plurality of through holes surrounding the periphery of the plane of flange 214. Bolt 211 may pass through each of the plurality of through holes and connect the first horn arm 216 and the second horn arm 218 to gearbox housing 208. In other embodiments, the first horn arm 216 and the second horn arm 218 may additionally or alternately couple to motor housing 207. The first horn arm 216, the second horn arm 218, motor housing 207, and gearbox housing 209 may all be made of metal (e.g., aluminum, steel, iron, combinations thereof), and each housing may be the same metal or different metals.

[0046] Motor 206 can provide power to differential (not shown) via gearbox 208 to provide rotational power to the first and second axle shafts of axle assembly 204 (to which drive wheels can be connected). The first and second axles are... Figure 2 The parts not shown are to be understood as being at least partially enclosed within the housings 212 of the first horn arm 216 and the second horn arm 218, respectively. In some embodiments, each of the first horn arm 216 and the second horn arm 218 has a main shaft connected to the housing 212 at its arm portion 222 outlet. For example, at the outlet 220 of each horn arm, a first main shaft 224 is connected to the first horn arm 216, and a second main shaft 226 is connected to the second horn arm 218, as detailed in [link to documentation]. Figure 3 A drive wheel can be mounted on the first spindle 224 and the second spindle 226 respectively. The first shaft and the second shaft can pass through the first spindle 224 and the second spindle 226 respectively to drive their respective drive wheels to rotate.

[0047] exist Figure 2 In the illustrated horn arm embodiment, one or both of the first horn arm 216 and the second horn arm 218 may be configured with a differential lock / bridge disconnect assembly 260, which may be at least partially enclosed within its respective housing 212. Figure 7 and Figure 10 As further described, the differential lock / bridge disconnect assembly 260 can be selectively paired with the differential's matching clutch to selectively couple the shaft extending through the respective horn arm to the differential, or in other cases selectively paired with the transmission 208's matching clutch to selectively decouple the shaft extending through the respective horn arm from the power path.

[0048] Figure 3 A cross-sectional view 300 of the electric drive system 200 is shown, including a first horn arm 216, a second horn arm 218, and an electric vehicle axle assembly 202. (See attached image.) Figure 2 The first horn arm 216 and the second horn arm 218 have the same structure, including a flange 214 with a flat surface 228 located at the first end 302 of the housing 212 and an outlet 220 located at the second end 304 opposite to the first end 302. An arm portion 222 extends between the flange 214 and the outlet 220, and intersects with the flange 214 at the flange / arm transition 306. Figure 2 and Figure 3 In the embodiment of the electric drive system 200 shown, such as Figure 4-12 The flange 214 includes an inclined extension from the plane 228 to the flange / arm transition portion 306. In other embodiments, such as Figure 14A-20 The flange 214 may include a curved extension from the plane 228 to the flange / arm transition 306.

[0049] Compared to the gradual transition between the flange and arm in axles such as the Banjo and Salisbury axles, the flange / arm transition 306 is a high-stress area due to the abrupt junction between the flange 214 and arm 222. For example, in vehicles including an electric drive system 200 (such as...) Figure 1 When the vehicle 100 (whose drive wheels are connected to the first main shaft 224 and the second main shaft 226 of the axle assembly 204, respectively) is traveling on a road, the drive wheels may traverse bumps and / or potholes in the road, causing the vehicle and the horn arm reference shaft system 150 to move up and down along the Z-axis. This may generate stress at the flange / horn arm transition 306, resulting in horn arm degeneration at the flange / horn arm transition 306.

[0050] The flared arm described herein is equipped with internal supports, and in some embodiments, external supports (trusses, stringers) are also provided to help alleviate stress at the flange / arm transition 306. For example... Figure 4-20 The inner support disposed within the housing 212 extends at least a first portion of the flange length 308 of the flange 214, passes through the flange / arm transition 306, and at least extends a portion of the arm length 312 of the arm 222. Figure 2-3 As shown, arm 222 has a rectangular shape and a rectangular cross-section in the zx plane relative to the shaft system 150. Figure 13 In other embodiments of the horn arm, the cross-section of the arm can be square, circular, elliptical, glass-shaped, or other shapes. For example... Figure 13 The different cross-sections of the arm 222 can achieve different configurations forming the inner supports of two or more legs. The cross-section of the arm can maintain a constant profile along the arm length 312. Furthermore, the outlet 220 of the flared arm (e.g., the first flared arm 216 and the second flared arm 218) can be annular, as shown herein, or in other embodiments can have the same shape as the cross-section of the arm 222. For example, the outlet 220 of the arm 222 can be configured to have a main shaft (e.g., the first main shaft 224, the second main shaft 226) connected thereto, and / or directly connected to the non-rotating portion of the drive wheel. Thus, the configuration of the flared arms (e.g., the first flared arm 216 and the second flared arm 218) allows the electric drive axle assembly to be contained within the rectangular envelope 310 of the electric drive axle, while achieving the required rigidity and strength of the electric drive axle at the flange / arm transition and along the length of the arm 222.

[0051] Figure 4 The first perspective view 400 and the second perspective view 450 of the flared arm 402 are shown, and the orientation of these two perspective views allows partial observation of the inner support. The flared arm 402 is... Figure 2-3 An example of the first horn arm 216 and the second horn arm 218. Figure 2-3 Included in Figure 4 The components in the data can use similar numbering (e.g., Figure 2-3 Flange 214 in the middle is equivalent to Figure 4 (Flange 414 in the middle).

[0052] The horn arm 402 includes a housing 412 having an arm portion 422 extending arm length 432, an outlet 420 at a second end 444, and a flange 414 having a plane 428 at a first end 442 opposite to the second end 444. The horn arm 402 also includes an inner support 408 disposed within the interior 410 of the housing 412 and extending through at least a first portion of the flange length of the flange 414, a flange / arm transition 406 where the flange 414 transitions to the arm portion 422, and at least a portion of the arm length 432, as shown below. Figure 6 , Figure 9 and Figure 11 The inner support 408 may be cast as part of the housing 412 (e.g., continuous with the housing 412). In some embodiments, the inner support 408 may be formed as a component separate from the housing 412 (e.g., a casting, stamping, forming, or machining) and welded or otherwise fixed within the interior 410 of the housing 412. The housing 412 and the inner support 408 may be formed of the same material, such as cast steel, ductile iron, or cast aluminum. In other embodiments, the housing 412 and the inner support 408 may be made of different metals or other rigid materials. In other embodiments, the housing 412 and the inner support 408 may be formed as various castings, stampings, or machining parts and fixed and assembled as welded parts.

[0053] like Figure 1-3 Briefly, flange 414 has a plurality of through holes 416 arranged around the periphery of flange 414, configured to allow fastening attachments such as bolts to pass through for connecting flared arm 402 to electric vehicle axle components such as gearbox housing and / or motor housing. In some embodiments, each of the plurality of through holes 416 has a raised bolt washer 418, which helps to position fastening attachments such as bolts and distribute bolt load. The raised bolt washer 418 further aids in the fabrication of flared arm 402. In some embodiments, raised washer may or may not be used. For example, a dotted surface may be used instead. Flange 414 also has an inclined extension 430 from plane 428 to flange / arm transition portion 406. Inclined extension 430 includes an actuator through hole 424 in which the actuator of the differential lock may be disposed, such as Figure 10 and Figure 11The angled extension 430 also includes an outer support (truss, stringer) 426, which may be formed as a three-dimensional triangle, wherein a first face of the triangle is connected to and / or continuous with the planar surface 428, and a second face of the triangle is connected to and / or continuous with the angled extension 430. Thus, the outer support (truss, stringer) 426 provides additional support and stiffness for the flange 414 and the flange / arm transition member 406, such as... Figure 12 As stated above.

[0054] Both first perspective view 400 and second perspective view 450 show the geometry of housing 412, wherein arm 422 is rectangular, extending along arm length 432, and outlet 420 is annular. Arm 422 can gradually transition to outlet 420, thus allowing a smooth transition from rectangle to annular shape without sharp (e.g., slanted) intersections. The rectangular shape of arm 422 provides space within the interior 410 of flared arm 402 for locating internal bracket 408 and shafts (e.g., shafts 115, 117) therein. The shape of arm 422 can also be used to mount suspension assemblies of different shapes and sizes (e.g., from different manufacturers). The annular shape of outlet 420 allows shafts to be positioned therein without contacting housing 412. The annular shape of outlet 420 can further allow main shafts (e.g., first main shaft 224, second main shaft 226) to be connected thereto. In other embodiments, outlet 420 can be directly connected to the non-rotating portion of the drive wheel. In other embodiments of flared arm 402 (e.g., as...), Figure 13 The horn arm 402 can have a cross-section of different shapes, and can be configured to mount different suspension components thereon and / or integrate the horn arm 402 into electronic axles of different sizes and shapes, for example, for different types of vehicles.

[0055] As can be seen in the second perspective view 450, the inner region 434 of the flange 414 gradually decreases in size from the first end 442 toward the flange / arm transition 406. The inner support 408 includes one or more legs continuous with the housing 412. In the flared arm 402, the inner support 408 includes four legs, such as... Figure 5 As described above. Each of the four legs extends from the plane 428 and the inclined extension 430 toward the central axis 436 of the flared arm 402. Each of the four legs further extends into the arm 422 of the housing 412 and is coupled and / or continuous with the wall of the arm 422, respectively. Figure 6 , Figure 9 and Figure 11 As shown, each of the four legs of the inner support 408 extends at least through a first portion of the flange length, the flange / arm transition portion 406 where the flange 414 transitions to the arm portion 422, and at least a portion of the arm length 432. Figure 5In the example of the flared arm 402 shown, the four legs of the inner support 408 form an "X" configuration. However, in other embodiments of the flared arm 402, the inner support 408 may consist of more or fewer than four legs arranged in different configurations to provide resistance to deformation stress along the arm length 432 of the arm portion 422 and at the flange / arm transition 406. Other configurations of the inner support 408 will be discussed later. Figure 13 As described in the text.

[0056] The outer support (truss) 426 and the inner support 408 form a first fulcrum on the plane 428 of the flange 414, and a second fulcrum on the flange / arm transition 406, as shown. Figure 12 In short, observing the top portion of the horn arm 402 in illustration 1250, when the arm portion 422 deflects in the first downward direction (e.g., toward the drive surface) indicated by the second arrow 1220 and the third arrow 1222, both the first fulcrum 1202 and the second fulcrum 1204 are rigid because the inner support rod 408 is in a compressed state while the outer support rod (truss, stringer) 426 is in a tensile state. As shown in Figure 1200, because the inner support rod 408 is in a tensile state and the outer support rod (truss, stringer) 426 is in a compressed state, when the arm portion 422 deflects in the second upward direction (e.g., away from the drive surface) indicated by the first arrow 1206, both the first fulcrum 1202 and the second fulcrum 1204 are rigid.

[0057] Figure 5 Showing Figure 4 First sectional view 500 and second sectional view 550 of the middle flared arm 402. For the sake of brevity, Figure 4 The components of the horn arm 402 described herein will not be repeated. First sectional view 500 shows the horn arm 402 along the Y-axis, from flange 414 to outlet 420 (e.g., from the first end 442 to the second end 444 of housing 412, as shown). Figure 4 The second sectional view 550 shows the interior 410 of the horn arm 402 along the Y-axis, from the outlet 420 to the flange 414 (e.g., from the second end 444 to the first end 442 of the housing 412).

[0058] like Figure 4 The inner support 408 has an "X" configuration, with the vertical extension 508 of each of the four legs (e.g., first leg 408a, second leg 408b, third leg 408c, and fourth leg 408d) coupling the inner support 408 to the arm portion 422 and the inclined extension 430. The vertical extension 508 can be understood as an extension of the "X" configuration, providing support for the inner support 408 in the flange 414, for example, by securing the inner support 408 to the flange 414. Figure 5The "x" structure can be seen in the first sectional view 500 and the second sectional view 550. The outer support (truss) 426 also has an "x" configuration, wherein the legs of the outer support 426 (e.g., the fifth leg 426a, the sixth leg 426b, the seventh leg 426c, and the eighth leg 426d) can be axially aligned with the legs of the inner support 408. The outer support 426 may also include an external vertical extension 526, which can help support (e.g., provide structural stability and stiffness for the inclined extension 430 of the flange 414).

[0059] The "X" configuration of the inner support 408 and the outer support (truss, stringer) 426 allows the inner support 408 and the outer support 426 to respond to vertical and horizontal forces as well as torsional forces on the flared arm 402, thus enabling the inner support 408 and the outer support 426 to react. For example, in vehicles with electronic axles using the flared arm 402 (such as... Figure 1 When vehicle 100 travels over protrusions and / or depressions on the road surface (such as speed bumps or potholes), the inner support 408 and outer support 426 may be subjected to vertical forces. When the vehicle brakes and / or accelerates, the inner support 408 and outer support 426 may be subjected to horizontal and torsional forces. Figure 12 As further described, the inner brace 408 and the outer brace (truss, stringer) 426 can keep the pivot point of the flared arm 402 rigid when the flared arm is subjected to vertical and / or horizontal forces (e.g., deflection of the flared arm), which can reduce the degradation of the flared arm 402, especially at the flange / arm transition 406.

[0060] Figure 6 A cross-sectional side view 600 of the horn arm 402 is shown. Figure 6 The cross-section is a partial cross-section along the central axis 436, wherein the elements above the central axis 436 are such as Figure 4 Line 650 is shown as truncated, while the elements below the central axis 436 are not truncated. For simplicity, Figure 4 and Figure 5 The components of the horn arm 402 described herein will not be further elaborated.

[0061] like Figure 4 and Figure 5 The flange 414 of the horn arm 402 has a flange length 608, the arm portion 422 has an arm length 432, and the inner support 408 extends through at least a first portion of the flange length 608, the flange / arm transition 406, and at least a portion of the arm length 432. Figure 6 An embodiment of the inner support 408 configuration within the housing 412 of the horn arm 402 is shown. In this embodiment of the horn arm 402, as described above, the inner support 408 includes four legs configured in an "X" shape. Figure 6The image shown is a cross-section of the first leg 408a. The first leg 408a extends along the entire flange length 608 and arm length 432. (See image.) Figure 5 Each of the four legs of the inner support 408 includes a vertical extension 508 that extends linearly toward the central axis 436 with a first length 604. The first leg 408a extends along an angled extension 430 of the flange 414, with the extension angle parallel to the angle of the angled extension 430, forming the second portion of the flange length 608. Before the flange / arm transition section 406, the first leg 408a transitions from an angle parallel to the inclined extension 430 to a horizontal extension parallel to the arm portion 422. The width 602 of the first leg 408a gradually decreases along the arm length 432, with the width 602 of the first leg 408a being maximum at the flange / arm transition 406. Thus, the construction of the first leg 408a, and the four legs of the inner support 408, provides stiffness and resistance to degradation at the flange / arm transition 406 and along the arm length 432, as described herein. Figure 12 As described. Figure 13 As further described, different embodiments of the inner support 408 may include more or fewer four legs oriented in a configuration different from the "X" configuration.

[0062] Flange 414 is configured to provide a rectangular envelope for positioning electric vehicle axle components in an electric vehicle axle. In some embodiments, plane 428 may be a face on the first end 442 of a plate or other planar structure. Angled extension 430 is coupled to and / or continuous with the plate or planar structure and extends from the plate or planar structure having plane 428 in a direction away from plane 428 (e.g., toward the second end 444). Angled extension 430 is funnel-shaped, wherein the interior area 434 of flange 414 decreases from the first end 442 toward the flange / arm transition portion 406. Outer supports (trusses, stringers) 426 extending along the outer side 610 of angled extension 430 can provide stiffness and resistance to stress degradation by coupling to and / or extending from the angled extension 430 and the plate or planar structure having plane 428. In other embodiments, flange 414 has different shapes and configurations. For example, as Figure 14A-20 As further described, the flange may have a curved extension from a plane (e.g., a plate or planar structure with a plane) to the flange / arm transition, rather than an inclined extension. Regarding Figure 14A-20 The flange embodiment described herein can provide structural stability and resistance to stress degradation in a manner similar to flange 414 described herein.

[0063] The shapes (e.g., cross-sections) of arm length 432 and arm portion 422 can be configured to accommodate different suspension mounting assemblies to or otherwise couple to arm portion 422. The different suspension mounting assemblies can be designed by the same or different manufacturers as those manufacturing the horn arm 402, so that arm portion 422 is large enough to accommodate suspension mounting assemblies of different shapes and sizes. In some embodiments, the suspension mounting assembly can be attached to part or all of arm length 432 to horn arm 402. For example, the suspension mounting assembly can be coupled to horn arm 402 along a portion 612 of arm portion 422, while not coupled to horn arm 402 at a portion of arm length 432, where the rectangular shape of arm portion 422 transitions to the annular shape of outlet 420. As further described herein, different embodiments of the horn arm can have arm portions of different shapes (e.g., circular cross-section, hourglass cross-section, etc.), all of which can be configured to accommodate multiple different suspension mounting assemblies.

[0064] Figure 7 The first perspective view 700 of the horn arm 402 is shown, as follows: Figure 4-6 As described, a main shaft 726 connected to the horn arm 402 is located at the outlet 420. The main shaft 726 can be an example of a first main shaft 224 or a second main shaft 226, such as... Figure 1-3 As described above. The main shaft 726 can be connected to the horn arm 402 by means of friction welding or other methods. Figure 1-3 The shaft that provides rotational motion from a rotational power source (e.g., motor 106) to the drive wheel may pass through the interior 410 of the horn arm 402 and through the interior of the main shaft 726 to couple to the drive wheel. In some embodiments, the main shaft 726 may be coupled to a non-rotatable element of the drive wheel. In other embodiments, the main shaft 726 may be adjacent to and axially aligned with the center of the drive wheel, but may not be in contact with the drive wheel.

[0065] Figure 8 A second perspective view 800 of the horn arm 402 is shown, as follows: Figure 7 As described, a main shaft 726 is mounted on the horn arm 402. The main shaft 726 is connected to the horn arm 402 at the outlet 420. The main shaft 726 is connected to the horn arm 402 at its first end 842, and a drive wheel (not shown) can be connected to the main shaft 726 at its second end 844, opposite to the first end 842. Figure 7 The shaft that provides rotational motion from the rotational power source to the drive wheel can pass through the interior of the horn arm 402 and through the interior 810 of the main shaft 726 to couple to the drive wheel. In some embodiments, the shaft can extend from a second end 844 of the main shaft 726, in which case the shaft can couple to the drive wheel, and the main shaft 726 does not contact the drive wheel.

[0066] Figure 9A first cross-sectional side view 900 of the horn arm 402 is shown, as... Figure 7 As described, a main shaft 726 is mounted on the horn arm 402. A first cross-sectional side view 900 along... Figure 7 Line 950 shown cuts through the horn arm 402 with the main shaft 726. (As shown) Figure 4-8 The inner support 408 has legs extending from the flange 414, passing through the flange / arm transition 406, and extending along the arm length 432 of the arm portion 422. Figure 9 In the embodiment of the horn arm 402 shown, the legs of the inner support 408 (e.g., first leg 408a and second leg 408b) extend toward the central axis 436 of the horn arm 402 in an "X" configuration. Alternatively, the first leg 408a and second leg 408b (as well as the third leg 408c and fourth leg 408d) Figure 9 Each leg (not shown) extends at an angle from its respective vertical extension 508 toward the central axis 436 of the flared arm 402, such that there is space between each leg of the inner leg, and also space between the inner leg 408 and the housing 412 (e.g., the wall of the arm 422). Figure 9 As shown, in some embodiments, the width 602 of the legs of the inner bracket 408 may decrease along the arm length 432. Alternatively, the legs of the inner support 408 may extend outward from the central axis 436 of the flared arm 402 within a portion 612 of the arm length 432, while still in an "X" configuration. This configuration provides strength and rigidity to the arm portion 422 while providing positioning space for the shaft. As described herein, the inner support 408 may not extend into the main shaft 726. Therefore, the inner support 408 provides rigidity and prevents degradation of the flared arm 402 at the flange 414, the flange / arm transition portion 406, and the arm length 432 of the arm portion 422.

[0067] Figure 10 The third perspective view 1000 shows the horn arm 402 with spindle 726, as shown. Figure 7-9 As stated above. Figure 10 The illustrated embodiment of the horn arm 402 further includes elements that aid in positioning the horn arm 402 relative to electric vehicle axle assemblies (such as gearboxes, differentials, and / or motors), such as... Figure 1-3The differential lock / bridge disconnect assembly 1002 may be positioned in flange 414 and may include a shift fork and a sliding collar 1004, which are connected to a differential lock / bridge disconnect actuator 1008 positioned in actuator through-hole 424. The differential lock / bridge disconnect assembly 1002 may be positioned in flange 414 such that the through-hole of the sliding collar 1004 is aligned with the central axis 436 of the horn arm 402. This alignment allows a shaft to pass through the through-hole of the sliding collar 1004. In other embodiments, the shaft may be engaged with the sliding collar 1004 at a position where a second face of the sliding collar 1004 opposes a first face of the sliding collar 1004 having teeth 1006. The sliding collar 1004 may be actuated to selectively engage with the differential (e.g., Figure 1 The shift fork and the sliding collar 1004 engage with the differential 110, thereby controlling the rotation of the shaft coupled to the sliding collar 1004 (e.g., by engaging the sliding collar 1004 with the differential). In other embodiments, the shift fork and the sliding collar 1004 are configured to selectively engage with the transmission (e.g., the gearbox). Figure 1 The clutch in the transmission 108 engages to control the rotation of the shaft located in the horn arm 402 and coupled to the drive wheel (not shown). Operation of the differential lock / axle disconnect actuator will then... Figure 11 Further description.

[0068] The horn arm 402 may further include one or more locating pins to aid in positioning the horn arm 402 relative to an electric vehicle axle assembly (e.g., gearbox 108, differential 110, motor 106, and / or its housing). For example, the horn arm 402 may include a first locating bolt 1012 extending from the upper right corner of plane 428 toward a first end 442 and a second locating bolt 1010 extending from the lower left corner of plane 428 toward the first end 442. For example, the first locating pin 1012 and / or the second locating pin 1010 may extend into the horn arm 402 and engage with the gearbox of the electric axle. The horn arm 402 may additionally or alternatively include one or more guide diameters (not shown) that extend into or out of flange 414 and are configured to receive one or more mating diameters of the motor to position the horn arm 402 onto the motor.

[0069] Figure 11 A second cross-sectional side view 1100 of the horn arm 402 is shown, as... Figure 10 The horn arm 402 has a main shaft 726, a differential lock / bridge disconnect assembly 1002, and a differential lock / bridge disconnect actuator 1008. Figure 10 The differential lock / bridge disconnect assembly 1002 is configured to engage with the motor (e.g., Figure 1 The motor 106 in the motor is matched with the clutch 1104. Figure 11In one embodiment, the mating clutch 1104 is shown as a Curvic clutch. However, in other embodiments, the mating clutch 1104 selectively engaging with the slip ring 1004 can be any of a dog clutch, synchronizer clutch, cone clutch, dry clutch, wet clutch, friction plate, etc., without departing from the scope of this disclosure. The differential lock / bridge disconnect actuator 1008 may extend through the flange 414 at the actuator through-hole 424 by a flange length 608, thereby enabling the differential lock / bridge disconnect actuator 1008 to selectively engage with components on the first end 442 or the second end 444 of the horn arm 402 (e.g., the differential, elements of the suspension assembly mounted on the arm 422, and / or other elements of the electronic axle). In one instance, the differential lock / bridge disconnect actuator 1008 and the differential lock / bridge disconnect assembly 1002 may be pneumatically, electromechanically, hydraulically, and / or magnetically actuated.

[0070] Figure 12 This illustrates a bell arm (e.g.) with internal and external supports (trusses, stringers) as described herein. Figure 4-11 The force distribution diagrams 1200 and 1250 on the flared arm (e.g., flared arm 402) are shown. As described herein, including internal and external bracing in the flared arm (e.g., flared arm 402) provides strength and stiffness at the flange / arm transition and along the arm section, thereby resisting flared arm degradation due to stresses generated by flared arm deflection. For example, internal and external bracing (trusses, stringers) can keep the pivot point of the flared arm rigid during flared arm deflection.

[0071] like Figure 3 In summary, when a vehicle is traveling on a road, it may deflect along its vertical axis when encountering bumps and / or potholes, and may deflect along its longitudinal axis during braking / acceleration. The flared arm described herein can be used to distribute deflection and provide stiffness to the electric drive axle using the flared arm, thereby reducing performance degradation of the flared arm, electric drive axle, and other components. In a simplified example, the deflection of the flared arm along its vertical axis (e.g., perpendicular to the road surface relative to the Z-axis of axle system 150) results in two pivot points around which the flared arm deflects upward / downward. The first pivot point 1202 is located at the intersection of plane 428 and the inclined extension 430 of flange 414. The second pivot point 1204 is located at flange / arm transition 406. An inner support 408 extending from flange 414 along the inside of arm 422 reinforces the second pivot point 1204 and increases the strength of arm 422. Installing an external support (truss) 426 on the outside of the flange 414 (e.g., on the angled extension 430) can strengthen the first fulcrum 1202.

[0072] Illustration 1200 shows the top portion of the horn arm 402 (e.g., Figure 11A cross-sectional side view (above the central axis 436). As shown in Figure 1200, when a load (indicated by the first arrow 1206) guides the flared arm 402 upward (e.g., away from the drive surface), the outer support (truss, stringer) 426 is in a compressed state along the first side 1208. The inner support 408 is in a tensile state along the second side 1210 and the third side 1212. The flared arm 402 deflects upward relative to the Y-axis, as shown by the first dashed line 1214. Compared to the deflection of a flared arm without an internal bracket (truss) and / or an external bracket, the amount of deflection at the first fulcrum 1202 and the second fulcrum 1204 is reduced, and the stress is reduced.

[0073] Illustration 1250 shows a cross-sectional side view of the flared arm 402. The lower half 1254 of the flared arm 402 undergoes deflection as described below. The upper half 1252 of the flared arm 402 can be understood as undergoing deformation as described in illustration 1200. The construction of the inner support 408 and the outer inner support (truss) 426, as well as the load direction of the lower half of the flared arm 402, are likely the same as those of the upper half 1252, both reflected on the central axis 436. As indicated by the second arrow 1220 and the third arrow 1222, both the upper half 1252 and the lower half 1254 of the flared arm 402 bear downward loads. Therefore, the flared arm 402 includes a pair of first fulcrums 1202 located at the intersection of the plane 428 and the inclined extension 430 of the flange 414, and a pair of second fulcrums 1204 located at the flange / arm transition portion 406. For the upper portion 1252 of the flared arm 402, when the load is downward, the outer support (truss, stringer) 426 is under tension along the first side 1208. The inner support 408 is under compression along the second side 1210 and the third side 1212. As shown by the second dashed line 1216, the flared arm 402 deflects downward relative to the Y-axis. Compared to the deflection of a flared arm without outer and / or inner supports, the deflection of the pair of first supports 1202 and the pair of second supports 1204 is reduced, and the stress is lowered. For the lower portion 1254 of the flared arm 402, when the load is downward, the outer support (truss, stringer) 426 is under compression along the first side 1208. The inner support 408 is under tension along the second side 1210 and the third side 1212. The horn arm 402 deflects downward relative to the Y-axis, as shown by the third dashed line 1218. Compared to the deflection of a horn arm without external and / or internal supports, the amount of deflection and stress at a pair of first pivot points 1202 and a pair of second pivot points 1204 are smaller. This reduction in horn arm deflection can extend the service life of the horn arm and the electric axle because horn arm degradation at the first and second pivot points may be reduced due to the strength and stiffness provided by the internal and external supports.

[0074] Figure 4-12One embodiment of a horn arm is described, comprising a housing having an arm portion extending the arm length, the arm portion having an outlet at a first end and a planar flange at a second end opposite the first end; and an inner support disposed within the housing and extending through the flange length for at least a first portion, a flange / arm transition point where the flange transitions to the arm portion, and at least a portion of the arm length. Different embodiments of the horn arm including the above-described elements may include different geometries that can be used to configure the horn arm for use in different systems, such as electric axles for vehicles of different sizes and shapes. For example, the cross-section of the arm portion can be adjusted during the manufacture of the horn arm to form a horn arm embodiment suitable for electric drive systems such as passenger cars and heavy vehicles. Furthermore, the shape and size of the cross-section of the arm portion 422 can also provide space for mounting and / or coupling different suspension mounting components. Similarly, the orientation of the inner support legs of the horn arm may also differ in different embodiments of the horn arm. For example, different configurations of the inner support may include two or more legs. Figure 13 The illustration shows a possible cross-section 1300 of the flared arm described herein and the leg orientation 1350 of the inner support 408. The cross-section of the arm can be described as: square 1302, rectangular 1304, circular 1308, elliptical 1310, glass-shaped 1312, or a combination of two or more of these shapes 1314. The orientation of the inner support leg can be inclined ("x" shaped structure 1352, such as...). Figure 4-11 The structures described are: a "y" shaped structure 1354, a horizontal structure 1358, a vertical structure 1360, a "+" shaped structure 1362, a curved structure 1364, or a combination of two or more of these directions 1366.

[0075] Figure 14A-20 A second embodiment of the horn arm described herein is shown. (Compared to...) Figure 4-11 Similar to the horn arm 402, the horn arm 1402 includes a flange with a planar surface, wherein the flange connects to the arm portion at a flange / arm transition on the side of the flange opposite to the planar surface. Figure 14A-20 As further described, the flange of flared arm 1402 includes a curved extension from the plane to the flange / arm transition. Compared to the progressive transition in a Banjo or Salisbury axle, the curved extension can have the same or similar advantages as the angled extension of flared arm 402, where the flanges of flared arms 402 and 1402 provide a relatively abrupt transition at the flange / arm transition. This relatively abrupt transition can help provide an envelope of basic dimensions for encapsulating the electric axle assembly. The inner bracing can also provide strength and stiffness at the flange / arm transition comparable to or greater than that of Banjo and / or Salisbury axles, where the inner bracing and the curved extension can resist degradation of the flared arm, which may be caused by the flared arm shifting over time.

[0076] Please see Figure 14A and 14B The figure shows a first perspective view 1400 and a second perspective view 1450 of the horn arm 1402. The horn arm 1402 is Figure 2-3 An example of the first horn arm 216 and the second horn arm 218. Included in Figure 14A and 14B In Figure 2-3 The components can be numbered similarly (e.g., Figure 2-3 Flange 214 in the middle is equivalent to Figure 14A and 14B The horn arm 1402 includes a housing 1412 having an arm portion 1422 extending arm length 1432, the arm portion 1422 having an outlet 1420 at a second end 1444, and a flange 1414 having a plane 1428 at a first end 1442 opposite to the second end 1444. The horn arm 1402 further includes at least a first portion of the flange length disposed in the interior 1410 of the housing 1412 and extending through the flange 1414, a flange / arm transition portion 1406 where the flange 1414 transitions to the arm portion 1422, and an internal support member 1408 (e.g., such as...) for at least a portion of the arm length 1432. Figure 16 , 17 (as shown in Figure 20), as regarding Figure 17 and 20 Further description. The inner support 1408 may be cast as part of the housing 1412 (e.g., continuous with the housing 1412). In some embodiments, the inner support 1408 is formed as a component separate from the housing 1412 (e.g., a casting, stamping, forming, or machining) and is welded or otherwise fixedly disposed within the interior 1410 of the housing 1412. The housing 1412 and the inner support 1408 may be formed of the same material, such as cast steel, ductile iron, or cast aluminum. In other embodiments, the housing 1412 and the inner support 1408 may be formed of different metals or other rigid materials.

[0077] If correct Figure 1-3In brief, flange 1414 has a plurality of through holes 1416 arranged around the periphery of flange 1414, configured to allow fastening attachments such as bolts to pass through in order to couple flared arm 1402 to an electric vehicle axle assembly such as a gearbox housing and / or a motor housing. In some embodiments, each of the plurality of through holes 1416 may have a raised bolt washer 1418, which helps to position the fastening attachment (such as a bolt) and distribute bolt load. The raised bolt washer 1418 can further aid in fabricating flared arm 1402. In some embodiments, raised washer may or may not be used. For example, a dotted surface may be used instead. Each of the plurality of through holes 1416 may be strategically positioned around the periphery of flange 1414 so that each through hole 1416 is aligned with a coupling hole in the gearbox housing and / or motor housing.

[0078] In the second embodiment of the horn arm 1402, the flange 1414 has a circular profile, and a first portion 1452 along the periphery of the flange 1414 has a cutout 1454, such as... Figure 14B As shown. The size and shape of the cutout 1454 allow the components of the electric drive system (e.g., the gearbox, differential, and / or motor) to be compactly positioned within the envelope of the electronic axle, which forms the space between the two flared arms 1402, as... Figure 1-3 The flange 1414 also includes an arcuate extension 1430 extending from the plane 1428 to the flange / arm transition portion 1406. The arcuate extension 1430, in conjunction with the plane 1428, gives the flange 1414 a dome shape (convex when viewed from the second end 1444 of the housing 1412 towards the first end 1442), excluding the cutout 1454. Alternatively, in another example, the arcuate extension 1430, in conjunction with the plane 1428, may give the flange 1414 a concave shape (when viewed from the second end 1444 of the housing 1412 towards the first end 1442), excluding the cutout 1454. Figure 15 , 16 As further described in 17, 19, and 20, the internal area of ​​flange 1414 gradually decreases from plane 1428 to flange / arm transition portion 1406. The curved extension 1430 with cutout 1454 provides space in which an internal bracket 1408 can be included, and the shaft can extend through the interior 1410 of flared arm 1402 without contacting housing 1412 or internal bracket 1408. Furthermore, as further described herein, the curved extension 1430 may function similarly to... Figure 4-12 The external brackets (trusses, stringers) 426 provide additional support and stiffness at the two pivot points of the flared arm 402, thereby enabling the flared arm 402 to resist deformation and degradation caused by forces in the upward / downward, forward / backward, and / or torsional directions. Figure 4-12In the first embodiment of the flared arm 402, the outer support (truss, stringer) 426 and the inner support 408 form a first fulcrum on the plane 428 of the flange 414, and a second fulcrum on the flange / arm transition 406. In the second embodiment of the flared arm 1402, the arcuate extension 1430 can form a first fulcrum around the arcuate periphery 1458, wherein the arcuate extension 1430 intersects with the angled extension region 1456 of the flange 1414, which couples the arcuate extension 1430 to the plane 1428. Figure 12 As described in the first embodiment of the horn arm 402, a second pivot point may be formed at the flange / arm transition region 1406. Similar to illustration 1250, when the arm portion 1422 deflects in a first downward direction (e.g., toward the drive surface), both the first and second pivot points are rigid; similar to FIG. 1200, when the arm portion 1422 deflects in a second upward direction (e.g., away from the drive surface), both the first and second pivot points are rigid because the inner support rod 1408 is in a compressed state while the arcuate extension rod 1430 is in a tensioned state.

[0079] Both first perspective view 1400 and second perspective view 1450 show the geometry of housing 1412, where arm 1422 has a rectangular shape extending along arm length 1432, and outlet 1420 has an annular shape. Arm 1422 can gradually transition to outlet 1420, thus allowing the rectangle to smoothly transition to the annular shape without sharp (e.g., sloping) intersections. The rectangular shape of arm 1422 provides space within the interior 1410 of flared arm 1402 to position internal bracket 1408 and shafts (e.g., shafts 115, 117) therein. Further shaping of arm 1422 allows for the mounting of suspension assemblies of different shapes and sizes (e.g., from different manufacturers). Figure 17 and Figure 20 The internal bracket 1408 may partially extend into the outlet 1420. The annular shape of the outlet 1420 allows the shaft to be positioned therein without contacting the housing 1412. The annular shape of the outlet 1420 may further allow connection of a main shaft (e.g., a first main shaft 224, a second main shaft 226). In other embodiments, the outlet 1420 may be directly coupled to the non-rotating portion of the drive wheel. In other embodiments, the horn arm 1402 (e.g., as per [reference to...]) Figure 13 The (described) can have cross-sections of different shapes, which can be configured to be able to mount different suspension components thereon and / or integrate the horn arm 1402 into, for example, electronic axles of different sizes and shapes for different vehicle types.

[0080] Go to Figure 15 The figure shows a first side view 1500 and a second side view 1550 of the second embodiment of the horn arm 1402. For the sake of brevity, it will not be described again. Figure 14A and 14B The horn arm 1402 is an element described herein. The flange 1414 of the horn arm 1402 has a flange length 1508, the arm portion 1422 has an arm length 1432, and the inner support 1408 extends through at least a first portion of the flange length 1508, the flange / arm transition portion 1406, and at least a portion of the arm length 1432, as shown below. Figure 16 , 17 And 20 more descriptions.

[0081] Figure 16 Showing Figure 14A-15 First sectional view 1600 and second sectional view 1650 of the middle flared arm 1402. For the sake of brevity, Figure 14A-15 The components of the horn arm 1402 described herein will not be repeated. First sectional view 1600 shows the horn arm 1402 along the Y-axis, from flange 1414 to outlet 1420 (e.g., from the first end 1442 to the second end 1444 of housing 1412, as shown). Figure 14A and 14B The internal region 1434 of the horn arm 1402 is observed in the second sectional view 1650 along the Y-axis, viewing the interior 1410 of the horn arm 1402 from the outlet 1420 to the flange 1414 (e.g., from the second end 1444 to the first end 1442 of the housing 1412). In some embodiments, the horn arm 1402 includes one or more bolt holes 1610 arranged around the periphery of the plane 1428 and extending through the thickness of the plane 1428. The one or more bolt holes 1610 may be configured to receive bolt extensions, for example, from the gearbox housing and / or the motor housing, to aid in positioning the horn arm 1402 relative to the gearbox housing and / or the motor housing. In some embodiments, the one or more bolt holes 1610 may be circular and may be the same size, larger, or smaller than the plurality of through holes 1416.

[0082] like Figure 14A and 14B The inner support 1408 has an "X" configuration formed by four legs (e.g., first leg 1408a, second leg 1408b, third leg 1408c, and fourth leg 1408d), connecting the inner support 1408 to the arm portion 1422 and the curved extension 1430. Figure 16 The "x" configuration can be seen in the first sectional view 1600 and the second sectional view 1650. The "X" configuration of the internal bracket 1408 allows it to respond to vertical and horizontal forces, as well as torsional forces on the flared arm 1402, thus enabling the internal bracket 1408 to react. For example, in vehicles with electronic axles using the flared arm 1402 (such as...) Figure 1When vehicle 100 travels over protrusions and / or depressions on a driving surface (such as speed bumps, potholes), the inner support 1408 may be subjected to vertical forces. When the vehicle brakes and / or accelerates, the inner support 1408 may be subjected to horizontal and torsional forces. Figure 14A and 14B As further described, the inner support 1408 and the arcuate extension 1430 (whose function may be similar to the outer support (truss, stringer) 426 of the first embodiment of the flared arm 402) can keep the pivot point of the flared arm 1402 rigid when the flared arm is subjected to vertical and / or horizontal forces (e.g., deflection of the flared arm). This reduces the degradation of the flared arm 1402, especially at the flange / arm transition 1406. The second embodiment of the flared arm 1402 may also have an inner support 1408 with different configurations. For example, the inner bracket 1408 may include more or fewer than four legs, which may be in a "Y" configuration, a "+" configuration, etc. Figure 13 As stated above.

[0083] Figure 17 Showing a cross-sectional side view 1700 of the horn arm 1402, the section axis is from Figure 14B The line 1750 indicates this. For simplicity, Figure 14A-16 The components of the horn arm 1402 described herein will not be repeated. Figure 17 An embodiment of the configuration of the inner support 1408 in the housing 1412 of the horn arm 1402 is shown. In this embodiment of the horn arm 1402, as described above, the inner support 1408 includes four legs configured in an "X" shape. Figure 17The diagram shows a third leg 1408c and a fourth leg 1408d. It is understood that the first leg 1408a and the second leg 1408b have the same positioning as the third leg 1408c and the fourth leg 1408d, respectively, reflected on line segment 1750. The third leg 1408c and the fourth leg 1408d extend along the first portion 1708 of the flange length 1508 and the entire length of the arm length 1432, respectively. The third leg 1408c and the fourth leg 1408d can further extend the first length 1710 to the outlet 1420. The third leg 1408c and the fourth leg 1408d extend along the arcuate extension 1430 of the flange 1414 at an angle parallel to the arcuate outer surface 1438 of the arcuate extension 1430 to the first portion 1708 of the flange length 1508. At the flange / arm transition 1406, the shapes of the third leg 1408c and the fourth leg 1408d transition from an angle parallel to the arcuate extension 1430 to a horizontal extension parallel to the arm portion 1422. The horizontal extension extends to the third portion 1714 of the arm length 1432. Both the third leg 1408c and the fourth leg 1408d are offset from the central axis 1436 of the flared arm 1402, extending towards the wall of the arm portion 1422, and extending to the fourth portion 1716 of the arm length 1432 and the outlet 1420. Thus, the configuration of the third leg 1408c and the fourth leg 1408d, and the configuration of the four legs of the inner support 1408, provides rigidity and resistance to degradation at the flange / arm transition 1406, along the arm length 1432, and at the transition between the arm portion 1422 and the outlet 1420. Figure 13 The different embodiments of the internal bracket 1408 may include more or fewer four legs, the orientation of which differs from the "x" configuration.

[0084] Flange 1414 is configured to provide a rectangular envelope for positioning electric vehicle axle components in the electric vehicle axle. In some embodiments, plane 1428 may be a face on a first end 1442 of a plate or other planar structure. The bent extension 1430 is coupled to and / or continuous with the plate or planar structure having plane 1428 and extends in a direction away from plane 1428 (e.g., toward a second end 1444). Figure 14A-15 The arcuate extension 1430 has a dome-shaped form with a cutout 1454, wherein the internal area 1434 of the flange 1414 decreases from the first end 1442 towards the flange / arm transition portion 1406. Alternatively, the flange 1414 has a concave shape, wherein a first diameter 1720 is located at the first end 1442 of the flared arm 1402, which can be connected to the electric vehicle axle assembly, and a concave second diameter 1722 is located at the flange / arm transition portion 1406, wherein the first diameter 1720 is larger than the second diameter 1722. The arcuate extension 1430 can serve as an external support, providing stiffness and resistance to stress degradation.

[0085] The shapes (e.g., cross-sections) of arm length 1432 and arm portion 1422 can be configured to allow different suspension mount assemblies to be mounted to or otherwise coupled to arm portion 1422. The different suspension mount assemblies can be designed by the same or different manufacturers as those manufacturing horn arm 1402, so that arm portion 1422 is large enough to accommodate suspension mount assemblies of different shapes and sizes. In some embodiments, the suspension mount assembly can be coupled to horn arm 1402 along part or all of arm length 1432. For example, the suspension mount assembly can be connected to horn arm 1402 along a third portion 1714 of arm portion 422, while not connected to horn arm 1402 at a fourth portion 1716 of arm length 432. The cutout 1454 of flange 1414 can also provide space for positioning of the gear cover. For example, at least a portion of the gear cover can extend from arm length 1432 through cutout 1454 into flange length 1508. Figure 13 The different embodiments of the horn arm may have arm cross sections of different shapes (e.g., circular cross section, small glass cross section, etc.), and all of these cross sections can be configured to accommodate multiple different suspension mounting components.

[0086] Figure 18 Showing about Figure 14A-17 The perspective view 1800 of the horn arm 1402 shows a main shaft 1826 connected to the horn arm 1402 at the outlet 1420. The main shaft 1826 can be an example of a first main shaft 224 or a second main shaft 226, such as... Figure 1-3 As described above. The main shaft 1826 is connected to the horn arm 1402 at its first end 1842, and a drive wheel (not shown) can be connected to the main shaft 1826 at its second end 1844, opposite to the first end 1842. For example, the main shaft 1826 can be coupled to the horn arm 1402 by friction welding. Figure 1-3 The shaft that provides rotational motion from a rotational power source (e.g., motor 106) to the drive wheel may pass through the interior 1410 of the horn arm 1402 and through the interior 1810 of the main shaft 1826 to couple to the drive wheel. In some embodiments, the main shaft 1826 may be coupled to a non-rotatable element of the drive wheel. In other embodiments, the main shaft 1826 may be adjacent to and axially aligned with the center of the drive wheel, but may not be in contact with the drive wheel. In some embodiments, the shaft may protrude from a second end 1844 of the main shaft 1826, in which case the shaft may be connected to the drive wheel, and the main shaft 1826 may not be in contact with the drive wheel. Figure 19 A side view 1900 of the horn arm 1402 is shown, as... Figure 18 The main shaft 1826 is connected to the horn arm 1402 at the outlet 1420.

[0087] Figure 20A cross-sectional side view 2000 of the horn arm 1402 is shown, on which the main shaft 1826 is connected, as shown. Figure 18-19 The first cross-sectional side view 2000 shows the horn arm 1402 and the main shaft 1826 along... Figure 18 The line shown is cut at 2050. (As shown) Figure 14A-19 The inner support 1408 has a leg that extends from the flange 1414, passes through the flange / arm transition portion 1406, and extends along the arm length 1432 of the arm portion 1422. Figure 20 In the embodiment of the horn arm 1402 shown, the arms of the inner support 1408 (e.g., the first leg 1408a and the second leg 1408b) extend toward the central axis 1436 of the horn arm 1402 in an "X" configuration. Alternatively, the first leg 1408a and the second leg 1408b (as well as the third leg 1408c and the fourth leg 1408d) Figure 20 Each leg of the inner bracket (not shown) extends at an angle from the arcuate extension 1430 toward the central axis 1436 of the flared arm 1402, such that there is space between each leg of the inner bracket and between the inner bracket 1408 and the housing 1412 (e.g., the wall of the arm 1422). Alternatively, in the fourth portion 1716 of the arm length 1432, the legs of the inner bracket 1408 can expand outward from the central axis 1436 of the flared arm 1402 while still in an "X" configuration. This configuration provides strength and rigidity to the arm portion 1422 while providing positioning space for the shaft. As described herein, the inner support 1408 can extend into the outlet 1420 but not into the main shaft 1826. Therefore, the inner support 1408 provides rigidity and prevents degradation of the flared arm 1402 at the flange 1414, the flange / arm transition portion 1406, and the arm length 1432 of the arm portion 1422.

[0088] The flared arm features internal support and a planar flange, which, compared to conventional axle arms, improves the strength, stiffness, and resistance to stress degradation at the flange / arm transition. The service life of the flared arm is also increased. Furthermore, the usability of the flared arm in electric vehicle axles is enhanced because the planar flange provides a rectangular envelope for mounting electric vehicle axle assemblies. In addition, the flared arm described herein can have different internal support leg configurations and arm section cross-sections, providing space for mounting different suspension components and giving the flared arm sufficient and desirable strength for use in various systems, such as passenger cars and / or heavy-duty electric vehicles.

[0089] This disclosure also provides a support device for a flared arm of an axle, the device comprising: a housing with an arm portion extending the arm length, the arm portion having an outlet at a first end and a planar flange at a second end opposite the first end; and an inner support disposed within the housing and extending through the flange length for at least a first portion, a flange / arm transition point where the flange transitions to the arm portion, and at least a portion of the arm length. In a first example of the system, the inner support comprises one or more legs extending from the housing wall into the housing in an "X", "Y", horizontal, vertical, "+", curved, or combination of two or more of the above shapes. In a second example of the system, optionally including the first example, the cross-section of the arm portion is square, rectangular, circular, elliptical, hourglass-shaped, or a combination of two or more of the above shapes. In a third example of the system, optionally including one or both of the first and second examples, the system further comprises: an outer support extending a second portion of the flange length to the flange / arm transition point, wherein the endpoint of the outer support is offset from the endpoint of the inner support. In a fourth example of the system, one or more of the first to third examples may be optionally included, wherein the flange includes an inclined extension from the plane to the flange / arm transition. In a fifth example of the system, one or more of the first to fourth examples may be optionally included, wherein the flange includes a curved extension from the plane to the flange / arm transition. In a sixth example of the system, one or more of the first to fifth examples may be optionally included, wherein the system further includes a spindle connected to the housing at the outlet of the arm portion. In a seventh example of the system, one or more of the first to sixth examples may be optionally included, wherein the cross-section of the arm portion maintains a constant profile throughout the arm length. In an eighth example of the system, one or more of the first to seventh examples may be optionally included, wherein the system further includes a plurality of through holes surrounding the periphery of the flange, wherein one or more of the plurality of through holes includes raised bolt pads. In a ninth example of the system, one or more of the first to eighth examples may be optionally included, wherein the internal area of ​​the flange decreases from the first end to the flange / arm transition. In the tenth example of the system, one or more of the first to ninth examples may be optionally included, wherein the housing and internal support are formed of cast steel, cast aluminum and / or ductile iron. In the eleventh example of the system, one or more of the first to tenth examples may be optionally included, wherein the housing and internal bracket are formed as various cast, stamped or machined component fixtures and assembled as welded parts.

[0090] This disclosure also provides a support device for an electronic axle, comprising: a motor, a first horn arm, and a second horn arm, wherein at least one of the first and second horn arms includes a housing having an arm portion extending the arm length, a flange having a planar shape at a first end of the arm length, and an inner support disposed within the housing, wherein the first and second horn arms are each configured to be coupled to the motor via their respective flanges. In a first example of the system, the inner supports of the first and second horn arms extend through at least a first portion of the flange length, a flange / arm transition (where the flange transitions to the arm portion), and at least a portion of the arm length. In a second example of the system, optionally including the first example, the system further includes: a differential lock / axle disconnect assembly having a shift fork and a slip ring disposed in the flange of the first or second horn arm, the shift fork and slip ring being configured to engage with a cooperating clutch of the motor, wherein the differential lock / axle disconnect assembly is pneumatically, hydraulically, electrically, or magnetically operated. In a third example of the system, optionally including one or both of the first and second examples, the differential lock / bridge disconnect assembly includes a differential lock / bridge disconnect actuator extending through the flange length of the first or second horn arm flange. In a fourth example of the system, optionally including one or more of the first to third examples, the system further includes: one or more positioning bolts extending from the flange of each of the first and second horn arms to a motor, and / or one or more guide diameters extending into the flange of each of the first and second horn arms and configured to receive one or more connectors of the motor. In a fifth example of the system, optionally including one or more of the first to fourth examples, the system further includes: a suspension assembly connected at its respective arm portion to at least one of the first and second horn arms. In a sixth embodiment of the system, which may optionally include one or more of the first to fifth embodiments, the system further includes: a first spindle and a second spindle, respectively coupled to each of the first and second horn arms, located at the second end of the arm length, opposite to the first end of the arm length, and located at the first spindle end of the respective spindle; and a first wheel and a second wheel, respectively coupled to each of the first and second spindles, located at the second spindle end of the respective spindle, opposite to the first spindle end of the spindle.

[0091] This disclosure also provides a bracket for an axle housing, comprising an arm segment extending the arm length, a flange extending the flange length and having a flat surface at a first end of the flange length, the flange connecting to the arm segment at a flange / arm transition, an inner support located inside the flange and the arm segment, the inner support extending at least a portion of the arm length and at least a first portion of the flange length, an outer support located outside the flange, the outer support extending at least a second portion of the flange length, a pair of first supports located on the plane of the flange, and a pair of second supports located at the flange / arm transition, wherein in the upper half of the axle housing... The internal support beam is in a compressed state, and the external support beam is in a stretched state. In the lower half of the axle housing, the internal support beam is in a stretched state, and the external support beam is in a compressed state. When the arm part deflects in the first downward direction, both the first support point and the second support point are rigid. In the upper half of the axle housing, the internal support is in a stretched state, and the external support is in a compressed state. In the lower half of the axle housing, the internal support is in a compressed state, and the external support is in a stretched state. When the arm part deflects in the second upward direction, both the first support point and the second support point are rigid.

[0092] Figure 1-20 Example configurations showing the relative positioning of various components are illustrated. If the components shown in the figure are in direct contact or directly coupled to each other, then in at least one example, these components may be referred to as being in direct contact or directly coupled, respectively. Similarly, in at least one example, components shown as adjacent or adjacent to each other may be referred to as being adjacent or adjacent to each other, respectively. For example, components that are face-to-face in contact with each other may be referred to as face-to-face contact components. Another example is that, in at least one example, components are placed apart from each other, with only space between them and no other components, which may be referred to as being placed apart from each other. Furthermore, components shown above / below each other, to the sides of each other, or to the left / right of each other relative to each other may be referred to as such components. Additionally, as shown in the figure, in at least one example, the topmost component or component point may be referred to as the "top" of the component, and the bottommost component or component point may be referred to as the "bottom" of the component. As used herein, up / down, up / down, and up / down may be relative to the vertical axis in the figure to describe the positioning of the elements in the figure relative to each other. Thus, in one example, an element shown above other elements is vertically positioned above the other elements. For example, the shapes of the elements depicted in the diagram can be described as having these shapes (e.g., circles, straight lines, flat surfaces, curved shapes, rounded corners, chamfered corners, beveled corners, or similar shapes). Furthermore, in at least one example, elements that intersect each other can be described as intersecting elements or intersecting with each other. Additionally, in one example, elements shown inside or outside another element can also be described as intersecting elements.

[0093] It is understood that the configurations and routines disclosed herein are exemplary in nature, and these specific implementations are not limiting, as many variations are possible. Furthermore, unless explicitly stated otherwise, the terms "first," "second," "third," etc., do not indicate any order, position, quantity, or importance, but are merely labels used to distinguish one element from another. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0094] The term "approximate" as used in this article, unless otherwise stated, should be understood as a range of plus or minus 5%.

[0095] The following claims specifically point to certain combinations and sub-combinations considered novel and non-obvious. These claims may refer to an "a" element or a "first" element or an equivalent element. These claims should be understood to include one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and / or characteristics may be claimed by amending these claims or by setting new claims in this application or related applications. These claims, whether broader or narrower in scope, identical or different from the original claims, are also considered to be included in the subject matter of this disclosure.

Claims

1. A flared arm (1402, 402) for an axle, comprising: A housing (412, 1412) having arms (1422, 422) extending arm lengths (1432, 432), the arms (1422, 422) having an outlet (1420, 420) at a first end (444, 1444) and a flange (414, 1414) with a flat surface (1428, 428) at a second end (1442, 442) opposite the first end (444, 1444); and An inner support (1408, 408) is disposed inside the housing (412, 1412) (1410, 410) and extends through at least a first portion (1708) of the flange length (608) of the flange, the flange / arm transition (406, 1406) where the flange transitions to the arm portion, and at least a portion (612) of the arm length.

2. The horn arm of claim 1, further comprising an outer support (426) extending a second portion of the flange length to the flange / arm transition, wherein the endpoint of the outer support is offset from the endpoint of the inner support.

3. The horn arm of claim 1, wherein the flange includes an inclined extension (430) from the plane to the transition of the flange / arm.

4. The horn arm of claim 1, wherein the flange includes a curved extension (1430) from the plane to the transition of the flange / arm.

5. The horn arm as claimed in claim 1 further includes a main shaft (154, 726, 1826), the main shaft (154, 726, 1826) being connected to the housing at the arm outlet.

6. The horn arm as claimed in claim 1, wherein the cross-section of the arm portion maintains a constant profile throughout the entire arm length.

7. The horn arm of claim 1, further comprising a plurality of through holes (416, 1416) surrounding the periphery of the flange, wherein one or more of the plurality of through holes includes a raised bolt washer (418, 1418).

8. The horn arm as claimed in claim 1, wherein the internal area (434, 1434) of the flange decreases from the first end toward the transition of the flange / arm.

9. The horn arm as claimed in claim 1, wherein the housing and the inner support are made of cast steel, cast aluminum and / or ductile iron.

10. The horn arm of claim 1, wherein the housing and the inner support are formed in the form of various casting, stamping or machining component fixtures and assembled together as welded parts.

11. Electronic axle (104), including: Motors (206, 106); First horn arm (1402, 402); as well as The second horn arm (1402, 402), wherein at least one of the first horn arm and the second horn arm includes a housing having an arm portion (1422, 422) extending the arm length (1432, 432), having a planar flange (414, 1414) at a first end (1444, 444) of the arm length, and an inner support (1408, 408) disposed inside the housing (1410, 410), wherein the first horn arm and the second horn arm are respectively coupled to the motor through their respective flanges (414, 1414).

12. The electronic axle of claim 11, wherein the inner support of the first horn arm and the second horn arm extends through at least a first portion (1708) of the flange length (608, 1508) of the flange, the flange / arm transition (406, 1406) where the flange transitions to the arm portion, and at least a portion (612) of the arm length.

13. The electronic axle of claim 11, further comprising a differential lock / axle disconnect assembly (1002, 260) having a shift fork and a sliding ring (1004) positioned in the flange of the first or second horn arm, the shift fork and sliding ring being paired with a mating clutch (1104) of the motor, wherein the differential lock / axle disconnect assembly is pneumatically, hydraulically, electrically, or magnetically operated.

14. The electronic axle of claim 13, wherein the differential lock / axle disconnect assembly includes a differential lock / axle disconnect actuator (1008) passing through the first horn arm or the second horn arm flange and extending along the flange length (608, 1508) of the first horn arm or the second horn arm flange.

15. The electronic axle of claim 11, further comprising a first spindle (224) and a second spindle (226) respectively coupled to each of the first and second horn arms, the first spindle (224) and the second spindle (226) being located at the second end (1442, 442) of the arm length, opposite to the first end of the arm length, and located at the first spindle end of their respective spindles; and a first wheel (112) and a second wheel (114) respectively coupled to each of the first and second spindles, the first wheel (112) and the second wheel (114) being located at the second spindle end of their respective spindles, opposite to the first spindle end of their respective spindles.

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