Integrated drive axle for electric motorcycle
By integrating an aluminum alloy axle and a permanent magnet synchronous motor, combined with a single-stage parallel gear transmission and an integrated structure, the problems of low efficiency and poor reliability of existing electric motorcycle drive axles have been solved, achieving high-efficiency and quiet drive axle performance to meet the needs of high-performance electric motorcycles.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- JIANGSU XINWEI POWER TECH CO LTD
- Filing Date
- 2025-06-13
- Publication Date
- 2026-07-07
AI Technical Summary
Existing electric motorcycle drive axles use steel axle bodies and brushless motors with built-in two-stage reducers, resulting in low efficiency, poor reliability, and high noise, which cannot meet the requirements of high-performance electric vehicles.
It adopts an integrated design of aluminum alloy bridge body and permanent magnet synchronous motor, combined with single-stage parallel gear transmission and integrated structure, including high-efficiency permanent magnet synchronous motor, driven gear and differential integrated design, motor and reducer integrated into one unit, and uses oil lubrication and magnetic encoder or resolver position sensor.
It improves the efficiency and reliability of the drive axle, reduces transmission losses, enhances the overall steering performance and driving comfort of the vehicle, and meets the power requirements of high-performance electric motorcycles.
Smart Images
Figure CN224465575U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of electric motorcycle technology, specifically to an integrated drive axle for electric motorcycles. Background Technology
[0002] With the widespread adoption of electric vehicles and the continuous improvement of relevant national regulations, there is an increasing demand for higher power, greater energy efficiency, higher power density, lighter weight, and quieter operation. Currently, the common practice in the drive axle industry is to use a steel axle body with a built-in two-stage reducer and a brushless motor, assembled separately. However, the brushless motor lacks magnetic reluctance torque, has low efficiency, and poor reliability in the long run. The reducer is noisy and has low transmission efficiency. Drive axles frequently experience motor burnout, which can no longer meet the needs of future high-performance electric vehicles. Utility Model Content
[0003] In view of this, the purpose of this utility model is to provide an integrated drive axle for electric motorcycles, to solve the current problems in the industry where the common practice is to use a steel axle body with a built-in two-stage reducer and a brushless motor, assembled separately. The brushless motor has no reluctance torque, low efficiency, and poor reliability. The reducer is noisy and has low transmission efficiency. The drive axle frequently experiences motor burnout, which no longer meets the technical requirements of future high-performance electric vehicles.
[0004] To achieve the above objectives, this utility model employs the following technical solution:
[0005] An integrated drive axle for an electric motorcycle includes an axle body, a sway mechanism, a brake, a hub flange, a half-shaft, a driven gear, a differential, a motor shaft, a motor stator, a motor rotor, and an encoder. The differential, half-shaft, hub flange, brake, axle body, and sway mechanism form an integrated drive axle. The axle body, consisting of a motor stator, motor rotor, and encoder, forms a high-efficiency permanent magnet synchronous motor.
[0006] As a preferred technical solution of this utility model, it also includes a speed reducer, which adopts a single-stage parallel gear transmission, and the input gear of the speed reducer is designed as an integral part of the motor shaft.
[0007] As a preferred technical solution of this utility model, the driven gear and the differential are designed as one unit.
[0008] As a preferred technical solution of this utility model, the bridge body is made of aluminum alloy or other lightweight alloy materials.
[0009] As a preferred technical solution of this utility model, the electric motorcycle frame is connected to the drive axle via a rocker arm to serve as the vehicle's suspension.
[0010] As a preferred technical solution of this utility model, the integrated drive axle is powered by a permanent magnet synchronous motor, and the position sensor is a magnetic encoder or a resolver.
[0011] As a preferred embodiment of this utility model, the reducer is integrated with the motor.
[0012] The beneficial effects of this utility model are as follows:
[0013] The integrated drive axle provided by this utility model consists of a motor stator, a motor rotor, and an encoder, forming a high-efficiency permanent magnet synchronous motor. The motor shaft transmits power to the driven gear, the driven gear transmits power to the differential, the differential transmits power to the half-shaft, the half-shaft transmits power to the wheel hub flange, and the wheel hub flange connects to the wheel hub, thereby driving the vehicle forward.
[0014] The integrated drive axle provided by this utility model uses aluminum alloy or other lightweight alloy materials for the axle body, which can significantly reduce its weight compared to traditional steel rear axles. The electric motorcycle frame is connected to the drive axle via a swingarm to serve as the vehicle's suspension. This improves the overall steering performance, agility, and driving comfort of the vehicle.
[0015] The drive axle is powered by a permanent magnet synchronous motor, which features high efficiency and high power density, resulting in higher output efficiency for the drive axle. Position sensors utilize magnetic encoders or resolvers, and the reducer is integrated with the motor. The lubricating oil serves both to lubricate the gears and cool the motor.
[0016] This utility model's reducer uses a single-stage parallel gear transmission. Its input gear is integrated with the motor shaft, reducing space requirements. Compared to traditional separate designs, it uses a spline connection, and the integrated design of the gear and motor shaft reduces transmission losses and potential failure points. The driven gear and differential are integrated, and the gears are lubricated with oil, which also effectively cools the motor.
[0017] Other advantages, objectives, and features of this invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination and study, or may be learned from practice of this invention. The objectives and other advantages of this invention can be realized and obtained through the following description. Attached Figure Description
[0018] Figure 1 This is a schematic diagram of the external structure of the integrated drive axle for electric motorcycles according to this utility model. Figure 1 ;
[0019] Figure 2 This is a schematic diagram of the external structure of the integrated drive axle for electric motorcycles according to this utility model. Figure 2 ;
[0020] Figure 3 This is a schematic diagram of the external structure of the integrated drive axle for electric motorcycles according to this utility model. Figure 3 ;
[0021] Figure 4 Appendix to the specification of this utility model Figure 4 A schematic diagram of the cross-sectional structure along direction A;
[0022] In the diagram: 1. Bridge body; 2. Oscillator; 3. Brake; 4. Hub flange; 5. Half shaft; 6. Driven gear; 7. Differential; 8. Motor shaft; 9. Motor stator; 10. Motor rotor; 11. Encoder. Detailed Implementation
[0023] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0024] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0025] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0026] In the above description of this utility model, it should be noted that the terms "one side," "the other side," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. In addition, the terms "first," "second," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0027] Furthermore, terms such as "identical" do not imply that components must be absolutely identical; minor differences are permissible. The term "perpendicular" simply means that the positional relationship between components is more perpendicular than "parallel," not that the structure must be perfectly perpendicular; a slight tilt is acceptable.
[0028] Example 1
[0029] Please see Figure 1-4 The present invention provides a technical solution: an integrated drive axle for an electric motorcycle, comprising an axle body 1, a rocker 2, a brake 3, a hub flange 4, a half shaft 5, a driven gear 6, a differential 7, a motor shaft 8, a motor stator 9, a motor rotor 10, and an encoder 11. The differential 7, half shaft 5, hub flange 4, brake 3, axle body 1, and rocker 2 form an integrated drive axle, and the axle body 1, consisting of the motor stator 9, motor rotor 10, and encoder 11, forms a high-efficiency permanent magnet synchronous motor.
[0030] Specifically, in this embodiment, the integrated drive axle provided by this utility model consists of a motor stator, a motor rotor, and an encoder, forming a high-efficiency permanent magnet synchronous motor. The motor shaft transmits power to the driven gear, the driven gear transmits power to the differential, the differential transmits power to the half-shaft, the half-shaft transmits power to the wheel hub flange, and the wheel hub flange connects to the wheel hub, thereby driving the vehicle forward.
[0031] Specifically, in this embodiment, the integrated drive axle for the electric motorcycle also includes a reducer. The reducer adopts a single-stage parallel gear transmission, and the input gear of the reducer is designed as an integral part of the motor shaft 8. The reducer of this invention uses a single-stage parallel gear transmission. Its input gear is designed as an integral part of the motor shaft, reducing the spatial dimensions compared to the traditional separate design. The spline connection and integrated design of the gear and motor shaft reduce transmission losses and potential failure points. The driven gear and differential are designed as an integral part, and the gear is lubricated with oil, which also plays a good role in heat dissipation for the motor.
[0032] Example 2
[0033] Please see Figure 1-4 This is another technical solution provided by the present invention. This embodiment has the same features as the above embodiment 1, and the similarities will not be described in this embodiment. The specific differences are as follows:
[0034] An integrated drive axle for an electric motorcycle includes an axle body 1, a rocker 2, a brake 3, a hub flange 4, a half shaft 5, a driven gear 6, a differential 7, a motor shaft 8, a motor stator 9, a motor rotor 10, and an encoder 11. The differential 7, half shaft 5, hub flange 4, brake 3, axle body 1, and rocker 2 form an integrated drive axle. The axle body 1, composed of the motor stator 9, motor rotor 10, and encoder 11, forms a high-efficiency permanent magnet synchronous motor.
[0035] Specifically, in this embodiment, the integrated drive axle provided by this invention comprises a motor stator, a motor rotor, and an encoder, forming a high-efficiency permanent magnet synchronous motor. The motor shaft transmits power to the driven gear.
[0036] Driven gear 6 and differential 7 are designed as a single unit. Driven gear transmits power to differential, differential transmits power to half-shaft, half-shaft transmits power to wheel hub flange, wheel hub flange connects to wheel hub, thus driving the vehicle forward.
[0037] Specifically, in this embodiment, the bridge body 1 is made of aluminum alloy or other lightweight alloy materials. The integrated drive axle provided by this utility model, with the bridge body made of aluminum alloy or other lightweight alloy materials, can greatly reduce its weight compared to the traditional steel rear axle.
[0038] The electric motorcycle frame is connected to the drive axle via the rocker arm 2 to serve as the vehicle's suspension, which improves the vehicle's steering performance, agility, and driving comfort.
[0039] Specifically, in this embodiment, the integrated drive axle is powered by a permanent magnet synchronous motor, and the position sensor is a magnetic encoder or resolver. The permanent magnet synchronous motor, with its high efficiency and high power density, contributes to higher output efficiency. The position sensor uses a magnetic encoder or resolver.
[0040] The reducer and motor are integrated into one unit, and the lubricating oil can both lubricate the gears and cool the motor.
[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of this utility model without departing from the spirit and scope of the technical solutions of this utility model, and all such modifications or substitutions should be covered within the scope of the claims of this utility model.
Claims
1. An integrated drive axle for an electric motorcycle, comprising an axle body (1), a sway bar (2), a brake (3), a hub flange (4), a half shaft (5), a driven gear (6), a differential (7), a motor shaft (8), a motor stator (9), a motor rotor (10), and an encoder (11), characterized in that: The differential (7), half shaft (5), hub flange (4), brake (3), axle body (1), and rocker (2) form an integrated drive axle. The axle body (1) is composed of motor stator (9), motor rotor (10), and encoder (11) forming a permanent magnet synchronous motor.
2. The integrated drive axle for an electric motorcycle according to claim 1, characterized in that: It also includes a speed reducer, which uses a single-stage parallel gear transmission. The input gear of the speed reducer is designed as an integral part of the motor shaft (8).
3. The integrated drive axle for an electric motorcycle according to claim 2, characterized in that: The driven gear (6) and the differential (7) are designed as one unit.