A high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models

Abstract

A high-efficiency integrated electric drive axle assembly designed for light commercial vehicles includes a motor, a reducer, an axle housing assembly, and wheel assemblies. The motor and reducer housings are mounted on the axle housing assembly, with wheel assemblies located on both sides of the axle housing assembly. The motor transmits power to the wheel assemblies via the reducer. The reducer includes an aluminum alloy housing containing a gearbox connected to an input shaft and an output shaft. An input shaft oil seal (a low-friction oil seal) is mounted on the input shaft, and an oil baffle is located below the input shaft and bolted to the inside of the housing. The wheel assemblies include a wheel hub with a brake disc mounted on it. An intelligent wheel speed sensor is mounted on the wheel assemblies, and a heat shield is located below the intelligent wheel speed sensor to insulate the brake disc from heat. This invention addresses issues of reliability, integration, efficiency, and lightweight design to a certain extent.

Description

Technical Field

[0001] This utility model belongs to the field of automotive parts technology, specifically relating to a high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models. Background Technology

[0002] The electric drive axle assembly is one of the core components of an electric vehicle, connected to the vehicle body via the suspension. The electric drive axle consists of an axle housing assembly, a reducer, a motor, half-shafts, brakes, etc., and has the functions of load bearing, torque transmission, and braking.

[0003] Axle housing assemblies can be divided into two categories based on their structure: integral and segmented. Currently, commercial vehicles mostly use integral structures. Axle housing assemblies can also be divided into two categories based on their manufacturing process: stamped and welded and cast. Due to their light weight and wide adaptability, stamped and welded axle housing assemblies are widely used.

[0004] Electric drive axle reducers are divided into coaxial and parallel shaft types. Coaxial electric drive axles are more expensive and difficult to maintain, making them unsuitable for light commercial vehicles. Parallel shaft structures currently have lower integration compared to coaxial structures, but they offer advantages in cost and maintenance. Parallel shaft electric drive axles are more commonly used in light commercial vehicles on the market, but they all suffer from higher overall axle weight and lower efficiency.

[0005] At present, the drive motors commonly used in pure electric vehicles mainly include permanent magnet synchronous motors and AC asynchronous motors, with the majority using permanent magnet synchronous motors and a small number of vehicles using AC asynchronous motors.

[0006] Currently, wheel rim assembly bearings are divided into three types: bearing units, ordinary oil-lubricated wheel rims, and ConMet wheel rims. Bearing unit type is maintenance-free and is more widely used in the market.

[0007] ① The BYD SEQ04 uses a parallel-shaft electric drive axle, suitable for 6-7 meter new energy buses and light trucks, covering scenarios such as urban public transport and logistics light trucks. It integrates the motor, reducer, differential, and axle housing into one unit, eliminating the traditional drive shaft and independent transmission, thus shortening the drive chain. The axle housing uses a commonly used stamped and welded design, while the reducer housing is made of steel-aluminum alloy. The entire axle load is 3500kg, and the reducer has three shafts and two stages with a speed ratio of 16.029.

[0008] ② The Jiangling + Bosch integrated electric drive axle also adopts a parallel shaft distribution, with a total axle load of 4000kg. The reducer has three shafts and two stages, with a speed ratio of 16.07, and the reducer housing is made of magnesium-aluminum alloy.

[0009] The disadvantages of the existing technology are shown in the table below: With the shift from large-scale to small-scale passenger transport, the main motivation for customers to purchase pure electric vehicles (converting from gasoline to electric) is to save on operating costs. The main pain points of existing products are lifespan and range. Therefore, electric light commercial vehicles have higher requirements for the reliability, integration, efficiency and lightweighting of the power system. Existing integrated electric drive axles can no longer meet market requirements. Utility Model Content

[0010] The technical problem to be solved by this utility model is: how to solve the problems of reliability, integration, efficiency and lightweighting of electric vehicles, and to provide a high-efficiency integrated electric drive axle assembly designed for light passenger vehicle models.

[0011] To solve the above problems, this utility model is achieved through the following technical solution: A high-efficiency integrated electric drive axle assembly designed for light commercial vehicles includes a motor, a reducer, an axle housing assembly, and wheel assemblies; the housings of the motor and reducer are disposed on the axle housing assembly, and wheel assemblies are disposed on both sides of the axle housing assembly; the motor transmits power to the wheel assemblies through the reducer. The reducer includes an aluminum alloy housing, a gearbox is installed inside the aluminum alloy housing, the gearbox is connected to an input shaft and an output shaft, an input shaft oil seal is installed on the input shaft, the input shaft oil seal is a low friction oil seal, and an oil baffle is installed below the input shaft, the oil baffle is fixed inside the housing by bolts; The wheel assembly includes a wheel hub, a brake disc is fitted over the wheel hub, an intelligent wheel speed sensor is mounted on the wheel assembly, and a heat shield is mounted below the intelligent wheel speed sensor to insulate the heat from the brake disc.

[0012] The motor has an aluminum alloy housing.

[0013] The bridge housing assembly includes a lightweight bridge housing, on which wiring harnesses and conduit supports are provided.

[0014] A dust cover is installed on the outside of the brake disc.

[0015] Compared with the prior art, the present invention has the following advantages: The electric drive axle of the present invention adopts a high-efficiency parallel shaft reducer structure, and the lightweight housing and axle housing can integrate the vehicle braking harness and pipeline, which solves the problems of reliability, integration, efficiency and lightweight to a certain extent. Attached Figure Description

[0016] Figure 1 This is an overall structural diagram of the present invention; Figure 2 This is a structural diagram of the oil baffle plate in the reducer; Figure 3 This is a structural diagram of the input shaft oil seal in the reducer; Figure 4This is a structural diagram of the dust cover in the wheel-side assembly; Figure 5 This is a structural diagram of the wheel speed sensor and heat shield in the wheel-side assembly. Detailed Implementation

[0017] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0018] In the description of this utility model, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. 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.

[0019] like Figure 1 As shown, a high-efficiency integrated electric drive axle assembly designed for light commercial vehicles includes a motor 1, a reducer 2, an axle housing assembly 3, and a wheel-side assembly 4. The electric drive axle assembly is optimized based on the actual road conditions of light commercial vehicles.

[0020] The housings of the motor 1 and the reducer 2 are mounted on the axle housing assembly 3. Wheel assemblies 4 are mounted on both sides of the axle housing assembly 3. The motor 1 transmits power to the wheel assemblies 4 through the reducer 2.

[0021] Among them, motor 1 adopts an aluminum alloy shell, uses high-grade magnets and low-loss 0.25mm silicon steel sheets, and optimizes the motor topology to reduce losses in the high-speed, low-torque region of the motor, achieving a maximum efficiency of over 98%, with a 3-6% improvement in constant speed point efficiency. It is suitable for vehicle application conditions, improving the efficiency of the motor system by 2-5%, ensuring product competitiveness. The motor weighs 49kg and has a design life of 20 years or 2 million kilometers.

[0022] like Figure 2 , Figure 3As shown, the reducer 2 includes an aluminum alloy housing 21, within which a gearbox is housed. The gearbox connects to an input shaft and an output shaft. An input shaft oil seal 22, which is a low-friction oil seal, is installed on the input shaft. An oil baffle 23 is located below the input shaft and is bolted to the inside of the housing. The oil baffle 23 is used to reduce oil churning losses in the gears. The gearbox uses 75W low-viscosity gear oil. The reducer weighs 37 kg and has a design life of 15 years (1.5 million kilometers).

[0023] like Figure 1 As shown, the axle housing assembly 3 includes a lightweight axle housing 31 with a cross-section of 86*90*7mm. The axle housing assembly 3 weighs 48kg and has a durability of 20 years or 2 million kilometers. Wiring harnesses and conduit supports 32 are installed on the lightweight axle housing 31, which is convenient for customers and saves space in the vehicle layout.

[0024] like Figure 4 , Figure 5 As shown, wheel assembly 4 adopts a maintenance-free bearing unit structure. The wheel assembly features a lightweight design, with bearing specifications of φ55*φ90*70. Wheel assembly 4 weighs 21kg, and the bearing life can meet 2 million km for light commercial vehicle operating conditions.

[0025] The wheel assembly 4 includes a wheel hub 41, a brake disc 45 is fitted over the wheel hub 41, and an intelligent wheel speed sensor 42 is installed on the wheel assembly 4. The intelligent wheel speed sensor 42 is used to detect the gear ring signal and can accurately detect the driving direction of the wheel. A heat shield 43 is installed below the intelligent wheel speed sensor 42. The heat shield 43 is used to isolate the heat of the brake disc 45 and protect the intelligent wheel speed sensor 42.

[0026] Even better, a dust cover 44 is provided on the outside of the brake disc 45. The dust cover 44 prevents sand and gravel from entering the wheel-side braking system and causing damage to the brake disc 45 and the brake. The structure of the heat insulation cover 43 and the dust cover 44 in this utility model extends the service life of the brake and wheel speed sensor.

[0027] The specific parameters of this utility model are as follows: The beneficial effects of this utility model are as follows: 1. Motor and reducer matching design scheme: Motor peak power / torque: 180Kw / 370Nm, reducer speed ratio: 12.665. Both the motor and reducer are made of aluminum alloy, meeting the requirements of lightweight design. The motor uses high-grade magnets and low-loss 0.25mm silicon steel sheets, and the motor topology is optimized to reduce losses in the high-speed, low-torque region, achieving a maximum efficiency of 98%. The reducer incorporates an oil baffle structure to reduce oil churning losses and uses 75W low-viscosity gear oil, both of which improve reducer efficiency.

[0028] 2. The electric drive axle assembly is highly integrated, with additional wiring harness and pipe supports added to the axle housing. This facilitates the installation of wiring harnesses and brake lines, and benefits the overall vehicle layout. Intelligent wheel speed sensors are applied to the wheel edges, and dust and heat shields are added, meeting the requirements of high-end light commercial vehicle models.

[0029] This utility model enhances the competitiveness of the company's electric drive axle for light commercial vehicles, supports the mid-to-high-end positioning of light commercial vehicles, and has a significant overall competitive advantage over competing products. Its efficiency reaches the level of the third-generation electric chassis of the whole vehicle, and its reliability and durability meet the design life of 20 years and 2 million kilometers. It supports the whole vehicle in establishing a differentiated advantage in terms of optimal TCO, high efficiency, safety and reliability, while other parts are on par with the mainstream level of mid-to-high-end vehicles.

[0030] The above description is only a preferred embodiment of the present utility model. It should be noted that those skilled in the art can make several changes and improvements without departing from the overall concept of the present utility model, and these should also be considered within the protection scope of the present utility model.

Claims

1. A high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models, characterized in that: It includes a motor (1), a reducer (2), an axle housing assembly (3), and a wheel assembly (4); the housings of the motor (1) and the reducer (2) are mounted on the axle housing assembly (3), and the wheel assemblies (4) are mounted on both sides of the axle housing assembly (3). The motor (1) transmits power to the wheel assembly (4) through the reducer (2). The reducer (2) includes an aluminum alloy housing (21), a gearbox is provided inside the aluminum alloy housing (21), the gearbox is connected to an input shaft and an output shaft, an input shaft oil seal (22) is provided on the input shaft, the input shaft oil seal (22) is a low friction oil seal, and an oil baffle (23) is provided below the input shaft, the oil baffle (23) is fixed inside the housing by bolts; The wheel assembly (4) includes a wheel hub (41), a brake disc (45) is fitted over the wheel hub (41), an intelligent wheel speed sensor (42) is provided on the wheel assembly (4), and a heat shield (43) is provided below the intelligent wheel speed sensor (42). The heat shield (43) is used to isolate the heat of the brake disc (45).

2. The high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models according to claim 1, characterized in that: The motor (1) uses an aluminum alloy housing.

3. The high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models according to claim 1, characterized in that: The bridge housing assembly (3) includes a lightweight bridge housing (31), on which a wiring harness and conduit support (32) are provided.

4. The high-efficiency integrated electric drive axle assembly designed for light commercial vehicle models according to claim 1, characterized in that: A dust cover (44) is provided on the outside of the brake disc (45).

Images