Housing component for a vehicle housing

Abstract

The invention relates to a housing component (10) for a housing (50) of a vehicle (100), comprising at least a first formed plate element (1) and a second formed plate element (2) inseparably connected thereto, wherein the at least two formed plate elements (1, 2) form walls for a cavity volume (3) formed at least partially between them.

Description

[0001] The invention relates to a housing component for a vehicle body. Furthermore, the invention relates to a housing for a transmission and / or for a drive unit of a vehicle, as well as a vehicle with such a housing.

[0002] Gearbox components, especially gearbox covers, such as a gearbox housing cover, can be designed to support and guide gearbox shafts. The housing cover forms a closed unit with the rest of the housing. Bearings can be integrated into the housing cover to rotatably support and guide the gearbox shafts.

[0003] Common housing components and housings for gearboxes and drive units are typically made of gray cast iron. Alternatively, graphite cast iron and cast steel are used. Light metal casting alloys are frequently employed in vehicle transmissions. Furthermore, housing components are known to feature ribbing to ensure a sufficiently robust design for bearing applications. This ribbing is also generally produced by primary forming. Ribbing is a structural design in which ribs or reinforcing elements are applied to the surface of a component.

[0004] For example, DE 10 2021 126 468 A1 discloses a planet carrier with a shaft section for transmitting torque, on which two support webs for bearing planet gears are provided, wherein the first support web is an integral part of the shaft section and the second support web engages with legs projecting from it in recesses of the first support web and is attached there by positive locking, material locking and / or force locking. At least one leg has a portal-like design for creating two mounting areas that are spaced apart from each other around the circumference.

[0005] The object of the present invention is to provide an alternative housing component that can be manufactured cost-effectively and in an environmentally friendly manner, and is lightweight and resistant to deformation. This object is achieved by the features of independent claim 1. Advantageous embodiments are the subject of the dependent claims, the following description, and the figures.

[0006] A first aspect describes a housing component for a vehicle housing, comprising at least one first formed plate element and a second formed plate element inseparably connected to it. The at least two formed plate elements create walls for a cavity volume formed at least partially between them, the cavity volume being continuous and closed. Thus, the at least two plate elements do not completely abut each other but form a double-walled housing component. For example, the cavity volume is filled with air. Alternatively, the cavity volume can be filled with a foamed material. The cavity volume between the two plate elements makes the housing component particularly lightweight. The cavity volume extends, for example, over at least 50% and at most 95% of the overlapping area of ​​the at least two plate elements.This creates sufficient stiffening of the plate elements to support a bearing element. In particular, it achieves sufficiently high deformation resistance and stability to prevent tilting of a bearing with line contact, such as a roller or tapered roller bearing. This prevents so-called edge support. The risk of tilting is particularly high with flat housing parts or housing covers, as these exhibit unfavorable leverage.

[0007] According to one embodiment, the housing component is designed as a housing cover. In particular, the housing component is ribless, i.e., without ribbing. Specifically, the housing component is designed as a gearbox cover for an electric drive comprising an electric motor and a gearbox. The housing component is understood as a structural unit consisting of at least two formed plate elements. The housing component thus functions as a single component. A formed plate element is understood to be a disc made of a metal, in particular a metal sheet, a polymer material, or a composite material, which is formed into its final shape by forming. This process saves material and weight, as well as CO2 emissions during manufacturing, compared to manufacturing by primary forming.

[0008] According to one embodiment, at least one of the plate elements is made of a steel sheet, an aluminum alloy, a polymer material, or a composite material. For example, the composite material is reinforced by fibers or particles. For example, both plate elements are made of a steel sheet, an aluminum alloy, a polymer material, or a composite material. For example, both plate elements are made of the same material. Alternatively, both plate elements are made of different materials.

[0009] According to one embodiment, at least one of the plate elements is formed at least partially by deep drawing, hydroforming, and / or forging. For example, both plate elements are manufactured at least partially or completely by deep drawing, hydroforming, and / or forging, i.e., also by a combination of these processes.

[0010] According to one embodiment, the at least two formed plate elements are permanently joined together by welding, bonding, and / or riveting. A non-destructive, permanently inseparable connection is thus produced by welding, bonding, and / or riveting, or by a combination of these methods.

[0011] According to one embodiment, the housing component has an opening designed to receive a bearing component. In particular, a bearing component is arranged in the opening of the housing component. For example, the bearing component is designed as a bearing ring, preferably as the outer ring of a roller bearing or tapered roller bearing. The double-walled structure with a cavity is sufficiently stable so that roller bearings or tapered roller bearings can be used. Compared to ball bearings, forces can be absorbed more effectively by the "line contact" of a roller bearing or tapered roller bearing. The use of a roller bearing or tapered roller bearing therefore enables extremely efficient bearing arrangement. In particular, the opening is designed as a central opening in the housing component and is thus formed in the at least two plate elements.For example, the at least two plate elements are designed as ring discs, with the opening being produced, for example, by a separation process.

[0012] According to one embodiment, the cavity volume is formed at least partially around the opening in the circumferential direction. In particular, the cavity volume is formed completely around the opening in the circumferential direction. Thus, the cavity volume is formed as a closed ring. This enables efficient and homogeneous support of the bearing element arranged in the opening, since the double wall is formed in the area of ​​the cavity volume.

[0013] According to one embodiment, the first formed plate element is essentially cup-shaped and has a first circumferential collar section for guiding a shaft and receiving the bearing component, as well as a second circumferential collar section for end-face contact with the housing. For example, the first collar section is essentially perpendicular to the second collar section. "Essentially perpendicular" includes angular deviations of up to 10 degrees. In particular, the bearing component rests radially against the first circumferential collar section. Furthermore, the first collar section is configured to center the second plate element on the first plate element, with the second collar section being configured to axially support the second plate element on the first plate element. For example, bores for guiding screws and fastening to a housing are arranged in the second collar section.

[0014] According to one embodiment, the second formed plate element is essentially star-shaped and has an inner circumferential surface that abuts the first collar section, with radial end sections of the second formed plate element abutting at least partially against the second collar section. In particular, the radial end sections of the second formed plate element are formed radially outwards such that they abut the second collar section axially over a flat surface. According to one embodiment, the second plate element abuts the first plate element axially with a circumferentially formed outer contour. This creates a large contact area with a simultaneously large cavity volume.

[0015] According to a second aspect, a housing for a transmission and / or for a drive unit of a vehicle is provided, comprising a housing component according to the first aspect. For example, the housing component is designed as a housing cover. For example, the housing has two such housing components.

[0016] According to a third aspect, a vehicle is provided with a housing according to the second aspect. The above definitions, as well as explanations of the technical effects, advantages, and advantageous embodiments of the housing component, also apply analogously to the housing and the vehicle. For example, the vehicle is designed as an electric motor vehicle.

[0017] Advantageous embodiments of the invention, which are explained below, are illustrated in the drawings, wherein identical or similar elements are designated with the same reference numeral. They show: Fig. 1 a schematic perspective section view of a housing component; Fig. 2 a schematic perspective section view of the housing component according to Fig. 1 in a mounted state on a housing; Fig. 3 a highly schematic representation of a housing with two housing components according to Fig. 1 and Fig. 4 a vehicle with a housing according to Fig. 3.

[0018] Fig. Figure 1 shows a housing component 10, which is formed from a first formed plate element 1 and a second formed plate element 2 that is permanently and non-destructively connected to it. The housing component 10 has an opening 4 in which a bearing component 5, designed as a bearing ring, is arranged. The two plate elements 1, 2 can be made of different materials.

[0019] In the present case, the two plate elements 1, 2 are made of steel sheets and form walls for a cavity volume 3 that is at least partially formed between them. The cavity volume 3 is closed and, in particular, filled with air. The second plate element 2, with its inner circumferential surface and a circumferential outer circumferential section that is appropriately shaped and designed to form a flat contact surface with the first plate element 1, comes into contact with the first plate element 1. Thus, the two plate elements 1, 2 do not lie completely against each other, but form a double-walled housing component 10, with the cavity volume 3 being continuous and closed.

[0020] The cavity volume 3 and the corresponding shaping of the first and second plate elements 1, 2 form a housing component 10 that is particularly lightweight and sufficiently rigid to serve as a bearing housing. The housing component 10 has a flat yet stable design, exhibiting high structural integrity and high resistance to deformation and mechanical loads. Furthermore, it is advantageous that ribbing can be omitted, thus simplifying manufacturing and saving material and costs. In this case, the two plate elements 1, 2 are manufactured by deep drawing steel sheet discs and joining these steel sheet discs, for example by bonding or welding. This saves material and weight, as well as CO2 emissions during manufacturing, compared to manufacturing by primary forming.

[0021] In the present case, the first formed plate element 1 is essentially cup-shaped and has a first circumferential collar section 6 for the passage of a shaft 21, which is in Fig. 2 is shown, as well as a second circumferential collar section 7 for frontal contact with the housing 50, which is in Fig. As shown in Figure 2, the first collar section 6 is essentially perpendicular to the second collar section 7. In particular, an outer surface of the first collar section 6 radially accommodates the second plate element 2. The second collar section 7 axially supports the second plate element 2 with uniform circumferential support.

[0022] The second formed plate element 2 is essentially star-shaped and comprises an inner circumferential surface 8 that abuts radially against the first collar section 6, as well as radial end sections 9 that are correspondingly formed and abut the second collar section 7. The cavity volume 3 extends circumferentially around the opening 4 and runs through each support arm of the star-shaped second plate element 2. Thus, the two plate elements 1 and 2 abut each other along both the entire inner contour and the entire outer contour of the second plate element 2. This creates a particularly rigid structure.Furthermore, in the second collar section 7, a bore 11 for the passage of screw means not shown in detail is formed in the circumferential direction between two support arms of the second plate element 2, wherein the housing component 10 designed as a housing cover is attached to the housing 50 at its front face via the screw means according to . Fig. 2 is fixed.

[0023] Fig. Figure 2 shows the housing component 10 according to Fig. 1 in an assembled state on a housing 50, which is only partially shown. Regarding the design of the housing component 10, see below. Fig. Reference is made to Figure 1. A gearbox 20 is arranged in the housing 50, of which only one output gear 22 is shown here. This output gear is effectively connected via a differential 23 to output shafts, of which only one output shaft 21 is shown here. A tapered roller bearing is arranged between the first circumferential collar section 6 and the output shaft 21, of which only the bearing component 5, designed as an outer ring, is shown here. The tapered rollers are spatially arranged between the bearing component 5 and a differential component 24, through which the output shaft 21 is guided. The housing component 10 is designed as a housing cover and is suitable for stable support and efficient tapered roller bearing arrangement. Efficient tapered roller bearing arrangement refers to the way in which tapered roller bearings are arranged in a gearbox to ensure optimal performance and efficiency and to resist tilting.An efficient tapered roller bearing minimizes friction and energy losses in the gearbox. This contributes to the overall efficiency of the gearbox. Tapered roller bearings are rolling bearings specifically designed to absorb radial and axial forces in rotating applications. They consist of an inner ring, outer ring, tapered rollers, and a cage.

[0024] Fig. Figure 3 shows the housing 50 with two housing components designed as housing covers according to Fig. 1 and Fig. 2 greatly simplified. The housing 50 encloses a drive device 30 designed as an electric machine and a gearbox 20.

[0025] Fig. Figure 4 shows a vehicle 100 with a first axle 101 with two wheels R1, R2 and a second axle 102 with two wheels R3, R4. In this case, the first axle 101 is designed as the rear drive axle of the vehicle 100 and is equipped with a drive unit. The drive unit comprises a drive device, designed as an electric machine and configured to generate drive power, and a transmission 20 with a differential for distributing the drive power to the two wheels R1, R2 of the first axle 101. The drive device 30 and the transmission 20 are housed together in a casing 50 according to Fig. 3 arranged. Vehicle 100 is designed as an electric vehicle. Reference sign 1 first transformed plate element 2 second transformed plate element 3 cavity volume 4 Opening 5 Bearing component 6 first circumferential collar section 7 second circumferential collar section 8 Inner perimeter area 9 radial end section 10 Housing component 11 bore 20 gearboxes 21 Output shaft 22 Output gear 23 Differential 24 Differential component 30 Drive device 50 cases 100 vehicles 101 first axis 102 second axis R1 wheel R2 wheel R3 wheel R4 wheel

Claims

[1] Housing component (10) for a housing (50) of a vehicle (100), comprising at least a first formed plate element (1) and a second formed plate element (2) inseparably connected thereto, wherein the at least two formed plate elements (1, 2) form walls for a cavity volume (3) formed at least partially between them, wherein the cavity volume (3) is continuous and closed. [2] Housing component (10) according to claim 1, wherein at least one of the plate elements (1, 2) is made of a sheet steel, an aluminium alloy, a polymer material or a composite material. [3] Housing component (10) according to one of the preceding claims, wherein at least one of the plate elements (1, 2) is formed at least partially by deep drawing, hydroforming and / or forging. [4] Housing component (10) according to one of the preceding claims, wherein the at least two formed plate elements (1, 2) are inseparably joined together by welding, gluing and / or riveting. [5] Housing component (10) according to one of the preceding claims, comprising an opening (4) designed to receive a bearing component (5). [6] Housing component (10) according to claim 5, wherein the cavity volume (3) is formed at least partially in the circumferential direction around the opening (4). [7] Housing component (10) according to claim 5 or 6, wherein the first formed plate element (1) is substantially cup-shaped and has a first circumferential collar section (6) for receiving the bearing component (5) and a second circumferential collar section (7) for end-face contact with the housing (50). [8] Housing component (1) according to claim 7, wherein the second formed plate element (2) is essentially star-shaped and has an inner circumferential surface (8) that comes into contact with the first collar section (6), wherein radial end sections (9) of the second formed plate element (2) come into contact at least partially with the second collar section (7). [9] Housing (50) for a transmission (20) and / or a drive device (30) of a vehicle (100) comprising a housing component (10) according to one of the preceding claims. [10] Vehicle (100) with a housing (50) according to claim 9.

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