trumpet arm with internal struts

Abstract

Trumpet arm (1402, 402) for one axis, comprising: a housing (412, 1412) with an arm section (1422, 422) extending over an arm length (1432, 432), the arm section (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; and internal struts (1408, 408) arranged in an interior (1410, 410) of the housing (412, 1412) and extending through at least a first section (1708) of a flange length (608) of the flange, a flange / arm transition (406, 1406) at which the flange transitions into the arm section, and at least one section (612) of the arm length.

Description

CROSS-REFERENCE TO RELATED REGISTRATIONS

[0001] The present application claims priority from U.S. Preliminary Application No. 63 / 582,182 entitled “TRUMPET ARM WITH INTERNAL BUTTRESSES”, which was filed on September 12, 2023. The entire contents of the above-mentioned application are hereby incorporated by reference for all purposes. TECHNICAL AREA

[0002] The present description refers generally to a trumpet arm for an axle of an electric vehicle (EV). GENERAL STATE OF THE TECHNOLOGY AND DEMOLITION

[0003] Axle assemblies are designed to transmit rotational power from a vehicle's power source to its wheels. An axle assembly typically includes a differential assembly rotatably mounted within a non-rotating housing (e.g., a carrier). The differential is connected between an input shaft, originating from the power source / transmission, and a pair of output axle shafts leading to the vehicle's wheels. The axle shafts are located within their respective non-rotating carrier housing sections, which are attached to a central axle housing. Thus, the rotation of the differential by the drive shaft causes a corresponding rotation of the axle shafts. The central axle housing and the carrier housing sections together form an axle housing for these drivetrain components of the axle assembly, in which the differential and axle shafts are rotatably mounted.

[0004] One type of axle housing comprises a single, central housing structure commonly referred to as a Salisbury axle assembly. In this design, the central axle housing (containing the differential assembly) is directly connected to the two steel tube sections (housing the rotatable axle shafts). Another type of axle housing comprises a central housing structure that extends through to two arm sections, each arm section forming a smooth, gradual, flared connection with the central housing. This central section is generally hollow and cylindrical, with a large, generally circular opening penetrating it. The overall shape of these axle housings generally resembles the shape of a banjo musical instrument. Therefore, this type of axle housing is commonly referred to as a banjo axle housing.

[0005] With the evolution of electric vehicles towards the use of electric axles, conventional banjo and Salisbury axles, with their streamlined housings, may not offer sufficient space to accommodate all the components required for an electric axle, such as one or more motors, gears, shafts, bearings, shift actuators, differentials, pumps, heat exchangers, filters, sensors, and so on. For example, the long, gradual transition from the arm section to the shell of a banjo axle can distribute road loads in a yz-plane (e.g., perpendicular to a drive surface), reducing stresses on the banjo axle. Some banjo axles may incorporate a stiffening ring within the shell to further stiffen it in the yz-plane. However, the shape of the shell, both with and without the stiffening ring, may provide less space than is desirable for housing the electric axle components.The geometry of a Salisbury axle can similarly restrict the installation space for the electrical axle components to a curved area that is smaller than desired. Therefore, an axle is needed that provides the desired installation space and shape for housing the electrical axle components. For example, a rectangular installation boundary might be desirable to accommodate the electrical axle components; however, the rectangular shape can interfere with structural reinforcements (e.g., the stiffening ring, the long, gradual transition) of the banjo axle and / or the Salisbury axle.

[0006] One possible solution is an axle with a gearbox housing featuring relatively flat sides and two trumpet arms extending along an output shaft. This can help achieve the required installation space for the electrical axle components. However, challenges arise where one arm of a trumpet arm meets a flange of the trumpet arm (e.g., a flange / arm transition), with the flange being used to bolt the trumpet arm to the gearbox housing. The transition between the flange and arm is a high-stress area. Reducing the arm length is undesirable, however, as the full length of the arm can be used to accommodate several different suspension mounting systems.To maintain the desired arm length while simultaneously creating the desired installation space, the trumpet arm may feature a gradual transition, a long chamfer, or external gussets to stiffen and reinforce the transition between the flange and the arm.

[0007] This document describes an axle housing configured as a trumpet arm, incorporating internal braces to stiffen and reinforce the flange / arm junction while maintaining a desired arm length. A trumpet arm comprises, for example, a housing with an arm section extending over an arm length, the arm section having an outlet at a first end and a flange with a flat surface at a second end opposite the first end. The trumpet arm further comprises internal braces arranged within the housing, extending through at least a first portion of the flange length, a flange / arm junction where the flange transitions into the arm section, and at least a portion of the arm length.In some embodiments, the trumpet arm also includes external braces (gussets, crossbeams) extending over at least a second section of the flange length, with the endpoints of the internal and external braces offset from each other. The flange may have a curved or angled extension from the flat surface to the flange / arm junction. In this way, the flange / arm junction can be desirablely resistant to deterioration due to arm deflection during use of the trumpet arm in a vehicle axle. Furthermore, the flat surface of the flange provides a rectangular enclosure in which components of an electric axle can be positioned, thus enabling the use of the trumpet arm in an e-axle for an electric vehicle (e.g., electric vehicle, hybrid electric vehicle, and / or plug-in electric vehicle).

[0008] It should be clarified that the above outline is provided to present, in simplified form, a selection of concepts that are described in more detail in the full description. It is not intended to identify crucial or essential features of the claimed subject matter, the scope of which is defined solely by the claims following the full description. Furthermore, the claimed subject matter is not limited to implementations that address any disadvantages mentioned above or in any part of the disclosure. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows a schematic representation of an electric drive system with trumpet arms. Fig. Figure 2 shows a perspective view of an electric drive system according to an example that includes two trumpet arms. Fig. Figure 3 shows a profile view of the electric drive system according to an example. Fig. Figure 4 shows perspective views of a trumpet arm. Fig. Figure 5 shows profile views of the trumpet arm of Fig. 4. Fig. Figure 6 shows a cross-sectional view of the trumpet arm. Fig. Figure 7 shows a first perspective view of a trumpet arm with a spindle. Fig. Figure 8 shows a second perspective view of the trumpet arm with the axle pivot made of Fig. 7. Fig. Figure 9 shows a cross-sectional view of the trumpet arm with the axle pin. Fig. Figure 10 shows a perspective view of a trumpet arm with a pivot pin and a differential lock / axle separating arrangement. Fig. Figure 11 shows a cross-sectional view of the trumpet arm with the axle journal and the differential lock / axle separation assembly of Fig. 10. Fig. Figure 12 shows a schematic representation of the load distribution through the internal struts of a trumpet arm. Fig. Figure 13 shows exemplary orientations of the internal struts and cross-sections of an arm section of a trumpet arm. Fig. 14A and Fig. Figure 14B shows perspective views of a trumpet arm with a curved flange. Fig. Figure 15 shows a first series of profile views of the trumpet arm with the curved flange of the Fig. 14A and Fig. 14B. Fig. Figure 16 shows a second series of profile views of the trumpet arm with the curved flange. Fig. Figure 17 shows a cross-sectional view of the trumpet arm with the curved flange. Fig. Figure 18 shows a perspective view of a trumpet arm with a curved flange and a pivot. Fig. Figure 19 shows a profile view of the trumpet arm with the curved flange and the axle pin made of Fig. 18. Fig. Figure 20 shows a cross-sectional view of the trumpet arm with the curved flange and the axle pin. DETAILED DESCRIPTION

[0009] The following description relates to systems for an electric axis and, in particular, to a trumpet arm comprising a housing with an arm section extending over one arm length, wherein the arm section has an outlet at a first end and a flange with a flat surface at a second end opposite the first end. The trumpet arm further comprises internal struts arranged in an interior space of the housing and extending through at least a first section of the flange length, a flange / arm transition where the flange joins the arm section, and at least one section of the arm length. The internal struts provide strength and stiffness to the trumpet arm. The flange with the flat surface allows the formation of a rectangular space between two trumpet arms oriented as described herein, in which electric axis components can be positioned.Furthermore, the length of the arm section is designed to accommodate suspension mounting systems of varying sizes and shapes. The trumpet arm configuration allows for the integration of electrical axle components into the electric drive axle (e.g., e-axle) while simultaneously achieving the desired stiffness and strength of the trumpet arm.

[0010] The trumpet arm, as further described herein, can have various embodiments designed to provide a system incorporating the trumpet arm with a desirable degree of space, rigidity, and resistance to deterioration. For example, in some embodiments, the flange body may be angled and have external braces (gussets, crossbeams), while in other embodiments, the flange body may be curved, with a convex or concave side of the flange body connected to the arm. The internal braces can have a variety of configurations comprising two or more legs (e.g., "x" configuration, "y" configuration, etc.), with different configurations being used in different vehicle applications. Furthermore, the cross-section (e.g., rectangular, circular, etc.) of the arm section can vary for different vehicle applications.The trumpet arm embodiments described herein can be used in an e-axle, in which a first and a second trumpet arm are connected to an electric motor via the flange of each arm. Furthermore, the dimensions of the arm section (e.g., arm length, cross-section) can allow for the mounting of various suspension systems on the trumpet arm. The e-axle can also incorporate a differential lock / axle disconnect in one or more of the trumpet arms, coupled to a differential, which serves to control the torque output from the electric motor to the wheels of the e-axle. As further described herein, reinforcing struts (e.g., internal and external struts) can provide stiffness at the pivot points (e.g., load points) of the trumpet arm.In this way, the trumpet arm described here offers a geometry that allows the mounting of electrical machine components and suspension mounting systems on an E-axis, while also providing strength and stiffness that can protect against deterioration of the trumpet arm due to bending force loads.

[0011] Fig. Figure 1 schematically shows an electric drive system in a vehicle with at least one trumpet arm used for an e-axle of the electric drive system, wherein the trumpet arm is set up as described herein and acts as a non-rotating beam housing part containing rotatable axle shafts. Fig. 2 and Fig. 3 show views of an electric drive system (e.g., from Fig. 1) wherein a first trumpet arm and a second trumpet arm are arranged to form a rectangular space in which a main gear housing can be arranged and coupled to the first trumpet arm and the second trumpet arm. Fig. Figures 4 to 11 show various profile, perspective, and cross-sectional views of a trumpet arm used in the systems of Fig. 1 to 3 may be included, including versions of the trumpet arm that include additional components such as a pivot pin and a differential lock / axle separator assembly. Fig. Figure 12 shows schematic representations of load reactions through the internal struts of a trumpet arm (e.g. from Fig. 4-11). Fig. Figure 13 shows different embodiments of cross-sections of the arm section and different orientations of the internal struts of the trumpet arm. Fig. Figures 14A-20 show various profile, perspective, and cross-sectional views of a second embodiment of a trumpet arm, in which the flange of the trumpet arm has a curved geometry. The second embodiment of the trumpet arm of Fig. 14A-20 can be integrated into the systems of Fig. 1-3 will be integrated. Fig. Figures 14A-16 show perspective and profile views, and Fig. Figure 17 shows a cross-sectional view of the second embodiment of the trumpet arm. Fig. Figures 18-20 show perspective views and a cross-sectional view of the second embodiment of the trumpet arm with an axle pin. Fig. Figures 2-11 and 14A-20 are drawn approximately to scale. However, other relative component dimensions may be used in other embodiments.

[0012] Fig. Figure 1 schematically shows an electric vehicle 100 with an electric drive system 102 that supplies power to and / or is integrated into an axle assembly 104 of the vehicle 100. The vehicle 100 can take on a variety of forms in different examples, such as a light, medium, or heavy-duty vehicle. Furthermore, the electric drive system 102 can be designed for use in front and / or rear axles and in steerable and non-steerable axles. To generate electricity, the electric drive system 102 can include an electric machine 106. In some examples, the electric machine 106 can be an electric motor-generator and can therefore include conventional components such as a rotor, a stator, and the like, which are housed in a casing 107 of the electric machine to generate mechanical energy and, in some cases, electrical current during a regenerative mode.Furthermore, in other examples, the vehicle 100 can include an additional source of kinetic energy, such as an internal combustion engine (ICE) (for example, a spark-ignition engine and / or a compression-ignition engine), to supply power to another axle. The electric drive system 102 can be used in an electric vehicle (EV), for example, a hybrid electric vehicle (HEV) or a battery electric vehicle (BEV).

[0013] In some examples, the housing of the electric machine 107 can be connected to a gearbox housing 109 of a gearbox 108 (e.g., via bolts). Furthermore, the electric machine 106 can supply mechanical power to a differential 110 via the gearbox 108. From the differential 110, the mechanical power can be transmitted via the axle shafts 117 and 115 of the axle assembly 104 to the drive wheels 112 and 114 (e.g., a first wheel 112, a second wheel 114). The differential 110 can distribute torque received from the electric machine 106 via the gearbox 108 to the drive wheels 112 and 114 of the axle shafts 117 and 115, respectively, during certain operating conditions. In some examples, the differential 110 can be a limited-slip differential, an active or passive limited-slip differential, or a torque-distributing differential.

[0014] One or both of the axle shafts 117, 115 can be housed in a trumpet arm, as further described here. For example, axle shaft 117 is housed in a first trumpet arm 118 and axle shaft 115 in a second trumpet arm 116. The first trumpet arm 118 and the second trumpet arm 116 each have the same trumpet arm configuration, comprising: a housing with an arm section 162 extending over one arm length, the arm section having an outlet at a first end and a flange 164 with a flat surface at a second end opposite the first end; and internal struts arranged in an interior of the housing and extending through at least a first part of a flange length of the flange, a flange / arm transition where the flange joins the arm section, and at least a part of the arm length.The first trumpet arm 118 and the second trumpet arm 116 can each be connected to the differential 110 on a flat surface of the flange.

[0015] In some embodiments, the axle assembly 104 comprises additional elements that are coupled to, attached to, or otherwise connected to the first trumpet arm 118 and / or the second trumpet arm 116. For example, a suspension 152 may be attached to both the first trumpet arm 118 and the second trumpet arm 116 along the respective arm section 162. In some embodiments, an axle pin 154 may be connected to the outlet of the first trumpet arm 118 and the second trumpet arm 116. For example, a first axle journal end of the axle journal 154 can be coupled to the respective trumpet arm, and drive wheels (e.g. the first wheel 112 or the second wheel 114) can be coupled to each of the first axle journal as well as the second axle journal at a second axle journal end of the respective axle journal, which is opposite the first axle journal end of the axle journal.

[0016] As further described here, one or more of the first trumpet arms 118 and the second trumpet arm 116 can also include a differential lock / axle disconnection assembly arranged in a body of the flange 164. The differential lock / axle disconnection assembly can be configured to engage optionally with a counter-coupling of the differential 110 and / or the transmission 108.

[0017] The transmission 108 can be a single-speed transmission, operating in one gear. However, other transmission arrangements are also conceivable, such as a multi-speed transmission designed for operation in several different gear ratios. Furthermore, in one example, the electric machine 106, the transmission 108, and the differential 110 can be integrated into the axle 104, forming an electric axle (E-axle) in the vehicle 100. The E-axle's function includes driving the wheels 112 and 114 during operation. Specifically, in the E-axle, the electric machine 106 and the transmission 108 can be coupled to and / or otherwise supported by the first trumpet arm 118 and the second trumpet arm 116. The E-axle can represent a compact arrangement for direct power supply to the axle 104.For example, the first trumpet arm 118 can be connected to a first side of the gearbox housing 109 and the second trumpet arm 116 to a second side of the housing of the electric machine 107 opposite the first side, as shown in the . Fig. 2-3 described in more detail.

[0018] The electric drive system 102 may further include an oil circuit 120 for circulating oil (e.g., natural and / or synthetic oil) through the gearbox housing 109 to lubricate and / or cool various system components. The oil circuit 120 may include a filter 123 and an oil pump 124, which draws oil from an oil reservoir 111 (e.g., a sump) in the gearbox housing 109 via an outlet 122 and drives a pressurized oil flow through a supply line 126 to an inlet 128 of the gearbox housing 109. In some examples, the pump 124 may be provided on an external part of the gearbox housing 109. In other examples, however, the pump may be contained within the gearbox housing 109. Various distribution components and arrangements (e.g.,Nozzles, valves, oil passages, and the like of the oil circuit 120 can be included in the electric drive system 102 to facilitate the flow of oil into the gearbox housing 109 and, in a specific example, to a portion of the housing 107 of the electric machine. In some cases, the oil circuit 120 can be used to supply oil to various gearbox bearings and gears, as well as to the motor stator, motor rotor, and rotor shaft bearings of the electric machine 106, thus providing an efficient system for the effective use of the gearbox oil for cooling these systems. In some embodiments, the oil circuit 120 can also include a heat exchanger (e.g., a radiator) that extracts heat from the oil exiting the gearbox housing 109 via the outlet 122.

[0019] The electric drive system 102 may further comprise a coolant circuit 130, which circulates coolant (e.g., water, glycol, and / or oil) through coolant channels 131 formed in the electric machine 106 or the electric machine housing 107. The coolant circuit 130 may include a coolant inlet 138 and a coolant outlet 132, which is located on (or in) the housing 107 of the electric machine. The coolant circuit 130 may further comprise a filter 133 and a pump 134, which circulates coolant from the coolant outlet 132 to the coolant inlet 138 via a coolant supply line 136. From the coolant inlet 138, the coolant flows into the coolant channels 131 formed in the electric machine 106 or in the housing of the electric machine 107, which dissipate heat from the components of the electric machine 106. In some examples, the coolant circuit 130 may also include a heat exchanger (e.g.cooler) which removes heat from the coolant leaving the housing 107 of the electric machine via the coolant outlet 132.

[0020] The vehicle 100 can also include a control system 140 with a control unit 141. The control unit 141 can include a processor 142 and a memory 144. The memory can contain instructions which, when executed by the processor, cause the control unit 141 to perform the various procedures, control techniques, etc., described herein. The processor 142 can contain a microprocessor unit and / or other types of circuitry. The memory 144 can include known data storage media, such as random access memory, read-only memory, persistent storage, combinations thereof, and the like. The control unit 141 can receive various signals from sensors 146 located at different points in the vehicle 100 and in the electric drive system 102.The control unit 141 can also send control signals to various actuators 148 connected at different points in the vehicle 100 and the electric drive system 102. For example, the control unit 141 can send command signals to the oil pump 124 and / or the pump 134, and in response, the actuator(s) in the pump(s) can be adjusted to change the flow rate of the oil and / or coolant supplied from there. In other examples, the control unit can send control signals to the electric machine 106, and in response to receiving the command signals, the electric machine can be adjusted to change a rotor speed or torque. The other controllable components in the system can be operated in a similar manner with respect to sensor signals and actuator settings.

[0021] A 150 axis system is used as a reference. Fig. 1 as well as in Fig. Figure 2-20 illustrates this. The z-axis can be a vertical axis (e.g., parallel to a gravitational axis), the x-axis can be a longitudinal axis (e.g., a horizontal axis), and / or the y-axis can be a lateral axis, in one example. However, the axes may have different orientations in other examples.

[0022] Fig. Figure 2 shows an example of an electric drive system 200 with electric axle components 202 for supplying power to an axle assembly 204. The electric axle components 202 of the electric drive system 200 can include an electric machine 206 which is operationally coupled to a gearbox 208 and can be installed in a vehicle, such as the one shown in Fig. The vehicle 100 shown in Figure 1 may contain similar components. The electric drive system 200 may therefore exhibit similarities to the electric drive system 102. For example, at least some of the components relating to the drive system 102 may be similar to those of the electric drive system 102. Fig. 1 were explained in which in Fig. The electric drive system 200 shown in the illustration may be included, or vice versa.

[0023] The axis arrangement 204 comprises a first trumpet arm 216 and a second trumpet arm 218, both examples of a trumpet arm comprising a housing 212 with an arm section 222 extending over one arm length, the arm section 222 having an outlet at a first end and a flange 214 with a flat surface 228 at a second end opposite the first end, and further comprising internal struts (in Fig. 2 (not shown) comprises components arranged in an interior of the housing 212, extending through at least a first part of a flange length of the flange 214, a flange / arm transition where the flange transitions into the arm section 222, and at least one section of the arm length. The flat surface of the flange 214 enables the positioning of the electrical axle components 202, such as the electric motor 206, the gearbox 208, and / or a differential (in Fig. 2 not shown) in the axle arrangement 204, while at the same time achieving a desired strength and stiffness of the axle arrangement 204, which distributes a road load and reduces the load on the trumpet arms, as further described herein.

[0024] The electric machine 206 may comprise an electric machine housing 207 coupled to a gearbox housing 209 of the gearbox 208. In some cases, the housing of the electric machine 207 may be connected to the gearbox housing 209 by any suitable fastening mechanism (e.g., bolts, clamps, welds, and / or combinations thereof), such as bolts 211. As further described herein, the flange 214 of the first trumpet arm 216 and the second trumpet arm 218 has several through holes along a circumference of the flange 214 on the flat surface. Bolts 211 may extend through any of the numerous through holes and connect the first trumpet arm 216 and the second trumpet arm 218 to the gearbox housing 208. In other embodiments, the first trumpet arm 216 and the second trumpet arm 218 can additionally or alternatively be connected to the housing of the electric machine 207.The first trumpet arm 216, the second trumpet arm 218, the housing of the electric machine 207 and the gearbox housing 209 can each be made of a metal (e.g. aluminium, steel, iron, combinations thereof, etc.), which can be the same or a different metal for each housing.

[0025] The electric machine 206 can supply current via the gearbox 208 to a differential (not shown) in order to supply rotational power to a first axle shaft and a second axle shaft (to which the drive wheels may be coupled) of the axle assembly 204. The first axle shaft and the second axle shaft are in Fig. 2 not shown and are to be understood as being at least partially enclosed in the housing 212 of the first trumpet arm 216 and the second trumpet arm 218, respectively. In some embodiments, both the first trumpet arm 216 and the second trumpet arm 218 have a pivot pin that is connected to the housing 212 at the outlet of the arm section 222. For example, a first pivot pin 224 is coupled to the first trumpet arm 216 and a second pivot pin 226 to the second trumpet arm 218 at an outlet 220 of each trumpet arm, as shown in Fig. 3 described in more detail. A drive wheel can be attached to each of the first axle journal 224 and the second axle journal 226, and the first axle shaft and the second axle shaft can extend through the first axle journal 224 and the second axle journal 226 respectively to drive the rotation of the respective drive wheel.

[0026] In the Fig. In the embodiment of a trumpet arm shown in Figure 2, the first trumpet arm 216 and the second trumpet arm 218, or both, can be equipped with a differential lock / axle separation arrangement 260, which may be at least partially enclosed in the respective housing 212. As shown in the Fig. 7 and Fig. As further described in section 10, the differential lock / axle separation arrangement 260 can optionally interact with a counter-coupling of the differential to optionally couple the axle shaft extending through the respective trumpet arm with the differential, or in other cases optionally interact with a counter-coupling of the transmission 208 to optionally decouple the axle shaft extending through the respective trumpet arm from the power path.

[0027] Fig. Figure 3 shows a profile view 300 of the electric drive system 200, including the first trumpet arm 216, the second trumpet arm 218, and the electric axle components 202. As shown in Fig. As described in Figure 2, both the first trumpet arm 216 and the second trumpet arm 218 have the same configuration and comprise the flange 214 with the flat surface 228 at a first end 302 of the housing 212 and the outlet 220 at a second end 304, which is opposite the first end 302. The arm section 222 extends between the flange 214 and the outlet 220 and intersects the flange 214 at a flange / arm transition 306. In the Fig. 2 and Fig. 3 embodiment of the electric drive system 200 shown and as in the Fig. As described in more detail in Figures 4-12, the flange 214 comprises an angled extension from the flat surface 228 to the flange / arm transition 306. In other embodiments, such as in the Fig. As described in 14A-20, the flange 214 can have a curved extension from the flat surface 228 to the flange / arm transition 306.

[0028] The flange / arm transition 306 is a high-stress area due to the abrupt transition between the flange 214 and the arm section 222, compared to a gradual transition between a flange and an arm section in axles such as the Banjo axle and the Salisbury axle. For example, if a vehicle (e.g., vehicle 100 of Fig. 1) When the electric drive system 200, whose drive wheels are each coupled to the first axle journal 224 and the second axle journal 226 of the axle assembly 204, travels along a road, the drive wheels can encounter unevenness and / or potholes in the road surface, causing the vehicle and thus the trumpet arms to move up and down along the z-axis with respect to the axle system 150. This can lead to stresses at the flange / arm junction 306, which can result in deterioration of the respective trumpet arm at the flange / arm junction 306.

[0029] The trumpet arms described here are equipped with internal braces and, in some embodiments, with external braces (gussets, crossbars) to reduce the load at the flange / arm junction 306. As described in the Fig. As further described in 4-20, internal struts arranged in the interior of the housing 212 can extend over at least a first part of a flange length 308 of the flange 214, through the flange / arm transition 306 and at least a part of an arm length 312 of the arm section 222. As described in Fig. As shown in Figures 2-3, arm section 222 has a rectangular shape with a rectangular cross-section in the zx-plane, with respect to the axis system 150. As in Fig. As described in Figure 13, the arm section can have a cross-section that is a square, a circle, an oval, an hourglass, or another shape in other embodiments of the trumpet arm. The different cross-sections of the arm section 222 are oriented such that they allow different configurations of internal struts forming two or more legs, as described in Figure 13. Fig. 13 further described. The cross-section of the arm section can have a constant profile over the entire arm length 312. Furthermore, the outlet 220 of the trumpet arm (e.g., of the first trumpet arm 216 and the second trumpet arm 218) can be annular, as shown here, or in other embodiments have the same shape as the cross-section of the arm section 222. For example, the outlet 220 of the arm section 222 can be configured such that a pivot pin (e.g., the first pivot pin 224, the second pivot pin 226) is coupled to it and / or directly connected to a non-rotating part of a drive wheel. In this way, the configuration of the trumpet arm (e.g.,the first trumpet arm 216 and the second trumpet arm 218) the inclusion of components of the electric axis in a rectangular shell 310 of the electric drive axis, while at the same time achieving a desired stiffness and strength of the electric drive axis at the flange / arm transition and along the length of the arm section 222.

[0030] Fig. Figure 4 shows a first perspective view 400 and a second perspective view 450 of a trumpet arm 402 in orientations that allow partial visibility of the internal struts. The trumpet arm 402 is an example of the first trumpet arm 216 and the second trumpet arm 218 of Fig. 2-3, and elements of Fig. 2-3, which are in Fig. The four components included may be similarly numbered (e.g., flange 214 corresponds to...) Fig. 2-3 a flange 414 of Fig. 4).

[0031] The trumpet arm 402 comprises a housing 412 with an arm section 422 extending over an arm length 432, the arm section 422 having an outlet 420 at a second end 444 and a flange 414 with a flat surface 428 at a first end 442 opposite the second end 444. The trumpet arm 402 further comprises internal struts 408 arranged in an interior 410 of the housing 412 and extending through at least a first part of a flange length of the flange 414, a flange / arm transition 406 where the flange 414 transitions into the arm section 422, and at least a part of the arm length 432, as shown in the Fig. 6, Fig. 9 and Fig. 11 is described in more detail. The internal struts 408 can be cast as part of the housing 412 (e.g., as a continuous part of the housing 412). In some embodiments, the internal struts 408 are formed as separate parts from the housing 412 (e.g., castings, stampings, formed parts, machined parts) and are welded or otherwise fixedly positioned within the interior 410 of the housing 412. The housing 412 and the internal struts 408 can be made of the same material, e.g., cast steel, ductile iron, or cast aluminum. In other embodiments, the housing 412 and the internal struts 408 can be made of different metals or other rigid materials. In still other embodiments, the housing 412 and the internal struts 408 can be formed from different cast, stamped, or machined components that are attached and assembled as a welded part.

[0032] As in the Fig. As briefly described in Figures 1-3, the flange 414 has several through holes 416 arranged along its circumference. These holes are configured to allow fasteners, such as bolts, to pass through them to connect the trumpet arm 402 to components of the electric axis, such as a gearbox housing and / or an electric machine housing. In some embodiments, each of the many through holes 416 has a raised bolt pad 418, which can be helpful in positioning a fastener, such as a bolt, and in distributing the bolt load. The raised bolt pad 418 can further facilitate the manufacture of the trumpet arm 402. In some embodiments, the raised pads may or may not be used. Instead, for example, a flattened surface may be used. The flange 414 also has an angled extension 430 from the flat surface 428 to the flange / arm transition 406.The angled extension 430 contains an actuator through-hole 424 in which an actuator for a differential lock can be positioned, as in the . Fig. 10 and Fig. 11 described in more detail. The angled extension 430 also includes external struts (gussets, crossbeams) 426, which can be configured as three-dimensional triangles, wherein a first face of a 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. In this way, the external struts (gussets, crossbeams) 426 provide additional support and stiffness to the flange 414 and the flange / arm transition 406, as described in Fig. 12 described in more detail.

[0033] Both the first perspective view 400 and the second perspective view 450 show the geometry of the housing 412, with the arm section 422 having a rectangular shape extending over the arm length 432, and the outlet 420 having an annular shape. The arm section 422 can transition gradually into the outlet 420, so that the rectangular shape smoothly merges into the annular shape without any sharp (e.g., angled) intersections. The rectangular shape of the arm section 422 can provide space within the interior 410 of the trumpet arm 402 for positioning the internal struts 408 and for positioning an axle shaft (e.g., the axle shaft 115, 117). The arm section 422 is also shaped to allow the mounting of suspension fastening systems of different shapes and sizes (e.g., from different manufacturers).The annular shape of the outlet 420 allows the axle shaft to be positioned within it without coming into contact with the housing 412. The annular shape of the outlet 420 also allows an axle journal (e.g., the first axle journal 224, the second axle journal 226) to be coupled to it. In other embodiments, the outlet 420 can be directly connected to a non-rotating part of a drive wheel. In other embodiments, the trumpet arm 402 (e.g., as in ) Fig. 13 described) have a differently shaped cross-section which can be configured to allow the attachment of various suspension mounting systems and / or the integration of the trumpet arm 402 into different sizes and shapes of e-axles for different vehicle types, for example.

[0034] As can be seen in the second perspective view 450, the inner surface 434 of the flange 414 decreases from the first end 442 towards the flange / arm transition 406. The internal struts 408 comprise one or more legs that are continuously connected to the housing 412. In the trumpet arm 402, the internal struts 408 comprise four legs, as shown in Fig. 5 described in more detail. Each of the four legs extends from the flat surface 428 and the angled extension 430 to a central axis 436 of the trumpet arm 402. Each of the four legs extends further into the arm section 422 of the housing 412 and is coupled to and / or connected to the walls of the arm section 422. As described in the Fig. 6, Fig. 9 and Fig. As shown in Figure 11, each of the four legs of the internal struts 408 extends through at least a first part of the flange length, the flange / arm transition 406, where the flange 414 transitions into the arm section 422, and at least a part of the arm length 432. The four legs of the internal struts 408 form in the Fig. In the example of the trumpet arm 402 shown in Figure 5, the internal struts 408 have an “x” configuration. However, in other embodiments of the trumpet arm 402, the internal struts 408 can be formed from more than four or fewer than four legs, arranged in different configurations to resist bending loads along the arm length 432 of the arm section 422 and at the flange / arm junction 406. Further configurations of the internal struts 408 are described in connection with Fig. 13 described.

[0035] The inclusion of external struts (spandrels, crossbeams) 426 and internal struts 408 creates a first pivot point on the flat surface 428 of the flange 414 and a second pivot point at the flange / arm transition 406, as shown in Fig. 12 described in more detail. In short, if one looks at the upper section of the trumpet arm 402 in a representation 1250, a first pivot point 1202 and a second pivot point 1204 are both rigid when the arm section 422 experiences a deflection in a first downward direction, indicated by a second arrow 1220 and a third arrow 1222 (e.g. in the direction of a drive surface), because the internal struts 408 are under compression and the external struts (spikes, trusses) 426 are under tension. As shown in illustration 1200, the first pivot point 1202 and the second pivot point 1204 are both rigid when the arm section 422 experiences a deflection in a second upward direction, indicated by a first arrow 1206 (e.g. away from the drive surface), since the internal struts 408 are under tension and the external struts (plinths, crossbeams) 426 are under compression.

[0036] Fig. Figure 5 shows a first profile view 500 and a second profile view 550 of the trumpet arm 402. Fig. 4. The elements of the trumpet arm 402, which are in Fig. The details described in section 4 are not repeated here for the sake of brevity. The first profile view 500 shows the trumpet arm 402 along the y-axis, looking into the interior 410 of the trumpet arm 402 from the flange 414 to the outlet 420 (e.g., from the first end 442 of the housing 412 to the second end 444, as in Fig. 4 described). The second profile view 550 shows the trumpet arm 402 along the y-axis with a view into the interior 410 of the trumpet arm 402 from the outlet 420 to the flange 414 (e.g. from the second end 444 of the housing 412 to the first end 442).

[0037] As in Fig. As described in Figure 4, the internal struts 408 have an “x” configuration with vertical extensions 508 from each of the four legs (e.g., a first leg 408a, a second leg 408b, a third leg 408c, and a fourth leg 408d) that connect the internal struts 408 to the arm section 422 and the angled extension 430. The vertical extensions 508 are to be understood as extensions of the “x” configuration that support the internal struts 408 in the flange 414, e.g., by anchoring the internal struts 408 to the flange 414. The “x” configuration can be seen in the first profile view 500 and the second profile view 550 of Figure 4. Fig. 5. The external struts (gussets, crossbeams) 426 also have an “x” configuration, with the legs of the external struts 426 (e.g., a fifth leg 426a, a sixth leg 426b, a seventh leg 426c, and an eighth leg 426d) being axially aligned with the legs of the internal struts 408. The external struts 426 may also include external vertical extensions 526, which may help to support the angled extension 430 of the flange 414 (e.g., to provide structural stability and stiffness).

[0038] The configuration of the internal struts 408 and the external struts (gussets, crossbeams) 426 in the “x” configuration allows the internal struts 408 and the external struts 426 to respond to vertical and horizontal forces as well as torsional forces on the trumpet arm 402 and thus on the internal struts 408 and the external struts 426. For example, the internal struts 408 and the external struts 426 can be subjected to vertical forces when a vehicle with the E-axle that uses the trumpet arm 402 (e.g., vehicle 100 of Fig. 1) travels over protrusions and / or depressions in a road surface (e.g., bumps, potholes). Horizontal and torsional forces can act on the internal struts 408 and the internal struts 426 when the vehicle brakes and / or accelerates. As in Fig. As further described in Figure 12, the internal struts 408 and the external struts (gussets, crossbeams) 426 can enable the pivot points of the trumpet arm 402 to remain rigid when the trumpet arm is subjected to vertical and / or horizontal forces (e.g. deflection of the trumpet arm), which can reduce the deterioration of the trumpet arm 402, especially at the flange-arm junction 406.

[0039] Fig. Figure 6 shows a side view 600 of the trumpet arm 402 in cross-section. The cross-section in Fig. 6 is a partial cross-section along the central axis 436, with the elements above the central axis 436 as defined by line 650 in Fig. 4 are indicated as cut and the elements below the central axis 436 have no cross-section. Elements of the trumpet arm 402, which are in the Fig. 4 and Fig. Items 5, which are described above, are not listed again for the sake of brevity.

[0040] As in the Fig. 4 and Fig. As described in 5, the flange 414 of the trumpet arm 402 has a flange length 608, the arm section 422 has an arm length 432, and the internal struts 408 extend through at least a first part of the flange length 608, the flange / arm transition 406 and at least a part of the arm length 432. Fig. Figure 6 shows an embodiment of a configuration of the internal struts 408 in the housing 412 of the trumpet arm 402. In the embodiment of the trumpet arm 402, the internal struts 408 comprise four legs in an “x” configuration, as described above. Fig. Figure 6 shows a cross-section through the first leg 408a. The first leg 408a extends over the entire flange length 608 and the arm length 432. As in Fig. As described in section 5, each of the four legs of the internal struts 408 comprises the vertical extension 508, which extends linearly to the central axis 436 over a first length 604. The first leg 408a extends along the angled extension 430 of the flange 414 at an angle parallel to that of the angled extension 430 over a second part of the flange length 608. Before the flange / arm junction 406, the first leg 408a transitions from an angle parallel to the angled extension 430 to a horizontal extension that runs parallel to the arm section 422. The width 602 of the first leg 408a can gradually decrease along the arm length 432, with the width 602 of the first leg 408a being greatest at the flange / arm junction 406.In this way, the configuration of the first leg 408a and thus of the four legs of the internal struts 408 can provide stiffness and resistance to deterioration at the flange / arm junction 406 and along the arm length 432, as described herein and in relation to . Fig. 12 further described. As in Fig. As further described in 13, different embodiments of the internal struts 408 can include more or less than four legs, which are aligned in a configuration other than the “x” configuration.

[0041] The flange 414 is configured to form a rectangular shell for positioning electrical axis components in an e-axis. In some embodiments, the flat surface 428 can be a surface at the first end 442 of a plate or other flat structure. The angled extension 430 is coupled to and / or continuously connected to the plate or flat structure with the flat surface 428 and extends from it in a direction away from the flat surface 428 (e.g., towards the second end 444). The angled extension 430 has a funnel-shaped form, with the inner surface 434 of the flange 414 decreasing from the first end 442 towards the flange / arm transition 406.External struts (splices, trusses) 426, extending along an outer surface 610 of the angled extension 430, can provide stiffness and resistance to load-induced deterioration by being connected to and / or extending from the angled extension 430 and the plate or planar structure with the planar surface 428. In other embodiments, the flange 414 has a different shape and configuration. As in . Fig. As further described in 14A-20, the flange can, for example, have a curved extension from the flat surface (e.g., a plate or flat structure with the flat surface) to the flange / arm transition instead of an angled extension. The [details of the following are missing from the original text.] Fig. The flange design described in 14A-20 can provide structural stability and resistance to load-induced deterioration in a similar manner to the flange 414 described here.

[0042] The arm length 432 and the shape (e.g., the cross-section) of the arm section 422 can be designed to allow the mounting or other forms of coupling of various suspension fastening systems to the arm section 422. Different suspension fastening systems can be designed by the same or different manufacturers as those who manufacture the trumpet arm 402, so that the arm section 422 is dimensioned to accommodate different shapes and sizes of suspension fastening systems. In some embodiments, a suspension can be connected to the trumpet arm 402 along a section or the entire length of the arm 432.For example, a suspension mounting system can be connected to the trumpet arm 402 along a section 612 of the arm section 422, but not to the trumpet arm 402 at the section of arm length 432 where the rectangular shape of the arm section 422 transitions into the annular shape of the outlet 420. As further described here, different embodiments of the trumpet arm can have differently shaped arm sections (e.g., circular cross-section, hourglass cross-section, etc.), all of which can be oriented to accommodate several different suspension mounting systems.

[0043] Fig. Figure 7 shows a first perspective view 700 of the trumpet arm 402, as in the Fig. 4-6, with a pivot 726 connected to the trumpet arm 402 at the outlet 420. The pivot 726 can be an example of the first pivot 224 or the second pivot 226, as described in Fig. 1-3 described. The axle journal 726 can be connected to the trumpet arm 402, for example, by friction welding. As described in the Fig. As described in Figures 1 to 3, an axle shaft, which supplies rotary motion from a rotary power source (e.g., the electric machine 106) to the drive wheels, can be guided through the interior 410 of the trumpet arm 402 and through an interior of the axle journal 726 in order to couple with a drive wheel. In some embodiments, the axle journal 726 can be connected to a non-rotating element of the drive wheel. In other embodiments, the axle journal 726 can be adjacent to the center of the drive wheel and axially aligned with it, but not in contact with the drive wheel.

[0044] Fig. Figure 8 shows a second perspective view 800 of the trumpet arm 402 with the axle pin 726 coupled to it, as in Fig. 7 described. The pivot 726 is connected to the trumpet arm 402 at the outlet 420. The pivot 726 is coupled to the trumpet arm 402 at a first end 842 of the pivot 726, and a drive wheel (not shown) can be coupled to the pivot 726 at a second end 844 of the pivot 726, which is opposite the first end 842 of the pivot 726. As in Fig. As described in Figure 7, an axle shaft, which supplies rotary motion to drive wheels from a rotary power source, can be guided through the interior of the trumpet arm 402 and through the interior 810 of the axle journal 726 to couple to a drive wheel. In some embodiments, the axle shaft can protrude from the second end 844 of the axle journal 726, wherein the axle shaft can be coupled to the drive wheel and the axle journal 726 is not in contact with the drive wheel.

[0045] Fig. Figure 9 shows a first cross-sectional side view 900 of the trumpet arm 402 with the axle pin 726 coupled to it, as in Fig. 7 described. The first cross-sectional side view 900 intersects the trumpet arm 402 with the axle journal 726 along line 950, which is in Fig. 7 is shown. As in the Fig. As described in Figures 4-8, the legs of the internal struts 408 extend from the flange 414 through the flange / arm transition 406 and along the arm length 432 of the arm section 422. In the Fig. In the embodiment of the trumpet arm 402 shown in Figure 9, the legs of the internal struts 408 (e.g., the first legs 408a and the second legs 408b) extend in an “x” configuration to the central axis 436 of the trumpet arm 402. In other words, the first legs 408a and the second legs 408b (and the third legs 408c and the fourth legs 408d, which are shown in Figure 9) extend to the central axis 436 of the trumpet arm 402. Fig. (9 not shown) from a respective vertical extension 508 at an angle towards the central axis 436 of the trumpet arm 402, so that space is provided between the individual legs of the internal struts as well as between the internal struts 408 and the housing 412 (e.g., the walls of the arm section 422). As in Fig. As further shown in Figure 9, the width 602 of the legs of the internal struts 408 can decrease along the arm length 432 in some embodiments. In other words, the legs of the internal struts 408 can extend away from the central axis 436 of the trumpet arm 402 over a portion 612 of the arm length 432 while still in the "x" configuration. This configuration can provide strength and stiffness to the arm section 422 while also providing space for positioning the axle shaft. As described here, the internal struts 408 must not extend into the axle journal 726. The internal struts 408 provide stiffness and resistance to deterioration to the trumpet arm 402 at the flange 414, at the flange / arm junction 406, and along the arm length 432 of the arm section 422.

[0046] Fig. Figure 10 shows a third perspective view 1000 of the trumpet arm 402 with the pivot pin 726, as in the Fig. 7-9 described. Fig. The embodiment of the trumpet arm 402 shown in Figure 10 further comprises elements that can assist in positioning the trumpet arm 402 in relation to electrical axle components, such as a gearbox, a differential and / or an electric machine, as shown in Figure 10. Fig. As described in Figures 1-3, a differential lock / axle disconnect assembly 1002 can be positioned in the flange 414 and can comprise a shift fork and a sliding sleeve 1004 coupled to a differential lock / axle disconnect assembly 1008 positioned in the actuator through-hole 424. The differential lock / axle disconnect assembly 1002 can be positioned in the flange 414 such that a through-hole of the sliding sleeve 1004 is aligned with the central axis 436 of the trumpet arm 402. This alignment allows the axle shaft to pass through the through-hole of the sliding sleeve 1004. In other embodiments, the axle shaft can be connected to the sliding sleeve 1004 at a second surface of the sliding sleeve 1004 opposite a first surface of the sliding sleeve 1004 by means of teeth 1006. The sliding sleeve 1004 can be actuated to select between a differential (e.g. the differential 110 of Fig. 1) to engage and thus control the rotation of the axle shaft coupled to the sliding sleeve 1004 (e.g., to enable rotation by engaging the sliding sleeve 1004 in the differential). In other embodiments, the shift fork and the sliding sleeve 1004 are optionally equipped with a counter-clutch of the transmission (e.g., the transmission 108 of Fig. 1) to interlock in order to control the rotation of the axle shaft positioned in the trumpet arm 402 and coupled to a drive wheel (not shown). The operation of the differential lock / axle disconnect actuator is explained using the following: Fig. 11 described in more detail.

[0047] The trumpet arm 402 may further include one or more fixing dowels to assist in positioning the trumpet arm 402 relative to electrical axle components (e.g., the gearbox 108, the differential 110, the electric motor 106, and / or their housings). For example, the trumpet arm 402 may include a first fixing dowel 1012 extending from an upper right corner of the flat surface 428 toward the first end 442, and a second fixing dowel 1010 extending from a lower left corner of the flat surface 428 toward the first end 442. The first fixing dowel 1012 and / or the second fixing dowel 1010 may extend into the trumpet arm 402 and connect it, for example, to the gearbox of the E-axle.The trumpet arm 402 may additionally or alternatively have one or more centering diameters (not shown) extending into or out of the flange 414 and arranged to accommodate one or more matching diameters of the electric machine in order to position the trumpet arm 402 on the electric machine.

[0048] Fig. Figure 11 shows a second cross-sectional side view 1100 of the trumpet arm 402 with the axle journal 726, the differential lock / axle disconnection assembly 1002 and the differential lock / axle disconnection actuator 1008 coupled thereto, as in Fig. 10 described. As in Fig. As described in section 10, the shift fork and the sliding sleeve 1004 of the differential lock / axle disconnection assembly 1002 are arranged so that they can be engaged with a counter-coupling 1104 of the electric machine (e.g., the electric machine 106 of Fig. 1) can be paired. In the embodiment of Fig. Figure 11 shows the counter-coupling 1104 as a Curvic coupling. In other embodiments, the counter-coupling 1104, with which the sliding sleeve 1004 selectively interacts, can be any jaw coupling, a synchronizing coupling, a cone coupling, a dry coupling, a wet coupling, friction plates, etc., without this deviating from the scope of the present disclosure. The differential lock / axle disconnection assembly 1008 can extend through the flange length 608 of the flange 414 at the actuator through-bore 424, thereby enabling the differential lock / axle disconnection assembly 1008 to selectively engage with components (e.g., the differential, elements of a suspension mounted on the arm section 422, and / or other elements of the E-axle) either at the first end 442 or at the second end 444 of the trumpet arm 402.The differential lock / axle disconnection device 1008 and the differential lock / axle disconnection device 1002 can in one case be pneumatically, electromechanically, hydraulically and / or magnetically actuated.

[0049] Fig. 12 shows the Fig. the force distribution on the trumpet arm described here with internal struts and external struts (spandrels, crossbeams) (e.g. the trumpet arm 402 of the Fig. 4-11). As described herein, the internal and external braces in the trumpet arm (e.g., in trumpet arm 402) provide strength and stiffness at the flange / arm junction and along the arm section, which can counteract deterioration of the trumpet arm due to deflection loads. For example, the internal and external braces (splices, crossbeams) can ensure that the pivot points of the trumpet arm remain rigid during deflection.

[0050] As in Fig. As briefly described in Section 3, a vehicle traveling on a road can be deflected along a vertical axis when it encounters bumps and / or potholes in the road surface, and along a longitudinal axis when it brakes / accelerates. The trumpet arm described here is designed to distribute the deflection in such a way as to impart stiffness to the electric drive axle in which it is used, thereby reducing wear on the trumpet arm, the electric drive axle, and other components thereof. In simplified examples, the deflection of the trumpet arm along a vertical axis (e.g., the z-axis with respect to the axis system 150, perpendicular to the road surface) results in two pivot points, which deflect the trumpet arm up / down about. A first pivot point 1202 is located at an intersection of the flat surface 428 and the angled extension 430 of the flange 414.A second pivot point 1204 is located at the flange / arm junction 406. The installation of internal braces 408, extending from the flange 414 along the inside of the arm section 422, stiffens the second pivot point 1204 and increases the strength along the arm section 422. The installation of external braces (splices, crossbeams) 426 outside the flange 414 (e.g., at the angled extension 430) stiffens the first pivot point 1202.

[0051] Fig. shows a lateral cross-sectional view of an upper part of the trumpet arm 402 (e.g. above the central axis 436 of Fig. 11). As in the Fig. As shown, when a load (indicated by the first arrow 1206) directs the trumpet arm 402 upwards (e.g., away from a driving surface), the external braces (plinths, crossbeams) 426 are compressed along a first side 1208. The internal brace 408 is under tension along a second side 1210 and a third side 1212. The trumpet arm 402 deflects with respect to the y-axis, as indicated by a first dashed line 1214, with a smaller amount and with lower loads at the first pivot point 1202 and the second pivot point 1204 compared to the upward deflection of trumpet arms without internal braces (plinths, crossbeams) and / or external braces.

[0052] Fig. Figure 1 shows a side view of the trumpet arm 402 in cross-section. A lower half 1254 of the trumpet arm 402 undergoes a deflection, as described below. The upper half 1252 of the trumpet arm 402 can be understood as undergoing a deflection, as shown in the figure below. Fig. described. The arrangement of the internal struts 408 and the external struts (gussets, trusses) 426, as well as the load direction of the lower half of the trumpet arm 402, can correspond to the upper half 1252 of the trumpet arm, which is reflected across the central axis 436. In other words, both the upper half 1252 and the lower half 1254 of the trumpet arm 402 are loaded in a downward direction, as indicated by the second arrow 1220 and the third arrow 1222. The trumpet arm 402 therefore comprises a pair of first pivot points 1202 at the intersection of the flat surface 428 and the angled extension 430 of the flange 414, and a pair of second pivot points 1204 at the flange / arm junction 406. For the upper half 1252 of the trumpet arm 402, the external brace (splice, crossbeam) 426 along the first side 1208 is under tension when the load is applied downwards. The internal brace 408 is compressed along the second side 1210 and the third side 1212.The trumpet arm 402 deflects downwards with respect to the y-axis, as indicated by a second dashed line 1216, with a smaller amount and less stress at the pair of first pivot points 1202 and the pair of second pivot points 1204 compared to the deflection of trumpet arms without external and / or internal braces. For the lower half 1254 of the trumpet arm 402, the external brace (spike, crossbeam) 426 is compressed along a first side 1208 when the load is applied downwards. The internal brace 408 is under tension along the second side 1210 and the third side 1212.The trumpet arm 402 is deflected downwards with respect to the y-axis, as indicated by a third dashed line 1218, by a smaller amount and with lower loads at the pair of first pivot points 1202 and the pair of second pivot points 1204 compared to the deflection of trumpet arms without external and / or internal braces. A smaller deflection of the trumpet arm can extend the service life of the trumpet arm and the E-axis, as the deterioration of the trumpet arm at the first and second pivot points can be reduced due to the strength and stiffness of the trumpet arm provided by the internal and external braces.

[0053] One embodiment of a trumpet arm is described in relation to the Fig. 4-12 described, wherein the trumpet arm comprises a housing with an arm section extending over an arm length, the arm section having an outlet at a first end and a flange with a flat surface at a second end opposite the first end; and internal struts arranged in an interior of the housing and extending through at least a first part of a flange length of the flange, a flange / arm transition where the flange transitions into the arm section, and at least a part of the arm length. Different embodiments of the trumpet arm incorporating the elements described above may have different geometries that can be used to configure the trumpet arm for use in various systems, e.g., as an e-axle for vehicles of different sizes and shapes.For example, the cross-section of the arm section can be adapted during the manufacture of the trumpet arm to form embodiments of the trumpet arm that can be used in an electric drive system for a passenger vehicle, a heavy-duty vehicle, etc. Additionally or alternatively, the cross-section of the arm section 422 can be shaped and sized to provide space for the mounting and / or coupling of various suspension fastening systems to it. Similarly, the orientation of the legs of the internal struts of the trumpet arm can differ in various embodiments of the trumpet arm. Different configurations of the internal struts may, for example, include two or more legs. Fig. Figure 13 shows illustrations of possible arm cross-sections 1300 and leg orientations 1350 of internal struts 408 for the trumpet arm described here. The cross-section of the arm section can be described as: box 1302, rectangle 1304, circle 1308, oval 1310, hourglass 1312, or a combination 1314 of two or more of these shapes. The orientation of the legs of the internal struts can be angled (“x” configuration 1352, as in Fig. 4-11 described), “y”-shaped 1354, horizontal 1358, vertical 1360, “+”-shaped 1362, curved 1364 or a combination 1366 of two or more of these orientations.

[0054] Fig. Figures 14A-20 show a second embodiment of the trumpet arm described here. Similar to the one described in the Fig. As described in Figure 4-11, the trumpet arm 402 comprises a flange with a flat surface, wherein the flange is connected to an arm section at a flange / arm transition on one side of the flange opposite the flat surface. As described in the Fig. As further described in 14A-20, the flange of the trumpet arm 1402 has a curved extension from the flat surface to the flange / arm junction. The curved extension can have the same or similar advantages as the angled extension of the trumpet arm 402, with the flange of both the trumpet arm 402 and the trumpet arm 1402 providing a relatively abrupt transition at the flange / arm junction, compared to the gradual transition of a banjo axle or a Salisbury axle. The relatively abrupt transition described here can help provide a substantially large enclosure in which electrical axle components can be housed.Internal braces can impart strength and stiffness to the flange / arm junction comparable to or greater than that of the banjo axle and / or the Salisbury axle, with the internal braces and curved extension counteracting the degradation of the trumpet arm that may be caused by sagging of the trumpet arm over time.

[0055] In the Fig. 14A and Fig. Figure 14B shows a first perspective view (1400) and a second perspective view (1450) of a trumpet arm (1402). The trumpet arm (1402) is an example of the first trumpet arm (216) and the second trumpet arm (218) of Fig. 2-3. Elements from Fig. 2-3, which are in Fig. 14A and Fig. Components included in 14B may be similarly numbered (e.g., flange 214 corresponds to...) Fig. 2-3 a flange 1414 made of Fig. 14A and Fig. 14B). The trumpet arm 1402 comprises a housing 1412 with an arm section 1422 extending over an arm length 1432, the arm section 1422 having an outlet 1420 at a second end 1444 and a flange 1414 with a flat surface 1428 at a first end 1442 opposite the second end 1444. The trumpet arm 1402 further comprises internal struts 1408 (e.g., as shown in the Fig. 16, Fig. 17 and Fig. 20), which are arranged in an interior 1410 of the housing 1412 and extend through at least a first part of a flange length of the flange 1414, a flange / arm transition 1406 at which the flange 1414 transitions into the arm section 1422, and at least a part of the arm length 1432, as shown in the Fig. 17 and Fig. 20 further described. The internal struts 1408 can be cast as part of the housing 1412 (e.g., as a single unit with the housing 1412). In some embodiments, the internal struts 1408 are formed as separate parts from the housing 1412 (e.g., castings, stampings, formed parts, machined parts) and are welded or otherwise fixedly positioned within the interior 1410 of the housing 1412. The housing 1412 and the internal struts 1408 can be made of the same material, e.g., cast steel, ductile iron, or cast aluminum. In other embodiments, the housing 1412 and the internal struts 1408 can be made of different metals or other rigid materials.

[0056] As in the Fig. As briefly described in Figures 1-3, the flange 1414 has several through holes 1416 arranged along its circumference and oriented to allow fasteners, such as bolts, to pass through them to couple the trumpet arm 1402 to components of the electric axis, such as a gearbox housing and / or an electric machine housing. In some embodiments, each of the numerous through holes 1416 may have a raised bolt pad 1418, which can aid in positioning a fastener, such as a bolt, and in distributing the bolt load. The raised bolt pad 1418 can further facilitate the manufacture of the trumpet arm 1402. In some embodiments, the raised pads may or may not be used. Instead, for example, a flattened surface may be used.Each of the numerous through-holes 1416 can be strategically positioned along the circumference of the flange 1414 to allow the alignment of each through-hole 1416 with a coupling hole of a gearbox housing and / or a housing of an electric machine.

[0057] The flange 1414 in the second embodiment of the trumpet arm 1402 has a circular profile with a cutout 1454 along a first section 1452 of the circumference of the flange 1414, as shown in Fig. 14B. The cutout 1454 can be dimensioned and shaped such that components of an electric drive system (e.g., a gearbox, a differential, and / or an electric machine) can be positioned compactly within a shell of an e-axle, the shell being designed as a space between two trumpet arms 1402, as shown in the Fig. described in Figures 1-3. The flange 1414 also includes a curved extension 1430 that extends from the flat surface 1428 to the flange / arm transition 1406. The curved extension 1430, in combination with the flat surface 1428, gives the flange 1414 a domed shape (convex as seen from the second end 1444 of the housing 1412 to the first end 1442), except for the cutout 1454. In another example, the curved extension 1430, in combination with the flat surface 1428, can give the flange 1414 a concave shape (as seen from the second end 1444 of the housing 1412 to the first end 1442), except for the cutout 1454. As described in the Fig. As further described, the interior of the flange 1414 decreases from the flat surface 1428 to the flange / arm transition 1406. The curved extension 1430 with the cutout 1454 can provide space in which internal struts 1408 can be accommodated and an axle shaft can pass through the interior 1410 of the trumpet arm 1402 without touching the housing 1412 or the internal struts 1408. Additionally, and as further described herein, the curved extension 1430 can be used similarly to the external struts (gussets, crossbars) 426 of Fig. 4-12 function and provide additional support for the trumpet arm 402 and rigidity for two of its pivot points, so that the trumpet arm 402 can resist deflection and deterioration due to forces in an upward / downward, forward / backward, and / or torsional direction. As in the Fig. As described in Figures 4-12, in the first embodiment of the trumpet arm 402, the external struts (splices, crossbeams) 426 and the internal struts 408 create a first pivot point at the flat surface 428 of the flange 414 and a second pivot point at the flange / arm junction 406. The curved extension 1430 of the second embodiment of the trumpet arm 1402 can form a first pivot point around a curved circumference 1458, where the curved extension 1430 intersects an angled extension section 1456 of the flange 1414, which connects the curved extension 1430 to the flat surface 1428. A second pivot point can be formed at the flange / arm junction 1406, as described in Figures 4-12. Fig. 12 described. Similar to in Fig. Are the first pivot point and the second pivot point both rigid when the arm section 1422 is in a first downward direction (e.g., similar to in Fig. The first pivot point and the second pivot point are both rigid when the arm section experiences a deflection in a second, upward direction (e.g. away from the drive surface) because the inner struts 1408 are under tension and the curved extension 1430 is under compression.

[0058] Both the first perspective view 1400 and the second perspective view 1450 show the geometry of the case 1412, with the arm section 1422 having a rectangular shape extending along the arm length 1432, and the outlet 1420 having an annular shape. The arm section 1422 can gradually transition into the outlet 1420, so that the rectangular shape smoothly merges into the annular shape without any sharp (e.g., angled) intersections. The rectangular shape of the arm section 1422 can provide space within the interior 1410 of the trumpet arm 1402 for positioning the internal struts 1408 and for positioning an axle shaft (e.g., the axle shaft 115, 117). The arm section 1422 is also shaped to allow the mounting of suspension fastening systems of different shapes and sizes (e.g., from different manufacturers). The internal struts 1408 can extend partially into the outlet 1420, as shown in the Fig. described in more detail. The annular shape of the outlet 1420 allows the axle shaft to be positioned within it without coming into contact with the housing 1412. The annular shape of the outlet 1420 also allows an axle journal (e.g., the first axle journal 224, the second axle journal 226) to be coupled to it. In other embodiments, the outlet 1420 can be directly connected to a non-rotating part of a drive wheel. In other embodiments, the trumpet arm 1402 (e.g., as in Fig. 13 described) have a differently shaped cross-section which can be oriented in such a way as to allow the mounting of various suspension fastening systems on it and / or the integration of the trumpet arm 1402 into different sizes and shapes of e-axles for different vehicle types, for example.

[0059] In Fig. Figure 15 shows a first side view 1500 and a second side view 1550 of the second embodiment of the trumpet arm 1402. The elements of the trumpet arm 1402, which are shown in Fig. 14A and Fig. The details described in 14B are not repeated here for the sake of brevity. The flange 1414 of the trumpet arm 1402 has a flange length 1508, the arm section 1422 has an arm length 1432, and the internal struts 1408 extend through at least a first part of the flange length 1508, the flange / arm transition 1406, and at least a section of the arm length 1432, as described in the Fig. 16, Fig. 17 and Fig. 20 described in more detail.

[0060] Fig. Figure 16 shows a first profile view 1600 and a second profile view 1650 of the trumpet arm 1402 of the Fig. 14A-15. Elements of the trumpet arm 1402, which are in the Fig. The details described in Figures 14A-15 are not repeated here for the sake of brevity. The first profile view, 1600, shows the trumpet arm 1402 along the y-axis, looking into an inner surface 1434 of the trumpet arm 1402 from the flange 1414 to the outlet 1420 (e.g., from the first end 1442 of the housing 1412 to the second end 1444, as shown in the figures). Fig. 14A and Fig. (described in Figure 14B). The second profile view 1650 shows the trumpet arm 1402 along the y-axis looking into the interior 1410 of the trumpet arm 1402 from the outlet 1420 to the flange 1414 (e.g., from the second end 1444 of the housing 1412 to the first end 1442). In some embodiments, the trumpet arm 1402 includes one or more dowel holes 1610 arranged along a circumference of the flat surface 1428 and extending through its thickness. The one or more dowel holes 1610 may be oriented to accommodate a dowel extension, e.g., from a gear housing and / or an electrical machine housing, to assist in the positioning of the trumpet arm 1402 relative to it. The one or more dowel holes 1610 can in some embodiments be circular and be the same size, a larger size or a smaller size than the multiple through holes 1416.

[0061] As in Fig. 14A and Fig. As described in Figure 14B, the internal struts 1408 have an “x” configuration formed from four legs (e.g., a first leg 1408a, a second leg 1408b, a third leg 1408c, and a fourth leg 1408d) that connect the internal struts 1408 to the arm section 1422 and the curved extension 1430. The “x” configuration can be seen in the first profile view 1600 and in the second profile view 1650. Fig. 16. The configuration of the internal struts 1408 in the “x” configuration allows the internal struts 1408 to respond to vertical and horizontal forces as well as torsional forces on the trumpet arm 1402 and thus on the internal struts 1408. For example, the internal struts 1408 may be subjected to vertical forces when a vehicle with the E-axle that uses the trumpet arm 1402 (e.g., vehicle 100 of Fig. 1) travels over protrusions and / or depressions in a road surface (e.g., speed bumps, potholes). The internal struts 1408 may be subjected to horizontal and torsional forces when the vehicle brakes and / or accelerates. As in Fig. 14A and Fig. As further described in Figure 14B, the internal struts 1408 and the curved extension 1430, which can function similarly to the external struts (gussets, crossbeams) 426 of the first embodiment of the trumpet arm 402, can allow the pivot points of the trumpet arm 1402 to remain rigid when the trumpet arm is subjected to vertical and / or horizontal forces (e.g., deflection of the trumpet arm), which can reduce deterioration of the trumpet arm 1402, particularly at the flange / arm junction 1406. The second embodiment of the trumpet arm 1402 can also have different configurations of the internal struts 1408. For example, the internal struts 1408 can have more or fewer than four legs, and the legs can be arranged in a “y” configuration, a “+” configuration, etc., as shown in Figure 14B. Fig. 13 described.

[0062] Fig. Figure 17 shows a side view 1700 of the trumpet arm 1402 in cross-section, with the section axis passing through line 1750. Fig. 14B is indicated. Elements of the trumpet arm 1402, which are in the Fig. The items described in 14A-16 are not listed again for the sake of brevity. Fig. Figure 17 shows an embodiment of a configuration of the internal struts 1408 in the housing 1412 of the trumpet arm 1402. In the embodiment of the trumpet arm 1402, the internal struts 1408 comprise four legs in an “x” configuration, as described above. The third leg 1408c and the fourth leg 1408d are in Fig. Figure 17 shows that the first leg 1408a and the second leg 1408b have the same positioning as described with respect to the third leg 1408c and the fourth leg 1408d, respectively, reflected across line 1750. The third leg 1408c and the fourth leg 1408d each extend over a first part 1708 of the flange length 1508 and over the entire arm length 1432. The third leg 1408c and the fourth leg 1408d can extend over a first length 1710 into the outlet 1420. The third leg 1408c and the fourth leg 1408d extend along the curved extension 1430 of the flange 1414 at an angle parallel to a curvature of an outer surface 1438 of the curved extension 1430 for the first section 1708 of the flange length 1508.At the flange / arm transition 1406, the shape of the third leg 1408c and the fourth leg 1408d transitions from an angle parallel to the curved extension 1430 into a horizontal extension that runs parallel to the arm section 1422. The horizontal extension extends over a third part 1714 of the arm length 1432. The third leg 1408c and the fourth leg 1408d both extend away from the central axis 1436 of the trumpet arm 1402, towards the walls of the arm section 1422, for a fourth section 1716 of the arm length 1432 and the outlet 1420. In this way, the configuration of the third leg 1408c and the fourth leg 1408d, and thus of the four legs of the internal struts 1408, can provide stiffness and resistance to deterioration at the flange / arm junction 1406, along the arm length 1432, and at the transition between the arm section 1422 and the outlet 1420. As in . Fig. As described in 13, different embodiments of the internal struts 1408 can include more or less than four legs, which are aligned in a configuration other than the “x” configuration.

[0063] The flange 1414 is configured to form a rectangular shell for positioning electrical axle components in an e-axis. In some embodiments, the flat surface 1428 can be a surface at the first end 1442 of a plate or other flat structure. The curved extension 1430 is coupled to and / or continuously connected with the plate or flat structure having the flat surface 1428 and extends from it in a direction away from the flat surface 1428 (e.g., towards the second end 1444). As shown in the Fig. As described in 14A-15, the curved extension 1430 has a dome-like shape with a cutout 1454, wherein the inner surface 1434 of the flange 1414 decreases from the first end 1442 towards the flange / arm junction 1406. In other words, the flange 1414 has a concave shape, with a first diameter 1720 located at the first end 1442 of the trumpet arm 1402 and potentially coupled to electrical axle components, and a second diameter 1722 of the concave shape located at the flange / arm junction 1406, the first diameter 1720 being larger than the second diameter 1722. The curved extensions 1430 can serve as external struts, providing stiffness and resistance to load-induced deterioration.

[0064] The arm length 1432 and the shape (e.g., the cross-section) of the arm section 1422 can be designed to allow the mounting or other forms of coupling of various suspension fastening systems to the arm section 1422. Different suspension fastening systems can be designed by the same or different manufacturers as those who manufacture the trumpet arm 1402, so that the arm section 1422 is dimensioned to accommodate different shapes and sizes of suspension fastening systems. In some embodiments, a suspension fastening system can be connected to the trumpet arm 1402 along part or all of the arm length 1432. For example, a suspension fastening system can be coupled to the trumpet arm 1402 along the third section 1714 of the arm section 422 and not to the trumpet arm 1402 at the fourth section 1716 of the arm length 432.The cutout 1454 of the flange 1414 can also provide space for positioning gearbox covers. For example, at least part of a gearbox cover with an arm length of 1432 can extend through the cutout 1454 into the flange length 1508. As shown in... Fig. As described in Figure 13, different embodiments of the trumpet arm can have differently shaped arm sections (e.g. circular cross-section, hourglass cross-section, etc.), all of which can be configured to accommodate several different suspension fastening systems.

[0065] Fig. Figure 18 shows a perspective view from 1800 of the trumpet arm from 1402, as in the Fig. 14A-17, with a pivot 1826 coupled to the trumpet arm 1402 at the outlet 1420. The pivot 1826 could be an example of the first pivot 224 or the second pivot 226 as described in the Fig. 1-3 are described. The axle journal 1826 is coupled to the trumpet arm 1402 at a first end 1842 of the axle journal 1826, and a drive wheel (not shown) can be coupled to the axle journal 1826 at a second end 1844 of the axle journal 1826, opposite the first end 1842 of the axle journal 1826. The axle journal 1826 can be coupled to the trumpet arm 1402, for example, by friction welding. As in the Fig. As described in Figures 1 to 3, an axle shaft, which transmits rotary motion from a rotary power source (e.g., the electric machine 106) to the drive wheels, can be guided through the interior 1410 of the trumpet arm 1402 and through an interior 1810 of the axle journal 1826 to couple to a drive wheel. In some embodiments, the axle journal 1826 can be connected to a non-rotating element of the drive wheel. In other embodiments, the axle journal 1826 can be adjacent to and axially aligned with the center of the drive wheel, but not in contact with the drive wheel. In some embodiments, the axle shaft can protrude from the second end 1844 of the axle journal 1826, in which case the axle shaft can be coupled to the drive wheel and the axle journal 1826 is not in contact with the drive wheel. Fig. Figure 19 shows a side view from 1900 of the trumpet arm 1402, as in Fig. 18 described, with the axle pin 1826, which is connected to the trumpet arm 1402 at the outlet 1420.

[0066] Fig. Figure 20 shows a cross-sectional side view 2000 of the trumpet arm 1402 with the axle pin 1826 coupled to it, as in the Fig. described on pages 18-19. The first cross-sectional side view 2000 cuts the trumpet arm 1402 with the axle journal 1826 along the in Fig. Line 2050, shown in Figure 18. As in the Fig. As described in 14A-19, the legs of the internal struts 1408 extend from the flange 1414 through the flange / arm transition 1406 and along the arm length 1432 of the arm section 1422. In the Fig. In the embodiment of the trumpet arm 1402 shown in Figure 20, the arms of the internal struts 1408 (e.g., the first leg 1408a and the second leg 1408b) extend in an “x” configuration toward the central axis 1436 of the trumpet arm 1402. In other words, the first leg 1408a and the second leg 1408b (as well as the third leg 1408c and the fourth leg 1408d, in Fig. (20 not shown) extend from the curved extension 1430 at an angle towards the central axis 1436 of the trumpet arm 1402, so that space is provided between the individual legs of the internal braces as well as between the internal braces 1408 and the housing 1412 (e.g., the walls of the arm section 1422). In other words, the legs of the internal braces 1408 can extend away from the central axis 1436 of the trumpet arm 1402 in the fourth section 1716 of the arm length 1432 while still in the "x" configuration. This configuration can provide strength and rigidity to the arm section 1422 while also providing space for positioning the axle shaft. As described here, the internal braces 1408 can extend into the outlet 1420 and not into the axle journal 1826.The internal struts 1408 give stiffness and resistance to deterioration to the trumpet arm 1402 at the flange 1414, at the flange / arm transition 1406 and along the arm length 1432 of the arm section 1422.

[0067] The technical benefit of the trumpet arm with internal struts and a flat-face flange is that it increases the strength, stiffness, and resistance of the trumpet arm at the flange / arm interface compared to conventional steering knuckles. This extends the service life of the trumpet arm. Furthermore, its suitability for e-axles is enhanced because the flat surface of the flange provides a rectangular area for mounting electric axle components. Additionally, the trumpet arm described here can feature various configurations of the internal strut legs and the cross-section of the arm section, providing space for mounting different suspension systems and ensuring sufficient and desirable strength for use in various systems, such as passenger and / or heavy-duty electric vehicles.

[0068] The disclosure also provides a support for a trumpet arm for an axis, comprising: a housing with an arm section extending over an arm length, the arm section having an outlet at a first end and a flange with a flat surface at a second end opposite the first end, and internal struts arranged in an interior of the housing and extending through at least a first part of a flange length of the flange, a flange / arm transition where the flange transitions into the arm section, and at least a part of the arm length.In a first example of the system, the internal struts comprise one or more legs extending from the case walls toward the interior of the case in an "x" configuration, a "y" configuration, a horizontal configuration, a vertical configuration, a "+" configuration, a curved configuration, or a combination of two or more of the aforementioned configurations. In a second example of the system, which optionally includes the first example, the cross-section of the arm section is a box, a rectangle, a circle, an oval, an hourglass, or a combination of two or more of the aforementioned shapes.In a third example of the system, optionally comprising one or both of the first and second examples, the system further comprises: external braces extending over a second part of the flange length to the flange / arm junction, wherein the endpoints of the external braces are offset from the endpoints of the internal braces. In a fourth example of the system, optionally comprising one or more or each of the first through third examples, the flange includes an angled extension from the flat surface to the flange / arm junction. In a fifth example of the system, optionally comprising one or more or each of the first through fourth examples, the flange includes a curved extension from the flat surface to the flange / arm junction.In a sixth example of the system, optionally comprising one or more or each of the first five examples, the system further comprises: a pivot pin connected to the housing at the outlet of the arm section. In a seventh example of the system, optionally comprising one or more or each of the first six examples, a cross-section of the arm section maintains a constant profile over the entire arm length. In an eighth example of the system, optionally comprising one or more or each of the first seven examples, the system further comprises: multiple through-holes along a circumference of the flange, one or more of the multiple through-holes having a raised bolt cushion. In a ninth example of the system, optionally comprising one or more or each of the first eight examples, the inner surface area of ​​the flange decreases from the first end towards the flange / arm junction.In a tenth example of the system, which may optionally include one or more or each of the first nine examples, the housing and internal struts are made of cast steel, cast aluminum, and / or ductile iron. In an eleventh example of the system, which may optionally include one or more or each of the first ten examples, the housing and internal struts are designed as various cast, stamped, or machined components forming a support and are welded together.

[0069] The disclosure also provides a mounting for an e-axis comprising: an electric machine, a first trumpet arm, and a second trumpet arm, wherein at least one of the first trumpet arm and the second trumpet arm comprise a housing with an arm section extending over one arm length, a flange with a flat surface at a first end of the arm length, and internal struts arranged inside the housing, the first trumpet arm and the second trumpet arm each being configured to be coupled to the electric machine via a respective flange. In a first embodiment of the system, the internal struts of the first trumpet arm and the second trumpet arm extend over at least a first part of the flange length, a flange / arm transition where the flange merges into the arm section, and at least a part of the arm length.In a second example of the system, which optionally includes the first example, the system further comprises: a differential lock / axle disconnection assembly with a shift fork and a sliding sleeve arranged in the flange of the first or second trumpet arm, wherein the shift fork and the sliding sleeve are configured to engage with a counter-coupling of the electric machine, and wherein the differential lock / axle disconnection assembly is actuated pneumatically, hydraulically, electromechanically, or magnetically. In a third example of the system, which optionally includes one or both of the first and second examples, the sliding sleeve contains a differential lock / axle disconnection assembly extending through a flange length of the flange of the first or second trumpet arm.In a fourth example of the system, which optionally includes one or more or each of the first through third examples, the system further comprises: one or more positioning dowels extending from the flange of each of the first and second trumpet arms to the electrical machine, and / or one or more centering diameters extending into the flange of each of the first and second trumpet arms and oriented to accommodate one or more connectors of the electrical machine. In a fifth example of the system, which optionally includes one or more or each of the first through fourth examples, the system further comprises: a suspension system coupled to at least one of the first and second trumpet arms at the respective arm section(s).In a sixth example of the system, which may optionally include one or more or each of the first to fifth examples, the system further comprises: a first pivot and a second pivot coupled to each of the first trumpet arm and the second trumpet arm, respectively, at a second end of the arm length opposite the first end of the arm length and at a first pivot end of the respective pivot, and a first wheel and a second wheel coupled to each of the first pivot and the second pivot, respectively, at a second pivot end of the respective pivot opposite the first pivot end of the pivot.

[0070] The disclosure also provides support for an axle housing comprising: an arm section extending over an arm length; a flange extending over a flange length and having a flat surface at a first end of the flange length, the flange being connected to the arm section at a flange / arm junction; internal struts arranged in an interior of the flange and the arm section, the internal struts extending at least one section of the arm length of the arm section and at least one first section of the flange length; external struts arranged on an outside of the flange, the external struts extending at least a second part of the flange length; a pair of first pivot points on the flat surface of the flange and a pair of second pivot points at the flange / arm junction, wherein: the pair of first pivot points and the pair of second pivot points are both rigid.if the arm section experiences a deflection in a first, downward direction because in an upper half of the axle housing the internal struts are under compression and the external struts are under tension, and in a lower half of the axle housing the internal struts are under tension and the external struts are under compression, and the pair of first pivot points and the pair of second pivot points are both rigid; if the arm section experiences a deflection in a second, upward direction because in the upper half of the axle housing the internal struts are under tension and the external struts are under compression, and in the lower half of the axle housing the internal struts are under compression and the external struts are under tension.

[0071] Fig.Figures 1-20 show exemplary configurations with the relative positioning of the various components. If such elements are shown to be directly touching or directly coupled, then they can be described as directly touching or directly coupled, respectively, in at least one example. Likewise, elements shown to be directly adjacent or adjoining can be described as directly adjacent or adjoining in at least one example. For instance, components that are in surface contact can be described as standing in surface contact. In another example, elements positioned far apart, with only space and no other components in between, can be described as such in at least one example.In yet another example, elements shown above / below each other, on opposite sides, or to the left / right of each other can be described as such in relation to one another. As shown in the figures, a topmost element or the highest point of an element can also be described as "at the top" of the component in at least one example, and a bottommost element or the lowest point of the element can be described as "at the bottom" of the component. As used here, top / bottom, top / bottom, and above / below can refer to a vertical axis of the figures and can be used to describe the positioning of elements of the figures in relation to one another. Thus, elements shown above other elements are, in one example, positioned vertically above the other elements. As a further example, the shapes of the elements depicted in the figures can be described as such (e.g.,circular, straight, flat, curved, rounded, beveled, angled, etc.). Furthermore, elements shown as intersecting each other may be described as intersecting elements or as intersecting each other in at least one example. In addition, an element shown inside or outside another element may be described as such.

[0072] It is understood that the configurations and routines disclosed herein are exemplary and that these specific embodiments are not to be considered limiting, as numerous variations are possible. Unless expressly stated otherwise, the terms "first," "second," "third," etc., do not denote any order, position, quantity, or significance, but serve only to distinguish the individual elements. The subject matter of this disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, as well as other features, functions, and / or properties disclosed herein.

[0073] Unless otherwise stated, the term "approximately" means plus or minus five percent of the range.

[0074] The following claims specifically indicate certain combinations and subcombinations that are considered novel and not obvious. These claims may refer to "one" element, "a first" element, or an equivalent thereof. These claims should be understood as including one or more such elements, but two or more such elements are neither required nor excluded. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application. Such claims, whether broader, narrower, of the same or a different width than the original claims, are also considered to be included in the subject matter of the present disclosure. QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited non-patent literature

[0000] TRUMPET ARM WITH INTERNAL BUTTRESSES", which was released on September 12, 2023

[0001]

Claims

[1] Trumpet arm (1402, 402) for an axle, comprising: a housing (412, 1412) having an arm portion (1422, 422) extending over an arm length (1432, 432), the arm portion (1422, 422) having an outlet (1420, 420) at a first end (444, 1444) and a flange (414, 1414) having a flat surface (1428, 428) at a second end (1442, 442) opposite the first end; and internal struts (1408, 408) disposed in an interior space (1410, 410) of the housing (412, 1412) and extending through at least a first portion (1708) of a flange length (608) of the flange, a flange / arm transition (406, 1406) at which the flange transitions into the arm portion, and at least a portion (612) of the arm length. [2] A trumpet arm according to any one of the preceding claims further comprising external struts (426) extending over a second portion (612) of the flange length to the flange / arm transition, and wherein the endpoints of the external struts are offset from the endpoints of the internal struts. [3] Trumpet arm according to one of the preceding claims, wherein the flange has an angled extension (430) from the flat surface to the flange / arm transition. [4] A trumpet arm according to any preceding claim, wherein the flange has a curved extension (1430) from the flat surface to the flange / arm transition. [5] A trumpet arm according to any one of the preceding claims, further comprising a journal (154, 726, 1826) coupled to the housing at the outlet of the arm portion. [6] A trumpet arm according to any one of the preceding claims, wherein a cross-section of the arm portion maintains a constant profile over the entire arm length. [7] A trumpet arm according to any preceding claim, further comprising a plurality of through holes (416, 1416) along a perimeter of the flange, wherein one or more of the plurality of through holes includes a raised bolt pad (418, 1418). [8] A trumpet arm according to any one of the preceding claims, wherein an inner surface (434, 1434) of the flange decreases from the first end to the flange / arm transition. [9] Trumpet arm according to one of the preceding claims, wherein the housing and the internal struts are made of cast steel, cast aluminum and / or ductile iron. [10] A trumpet arm according to any one of the preceding claims, wherein the housing and the internal struts are formed as separate cast, stamped or machined components joined together as a weldment. [11] An E-axle (104) comprising: an electric machine (206, 106); a first trumpet arm (1402, 402); and a second trumpet arm (1402, 402), wherein at least one of the first trumpet arm and the second trumpet arm comprises a housing having an arm portion (1422, 422) extending over an arm length (1432, 432), a flange (414, 1414) having a flat surface at a first end (1444, 444) of the arm length, and internal struts (1408, 408) disposed in an interior space (1410, 410) of the housing, wherein the first trumpet arm and the second trumpet arm are each configured to couple to the electric machine via a respective flange (414, 1414). [12] The E-axle of claim 11, wherein the internal struts of the first trumpet arm and the second trumpet arm extend through at least a first portion (612, 1708) of a flange length (608, 1508) of the flange, a flange / arm transition (406, 1406) where the flange transitions into the arm portion, and at least a portion (612) of the arm length. [13] E-axle according to claim 11 or 12, further comprising a differential lock / axle disconnect assembly (1002, 260) having a shift fork and a sliding sleeve (1004) arranged in the flange of the first trumpet arm or the second trumpet arm, wherein the shift fork and the sliding sleeve are arranged to engage with a mating clutch (1104) of the electric machine, and wherein the differential lock / axle disconnect assembly is actuated pneumatically, hydraulically, electromechanically or magnetically. [14] The E-axle of claim 13, wherein the differential lock / axle disconnect assembly comprises a differential lock / axle disconnect actuator (1008) extending through a flange length (608, 1508) of the flange of the first trumpet arm or the second trumpet arm. [15] The electric axle of any one of claims 11 to 14, further comprising a first axle journal (224) and a second axle journal (226) each coupled to the first trumpet arm and the second trumpet arm at a second end (1442, 442) of the arm length opposite the first end of the arm length and at a first axle journal end of the respective axle journal, and a first wheel (112) and a second wheel (114) each coupled to the first axle journal and the second axle journal at a second axle journal end of the respective axle journal opposite the first axle journal end of the axle journal.

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