Electric Drive Axle Disconnect Device Integration
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Solution Overview
Problem
There is a need for an electric drive axle with a disconnect device that is compact in size and weight, capable of decoupling the electric motor from the vehicle wheels without requiring complex and expensive components, to provide flexibility in vehicle speed and power distribution.
Innovation Solution
The electric drive axle comprises an electric motor, a gear arrangement, a differential, and a disconnect device, where the gear arrangement produces a specific gear ratio between the electric motor and the differential, and the disconnect device includes a piston member within an annular hub and pinion sleeve, allowing for axial movement to engage or disengage the motor's power transfer to the wheels, utilizing a fluid or actuator to adjust the piston's position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a disconnect device is added to decouple the electric motor from the vehicle wheels, then vehicle speed flexibility is improved, but device complexity increases
Solution Approach 1:
The disconnect device is integrated into the differential assembly, merging the disconnect function with the existing differential structure. This reduces overall device complexity by eliminating separate disconnect mechanisms while maintaining the ability to decouple the electric motor from the wheels.
Solution Approach 2:
The differential assembly serves multiple functions: it provides both the differential gear function for wheel speed variation and the disconnect function for motor decoupling. This multi-functionality reduces the need for additional specialized components, thereby reducing device complexity while improving vehicle speed flexibility.
2Volume of moving object
If a compact disconnect device is designed, then size and weight are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The piston member is concentrically disposed within the annular hub, creating a nested configuration. This nesting approach minimizes the radial space required for the disconnect device, reducing overall size and weight while maintaining functional effectiveness through precise axial positioning rather than complex radial arrangements.
Solution Approach 2:
The disconnect device is segmented into distinct functional components (piston member, annular hub, protuberances) with clear separation of concerns. This segmentation allows each component to be manufactured and assembled independently, reducing cumulative precision requirements compared to monolithic designs.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables efficient power transfer from the electric motor to the wheels while maintaining a compact and lightweight design, allowing for seamless transition between electric and internal combustion engine power sources, enhancing vehicle performance and efficiency.
Implementation Method 1
a biasing member concentrically disposed about the piston member and configured to urge the piston member in a first axial direction away from the pinion sleeve
Data Source
AI summary
An electric drive axle including an electric motor, a gear arrangement, a differential, and a disconnect device at least partially disposed within a differential case. The gear arrangement is configured to produce a certain gear ratio between the electric motor and the differential.