Parallel-Shaft Axle Drive With Integrated Brake Disk Layout

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Solution Overview

Problem

The challenge is to design an axle drive for vehicles that incorporates a brake, particularly a parking brake, while maintaining a compact form factor to accommodate limited installation space and managing high rotational speeds from electric motors, which often lead to unwanted vibrations and noise due to large brake disks.

Innovation Solution

The axle drive features a parallel offset configuration of drive and driven shafts, with the brake disk integrated between the shafts, allowing for a compact design and reduced rotational speed of the brake disk through a speed reduction stage, thereby minimizing vibrations and noise.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a brake disk is added to the axle drive, then braking function is provided, but installation space increases

Engineering Contradiction:

Improvebraking functionVSAvoidinstallation space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The brake disk is nested between the drive shaft and driven shaft in the axial direction, utilizing the existing space between these two shafts. This allows the brake disk to be integrated into the axle drive without requiring additional installation space, as it fits within the existing structural envelope of the transmission system.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The brake disk is arranged in the axial dimension between the drive shaft and driven shaft, rather than extending in the radial or longitudinal directions. This dimensional arrangement allows the brake function to be added without increasing the overall footprint or width of the axle drive assembly.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Force

If a large diameter brake disk is used, then sufficient braking effect is achieved, but vibrations and noise increase

Engineering Contradiction:

Improvebraking effectVSAvoidvibrations and noise

Core Design Contradiction:

ForceVSObject-generated harmful factors

Solution Approach 1:

The patent changes the rotational speed parameter of the brake disk by introducing a speed reduction stage between the electric motor and the brake disk. This reduces the rotational speed from the motor's high speed to a lower speed at the brake disk, which eliminates vibrations and noise while maintaining sufficient braking effect through the speed-reduced rotation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

A speed reduction stage is introduced as an intermediary mechanism between the electric motor and the brake disk. This intermediary component reduces the rotational speed transmitted to the brake disk, thereby preventing the high-speed vibrations and noise that would otherwise occur with large diameter brake disks.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Device complexity

If the number of components is reduced, then compact design is achieved, but braking function may be compromised

Engineering Contradiction:

Improvenumber of componentsVSAvoidbraking function

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The brake disk is merged with the existing shaft structure by positioning it between the drive shaft and driven shaft. This integration allows the brake function to be added without requiring separate mounting structures or additional components, maintaining device simplicity while ensuring reliable braking performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The space between the drive shaft and driven shaft serves multiple functions: it accommodates the brake disk for braking operations, while the drive shaft and driven shaft continue to perform their primary transmission functions. This multi-functional use of space allows the brake system to be integrated without adding component complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 a compact, space-saving axle drive with improved acoustic behavior and reduced vibrations, allowing for effective use with fast-rotating electric motors while ensuring reliable braking performance.

Implementation Method 1

reduced rotational speed of the brake disk through a speed reduction stage

Methodology Applied

Scientific EffectSpeed reduction stage: Gear

Implementation Method 2

a brake, in particular a parking brake, having a brake disk

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12072001B2Axle drive

Publication Date: 2024.08.27 KESSLER & CO GMBH CO KG

AI summary

An axle drive for a vehicle includes at least one drivable vehicle axle oriented transversely to a longitudinal direction of the vehicle. A drive shaft extends parallel with the longitudinal direction and receives drive power from an electric motor at an input section and outputs said drive power at an output section. A driven shaft extends parallel with the drive shaft and receives drive power from the output section of the drive shaft at an input section and outputs said drive power to the vehicle axle via a bevel gear arranged at a first end of the driven shaft. A brake, in particular a parking brake, includes a brake disk arranged at a second end of the driven shaft and between the input section of the drive shaft and the input section of the driven shaft with respect to the longitudinal direction.