Electric Vehicle Axle Layout for Driveshaft-Free Battery Packaging
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Solution Overview
Problem
Existing live axle rear suspension configurations in electric commercial vehicles hinder packaging efficiency due to the need for driveshafts, leading to reduced cargo space, increased vibration risks for electric motors, and reliability issues, as well as limitations in load carrying capacity and ground clearance.
Innovation Solution
The configuration of an electric commercial vehicle with a ladder frame, where the electric motor and drivetrain are positioned between frame rails without a driveshaft, utilizing a dead or de Dion axle rear suspension, allowing for battery placement between frame rails and improved packaging, while maintaining load carrying capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a live axle suspension configuration with driveshaft is used, then load carrying capacity is improved, but packaging efficiency deteriorates due to reduced space between frame rails
Solution Approach 1:
The patent extracts the driveshaft from the system by using a dead axle or de Dion axle configuration that eliminates the need for a driveshaft to transmit power to the rear wheels. This removes the component occupying space between the frame rails, thereby improving packaging efficiency while maintaining load carrying capacity through the rigid axle structure.
2Power
If a driveshaft is positioned between frame rails, then power transmission is achieved, but space utilization deteriorates preventing other components from being packaged
Solution Approach 1:
The driveshaft is completely removed from the power transmission system by implementing a dead axle or de Dion axle configuration where power is transmitted directly through the axle housing or via half-shafts, eliminating the intermediate driveshaft component that consumes valuable space between the frame rails.
Solution Approach 2:
The patent replaces the traditional driveshaft-based mechanical power transmission system with an alternative configuration using dead axle or de Dion axle designs, where power transmission is achieved through different mechanical means that do not require a long driveshaft extending between the frame rails.
3Adaptability or versatility
If live axle suspension is used, then integration of drive shafts is improved, but vibration risks increase for electric motors
Solution Approach 1:
The driveshaft is extracted from the system, eliminating the source of vibration and reliability issues associated with live axle configurations. The dead axle or de Dion axle design separates the suspension function from the power transmission function, reducing vibration transmission to the electric motor.
4Volume of moving object
If frame rails are notched for rear suspension, then rear suspension packaging is improved, but frame strength deteriorates
Solution Approach 1:
The patent eliminates the need for notching the frame rails by using a dead axle or de Dion axle configuration that does not require the frame rails to be cut away for suspension component clearance. This maintains the structural integrity and strength of the frame rails while still achieving proper rear suspension packaging.
Data Source
AI summary
Described herein are methods and systems of a chassis of a commercial electric vehicle. In various embodiments, the chassis may include a ladder frame with a plurality of frame rails. Batteries and drive units may be packaged within the frame rails of the ladder frame. The chassis may further include an independent front suspension and batteries may be disposed between the suspension members of the independent front suspension.