Electric Axle Motor Module Layout for Cooling and Service Access
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Solution Overview
Problem
Existing axle assemblies with electric motor modules face challenges in efficiently integrating and cooling the motor components, leading to increased weight, cost, and reduced accessibility for servicing, while also limiting the performance and packaging flexibility of the electric motor.
Innovation Solution
The axle assembly incorporates an electric motor module with a rotor, stator, coolant jacket, and end plate, where the coolant jacket has channels that are partially received in the motor housing and partially in the transmission housing, allowing for improved cooling and reduced weight, and the motor is partially enclosed to enhance accessibility and packaging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electric motor module is fully enclosed in the motor housing, then the motor is protected and structurally complete, but the weight increases, cost increases, and accessibility for servicing is reduced
Solution Approach 1:
The motor housing is segmented into two distinct parts: the motor housing that contains the motor components, and the transmission housing that contains the transmission components. This segmentation allows the motor to be partially accessible while maintaining structural integrity, resolving the contradiction between protection and accessibility.
Solution Approach 2:
The motor housing and transmission housing are positioned in different spatial dimensions and orientations. The motor housing is oriented with its opening facing a different direction than the transmission housing, allowing accessibility to motor components without compromising the structural enclosure, thus resolving the contradiction between accessibility and structural completeness.
2Adaptability or versatility
If the coolant jacket is fully received inside the motor housing, then the cooling system is enclosed and protected, but the weight increases and packaging flexibility is reduced
Solution Approach 1:
The coolant jacket is divided into two functional segments: a first portion received within the motor housing for motor cooling, and a second portion extending outside the motor housing into the transmission housing for transmission cooling. This segmentation enables flexible packaging and weight reduction while maintaining complete cooling functionality.
Solution Approach 2:
The single coolant jacket performs multiple cooling functions by serving both the motor and transmission systems. The first portion cools the motor while the second portion cools the transmission, eliminating the need for separate cooling systems and increasing packaging flexibility without compromising cooling effectiveness.
3Reliability
If multiple channels are provided in the coolant jacket, then cooling efficiency is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The coolant jacket incorporates multiple segmented channels that are distributed along its length. These channels are integrated into the single-piece coolant jacket structure, allowing efficient cooling of both motor and transmission components while maintaining manufacturing feasibility through standardized production processes.
4Adaptability or versatility
If the motor housing and transmission housing are spaced apart, then accessibility and packaging flexibility are improved, but the structural integrity and rigidity may be reduced
Solution Approach 1:
The housing system is segmented into separate motor housing and transmission housing components that are positioned at different locations and orientations. This segmentation provides packaging flexibility and accessibility while each housing maintains its own structural integrity for supporting its respective components.
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 reduces the weight and cost of the axle assembly, improves cooling efficiency, and simplifies assembly and servicing, while maintaining performance and increasing packaging flexibility, allowing for a lower floor profile and wider aisle in vehicles.
Implementation Method 1
The coolant jacket may encircle the stator and may have a set of channels that may be open in a direction that faces away from the rotor axis
Data Source
AI summary
An axle assembly having an electric motor module. The electric motor module may include a rotor, a rotor shaft, a stator, a coolant jacket, an end plate, and a motor housing. The motor housing may encircle a portion of the coolant jacket. The end plate may be disposed outside and may not be received in the motor housing.