Axle Assembly Motor Module Integration for Compact Torque Transmission
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Solution Overview
Problem
Existing axle assemblies with electric motor modules face challenges in compact design and efficient torque transmission, leading to increased package space and imbalance issues.
Innovation Solution
The axle assembly integrates an electric motor module within a differential carrier, utilizing a drive pinion and gear reduction module to provide torque to the differential, while minimizing axial length and optimizing the center of mass for better balance and mounting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the electric motor module is integrated within the differential carrier, then the package space is reduced and balance is improved, but the device complexity increases
Solution Approach 1:
The electric motor module is nested within the differential carrier, with the motor housing received inside the differential carrier and the rotor positioned within the motor housing. This nesting arrangement allows the motor to be integrated into the existing differential structure, reducing overall package space while maintaining functional separation of components.
Solution Approach 2:
The patent combines the electric motor module with the differential carrier into a single integrated assembly. The motor module merges with the differential carrier structure, where the motor housing is received inside the differential carrier and the drive pinion extends through the carrier to engage the ring gear, creating a compact combined unit that reduces total volume.
2Length of moving object
If the electric motor module is received inside the differential carrier, then the axial length is minimized, but the manufacturing precision requirements increase
Solution Approach 1:
The motor module is nested within the differential carrier along the axial direction, with the motor housing received inside the carrier and the rotor positioned within the housing. This nested arrangement minimizes axial length by stacking components vertically rather than extending them horizontally, while the bearing support walls provide precise locating surfaces.
Solution Approach 2:
The differential carrier includes specific bearing support walls with holes positioned at precise locations to accommodate the drive pinion and support bearings. These localized precision features are provided only where needed for motor integration, allowing minimal manufacturing precision requirements for the overall carrier while ensuring accurate positioning where the motor components interface.
3Power
If the drive pinion extends through the differential carrier, then torque transmission efficiency is enhanced, but the device complexity increases
Solution Approach 1:
The drive pinion serves multiple functions: it transmits torque from the motor rotor to the ring gear, provides a mounting interface for the motor assembly, and acts as a structural element that extends through the differential carrier. This multi-functionality reduces the need for separate torque transmission components, simplifying the overall device while maintaining efficient power transfer.
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 package space, improves balance, and enhances torque transmission efficiency, addressing the challenges of compact design and balance in axle assemblies with electric motor modules.
Implementation Method 1
The electric motor module may be received inside the differential carrier and may have a rotor that is rotatable about the axis. The drive pinion may be operatively connected to the rotor between an end of the bearing support wall and the differential carrier cover. The electric motor module may provide torque to the differential via the drive pinion.
Data Source
AI summary
An axle assembly that includes an axle housing, a differential carrier, and an electric motor module. The differential carrier that is mounted to the axle housing and rotatably supports a differential. The electric motor module is received inside the differential carrier and is operatively connected to and provides torque to the differential.