Beam Axle Electric Drive Module for ICE-to-EV Conversion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The integration of electric propulsion into vehicle frameworks designed for internal combustion engines has not been met with widespread commercial acceptance.
Innovation Solution
An electric drive module comprising a housing, axle tubes, an electric motor, transmission, and differential, with a lubrication and cooling system, is designed to convert vehicles to electric propulsion efficiently and cost-effectively, featuring a multi-phase electric motor, transmission, and differential assembly for rotary power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electric propulsion is integrated into vehicle frameworks designed for internal combustion engines, then the vehicle can be converted to electric propulsion, but the integration has not been met with widespread commercial acceptance due to various challenges
Solution Approach 1:
The electric drive module is designed as a universal solution that can be integrated into existing vehicle frameworks regardless of their original powertrain type. The module combines multiple functions (motor, transmission, differential, lubrication, cooling) into a single adaptable unit that can serve different vehicle platforms, thereby improving adaptability while maintaining ease of manufacture through standardized design.
Solution Approach 2:
The patent merges the electric motor, transmission, differential, lubrication system, and cooling system into a single integrated electric drive module. This consolidation simplifies the conversion process from internal combustion engine vehicles to electric propulsion, making the integration more commercially viable by reducing the number of separate components that need to be installed and configured.
2Reliability
If a separate lubrication and cooling system is added to the electric drive module, then components are properly lubricated and cooled, but the device complexity increases
Solution Approach 1:
The lubrication system and cooling system are merged into the electric drive module as integrated subsystems rather than separate external systems. The lubrication system uses a pump, filter, and gallery network within the module housing, while the cooling system uses a heat exchanger mounted on the module. This integration ensures proper component lubrication and cooling while minimizing overall system complexity by consolidating these functions within the existing module structure.
3Weight of moving object
If a beam axle housing configuration is used with integrated motor, transmission, and differential, then the overall system weight is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The electric motor, transmission, differential, lubrication system, and cooling system are merged into a single beam axle housing structure. This consolidation eliminates the need for separate mounting structures and reduces overall weight while distributing manufacturing precision requirements across multiple standardized components rather than requiring ultra-precise integration of all elements into a single monolithic structure.
Solution Approach 2:
The beam axle housing is segmented into functional sections (motor mounting area, transmission housing, differential housing, lubrication galleries, cooling channels) that can be manufactured and assembled separately with standard tolerances, then integrated into the final lightweight structure. This segmentation approach reduces the overall manufacturing precision requirements compared to creating a single precision-critical monolithic housing.
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
The solution provides a cost-effective and lightweight conversion of vehicles to electric propulsion, ensuring efficient lubrication and cooling of components, enhancing the integration of electric propulsion systems into existing vehicle frameworks.
Implementation Method 1
a pinion gear, which is coupled to the motor output shaft for rotation therewith, a pair of first compound gears, and a transmission output gear that is rotatable about the output axis. Each of the first compound gears has a first gear, which is meshingly engaged to the pinion gear, and a second gear that is fixedly coupled to the first gear. The first compound gears transmit rotary power between the pinion gear and the transmission output gear.
Implementation Method 2
The first bearing is coupled to the housing and the transmission output gear and supports the transmission output gear axially along the output axis and radially about the output axis.
Implementation Method 3
The differential has a differential input member, which is fixedly coupled to the transmission output gear, and a pair of differential output members that are rotatable relative to the differential input member about the output axis.
Implementation Method 4
The heat exchanger is mounted to the heat exchanger mount on the second housing portion. The heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet.
Implementation Method 5
The pump mount is in fluid communication with the sump. A first internal gallery in the housing assembly fluidly couples the pump mount to an inlet on the filter mount.
Implementation Method 6
The sump is configured to hold a first liquid that is employed in the electronic drive module to lubricate the motor assembly, the differential assembly and the transmission and to cool the motor assembly.
Implementation Method 7
The sump is configured to hold a first liquid that is employed in the electronic drive module to lubricate the motor assembly, the differential assembly and the transmission and to cool the motor assembly.
Implementation Method 8
The motor controller includes an inverter. The inverter is configured to control a supply of electrical power to each of the field windings.
Data Source
AI summary
An electrically-operated electric drive module for use in a vehicle framework that is configured for a powertrain that includes an internal combustion engine. The electrically-operated electric drive module permits the vehicle to be converted to an electrically propelled vehicle in a manner that is cost-effective and which is relatively low in weight.