Cast Axle Bridge Layout for Electric Commercial Vehicle Chassis
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Solution Overview
Problem
Existing axle constructions for commercial vehicles are not suitable for electric drives due to limited installation space, especially in truck trailers, as they require large wheels and sufficient ground clearance, making it difficult to accommodate electric drive components while maintaining safe driving behavior and comfort.
Innovation Solution
The axle bridge is positioned on the side of the wheel axle away from the pivot bearings, freeing up space between the handlebar arms for electric drive components, and is designed as a cast part using cast iron for improved strength, durability, and adaptability, with handlebar arms connected via a U-shaped swing arm mechanism to distribute forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional rigid axles are used, then the axle construction is simple and robust, but there is insufficient installation space for electric drive components
Solution Approach 1:
The axle construction is divided into separate functional components: the axle bridge (22) positioned offset from the wheel axle, control arms (8) for suspension, and space reserved for electric drive components. This segmentation allows each component to be optimized independently while creating sufficient installation space for electric drives without compromising structural integrity.
2Area of stationary object
If the axle bridge is positioned below the wheel axle, then ground clearance is maximized for low-floor buses, but installation space for electric drives is reduced
Solution Approach 1:
Instead of positioning the axle bridge directly below the wheel axle as in conventional designs, the invention inverts this arrangement by positioning the axle bridge offset to one side of the wheel axle. This inversion creates unused space on the opposite side that can be utilized for installing electric drive components, while the axle bridge maintains its load-bearing function through offset positioning.
3Strength
If the axle bridge is designed as a welded sheet metal box, then manufacturing is straightforward, but strength and durability for electric drive applications are insufficient
Solution Approach 1:
The axle bridge is designed as a composite structure combining different materials and manufacturing approaches: cast iron sections for high-strength load-bearing areas, steel components for structural integrity, and rubber elements for vibration damping. This composite approach achieves the required strength and durability for electric drive applications while distributing manufacturing complexity across different production processes.
4Strength
If wheel size is increased to support vehicle weight and load, then load-bearing capacity is improved, but available space for electric drive components is reduced
Solution Approach 1:
The invention utilizes the lateral dimension by positioning the axle bridge offset from the wheel axle rather than directly below it. This dimensional shift creates previously unused space in the lateral direction that can accommodate electric drive components, allowing large wheels to maintain their load-bearing capacity while providing sufficient installation space for electric drives through spatial optimization.
Data Source
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AI summary
The present invention relates to an axle assembly (6) for a commercial vehicle chassis. In order to create an axle assembly (6) that leaves sufficient installation space to equip the commercial vehicle with an electric drive in the area of the axle assembly (6) and that nevertheless enables safe driving behavior and a high level of driving comfort, it is proposed that the control arms (8) be formed in one piece or in multiple parts and be connected to each other at least on the side of the wheel axle (R) facing away from the pivot bearings (10) via an axle bridge (22) that is at least partially formed as a cast part.