Continuous Tubular Rigid Axle for High-Load E-Drive Integration
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Solution Overview
Problem
Existing rigid axles with integrated electrical energy converter machines have lower load-bearing capacity due to numerous joints and complex structures, limiting their construction volume and weight efficiency.
Innovation Solution
A continuous, uninterrupted tubular component forms the axle carrier, with the electromechanical functional module positioned outside the chassis' force flux, enhancing rigidity and reducing weight by eliminating overlapping tubular sections and solid connecting plates, and using separate electrical energy converters for each wheel flange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a multi-part axle carrier with overlapping tubular sections and solid connecting plates is used, then the structural complexity increases, but the load-bearing capacity decreases
Solution Approach 1:
The patent merges multiple separate tubular sections and connecting plates into a single continuous tubular component that forms the entire axle carrier. This integration eliminates the need for separate parts and joints, directly resolving the contradiction by simplifying the structure while maintaining or improving load-bearing capacity through a unified continuous design.
Solution Approach 2:
The continuous tubular component is designed with strategically positioned drop regions that create functional segments for mounting electrical energy converter machines, while maintaining structural continuity. This segmentation approach allows functional differentiation without compromising the overall structural integrity and load-bearing capacity of the axle carrier.
2Weight of stationary object
If overlapping tubular sections and solid connecting plates are used to form the axle carrier, then the construction volume increases, but the weight efficiency decreases
Solution Approach 1:
By combining multiple separate components (tubular sections and connecting plates) into a single continuous tubular component, the patent eliminates redundant material and reduces overall construction volume. This merging strategy directly addresses the contradiction by reducing both weight and volume while maintaining structural functionality.
Solution Approach 2:
The patent extracts and eliminates unnecessary overlapping sections and solid connecting plates from the traditional multi-part design. By removing these redundant elements, the design achieves better weight efficiency and reduced construction volume while still providing the necessary structural support and mounting capabilities.
3Adaptability or versatility
If electrical energy converter machines are integrated into the axle carrier structure, then the functionality increases, but the structural integrity is compromised
Solution Approach 1:
The continuous tubular component is designed with dedicated drop regions that segment the structure into functional zones for mounting electrical energy converter machines. This segmentation allows functional integration while maintaining structural continuity through the remaining tubular sections, resolving the contradiction by providing mounting capability without compromising overall structural integrity.
Solution Approach 2:
The axle carrier exhibits local quality variations with thicker or reinforced sections in critical load-bearing areas and drop regions for machine mounting. This localized structural differentiation allows the design to accommodate functional requirements (machine integration) while maintaining high structural integrity in essential areas through targeted reinforcement.
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 design achieves a robust, high-load-bearing capacity axle with broad functionality, allowing efficient torque transmission and electrical energy generation or storage without compromising structural integrity.
Implementation Method 1
as a generator induction unit for generating electrical energy by transmitting torque from the at least one wheel flange to the energy converter machine
Implementation Method 2
as an electromotive drive unit for transmitting torque from the energy converter machine to the at least one wheel flange
Data Source
AI summary
A rigid axle having an axle carrier, at each of the axial longitudinal end regions of which one wheel hub assembly is disposed, wherein: each wheel hub assembly has a rotatable wheel flange; the axle carrier is dropped in a drop region located between its longitudinal end regions; an electromechanical functional module having an electric energy converter machine is disposed in the drop region, which electric energy converter machine is connected to at least one wheel flange for transmitting a rotation, so that the energy converter machine can be used as at least one of the functional units stated hereinafter: i) as an electric drive unit for transmitting torque onto the at least one wheel flange, and ii) as an induction unit which can be operated as a generator for generating electric energy by transmitting torque from the at least one wheel flange to the energy converter machine; the axle carrier having a dropped tubular component which is continuous between its longitudinal end regions.