Convertible E-Axle Assembly Using Prefabricated Beams
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Solution Overview
Problem
Modifying banjo and other axle housing systems for electrification is challenging, leading to increased scrap and weight due to retooling, re-stamping, and adding components, which is not efficient for electrified vehicles with independent suspension systems.
Innovation Solution
An axle assembly using prefabricated beams, such as I-beams, that do not require machining, with a gearbox housing that fastens to a centrally located cover, enclosing a differential gearset, reducing the need for additional components and lubrication, thus minimizing scrap and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If banjo housing systems are modified for electrification by retooling, re-stamping, and adding components, then electrification functionality is achieved, but scrap and weight increase
Solution Approach 1:
The axle assembly is divided into separate functional modules: a first module containing the electric machine and transmission, and a second module containing the differential assembly. These modules are coupled together but remain independently manufacturable, allowing electrification functionality to be added without modifying the entire banjo housing system. This modular approach reduces scrap by enabling selective manufacturing of only the electrified components.
Solution Approach 2:
The patent combines the electric machine, transmission, and differential assembly into a single integrated axle assembly that functions as a complete electrified axle unit. This merging allows the assembly to be manufactured as a unified structure rather than modifying existing components, thereby reducing scrap while achieving electrification functionality.
2Adaptability or versatility
If banjo housing systems are modified for electrification by adding components, then electrification functionality is achieved, but weight increases
Solution Approach 1:
By segmenting the axle assembly into separate modules (electric machine/transmission module and differential module), the design allows for optimized weight distribution and eliminates the need to add unnecessary components to the entire banjo housing system. Only the essential electrification components are manufactured and assembled, reducing overall assembly weight.
Solution Approach 2:
The first beam is designed to serve multiple functions: it supports the electric machine, transmits torque, and provides structural support for the entire axle assembly. This multi-functionality reduces the need for additional dedicated components, thereby minimizing weight increase while achieving electrification functionality.
3Adaptability or versatility
If traditional electrification conversions are performed on axles, then electrification is achieved, but manufacturing complexity and scrap increase due to machining housing and beams
Solution Approach 1:
The first and second beams are manufactured as prefabricated components with the necessary structural features and mounting points already incorporated into their design. This preliminary action eliminates the need for subsequent machining operations on the banjo housing and beams during electrification conversion, significantly reducing manufacturing complexity and scrap while enabling electrification capability.
Data Source
AI summary
An axle assembly comprising: a central cover; a first beam; a second beam; a first wheel flange; and a second wheel flange; where the first beam and the second beam join to the central cover via welding, where a first shaft received via the first wheel flange is positioned along the first beam and is not covered by housing between the first wheel flange and a differential assembly, where the first beam and the second beam have a uniform cross-section lengthwise.