Electric Drive Axle Tube Assembly for Flexible Vehicle Packaging
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Solution Overview
Problem
Existing electric drive axles are limited in their adaptability to different vehicle applications due to their fixed design, which restricts the proliferation of electric vehicles across various configurations.
Innovation Solution
The system involves pressing tubes into a differential housing, where mounts, reinforcement rings, wheel hubs, and brake housings are physically coupled to the tubes, allowing the tubes to be shaped at different lengths to accommodate various vehicle arrangements. This includes replacing original tubes with new ones of varying lengths, using a new support ring to couple the electric motor housing, and adapting the system to use new machined tubes and spring-like supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric drive axle uses a fixed design with original tubes and support structures, then the structural integrity and original performance are maintained, but the adaptability to different vehicle configurations is limited
Solution Approach 1:
The original integrated tube and support structure is segmented into separate components: removable tubes of different lengths can be selected and installed independently, while the support structure remains as a separate element. This allows customization for different vehicle configurations without redesigning the entire system.
Solution Approach 2:
The support structure is designed with universal mounting capabilities that can accommodate multiple tube length variations. The same support structure serves multiple functions across different vehicle applications by simply changing the tube length, making the system multi-functional and adaptable.
2Adaptability or versatility
If tubes of different lengths are pressed into the differential housing, then the system can accommodate various vehicle arrangements, but the manufacturing precision and assembly difficulty increase
Solution Approach 1:
Tubes are pre-formed to specific lengths before installation into the differential housing. This preliminary preparation ensures that when the tubes are pressed into place, they fit precisely without requiring complex adjustment or rework during assembly, maintaining manufacturing precision while enabling length variations.
Solution Approach 2:
The tube length parameter is varied to accommodate different vehicle arrangements, while other critical parameters such as outer diameter, wall thickness, and pressing depth are standardized. This selective parameter change allows adaptability without compromising manufacturing precision in critical dimensions.
3Adaptability or versatility
If the original support structures are removed and replaced with spring-like supports, then the system becomes more adaptable to customer chassis requirements, but the structural strength and reliability may be reduced
Solution Approach 1:
The support structure transitions from rigid to spring-like by changing the material properties and geometric parameters. The spring-like supports are designed with controlled elasticity that provides both adaptability to chassis variations and sufficient strength through elastic deformation capability, rather than rigid failure modes.
Solution Approach 2:
The spring-like supports may utilize composite material structures that combine materials with different properties to achieve both flexibility for adaptation and sufficient strength for load-bearing requirements. The composite structure allows the support to be both compliant and strong.
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 solution enables the electric drive axle system to be more flexible and adaptable to different vehicle configurations, reducing manufacturing difficulties and expanding the potential applications of electric vehicles.
Implementation Method 1
pressed together with the electric motor housing with a new support of ring of reinforcement, where it joins by friction and welds the original motor housing to the new tubes
Implementation Method 2
joins by friction and welds the original motor housing to the new tubes
Implementation Method 3
use supports as a spring, stop and suspension damper applicable to the customer's chassis
Data Source
AI summary
Methods and systems are provided for an electric drive axle. In one example, a tube is pressed into a portion of a differential housing, wherein a mount, a reinforcement ring, a wheel hub assembly, and a brake housing are physically coupled to the tube. The tube defines an axle path of an electric drive axle from an electric motor to a wheel.