Compact E-Axle Rotor Packaging for Space and Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional e-axle assemblies for electric and hybrid vehicles require large package space and weight due to integrated motor and gear reduction structures, making them difficult to fit within the space and weight allotments of these vehicles.
Innovation Solution
The e-axle assembly incorporates a housing with an internal compartment containing an electric motor and a rotor with a hollow interior, where gearing mechanisms, shifting actuators, and differentials are packaged within the rotor, reducing the overall size and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional motor structure and parallel axis gearing are integrated into the e-axle assembly, then the e-axle assembly can provide power transmission and gear reduction functions, but the space and weight requirements increase significantly
Solution Approach 1:
The patent places the gearing mechanism, shifting actuator, and differential inside the hollow interior of the rotor. This nesting arrangement allows these components to share the same space that would otherwise be empty, significantly reducing the overall space and weight of the e-axle assembly while maintaining all necessary power transmission and gear reduction functions
Solution Approach 2:
The patent combines multiple functional components (gearing mechanism, shifting actuator, differential) into a single integrated package within the rotor. This merging of functions into one unified structure eliminates the need for separate housings and mounting structures, reducing both space claims and weight compared to conventional separate component arrangements
2Adaptability or versatility
If conventional motor structure and parallel axis gearing are integrated into the e-axle assembly, then the e-axle assembly can provide power transmission and gear reduction functions, but the space requirements increase significantly
Solution Approach 1:
The patent places the gearing mechanism, shifting actuator, and differential inside the hollow interior of the rotor. This nesting arrangement allows these components to share the same space that would otherwise be empty, significantly reducing the overall space and weight of the e-axle assembly while maintaining all necessary power transmission and gear reduction functions
Solution Approach 2:
The patent utilizes the vertical dimension by stacking components within the rotor's hollow interior along the rotational axis. This three-dimensional arrangement allows multiple components to occupy overlapping footprints when viewed from above, reducing the horizontal space claims of the e-axle assembly
Data Source
AI summary
An e-axle assembly includes a housing extending from a first housing end to a second housing end to define an internal compartment. At least one electric motor is disposed in the internal compartment and includes a stator and a rotor rotatable relative to the stator about an axis. The rotor defines a hollow extending internally within the rotor, and at least one of a gearing mechanism, a shifting actuator, and/or a differential is disposed within the hollow (and thus packaged within the rotor). In a preferred arrangement, all and any of the gearing mechanisms, shifting actuators, and differential are disposed within the hollow of the rotor. This internal packaging of the drive components within the rotor reduces an overall space and weight of the e-axle assembly relative to the prior art designs to more easily and readily achieve the smaller space and weight allotments afforded by electric and/or hybrid vehicles.