Preassembled eAxle Housing Cover With Integrated Lubrication
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Solution Overview
Problem
Existing electric axles in electric vehicles face challenges with space constraints and complex assembly processes due to the integration of lubrication and cooling components, which can reduce efficiency and increase costs.
Innovation Solution
A pre-assembled cover assembly for the electric axle, incorporating an integrated housing with oil pump, filter, and oil cooler, which is attached to the eAxle casing, allowing for efficient space utilization and simplified assembly by pre-assembling these components before final assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If lubrication and cooling components (pump, filter, heat exchanger) are integrated into the eAxle housing, then the lubrication and cooling functions are provided, but the space requirements in the eAxle housing increase and assembly complexity increases
Solution Approach 1:
The housing is divided into a main housing and a separate cover assembly. The cover assembly contains the oil pump, oil filter, and oil cooler mounts, while the main housing contains the motor and gear components. This segmentation allows the lubrication components to be pre-assembled in a dedicated sub-assembly, optimizing space utilization within the overall eAxle housing envelope.
Solution Approach 2:
The cover assembly acts as a nested sub-assembly that integrates multiple lubrication components (pump, filter, cooler) within a compact housing structure. This nested arrangement allows these components to be contained within the overall eAxle housing volume without requiring separate external mounting, thereby optimizing space utilization.
2Reliability
If separate tubes and lubrication system components are installed on the eAxle housing during assembly, then the lubrication system is complete, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The cover assembly is pre-assembled with the oil pump, oil filter, and oil cooler mounts before being installed on the main housing. This preliminary assembly allows for pre-testing and quality assurance of the lubrication components, and simplifies the final assembly process by reducing the number of separate installation steps required.
Solution Approach 2:
Multiple lubrication system components (pump, filter, cooler) that would traditionally be installed separately on the housing are merged into a single integrated cover assembly. This merging reduces the number of separate assembly operations required and simplifies the overall assembly process while maintaining complete lubrication system functionality.
3Volume of stationary object
If the eAxle envelope is reduced to meet vehicle manufacturer demands, then the overall vehicle size is reduced, but the space for lubrication and cooling components becomes more constrained
Solution Approach 1:
The cover assembly utilizes the vertical dimension and end-closure space of the eAxle housing, rather than requiring additional lateral or axial space. By positioning the lubrication components in the cover assembly that closes one end of the housing, the design accommodates these components within the existing envelope constraints while maintaining full lubrication and cooling functionality.
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 enhances space efficiency, simplifies assembly, and improves quality by allowing for separate testing and integration of lubrication and cooling components, reducing overall assembly time and costs.
Implementation Method 1
an oil pump is connected to the oil pump mount
Implementation Method 2
an oil filter is connected to the filter mount
Implementation Method 3
an oil cooler mount is formed on the housing, an oil cooler is connected to the oil cooler mount, and the at least one oil passage defined at least partially in the housing extends to and is in fluid communication with the oil cooler mount
Implementation Method 4
at least one oil passage at least partially defined in the housing
Data Source
AI summary
A cover assembly for an electric axle assembly is provided, with the electric axle assembly having a casing with a stator, a rotor and gears for the electric axle assembly therein. The cover assembly includes a housing that is adapted to close an open end of the electric axle casing. The housing includes a first bearing support for a bearing of the rotor, an oil pump mount connected to at least one oil passage at least partially defined in the housing, and a filter mount in communication with the at least one oil passage. An oil pump is fluidly connected to the oil pump mount, and an oil filter connected to the filter mount. The cover assembly is a preassembled sub-assembly that can be installed as one piece on the electric axle assembly. An electric axle assembly is also provided.