Electric Axle Cooling Layout for Integrated Drive Unit Packaging
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Solution Overview
Problem
There is a need to efficiently package electric drive units into vehicle axles while optimizing efficiency and performance, particularly in the context of electric and hybrid propulsion systems.
Innovation Solution
An electric axle assembly is designed with a drive assembly and a cooling system that includes a pump, heat exchanger, and fluid-delivery network to manage heat and lubrication, utilizing conduits and passageways for cooling fluid distribution to drive units and drive trains.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric drive units are packaged into the vehicle axle, then the propulsion system efficiency is improved, but the heat management becomes more challenging
Solution Approach 1:
The patent combines the cooling system components (pump, heat exchanger, fluid-delivery network) with the drive assembly housing into an integrated unit. The fluid-delivery network uses conduits and passageways formed into the case itself, merging the cooling infrastructure with the structural housing to efficiently manage heat from the electric drive units while maintaining propulsion system efficiency.
Solution Approach 2:
The patent introduces a cooling fluid as an intermediary substance that transfers heat away from the electric drive units. The pump circulates this fluid through the fluid-delivery network, and the heat exchanger uses it to extract thermal energy, creating an effective heat management pathway that preserves propulsion efficiency.
2Temperature
If a cooling system with pump, heat exchanger, and fluid-delivery network is added, then the heat management capability is improved, but the device complexity increases
Solution Approach 1:
The patent reduces complexity by merging the cooling system with the drive assembly housing. The case is formed to include integrated passageways and the fluid-delivery network is built into the housing structure itself, eliminating the need for separate, complex cooling infrastructure while achieving effective heat management.
Solution Approach 2:
The case serving as the housing also serves as part of the cooling system infrastructure through its integrated passageways and fluid-delivery network. This multi-functionality reduces the number of separate components needed, thereby reducing overall device complexity while maintaining heat management capability.
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 solution effectively cools and lubricates drive units and drive trains, enhancing the efficiency and performance of electric propulsion systems by managing heat and maintaining optimal operating conditions.
Implementation Method 1
The heat exchanger may be configured to draw heat from the cooling fluid
Implementation Method 2
The pump may be configured to pass a cooling fluid from the case to the heat exchanger
Data Source
AI summary
An electric axle assembly includes a drive unit and a drive train stored in a case, and a cooling system coupled to the case for circulating a cooling fluid through the case. The electric axle assembly is mounted on a vehicle to support the vehicle for movement along a ground surface. The drive unit provides motive force through the drive train to wheels of the vehicle for propelling the vehicle along the ground.