Integrated Electric Axle Housing for Simpler Differential Packaging
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Solution Overview
Problem
Existing axle assemblies for vehicles lack an efficient integration of electric drive units and differential components, leading to complex machining requirements and unnecessary components such as differential covers and bearing caps.
Innovation Solution
An electric axle assembly featuring a banjo axle housing with integrated electric drive units, including a motor and differential, where the housing components define a motor housing region and gearbox region that extend through openings, simplifying machining and eliminating the need for external differential covers and bearing caps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If traditional axle assemblies use separate housings for differential and bearing components, then component protection is provided, but device complexity and machining requirements increase
Solution Approach 1:
The patent merges the differential housing and bearing housing into a single integrated banjo-style housing structure. This consolidation eliminates the need for separate housings while maintaining all necessary protective functions, directly reducing device complexity without compromising component protection
Solution Approach 2:
The integrated housing structure performs multiple functions simultaneously: it houses the differential mechanism, supports bearing components, provides structural mounting for the axle assembly, and offers protection for internal components. This multi-functionality reduces the number of separate parts needed
2Ease of manufacture
If traditional axle assemblies include external differential covers and bearing caps, then component access and protection are enabled, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple separate components (differential cover, bearing caps, housing) into a single integrated housing structure. This eliminates the need for separate fastening components and simplifies the manufacturing process by reducing the number of parts that need to be manufactured, assembled, and sealed
3Volume of moving object
If electric drive units are integrated into axle assemblies, then space utilization is improved, but housing design complexity increases
Solution Approach 1:
The banjo-style housing serves multiple functions: it houses the differential, supports bearing components, provides structural mounting for the electric drive unit, and offers protection for all internal components. This multi-functional design achieves efficient space utilization without proportionally increasing housing design complexity
Data Source
AI summary
An electric axle assembly includes a banjo axle housing, first and second half shafts, and an electric drive unit. The banjo axle housing has a central portion that defines a receiving space and first and second openings providing access to the receiving space, first and second beams extending from the central portion in opposite first and second axial directions, and defining first and second beam hollows in communication with the receiving space. The half shafts extend within the first and second beam hollows. The electric drive unit includes a motor, a differential, and a housing having first and second housing components. At least one of the first and second housing components defines a motor housing region, the first and second housing components define a gearbox region, and the first and second housing components define first and second apertures that provide access for coupling the half shafts with the differential.