Electric Axle Drivetrain Assembly with Segmented Suspension
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Solution Overview
Problem
Conventional electric axle drivetrain assemblies increase unsprung weight and reduce packaging space in vehicles, leading to poor riding and handling characteristics, particularly in commercial vehicles.
Innovation Solution
The electric axle drivetrain assembly design includes a motor connected to a differential assembly with axle half shafts, hub carrier portions, leaf spring assemblies, and a support member, which reduces unsprung weight and improves packaging by using a De Dion suspension system and various gear and joint assemblies to optimize weight distribution and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the motor is attached to the unsprung beam axle assembly, then the drivetrain can be integrated, but the unsprung weight increases and handling characteristics deteriorate
Solution Approach 1:
The drivetrain components are segmented into sprung and unsprung portions. The motor and differential assembly are mounted on the sprung chassis, while only the essential drive components (half shafts, wheel end assemblies) remain unsprung. This segmentation reduces unsprung weight while maintaining drivetrain integration benefits.
Solution Approach 2:
The motor and differential assembly are extracted from the traditional unsprung axle location and relocated to the sprung chassis. This extraction removes significant weight from the unsprung portion while the drivetrain remains integrated through the half shafts connecting to the wheel end assemblies.
2Ease of manufacture
If conventional electric axle drivetrain components are used, then the drivetrain can be assembled, but the available packaging space is reduced
Solution Approach 1:
The drivetrain components are arranged in a three-dimensional configuration that optimizes space utilization. The motor and differential assembly are positioned to utilize vertical and lateral space efficiently, with the half shafts and wheel end assemblies arranged to minimize interference with other vehicle systems while maintaining ease of assembly.
Data Source
AI summary
An electric axle drivetrain assembly for use in a vehicle. The electric axle drivetrain assembly includes a motor that is drivingly connected to at least a portion of a differential assembly. Drivingly connected to ends of the differential assembly is a first axle half shaft and a second axle half shaft. At least a portion of a first and second wheel end assembly is connected to at least a portion of an end of the first and second axle half shafts opposite the differential assembly. A vehicle suspension system having a support member has a first hub carrier portion connected to a first end portion thereof and a second hub carrier portion connected to a second end portion thereof. Connected to at least a portion of a chassis is the motor and/or the differential assembly.