Integrated Electric Axle Assembly Torque Distribution
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Solution Overview
Problem
Existing axle assemblies lack integrated electric motor modules that can efficiently provide torque and regenerative braking capabilities while being easily adaptable to various vehicle types and configurations.
Innovation Solution
An axle assembly incorporating a differential assembly, a first coupling, and an electric motor module with a motor housing, stator, rotor, and second coupling, where the motor module is fixedly coupled to the differential assembly, allowing for torque transmission and regenerative braking, and can be retrofitted with minimal modifications to existing axle housing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If an electric motor module is integrated into the axle assembly, then torque distribution and regenerative braking capabilities are improved, but device complexity increases
Solution Approach 1:
The electric motor module is merged with the differential assembly to form an integrated electric axle assembly. The motor housing is coupled to the differential assembly, and the rotor is fixedly coupled to the first coupling that rotates with the pinion, combining power generation and torque distribution functions in a single integrated unit.
Solution Approach 2:
The integrated electric axle assembly performs multiple functions: the electric motor module provides both propulsion torque and regenerative braking capabilities, while the differential assembly distributes torque to traction wheels. This multi-functional design eliminates the need for separate motor and differential components.
2Power
If an electric motor module is integrated into the axle assembly, then regenerative braking capability is improved, but ease of manufacture deteriorates
Solution Approach 1:
The electric motor module is designed as a separate, self-contained unit with its own housing, stator, rotor, and couplings. This modular segmentation allows the motor module to be manufactured and tested independently before integration with the differential assembly, simplifying the overall manufacturing process.
Solution Approach 2:
The first coupling acts as an intermediary component that connects the pinion to the rotor. This intermediary element facilitates the integration process by providing a standardized interface between the differential assembly and the electric motor module, making assembly and disassembly easier.
3Power
If the motor module is fixedly coupled to the differential assembly, then torque transmission efficiency is improved, but adaptability to various vehicle configurations deteriorates
Solution Approach 1:
The integrated electric axle assembly is designed with universal mounting features and standardized interfaces that allow it to be adapted to various vehicle types and configurations. The motor housing can be coupled to different differential assemblies, and the assembly can be installed in different axle positions depending on vehicle requirements.
Solution Approach 2:
The fixed coupling between the motor module and differential assembly provides rigid torque transmission for optimal efficiency, while the overall system maintains adaptability through modular design that allows the entire assembly to be repositioned or reconfigured for different vehicle applications.
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
Enables efficient torque distribution to traction wheels, regenerative braking, and easy integration of electric drive capabilities, accommodating various vehicle designs and configurations with scalable options for water cooling and lubrication systems.
Implementation Method 1
The rotor may be fixedly coupled to the first coupling. The second coupling may be fixedly coupled to the first coupling. The first and second couplings may rotate with the pinion about the axis of rotation.
Data Source
Figure 1
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Figure 3
AI summary
An axle assembly having an electric motor module. The electric motor module may be coupled to a differential assembly. A rotor of the electric motor module may be coupled to a pinion of the differential assembly with a first coupling.