Electric Drive Axle Layout for Heavy-Duty Vehicle Conversion
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Solution Overview
Problem
Conventional work vehicles require large, emissions-producing diesel engines for high torque and tractive forces, necessitating complex and costly redesigns to integrate electric power trains for reduced emissions.
Innovation Solution
The implementation of self-contained electric drive axles with motors, battery packs, and power electronics that fit within existing vehicle platforms or replace conventional axle assemblies, including structural components for support and a robust DC bus system for electrical connections, along with cooling and heating management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If large diesel engines are used to provide high torque and tractive forces, then power and force requirements are met, but emissions increase and device complexity increases due to redesign requirements
Solution Approach 1:
The patent divides the electric powertrain into modular components: battery packs mounted in the engine compartment, electric motors coupled to each wheel, and control systems distributed throughout the vehicle. This segmentation allows the electric drive system to replace the conventional diesel engine while maintaining the vehicle's structural integrity and reducing emissions.
Solution Approach 2:
The electric motor assembly serves multiple functions: providing tractive force for vehicle movement, enabling steering through differential motor control, and potentially serving as a generator during regenerative braking. This multi-functionality replaces the need for separate mechanical systems that would otherwise be required in a conventional diesel-powered vehicle.
2Object-generated harmful factors
If electric power trains are integrated into existing vehicle platforms, then emissions are reduced, but device complexity increases due to platform redesign requirements
Solution Approach 1:
The patent divides the electric powertrain into modular components: battery packs mounted in the engine compartment, electric motors coupled to each wheel, and control systems distributed throughout the vehicle. This segmentation allows the electric drive system to replace the conventional diesel engine while maintaining the vehicle's structural integrity and reducing emissions.
Solution Approach 2:
The electric motors are integrated within the wheel assemblies, with each motor housed in the wheel hub structure. The battery packs are positioned within the engine compartment space, nesting the electric powertrain components within the existing vehicle platform architecture rather than requiring complete platform redesign.
3Adaptability or versatility
If conventional axle assemblies are replaced with self-contained electric drive axles, then adaptability to different vehicle platforms is improved, but device complexity increases due to integration of multiple components
Solution Approach 1:
The patent combines the battery pack, electric motor, and control systems into integrated assemblies that can function as complete wheel-end units or modular axle components. This merging reduces the number of separate components that need to be installed and connected, simplifying the conversion process from conventional to electric drive systems.
Solution Approach 2:
The electric motor assembly serves multiple functions: providing tractive force for vehicle movement, enabling steering through differential motor control, and potentially serving as a generator during regenerative braking. This multi-functionality replaces the need for separate mechanical systems that would otherwise be required in a conventional diesel-powered vehicle.
4Volume of moving object
If battery packs and power controllers are mounted within the axle housing, then space utilization is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent introduces a coolant circulation system with coolant manifolds and channels that act as intermediaries between the heat-generating components (battery packs and power controllers) and the external environment. The coolant absorbs heat from the components and transports it to external heat exchangers for dissipation, enabling compact component placement while maintaining effective thermal management.
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 the conversion of various vehicle platforms to electric power trains, reducing emissions and operational costs while maintaining performance, by providing a scalable and efficient electric drive solution that supports heavy-duty work operations.
Implementation Method 1
a battery pack mounted within the axle housing between the wheel end units
Implementation Method 2
Each power controller is configured to control conversion of direct current (DC) from the associated battery pack to alternating current (AC) supplied to the electric machines
Implementation Method 3
each of the wheel end units comprises an electric machine coupled to the associated power controller
Implementation Method 4
plumbing lines are included in the axle housing and configured to convey coolant to and from the battery packs, the wheel end units, or the power controller
Data Source
AI summary
A work vehicle includes front and rear electric drive axles mounted to its chassis. Each electric drive axle has an axle housing defining chassis mounts configured to mount to the chassis. The axle housing defines an interior cavity disposed between opposite ends defining openings. Wheel end units are secured at least partially within the axle housing. Each wheel end unit defines a hub for engaging a ground-engaging member of the work vehicle through an associated one of the openings. Each wheel end unit has drive components configured to rotate the hub of each wheel end unit. A battery pack is mounted within the axle housing between the wheel end units. A power controller is mounted within the axle housing between the wheel end units, the power controller electrically coupled to the wheel end units and the battery pack and configured to control supply of power from the battery pack to the wheel end units. A drive component is mounted to the chassis external to the axle housings of the front and rear electric drive axles and coupled to the power controller of each of the front and rear electric drive axles to supply to or receive power from the front and rear electric drive axles.