Electric Transaxle Motor Mounting for Compact Multi-Orientation Packaging
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Solution Overview
Problem
Existing transaxles for vehicles like lawn mowers and utility vehicles face challenges in minimizing their footprint and adapting to different vehicle models due to their complex component arrangement and fixed installation positions.
Innovation Solution
The development of an electric transaxle with a compact design, featuring a main housing and side housing with integrally-formed or bolt-on axle horns, allowing for rotational orientation of the electric motor assembly and adjustable axle bearing locations for improved support and versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a transaxle combines motor, reduction gearing, differential, and drive axles in a single unit, then it achieves integrated functionality, but it becomes difficult to minimize the footprint and adapt to different vehicle models
Solution Approach 1:
The transaxle is divided into separate modular components: a motor assembly, a reduction gear assembly, and a differential assembly. Each component can be independently manufactured and then assembled together, allowing the overall footprint to be minimized while maintaining adaptability to different vehicle models through selective configuration of the modular units.
Solution Approach 2:
The motor assembly is designed with universal mounting features that allow it to be configured in multiple orientations and positions relative to the reduction gear and differential assemblies. This multi-functional mounting capability enables the same transaxle design to adapt to different vehicle models without increasing the minimum footprint required for operation.
2Adaptability or versatility
If the transaxle is designed for a particular position and orientation in a vehicle, then it ensures proper component arrangement, but it becomes difficult to use the same transaxle design for different vehicle models
Solution Approach 1:
The motor assembly incorporates dynamic mounting capabilities with multiple orientation options, allowing the assembly to be positioned and oriented differently depending on the specific vehicle model requirements. The mounting structure includes features that accommodate various angular positions while maintaining proper component arrangement and functionality.
Solution Approach 2:
The motor assembly can be mounted in different dimensional orientations (e.g., horizontal, vertical, angled positions) relative to the reduction gear and differential assemblies. This multi-dimensional mounting capability allows the same transaxle design to be adapted to different vehicle models without increasing device complexity, as the components can be reconfigured in space rather than requiring design modifications.
3Reliability
If oil is present in the axle horn volume, then it provides lubrication, but it increases volume, weight, and risk of leaks through worn axle seals
Solution Approach 1:
The patent extracts the oil from the axle horn volume by providing a separate lubrication path through sealed bearings. The axle horn is designed to accommodate sealed bearings that receive lubrication independently, eliminating the need for oil to be present in the axle horn cavity. This extraction of oil from the axle horn volume reduces the quantity of oil required, minimizes weight, and eliminates leak risks associated with worn axle seals in that region.
Solution Approach 2:
Sealed bearings act as intermediaries between the axle and the housing, providing a lubricated interface without requiring oil to be present in the axle horn volume. The sealed bearings contain their own lubrication system, serving as a mediator that enables proper axle support and rotation while isolating the axle horn cavity from oil, thereby reducing leak risks and oil quantity requirements.
Data Source
AI summary
An electric transaxle includes a main housing defining threaded holes. The transaxle includes a first axle horn connected to the main housing. The transaxle includes an electric motor assembly that includes an electrical connector and the electric motor assembly is attached to the main housing next to the first axle horn to form a compact arrangement. The electric motor assembly defines through-holes. The electric motor assembly includes fasteners, each of which extends through a respective one of the through-holes and engages a respective one of the threaded holes, to attach the electric motor assembly to the main housing. The through-holes and the threaded holes are arranged in a first regular polygon shape to enable attachment of the electric motor assembly to the main housing in multiple orientations to orient the electrical connector away from the first axle horn in various installed orientations of the transaxle.