Electric Vehicle Axle Positioning via 3D Joining Areas
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Solution Overview
Problem
Conventional electric vehicle axle devices face challenges in achieving precise positioning of bearings due to axial and radial offsets caused by arbitrary placement of dowel pins or dowel bolts, leading to suboptimal centering.
Innovation Solution
The use of three-dimensional joining areas on the housing and bearing cap for a positive surface contact, forming a radial form fit that aligns with the motor or bearing axis, allowing for improved axial positioning of the bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional dowel pins or bolts are used for positioning, then the structure is simple and easy to manufacture, but positioning precision and bearing centering are insufficient due to axial and radial offsets
Solution Approach 1:
The patent transitions from conventional point-contact dowel pins to three-dimensional joining areas with surface contact. The first three-dimensional joining areas on the housing and second three-dimensional joining areas on the bearing cover create a lid and pot fit with radial positive fit, adding dimensional complexity to achieve superior positioning precision and eliminate axial and radial offsets
Solution Approach 2:
The positioning device acts as an intermediary between the housing and bearing cover, using the lid and pot fit geometry to establish a new axis that aligns with the motor or bearing axis. This intermediary structure mediates the connection to achieve precise bearing centering and positioning
2Manufacturing precision
If arbitrary placement of dowel pins is used, then assembly is quick and easy, but positioning accuracy deteriorates due to offsets
Solution Approach 1:
The lid and pot fit geometry is pre-designed with specific three-dimensional joining areas that automatically guide the bearing cover to the correct position during assembly. The radial positive fit and new axis alignment are built into the geometry beforehand, enabling self-centering and preliminary positioning action that ensures axial positioning accuracy
Solution Approach 2:
The patent employs curved three-dimensional joining areas with radial positive fit geometry instead of straight dowel pins. The lid and pot fit creates a geometric relationship where the curved surfaces guide alignment and centering, making the assembly process more precise while maintaining ease of manufacture through self-aligning features
Data Source
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AI summary
The invention relates to an electric vehicle axle assembly (1) for a motor vehicle, wherein the positioning device (18) has first three-dimensional joining areas (22a, 22b, 22c) formed on a surface (14a) of the housing (14) and second three-dimensional joining areas (24a, 24b, 24c) formed on an inner surface (20a) of the bearing cover (20), wherein the first three-dimensional joining areas (22a, 22b, 22c) of the housing (14) and the second three-dimensional joining areas (24a, 24b, 24c) of the bearing cover (20) are positively joined. The invention further relates to a method for positioning a bearing cover (20) relative to a housing (14) in an electric vehicle axle assembly (1) for a motor vehicle.