Front Hybrid Driving Axle Layout for Compact Power Integration
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Solution Overview
Problem
Existing hybrid vehicle designs for agricultural vehicles face challenges in reducing product complexity and cost due to the need for significant space occupation by electric machines, which requires a global redesign of the vehicle's axle arrangement and specific reconfiguration for different gearbox typologies, leading to high costs.
Innovation Solution
A compact hybrid driving axle arrangement that integrates electric machines and electronic control means with the internal combustion engine, using a transmission group with a housing connected via lateral arms and a transversal member, allowing for efficient space utilization and cost-effective installation, with the electric machines and control elements placed on the opposite side of the engine, and a transmission group that includes gear wheels and shafts for torque transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If electric machines are integrated into the hybrid driving axle, then fuel consumption and emissions are reduced, but the space occupied by electric machines increases and requires global redesign of the vehicle
Solution Approach 1:
The patent merges the electric machine housing with the front axle housing to create an integrated hybrid driving axle assembly. The electric machine is positioned within the front axle housing, combining two previously separate components (electric machine and axle) into a single integrated unit, thereby eliminating the need for separate mounting space and global vehicle redesign
Solution Approach 2:
The front axle housing serves multiple functions: it houses the electric machine, contains the differential assembly, and provides structural support for the front wheels. This multi-functional design allows the same housing to accommodate both conventional mechanical components and electric propulsion components without requiring additional space
2Use of energy by moving object
If electric machines are integrated into the hybrid driving axle, then fuel consumption and emissions are reduced, but product complexity and redesign costs increase
Solution Approach 1:
The patent combines the electric machine housing with the front axle housing into a single integrated structure. This merging reduces product complexity by eliminating the need for separate mounting brackets, additional fastening systems, and separate structural supports that would be required if the electric machine were installed as a separate component
Solution Approach 2:
The hybrid driving axle is segmented into distinct functional modules: the electric machine assembly, the differential assembly, and the wheel hub assembly. Each module can be independently designed, manufactured, and maintained, reducing overall system complexity while enabling flexible configuration
3Adaptability or versatility
If different gearbox configurations are used in agricultural vehicles, then vehicle functionality is improved, but specific reconfiguration of the hybrid vehicle is needed for each gearbox typology
Solution Approach 1:
The front axle housing is designed with a universal mounting structure that can accommodate different types of differentials (open differential, limited-slip differential, locking differential) and various electric machine configurations. Standardized mounting interfaces and flexible internal layout allow the same basic housing design to work with multiple gearbox typologies without requiring specific reconfiguration
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
The solution provides a cost-effective and space-efficient hybrid axle design that allows for optimized installation, enabling both electric and conventional traction modes, reducing load stresses on electrical components, and allowing for independent front axle traction or four-wheel drive, with minimal additional components and easy lubrication, while supporting full electric vehicle operation.
Implementation Method 1
powered, at least in part, by one or more electric machines
Implementation Method 2
internal combustion engine (5) and a front axle (3)
Implementation Method 3
transmission group (25) that includes a first shaft (28) selectively coupled to the internal combustion engine (5) via coupling means (26), a second shaft (31) configured to be coupled to a rear transmission arrangement (6), a third shaft (33) configured to transfer energy between the first shaft (28) and the second shaft (31)
Data Source
Figure 1
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AI summary
Front hybrid driving axle (3) for an agricultural vehicle (1), comprising: - a casing (7) configured to be fixed to an internal combustion engine (5) and defining an inner space (17); - at least a pair of electric machines (18) electrically connected one with respect to the other and an electric control unit (19) electrically connected to the machines (18) for managing the operation thereof, the at least a pair of electric machines (18) and electric control unit (19) being carried by the casing (7); - a differential gearing (55) for providing torque to a pair of wheel hub (15) carried by the front hybrid driving axle (3); and - a transmission group (25) comprising a plurality of gears and shafts housed in the inner space (17), the transmission group (25) operatively connecting the at least a pair of electric machine (18), the differential gearing (55) and the internal combustion engine (5).