Hybrid Axle Support Frame with Integrated Electric Machine Nesting
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Solution Overview
Problem
Existing axle supports for hybrid vehicles face challenges in accommodating additional components like electric machines and control systems without increasing weight or requiring more installation space, while maintaining rigidity and efficient production.
Innovation Solution
The axle carrier features a frame structure with upper and lower side rail sections that surround the driveshaft, allowing for integration of additional components between cross members, with a support strut distributing forces to reduce stress on upper brackets and enabling the use of smaller cross-sectional structural elements, thus minimizing space, weight, and material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the axle carrier is adapted to accommodate additional components like electric machines and control systems, then the functionality and versatility are improved, but the weight and installation space requirements increase
Solution Approach 1:
The patent integrates additional components (electric machine, control components) within the existing axle carrier structure by utilizing the installation space between the cross members. The frame structure is designed to surround the driveshaft while providing dedicated spaces for these additional components, effectively nesting them within the existing structural envelope without requiring external additions that would increase overall weight.
Solution Approach 2:
The axle carrier frame structure is designed to serve multiple functions: it provides structural support, accommodates the driveshaft, and integrates additional components such as electric machines and control systems. This multi-functional design allows a single structural element to fulfill multiple roles, improving versatility without proportionally increasing weight.
2Volume of stationary object
If the cross members are spaced further apart to accommodate additional components, then the installation space is improved, but the structural rigidity and strength are reduced
Solution Approach 1:
The frame structure is divided into upper and lower longitudinal member structure sections that surround the driveshaft. This segmentation allows the structure to maintain strength through distributed load paths while creating adequate spacing between cross members for component integration. The upper and lower sections work together to maintain rigidity even with increased spacing.
Solution Approach 2:
The patent utilizes the vertical dimension by positioning upper and lower longitudinal member structure sections at different heights relative to the driveshaft. This three-dimensional arrangement allows the frame to maintain structural integrity through vertical load distribution while providing horizontal space between cross members for additional components.
3Strength
If larger cross-sectional structural elements are used to maintain rigidity, then the strength is improved, but the material usage and weight increase
Solution Approach 1:
The frame structure uses segmented upper and lower longitudinal member structure sections that distribute loads efficiently. This segmentation allows the use of optimized cross-sectional dimensions in each segment rather than uniformly large sections throughout, reducing material usage while maintaining overall structural strength.
Solution Approach 2:
The frame structure is designed with locally optimized properties where the upper and lower longitudinal member sections have specific geometric characteristics suited to their load conditions. This local optimization allows adequate strength with minimized material usage, avoiding the need for uniformly large cross-sections throughout the entire structure.
4Force
If the upper brackets carry more stress to support additional components, then the load-bearing capacity is improved, but the stress concentration and potential failure points increase
Solution Approach 1:
The frame structure divides the load-bearing function between upper and lower longitudinal member structure sections. This segmentation distributes the stress from additional components across multiple structural elements rather than concentrating it all in the upper brackets, improving reliability while maintaining load-bearing capacity.
Solution Approach 2:
The lower longitudinal member structure section acts as an intermediary that shares the load-bearing responsibility. By introducing this intermediate load path, the structure distributes stresses more evenly across the frame, reducing stress concentration in the upper brackets while maintaining overall load-bearing capacity.
Data Source
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AI summary
The technology disclosed here relates to an axle support 10. The axle support 10 comprises a frame structure 100 and a supporting strut 400. The frame structure 100 is equipped with an upper longitudinal member structure portion 110, a lower longitudinal member structure portion 120, a lower frame structure connection region 162 and an upper frame structure connection region 150. The upper longitudinal member structure portion 110 runs above a drive shaft 200, and the lower longitudinal member structure portion 120 runs below the drive shaft 200. The lower frame structure connection region 162 is formed integrally with the lower longitudinal member structure portion 110 or is connected thereto. The supporting strut 400 connects the lower frame structure connection region 162 to the upper frame structure connection region 150. The upper frame structure connection region 150 is arranged closer than the lower frame structure connection region 162 to the body connection 180.