Integrated Drivable Axle Structure Without a Cardan Shaft
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Solution Overview
Problem
The existing drivable axles for vehicles, particularly those with rigid axles, occupy significant space due to the complex and costly connection between the drive unit at the front and the rear axle, leading to increased weight and reduced vehicle range.
Innovation Solution
A drivable axle design that integrates a receiving structure with openings for the axle shaft and a fixing area for the drive unit, allowing direct integration of the drive unit within the axle, reducing the need for a lengthy cardan shaft and enabling a compact, lightweight configuration with symmetric and material-merged connections, damping elements, and a U-shaped bracket for secure power flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a cardan shaft is used to connect the drive unit to the rear axle, then the drive-train can be separated into front and rear sections, but the overall fitting space and vehicle weight increase significantly
Solution Approach 1:
The patent merges the drive unit with the rear axle by providing a receiving structure integrated into the axle body that directly accommodates the drive unit. This eliminates the need for a separate cardan shaft connection, thereby reducing fitting space while maintaining drive-train functionality. The receiving structure is connected to the axle body in one piece, creating a compact integrated assembly.
2Ease of manufacture
If a cardan shaft connection is used between drive unit and rear axle, then the drive-train can be assembled in sections, but the manufacturing cost and complexity increase
Solution Approach 1:
The receiving structure is designed as an integral part of the axle body, formed in one piece with it. This integration simplifies the connection structure by eliminating the need for separate mounting brackets, bolts, and alignment mechanisms that would be required for a cardan shaft connection. The drive unit is directly received and secured within the integrated receiving structure, reducing overall assembly complexity.
3Adaptability or versatility
If a cardan shaft is used to connect the drive unit to the rear axle, then the drive-train can be installed in standard configurations, but the vehicle weight increases reducing range
Solution Approach 1:
By integrating the receiving structure into the axle body as a single-piece construction, the patent eliminates the weight of the cardan shaft and its associated mounting hardware. The drive unit is directly coupled to the axle through the integrated receiving structure, significantly reducing the overall weight of the drive-train assembly and thereby improving vehicle range.
4Reliability
If the receiving structure is connected to the axle body as one piece, then the connection reliability is improved, but the manufacturing complexity increases
Solution Approach 1:
The receiving structure and axle body are formed as a single integral component, which eliminates potential failure points at connection interfaces such as welds, bolts, or rivets. This monolithic construction ensures reliable power transmission from the drive unit to the axle shaft without risk of connection failure. The integrated design can be manufactured using casting or forging processes that are well-suited for producing complex three-dimensional structures in a single operation.
Data Source
AI summary
A drivable axle for a vehicle, in particular a rigid axle. The drivable axle has an axle body designed to accommodate an axle shaft and a receiving structure for receiving a vehicle element which is integrated into a drive-train of the vehicle. The receiving structure is connected to the axle body and is designed to receive a drive unit of the vehicle and has openings for connection to the axle shaft. The receiving structure has at least one fixing area for fixing the drive unit to the receiving structure.