Integrated E-Axle Assembly for Simpler Power Distribution

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Solution Overview

Problem

Existing electrified vehicles require complex and costly e-axle designs that integrate electric motors with differential mechanisms, necessitating a simpler and cost-effective solution.

Innovation Solution

An electrically driven axle assembly with a main housing, differential plate, differential assembly, drive shafts, and electric machines, featuring a lubricant and coolant system, and a mechanical transmission for efficient power distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If complex gearing arrangements are integrated into e-axles, then power distribution is improved, but device complexity increases

Engineering Contradiction:

Improvepower distributionVSAvoidgearing arrangements

Core Design Contradiction:

PowerVSDevice complexity

Solution Approach 1:

The patent combines the differential mechanism and gear assembly into a single integrated e-axle unit, merging previously separate components (differential, gears, electric motor) into one consolidated assembly that reduces overall system complexity while maintaining power distribution functionality

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The e-axle assembly performs multiple functions within a single integrated structure: the differential plate and assembly handle power distribution to wheels, the gear assembly provides mechanical advantage, and the electric machine provides propulsion, eliminating the need for separate transmission components

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Device complexity

If integrated e-axle designs are implemented, then device complexity is reduced, but manufacturing precision requirements increase

Engineering Contradiction:

Improvee-axle designVSAvoidcomponent integration

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The integrated e-axle is designed with modular segments including a differential plate with integrated orifices, separable housing sections, and distinct gear assemblies that can be manufactured and assembled in a standardized sequence, reducing the precision challenges of fully integrated manufacturing

Inventive Principle:

Principle #1Segmentation

3Reliability

If differential assembly with bearing is used, then reliability is improved, but weight increases

Engineering Contradiction:

Improvedifferential assemblyVSAvoidaxle assembly

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The bearing is positioned specifically within the differential plate at the exact location where rotational support is needed, providing reliability only where required rather than using bearings throughout the entire assembly, thus minimizing weight while maintaining functional reliability

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12539755B2Drive system for an electric vehicle

Publication Date: 2026.02.03 NIKOLA CORP

AI summary

An electrically driven axle assembly is disclosed. In various embodiments, the electrically driven axle assembly includes a main housing; a differential plate configured for mounting within the main housing; a differential assembly, the differential assembly disposed adjacent the differential plate and having a bearing configured for mounting within a plate orifice that extends within the differential plate; a first drive shaft having a first inboard end connected to the differential assembly and a first outboard end configured to receive a first wheel; a first electric machine configured to drive the differential assembly; and a first gear assembly configured to operably couple the first electric machine to the differential assembly.