Integrated Electric Drive Axle System with Planetary Gearsets
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Solution Overview
Problem
The separate packaging of power sources, transmissions, and differentials in axle systems for work vehicles increases design complexity, cost, and development time, especially when transitioning to alternative power sources like electric motors.
Innovation Solution
An integrated electric drive axle system with a motor having a rotor shaft aligned with output shafts, featuring planetary gearsets for transmission and a clutch-controlled differential mechanism to enable simultaneous or differential wheel speed operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If power sources, transmissions, and differentials are packaged separately, then each component can be optimized independently, but design complexity, cost, and development time increase
Solution Approach 1:
The patent combines the transmission and differential functions into a single integrated axle assembly housing. The planetary gearset (transmission) and differential gearset are merged within the same housing, sharing common components like the carrier and planet gears. This integration eliminates the need for separate packaging of transmission and differential components, reducing overall system complexity and packaging requirements while maintaining independent optimization capabilities through modular design elements.
2Adaptability or versatility
If electric motors are located at each corner of the vehicle, then drive system functionality is achieved, but design and packaging complexity of other components increases
Solution Approach 1:
The integrated axle assembly serves multiple functions within a single component package: it provides motor mounting, transmission (planetary gearset), differential (second planetary gearset), and wheel drive functionality. This multi-functional design eliminates the need for separate packaging of transmission and differential components that would be required with traditional corner-mounted electric motors, reducing overall system complexity while maintaining full drive system functionality.
3Ease of repair
If separate packaging is used for transmission and differential, then component maintenance is easier, but overall system cost and development time increase
Solution Approach 1:
While integrating the transmission and differential into a single housing, the patent maintains functional segmentation through distinct planetary gearsets with separate carriers. The first planetary gearset (transmission) and second planetary gearset (differential) are clearly defined as separate functional units within the integrated assembly. This segmentation allows for targeted maintenance and repair of specific subsystems while benefiting from the overall integration that reduces development time and system cost.
Data Source
AI summary
An electric drive axle system has an integral electric machine. An axle system includes a pair of output shafts and a motor with a rotor shaft disposed in line with the output shafts. A gearset is coupled between the rotor shaft and one output shaft. Another gearset is coupled between the rotor shaft and the other output shaft. Each gearset has a sun gear meshing with a set of planet gears supported on a carrier. The rotor shaft is fixed to the sun gears and the output shafts are fixed to the carriers. A clutch may alternately prevent or allow rotation of ring gears of the gearsets.