Lockable Electric Axle for Independent Drive and Traction
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Solution Overview
Problem
Existing electric axles face challenges such as reduced durability and load-carrying capacity due to the use of cardan joints in independent suspension systems, and they often struggle to achieve desired traction in variable environments.
Innovation Solution
An electric axle design that includes a locking clutch to selectively lock the rotation of separate electric machines, allowing for increased traction in certain conditions while enabling independent motor control in other scenarios. The axle features axial flux motors and compound planetary gear sets to enhance compactness and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If cardan joints are used in independent suspension systems, then the suspension flexibility is improved, but the durability and load carrying capacity deteriorate
Solution Approach 1:
The patent removes cardan joints from the electric axle system entirely, replacing them with a rigid beam axle configuration that directly couples the electric motors to the wheels. This extraction of the problematic cardan joint component eliminates the durability issues while maintaining suspension flexibility through the rigid axle design itself.
2Ease of operation
If separate electric machines independently drive each wheel, then the ease of operation is improved, but the traction capability in variable environments deteriorates
Solution Approach 1:
The patent implements a dynamic system where a locking clutch can selectively couple the two electric machines together. When unlocked, the machines operate independently for ease of control; when locked, they operate together to maximize traction. This dynamic switching between operational modes resolves the contradiction between independent control and traction capability.
Solution Approach 2:
The locking clutch mechanism provides multi-functionality by enabling the electric axle to operate in two distinct modes: independent wheel drive mode for normal operation and locked differential mode for high-traction situations. This universal design allows the system to adapt to different driving conditions and achieve both ease of operation and superior traction capability.
3Device complexity
If traditional electric axle configurations are used, then the packaging simplicity is maintained, but the adaptability to various vehicle platforms deteriorates
Solution Approach 1:
The patent employs modular electric motor units that can be independently positioned and configured within the axle assembly. This segmentation allows the same basic electric axle design to be adapted to different vehicle platforms by adjusting motor positions and configurations, thereby improving platform compatibility without significantly increasing packaging complexity.
Data Source
AI summary
Systems and methods for a lockable electric axle are provided. The electric axle includes a first electric machine coupled to a first drive wheel via a first gear set. The electric axle further includes a second electric machine coupled to a second drive wheel via a second gear set, and a locking clutch designed to selectively lock the rotation of a first rotor shaft and a second rotor shaft in the first and second electric machines, respectively.