Modular Electric Axle Head Assembly Segmentation
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Solution Overview
Problem
Conventional hybrid vehicles require expensive and complex drive-line and axle system components to combine internal combustion engines and electric motors, making them costly to manufacture and maintain.
Innovation Solution
A modular electric axle head assembly that includes a gear assembly, motor assembly, and mounting assemblies, allowing for the integration with conventional axle assemblies to create various electric axle configurations in a cost-efficient manner, with features like helix-angled gears to reduce axial force and a modular parking mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional drive-line and axle system components are used to combine internal combustion engines and electric motors, then the vehicle can achieve hybrid power delivery, but the manufacturing and maintenance costs increase significantly
Solution Approach 1:
The invention divides the axle system into separate functional modules: a conventional axle assembly and a modular electric axle head assembly. This segmentation allows the electric motor components to be independently manufactured and integrated with the conventional axle, reducing overall manufacturing complexity and cost while maintaining hybrid power delivery capability.
Solution Approach 2:
The modular electric axle head assembly is designed to be universally applicable and can be integrated with conventional axle assemblies to create hybrid vehicle drive systems. This multi-functional design enables the same modular assembly to work across different vehicle platforms, reducing per-unit manufacturing costs and simplifying maintenance procedures.
2Power
If specialized drive-line and axle system components are used for hybrid vehicles, then the vehicle performance is improved, but the complexity of the system increases
Solution Approach 1:
By segmenting the drive system into a conventional axle assembly and a separate modular electric axle head assembly, the invention reduces system complexity. Each module can be optimized independently for its specific function, while the modular interface simplifies integration, thereby maintaining high vehicle performance without proportionally increasing overall system complexity.
3Ease of manufacture
If modular electric axle head assembly is used, then manufacturing and maintenance costs are reduced, but the integration with conventional axle assemblies requires precise design
Solution Approach 1:
The modular electric axle head assembly incorporates universal mounting interfaces and standardized connection points that simplify integration with conventional axle assemblies. This universal design approach reduces the need for custom fabrication and minimizes integration precision requirements while maintaining cost-effectiveness in manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of cost-efficient, versatile electric axle systems that reduce manufacturing and maintenance costs while improving efficiency and flexibility in vehicle applications.
Implementation Method 1
The first gear has a plurality of first gear teeth, the second gear has a plurality of second gear teeth, the third gear has a plurality of third gear teeth and the plurality of first gear teeth, the second gear teeth and the third gear teeth have a helix angle that reduces or eliminates an amount of axial force experienced by the second gear shaft of the gear assembly when in operation.
Data Source
AI summary
A modular electric axle head assembly for a vehicle, including a gear assembly including a gear assembly housing defining a hollow portion therein, a first gear shaft having a first gear, a second gear shaft having a second gear and a third gear, wherein at least a portion of the second gear is drivingly connected to the first gear and the third gear, and at least a portion of the gear assembly is disposed within the hollow portion of the gear assembly housing; a motor assembly having an output shaft that is drivingly connected to at least a portion of the gear assembly; and a first mounting assembly including a portion integrally connected to the modular electric head assembly and a portion integrally connected to a support member of the vehicle, wherein at least a portion of the third gear is drivingly connected to a pair of drive shafts.