Modular Electric Axle Assembly With Banjo Housing Service Access
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Solution Overview
Problem
Existing electric axles face challenges in minimizing weight while maintaining efficiency and durability, particularly in compact vehicle installations, where traditional materials and assembly methods may not adequately address the need for lightness and ease of serviceability.
Innovation Solution
The electric axle assembly incorporates a banjo-type axle housing with a stamped steel construction and an aluminum electric drive unit, featuring a bolted connection with a stiffening plate and a sealing mechanism, allowing for modular assembly and disassembly, which includes a cover plate with a sealing flange and O-ring or overmolded seal for enhanced sealing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional materials and assembly methods are used, then structural strength is maintained, but weight increases and serviceability deteriorates
Solution Approach 1:
The axle housing is divided into two separate members (first and second members) that are fixed together, creating a modular structure. This segmentation allows the housing to be disassembled for serviceability while maintaining structural strength, and the modular design enables easier repair and maintenance operations compared to traditional monolithic housings.
2Ease of repair
If modular assembly with bolted connections is used, then serviceability improves, but structural strength may deteriorate
Solution Approach 1:
Stiffening plates are pre-fixed to the axle housing members before final assembly. These stiffening plates are strategically positioned to reinforce the areas where bolted connections will be made, ensuring that the modular assembly maintains structural strength equivalent to or greater than traditional welded constructions while preserving serviceability.
3Manufacturing precision
If stamped construction is used, then manufacturing precision and weight are improved, but structural strength may worsen
Solution Approach 1:
The axle housing employs a composite construction combining stamped metal members with added stiffening plates. The stamped members provide weight reduction and manufacturing precision, while the stiffening plates (which may be of different material composition) compensate for any strength deficiencies, creating a composite structure that achieves both lightness and structural integrity.
Data Source
AI summary
An electric axle assembly that includes an electric drive unit mounted in a banjo-style axle housing. The electric drive unit includes a motor, gear box, and differential within a housing. The electric drive unit is inserted into the banjo-style axle housing from a first side of the banjo-style axle housing such that at least a portion of the housing of the electric drive unit is contained within the banjo-style axle housing. Fasteners are installed from a second side of the banjo-style axle housing opposite the first side for securing the housing of the electric drive unit to the banjo-style axle housing.