Off-Axis Electric Traction Axle for Compact High-Power Packaging
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Solution Overview
Problem
Existing electric traction axles/beans face challenges in reducing dimensions while maintaining a wide operational range for torque and power delivery, which is essential for diverse vehicle operating conditions.
Innovation Solution
The electric traction axle/beam employs an off-axis configuration where the electric machine is coaxial to an axis parallel and spaced from the axle's longitudinal axis, incorporating a first and second transfer system, a differential unit, and a lubrication system to optimize space and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the electric machine is positioned in an on-axis configuration (coaxial to the axle drive shafts), then the assembly is simplified and elements can be directly assembled on the axles, but the longitudinal dimension of the axle increases, limiting the positioning of other functional elements and reducing versatility
Solution Approach 1:
The patent transitions from an on-axis configuration to an off-axis configuration, moving the electric machine's axis from being coaxial with the drive shafts to being parallel and spaced apart from it. This dimensional repositioning allows the electric machine to be integrated without extending the longitudinal dimension of the axle, thereby resolving the contradiction between assembly simplicity and compact longitudinal size.
2Adaptability or versatility
If the longitudinal dimension of the axle is increased to accommodate the electric machine, then the electric machine can be properly positioned, but the positioning of other functional elements (suspension, brake system, frame components) is limited and the versatility of torque and power provision is undermined
Solution Approach 1:
By repositioning the electric machine off-axis and parallel to the drive shaft axis, the patent creates spatial freedom in the longitudinal dimension. This allows other functional elements such as suspension, brake system, and frame components to be positioned without interference, thereby maintaining versatility while avoiding the need to increase the axle's longitudinal dimension.
3Length of moving object
If the electric machine and transmission are resized to reduce longitudinal dimension, then the axle dimensions are reduced, but the power and performance available to the axle actually decrease
Solution Approach 1:
The off-axis configuration allows the electric machine to be positioned in a different spatial arrangement that does not require resizing. The machine can maintain its full power and performance capabilities while the longitudinal dimension of the axle is reduced, because the machine is positioned parallel to and spaced from the drive shaft axis rather than being coaxial with it.
Data Source
Figure 1
AI summary
An electric traction axle/beam, e-axle/e-beam, (1) for a vehicle comprising at least one electric machine (2), a pair of drive shafts (4', 4'') each connected to a respective wheel of the vehicle and a transmission chain operationally connecting the electric machine (2) to the pair of drive shafts (4', 4''), the transmission chain comprising a first transfer system (5), a second transfer system (7), and a differential unit (8) operationally interposed in series between them, the drive shafts (4', 4'') being coaxial to a longitudinal axis (A) of the axle (1), the electric machine (2) being subtended by a parallel and separate axis (B) of the longitudinal axis (A), the e-axle/e-beam (1) comprising a lubrication system (13) for the transmission chain, the lubrication system (13) being placed between/integrated with one of the drive shafts (4', 4").