Off-Axis Electric Traction Axle for Compact High-Torque Packaging
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Solution Overview
Problem
Existing electric traction axles/beans have bulky electric machines that limit the positioning of other functional elements, necessitating increased longitudinal dimensions or reduced power and performance, which is not feasible in all vehicle configurations.
Innovation Solution
An electric traction axle/beam with an off-axis configuration, where the axis of the electric machine is parallel and spaced apart from the longitudinal axis of the axle, allowing for reduced longitudinal dimensions while maintaining high torque and power delivery through optimized transfer systems and clutch speed shift systems.
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/beam drive shafts), then the assembly of elements on the axles is facilitated, but the longitudinal dimension of the axle increases, limiting the positioning of other functional elements
Solution Approach 1:
The patent transitions from a conventional on-axis (coaxial) configuration to an off-axis configuration where the electric machine's rotation axis is offset from the drive shaft axis. This dimensional repositioning allows the electric machine to be mounted laterally on the axle housing rather than extending axially, thereby reducing the longitudinal dimension while maintaining assembly feasibility through the axle housing's lateral mounting structures
2Volume of moving object
If the longitudinal dimension of the axle is increased to accommodate the electric machine, then the electric machine can be positioned, but the positioning of other functional elements (suspensions, brake system components, frame components) is limited
Solution Approach 1:
By repositioning the electric machine off-axis and mounting it laterally on the axle housing, the patent frees up longitudinal space that can then be utilized by other functional elements such as suspension components, brake system components, and frame components, thereby maintaining adaptability and versatility of the axle system
3Length of moving object
If the electric machine or transmission is resized to reduce longitudinal dimension, then the axle dimensions are reduced, but the power and performance available to the axle decreases
Solution Approach 1:
The off-axis configuration allows the electric machine to be positioned laterally rather than axially, maintaining its full size and power capabilities while reducing the longitudinal dimension of the axle assembly. This spatial reconfiguration enables the electric machine to deliver its designed power and performance without being constrained by reduced dimensions
4Ease of manufacture
If the on-axis configuration is used, then the electric machine can be directly assembled on the axles, but the versatility of torque and power provision over an extended interval is undermined
Solution Approach 1:
The off-axis configuration maintains assembly ease through lateral mounting structures on the axle housing while providing greater design flexibility. This spatial arrangement allows for optimized transmission system layout and enables a broader range of torque and power delivery characteristics to be achieved, enhancing versatility for diverse vehicle operating conditions
Data Source
AI summary
Electrically driven axle, e-axle/e-beam, for a vehicle, e-axle/e-beam comprising a casing defining a space separated from the external environment and at least one electric machine and a pair of drive shafts each connected to a respective wheel of the vehicle and supported by the casing,the e-axle comprising a transmission chain housed in the space operationally connecting at least one electric machine to the pair of drive shafts,the transmission chain comprising operationally interposed in series between the at least one electric machine and the pair of drive shafts a first transfer system, a speed shift system, and a second transfer system and a differential assembly,wherein the speed shift system comprises a clutch shift system.