Remote Electric Drive Axle Layout for Easier EV Retrofitting
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Solution Overview
Problem
Existing electric drive units are inefficiently integrated with axle assemblies, leading to space constraints and increased retrofitting costs when converting internal combustion engines to electric propulsion systems.
Innovation Solution
A remotely positioned electric drive unit with a housing assembly that includes a support housing and drop gear set, allowing for independent installation from the axle assembly, and a lubricant pump system for efficient lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the electric drive unit is integrated with the axle assembly, then the torque transmission efficiency is improved, but the space constraints and retrofitting costs increase
Solution Approach 1:
The electric drive unit is divided into separate modular components: the electric motor module (with motor and transmission) and the drop gear module (with differential and axles). This segmentation allows independent installation and positioning, reducing integration complexity while maintaining functional efficiency through separate torque transmission paths.
2Loss of time
If the electric drive unit is remotely positioned from the axle assembly, then the retrofitting time and costs are reduced, but the torque transmission path becomes longer
Solution Approach 1:
A drive shaft serves as an intermediary component connecting the electric motor module to the drop gear module. This intermediary element enables remote positioning of the motor module (reducing retrofitting complexity) while efficiently transmitting torque over the extended distance through the drive shaft, which can be routed through the vehicle frame or chassis.
3Strength
If the housing assembly is designed to receive all components, then the structural integrity is improved, but the manufacturing complexity increases
Solution Approach 1:
The housing assembly merges multiple functions into a single structural component: it houses the electric motor, transmits torque through the drive shaft, supports the drop gear module, and provides mounting points for the entire assembly. This consolidation maintains structural integrity while simplifying manufacturing compared to multiple separate housing components.
Data Source
Figure 1
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AI summary
An electric drive unit (22) and a drive axle system (12) having an electric drive unit (22). The drive axle system also includes a drive shaft (40) and an axle assembly (20) that that is remotely positioned from the electric drive unit. The drive shaft operatively connects the electric drive unit to the axle assembly.