Remote Electric Drive Unit Layout for Existing Axle Integration
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Solution Overview
Problem
Existing electric drive systems for vehicles are limited by the need for direct integration with the axle assembly, which restricts design flexibility and increases retrofitting costs and complexity.
Innovation Solution
An electric drive unit is positioned remotely from the axle assembly, allowing for flexible placement within the vehicle and utilizing existing axle assemblies, with a lubrication system that includes a support housing and lubricant pump to maintain efficient lubrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the electric drive unit is directly integrated with the axle assembly, then the structural stability is improved, but the adaptability and design flexibility are reduced
Solution Approach 1:
The drive system is divided into separate functional modules: the electric drive unit (motor, transmission, housing) is segmented from the axle assembly. This allows the electric drive unit to be independently designed, manufactured, and positioned remotely while maintaining stable connections through standardized mounting interfaces and drive shafts.
Solution Approach 2:
The electric drive unit is designed as a universal module that can be applied to various vehicle configurations and axle types. The standardized housing assembly with mounting flanges and adaptable transmission outputs enables the same basic unit to serve multiple functions and be installed in different locations throughout the vehicle.
2Stability of the object's composition
If the electric drive unit is directly integrated with the axle assembly, then the structural stability is improved, but the retrofitting cost and complexity are reduced
Solution Approach 1:
The electric drive unit is pre-assembled as a complete, tested module with all necessary components (motor, transmission, housing, lubrication system) integrated before delivery to the customer. This preliminary assembly allows for quality control and system testing to be performed during manufacturing rather than during field installation, reducing retrofitting complexity.
Solution Approach 2:
Standardized interface components serve as intermediaries between the electric drive unit and the existing axle assembly. These include mounting flanges, drive shafts, and coupling mechanisms that facilitate easy connection to various axle types without requiring custom integration work or modification of the existing axle structure.
3Adaptability or versatility
If the electric drive unit is positioned remotely from the axle assembly, then the adaptability is improved, but the device complexity is increased
Solution Approach 1:
A drive shaft serves as an intermediary mechanical element connecting the remotely positioned electric drive unit to the axle assembly. This single intermediate component enables flexible positioning of the motor while maintaining efficient power transmission, avoiding the need for complex multi-component coupling systems.
Solution Approach 2:
The lubrication system uses hydraulic principles to deliver lubricant remotely from the electric drive unit to the transmission and gear interfaces. A lubricant pump and delivery system transport lubricant through passages in the housing and external conduits to remote contact points, enabling centralized lubrication without complex mechanical linkages.
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 efficient lubrication and reduces retrofitting time and costs by allowing the electric drive unit to be integrated into various vehicle configurations without altering the axle assembly, enhancing design flexibility and space utilization.
Implementation Method 1
A lubricant pump that is driven by the shaft may pump lubricant from the sump portion
Implementation Method 2
The bearing may receive the shaft. The bearing may rotatably support the rotor shaft
Implementation Method 3
The second opening may receive a seal. The seal may extend from the second internal wall to the shaft
Data Source
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AI summary
An electric drive unit and a drive axle system (22) having an electric drive unit. The drive axle system also includes a drive shaft (40) and an axle assembly (20) that is remotely positioned from the electric drive unit. The drive shaft operatively connects the electric drive unit to the axle assembly.