Ribbed Cable Support Beam for E-Axle Fatigue Control
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Solution Overview
Problem
The durability of power cables in trucks with E-axles is compromised due to fatigue issues caused by the deflection and bending during relative movement between the E-axle and the electric power source, exacerbated by varying road and load conditions.
Innovation Solution
A support beam with varying bending stiffness elements is used to distribute the bending stress evenly along the cable path, incorporating a conductive core for grounding and insulating features, and designed to guide power cables with flanges and carriers to prevent local fatigue failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the power cable is allowed to bend and deflect with the movement of the E-axle, then the cable can accommodate relative movement between the E-axle and electric power source, but the cable suffers from fatigue failure due to repeated bending
Solution Approach 1:
A support beam with varying bending stiffness is introduced as an intermediary structure between the chassis and E-axle. This support beam guides the power cable along a controlled cable path, allowing the cable to bend in a predetermined manner while preventing uncontrolled deflection that would cause fatigue. The support beam mediates between the need for cable flexibility and the need to prevent fatigue failure.
2Stability of the object's composition
If the support beam has high bending stiffness to prevent cable deflection, then the cable path is stable, but the bending stress concentrates in specific locations causing local fatigue failure
Solution Approach 1:
The support beam is designed with non-uniform bending stiffness along its length, creating different structural properties in different sections. The middle section has higher bending stiffness to maintain cable path stability, while the sections near the chassis mount and E-axle mount have lower bending stiffness to reduce stress concentration. This local variation in stiffness prevents uniform stress distribution that would lead to fatigue failure.
3Reliability
If the support beam structure is made complex to evenly distribute bending stress, then cable fatigue is reduced, but the device complexity increases
Solution Approach 1:
The support beam's bending stiffness parameter is varied continuously or in steps along the cable path rather than being uniform. This parameter change is achieved through varying the cross-sectional geometry, material distribution, or structural configuration of the support beam. By controlling the bending stiffness parameter along the length, the structure evenly distributes bending stress while maintaining a relatively simple overall form.
Data Source
AI summary
A truck with cable support is disclosed, including a chassis, accommodating an electric power source for powering an electric motor; an E-axle, comprising the electric motor and arranged as a rear wheel driving axle of the truck; a suspension system, suspending the E-axle to the chassis and allowing movement of the E-axle in a vertical direction relative to the chassis; a power cable, electrically connecting the electric power source to the E-axle; and a support beam, forming a mechanical support structure to lead the power cable along a cable path extending between a chassis mount and an E-axle mount. The support beam includes one or more bending stiffness elements, forming a stiffness of the support beam that is highest in a middle section and that decreases towards the chassis mount and the E-axle mount, evenly distributing the bending stress in the support beam along the cable path when the E-axle moves relative to the chassis, to prevent local fatigue failure of the power cable.