Hollow Rigid Vehicle Axle for Integrated E-Drive Vibration Damping
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Solution Overview
Problem
Existing rigid vehicle axles with integrated electric drives face challenges in torsion and bending resistance, and mechanical damping, particularly due to insufficient flange connections and reduced tolerance to vibrations and impacts.
Innovation Solution
A vehicle rigid axle design featuring a hollow body formed by two shell elements connected by welding, with an insertion opening for electric drive components perpendicular to the drive shaft, and mechanical damping elements to mitigate vibrations and impacts, ensuring increased installation space and improved structural rigidity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a flange connection is used to connect the electric drive to the axle journal, then the assembly is simplified and easier to manufacture, but the torsion and bending rigidity is insufficient
Solution Approach 1:
The patent merges the electric drive housing with the axle hollow body, creating an integrated structure where the electric drive is directly mounted within the hollow body rather than connected via a separate flange. This integration eliminates the weak flange connection while maintaining ease of assembly through direct mounting surfaces and fastening elements built into the hollow body structure.
Solution Approach 2:
The electric drive is nested within the hollow body of the axle, with the drive shaft extending coaxially through the hollow body to connect with the wheel carrier. This nesting arrangement allows the electric drive components to be housed within the existing axial space, eliminating the need for external flange connections while maintaining structural integrity.
2Volume of moving object
If the hollow body dimensions are increased to accommodate the electric drive, then the installation space is improved, but the torsion and bending rigidity may be reduced
Solution Approach 1:
The patent applies local quality by strategically thickening the hollow body walls in critical areas where torsion and bending stresses are highest, such as near the axle journals and mounting surfaces for the electric drive. This allows the hollow body to accommodate larger electric drive components while maintaining sufficient rigidity through localized reinforcement rather than uniformly increasing wall thickness throughout.
Solution Approach 2:
The patent utilizes parameter changes by varying the wall thickness of the hollow body at different locations and orientations. The hollow body is designed with non-uniform wall thickness, being thicker in regions subjected to higher mechanical loads and thinner in regions where space is needed for electric drive components, thereby optimizing both installation space and structural rigidity.
3Reliability
If mechanical damping elements are added to protect electric drive components from vibrations and impacts, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The patent merges the mechanical damping function with the mounting structure for the electric drive. The damping elements are integrated into the mounting brackets or support structures that already exist for securing the electric drive within the hollow body, rather than being separate additional components. This integration provides vibration protection while minimizing increases in overall structural complexity.
Solution Approach 2:
The patent introduces mechanical damping elements as intermediary components between the electric drive and the hollow body structure. These damping elements act as mediators that absorb and dissipate vibrations and impacts, protecting the sensitive electric drive components while being relatively simple to implement through rubber mounts, elastomeric elements, or viscoelastic materials incorporated into the mounting structure.
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
The design enhances torsion and bending resistance, allows for easier assembly and maintenance, and effectively dampens vibrations, reducing the risk of damage to electric drive components.
Implementation Method 1
The two shell elements are connected to each other, preferably by welding, as described in the aforementioned prior art document DE 10 2019 201 518 A1. This results in a dimensionally stable hollow body.
Implementation Method 2
The damping element dampens the vibrations or Impacts to which the vehicle's rigid axle is exposed so far reduced compared to at least one component of the electric drive that there is no risk of damage to the corresponding component due to the impacts.
Data Source
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AI summary
A rigid vehicle axle (8) with an axle body (2) at each end of which axle journals (16) are arranged, and with at least two longitudinal control arms (12) rigidly attached to the axle body (2) and with at least one air spring bellows (62) assigned to each longitudinal control arm (12), wherein at least one axle body section (10) extending between the two longitudinal control arms (12) and a longitudinal control arm (12) adjoining it are formed by two interconnected shell elements (4, 6) which form a hollow body (26) between them. To adapt the rigid vehicle axle (8) to modern drive concepts, the present invention proposes providing at least one component of an electric drive (52, 54) in the hollow body (26), with a drive shaft (50) that passes through the axle journal (16) arranged at the corresponding end of the axle body.