Split Halfshaft Flange for Rear Drive Module Removal
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Solution Overview
Problem
Traditional electronic rear drive modules require the removal of suspension components to facilitate their removal from a vehicle, making the process time-consuming.
Innovation Solution
The electronic rear drive module incorporates a split halfshaft flange design with a separable outer flange and inner flange configuration, allowing for minimal axial movement of the halfshaft to clear the flange, thereby enabling the module to be removed without disassembling suspension components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional solid flange design is used, then the structural strength is improved, but the removal time increases due to required suspension component disassembly
Solution Approach 1:
The flange is divided into two separate parts: an inner flange integrated with the drive module housing and an outer flange integrated with the halfshaft. These segmented flanges can be easily separated by axial movement, allowing the drive module to be removed without disassembling suspension components, thus resolving the contradiction between structural strength and removal time.
Solution Approach 2:
The inner flange and outer flange are designed to nest together during operation, with the inner flange positioned within the outer flange structure. This nested configuration maintains structural integrity during operation while enabling easy separation for removal, addressing both strength requirements and removal efficiency.
2Ease of operation
If a separable flange design is used, then the removal process is simplified, but the device complexity increases
Solution Approach 1:
The flange system is segmented into two functional parts that simplify the removal process. Each flange is integrated with its respective component (drive module and halfshaft), eliminating the need for complex suspension disassembly while maintaining operational simplicity through straightforward axial separation.
3Productivity
If minimal axial movement is required, then the removal efficiency is improved, but the clearance requirement becomes more difficult to achieve
Solution Approach 1:
By segmenting the flange into inner and outer portions that can separate axially, the design enables the halfshaft to clear the drive module housing with minimal axial movement. The segmented structure allows the halfshaft to simply move axially to disengage the outer flange from the inner flange, achieving high removal efficiency without requiring excessive axial travel.
Data Source
AI summary
The present teachings provide for a vehicle drive module including a housing, an electric motor, a transmission gear set, a differential assembly, and a pair of output members. The transmission gear set can transmit rotary power between a motor output shaft and an output of the transmission gear set. The differential assembly can include a case, a pair of pinion gears, and a pair of side gears. Each of the side gears can be meshingly engaged with the pair of pinion gears. Each output member can include a driven body and an outer flange. The driven body can have a first end drivingly coupled to one of the side gears. The outer flange can have a first side that is releasably coupled to the second end of the driven body, and a second side that is adapted to be releasably coupled to a constant velocity joint.