The open differential configuration of an e-axle is a gear arrangement that is used in electric vehicles. It distributes torque between the wheels on the same axle and allows differentiation in wheel speeds, especially during turns. This mechanism serves the same purpose in electric vehicles (EVs) as in traditional internal combustion engine vehicles. However, in EVs, the differential operation is based on electric power rather than internal combustion engines.

This differential action is necessary for electric vehicles to navigate corners smoothly and maintain stability, especially when turning or driving on uneven surfaces. During turns, the outer wheel needs to travel a greater distance than the inner wheel. The open differential enables individual wheel rotation speeds during cornering, ensuring controlled turns by allowing the outer wheel to rotate faster than the inner wheel. Without a differential, this speed difference would cause binding or tire scrubbing resulting in potential damage to the drivetrain.

Components of Open Differential Configuration

Ring Gear: This outermost gear receives power from the driveshaft and transmits it to the side gears.

Pinion Gear: The pinion gear is connected to the driveshaft and acts with the ring gear to transfer power into the differential.

Side Gears: These gears are connected to the half-shafts that drive the wheels. They receive power from the ring gear and transmit it to the wheels.

Spider Gears/Planet Pinions: These gears allow the wheels to rotate at different speeds during turns. They are positioned between the side gears and allow them to spin at different rates.

Axle Housing: This contains and supports all the other components, allowing the differential to function as a unit.

Thus the components of open differential configuration work together to enable the wheels to rotate at different speeds while distributing power evenly between them.

Design Considerations for Open Differential Configuration

Torque Distribution: The open differential must evenly distribute the torque from the electric motor(s) to the left and right wheels, even when they are rotating at different speeds during turns or on uneven surfaces.

Wheel Speed Differentiation: The differential mechanism must allow the wheels to rotate at different speeds, enabling smooth and controlled turns by allowing the outer wheel to spin faster than the inner wheel.

Packaging and Integration: The open differential design must be compact and integrated with the electric motor, gearbox, and other e-axle components to fit the packaging requirements of electric vehicles.

Efficiency and Weight: The open differential should be lightweight and efficient to maximize the overall powertrain efficiency and range of the electric vehicle.

Cost-Effectiveness: The open differential mechanism should be relatively simple and cost-effective to manufacture, as it is the most common type found in passenger vehicles.

Noise and Vibration: The gear geometry and bearing selection must be carefully considered to minimize noise and vibration, which is more noticeable in electric vehicles without an internal combustion engine.

Thermal Management: The lubrication and thermal efficiency of the open differential must be properly addressed to ensure that it operates within the optimal temperature range.

Advantages of Open Differential Configuration

The main advantages of an open differential in electric vehicles include:

Improved Cornering Performance: The open differential configuration enables the wheels to rotate at different speeds during turns, ensuring a smooth and controlled turn by ensuring the outer wheel rotates faster than the inner wheel.

Enhanced Driveability: Open differentials provide excellent driveability, making them ideal for electric vehicles.

Lightweight and Efficient: Open differentials are relatively lightweight and efficient, resulting in improved overall efficiency and reduced energy loss.