New Generation Front Axle for EV and FCEV Buses 2024-26-0321

Front axle is one of the major load-carrying members of Heavy Commercial Buses. With the conversion of the Power train from ICE to Battery electric vehicle, there is a marginal increase in front axle weight due to the Electric and Fuel Cell Electric vehicle architecture. This paper describes various methodologies deployed in front axle design to enhance the Axle durability performance, improve vehicle handling, and lower the total cost of ownership. A Lightweight heavy-duty front axle beam has been designed and validated, digitally and at test bench level for a 12m long low floor EV and FCEV Bus used for mass transportation. Also, major components like stub axle, hub, steering arm, tie rod arm, and tie rod assembly are analyzed for strength, durability, fatigue life, and joint analysis. Fatigue behavior is evaluated in differently manufactured components. Also, the strength of the axle beam is compared for different cross sections for weight optimization and durability improvement. The axle is integrated with a hydraulically assisted steering system, Air suspension, and Air Disc brakes.