Rigid support bars for banjo-style electric axle stamped differential cover

A banjo axle case comprising:

• an upper half member;
• a lower half member, wherein the upper half member and the lower half member define a first tube portion, a second tube portion, and a central portion, wherein the central portion is disposed between the first tube portion and the second tube portion;
• an upper-to-lower weld joint, wherein the upper half member and the lower half member abut together and are welded together by the upper-to-lower weld joint;
• a cover assembly comprising:
• a differential cover, wherein the differential cover comprises a body portion and a flange portion, wherein the body portion bulges outward from the flange portion, wherein the flange portion is disposed around and extends from the body portion;
• a support plate, wherein the support plate and the flange portion are flat members, wherein the support plate and the flange portion overlap, wherein the support plate and the body portion do not overlap;
• and
• a plate-to-cover weld joint, wherein the differential cover and the support plate are welded together by the plate-to-cover weld joint;
• and
• a cover-to-center weld joint, wherein the differential cover and the central portion are welded together by the cover-to-center weld joint.

An electric beam axle comprising:

• a banjo axle casing comprising:
• an upper half member;
• a lower half member, wherein the upper half member and the lower half member define a first tube portion, a second tube portion, and a central portion, wherein the central portion is disposed between the first tube portion and the second tube portion;
• an upper-to-lower weld joint, wherein the upper half member and the lower half member abut together and are welded together by the upper-to-lower weld joint;
• a cover assembly comprising:
• a differential cover, wherein the differential cover comprises a body portion and a flange portion, wherein the body portion bulges outward from the flange portion, wherein the flange portion is disposed around and extends from the body portion;
• a support plate, wherein the support plate and the flange portion are flat members, wherein the support plate and the flange portion overlap, wherein the support plate and the body portion do not overlap;
• and
• a plate-to-cover weld joint, wherein the differential cover and the support plate are welded together by the plate-to-cover weld joint;
• and
• a cover-to-center weld joint, wherein the differential cover and the central portion are welded together by the cover-to-center weld joint;
• and
• an electric drive unit comprising a differential, an electric motor, and a transmission, wherein the differential is disposed within the central portion, wherein the banjo axle casing and the differential are fastened together by a plurality of fasteners.