Electric drive axle with multi-speed gearbox

Patent metadata

Field	Value
Publication number	US-11207962-B2
Application number	US-201816966858-A
Country	US
Kind code	B2
Filing date	Apr 23, 2018
Priority date	Feb 2, 2018
Publication date	Dec 28, 2021
Grant date	Dec 28, 2021

Abstract

An electric drive axle including a first shaft in driving engagement with an electric motor. A first gear and a second gear are coupled with the first shaft. A second shaft is disposed offset from the first shaft. A third gear is selectively coupled with the second shaft, and the third gear is meshed with the first gear. A fourth gear is selectively coupled with the second shaft, and the fourth gear is meshed with the second gear. A fifth gear is coupled with the second shaft and meshed with a sixth gear coupled with a differential case.

First claim

What is claimed is:

1. An electric drive axle, comprising:
an electric motor;
a first shaft in driving engagement with said electric motor;
a first gear coupled with said first shaft;
a second gear coupled with said first shaft;
a second shaft disposed offset from said first shaft;
a third gear selectively coupled with said second shaft, wherein said third gear is meshed with said first gear;
a fourth gear selectively coupled with said second shaft, wherein said fourth gear is meshed with said second gear;
a fifth gear coupled with said second shaft;
a sixth gear coupled with a differential case, wherein said sixth gear is meshed with said fifth gear;
a first clutch disposed at least partially concentrically within said second gear or said third gear;
a first fluid conduit disposed at least partially through said first shaft or said second shaft and in fluid communication with a clutch drum in said first clutch;
a second clutch disposed at least partially concentrically within said fourth gear; and
a second fluid conduit disposed at least partially through a second end of said second shaft, wherein said second clutch comprises a clutch drum rotatably supported on said second shaft in fluid communication with said second fluid conduit;
wherein said first clutch is at least partially concentrically disposed within said third gear; and
wherein the first fluid conduit is disposed at least partially through a first end of said second shaft and wherein the clutch drum is rotatably supported on said second shaft.

2. The electric drive axle according to claim 1 , wherein said first clutch comprises:
a clutch hub coupled with said second shaft; and
a clutch drum disposed concentrically about said clutch hub, wherein said third gear is coupled with a radially outer surface of said clutch drum.

3. The electric drive axle according to claim 1 , wherein said fifth gear is disposed axially between said third gear and said fourth gear.

4. The electric drive axle according to claim 1 , further comprising:
a housing, wherein said first shaft, said second shaft, and said differential case are rotatably supported within the housing.

5. The electric drive axle according to claim 1 , wherein:
said first clutch and said second clutch are selectively hydraulically actuated.

6. The electric drive axle according to claim 1 , wherein said first clutch comprises:
a clutch hub coupled with said second shaft;
a clutch drum disposed concentrically about said clutch hub, wherein said third gear is coupled with a radially outer surface of said clutch drum;
a first plurality of clutch plates in splined engagement with said clutch drum;
a second plurality of clutch plates in splined engagement with said clutch hub, wherein said first and second pluralities of clutch plates are interleaved;
a pressure plate disposed within said clutch drum axially adjacent to the first and second pluralities of clutch plates;
a support plate disposed axially adjacent to said pressure plate, wherein said support plate comprises one or more apertures;
an apply plate having one or more axially projecting lugs disposed through said one or more apertures in said support plate; and
a piston member disposed axially adjacent to said apply plate.

7. An electric drive axle, comprising:
a motor output shaft including a first gear and a second gear;
an idler shaft including:
a third gear in meshed engagement with the first gear; and
a fourth gear in meshed engagement with the second gear;

a first clutch disposed at least partially concentrically within the third gear;
a first fluid conduit axially extending through the idler shaft and in fluid communication with a piston member in the first clutch; and
a second clutch disposed concentrically within the fourth gear, wherein the first clutch and second clutch are configured to simultaneously engage in a parking brake mode.

8. The electric drive axle according to claim 7 , further comprising:
a second fluid conduit extending through the idler shaft and in fluid communication with a piston member in the second clutch.

9. The electric drive axle according to claim 7 , wherein:
the first fluid conduit and the second fluid conduit are disposed on opposing sides of the idler shaft.

10. An electric drive axle, comprising:
a motor output shaft including a first gear and a second gear;
an idler shaft including:
a third gear in meshed engagement with the first gear; and
a fourth gear in meshed engagement with the second gear;

a first clutch disposed at least partially concentrically within the third gear;
a first fluid conduit axially extending through the idler shaft and in fluid communication with a piston member in the first clutch; and
a needle bearing coupled to a clutch drum and a clutch hub in the first clutch.

11. The electric drive axle according to claim 10 , further comprising a second clutch disposed within the second gear.

12. The electric drive axle according to claim 11 , wherein the second clutch is axially offset from the first clutch.

13. The electric drive axle according to claim 10 , further comprising a second clutch disposed concentrically within the fourth gear, wherein the first clutch and second clutch are configured to simultaneously engage in a parking brake mode.

14. The electric drive axle according to claim 13 , further comprising a second fluid conduit extending through the idler shaft and in fluid communication with a piston member in the second clutch.

15. The electric drive axle according to claim 14 , wherein the first fluid conduit and the second fluid conduit are disposed on opposing sides of the idler shaft.

16. The electric drive axle according to claim 10 , further comprising:
a hydraulically actuated apply plate with a plurality of lugs which are adjacent to a pressure plate in the first clutch; and
a support plate including a plurality of apertures with the plurality of lugs extending therethrough.

Assignees

• Dana Automotive Systems Group

Inventors

• Engerman Eric M

Classifications

• F16H2702/04

  Combinations of a speed-change mechanism without planetary gearing with a differential for driving a vehicle drive axle · CPC title

• F16H2200/0021

  specially adapted for electric vehicles · CPC title

• F16H37/042

  change gear transmissions in group arrangement · CPC title

• B60Y2400/424

  Friction clutches · CPC title

• B60K1/00 Primary

  Arrangement or mounting of electrical propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) · CPC title