Electric vehicle drive units

Patent metadata

Field	Value
Publication number	US-2019186617-A1
Application number	US-201816220741-A
Country	US
Kind code	A1
Filing date	Dec 14, 2018
Priority date	Dec 15, 2017
Publication date	Jun 20, 2019
Grant date	—

Abstract

A dual drive unit may include two motors, two power transfer mechanisms, and two output shafts. The output shafts are co-linear. The dual drive unit may include two single drive units, which may be similar to each other, coupled together at a joint, which may optionally include a clutch. A drive unit may be modular, and various components may be combined to provide power to an output shaft. For example, a drive unit may include a differential at a first interface, which may be removable, and two drive units may be coupled together at the first interface. A drive unit may have a Z configuration, wherein a motor on a first side of a vehicle powers a wheel on an opposite side of the vehicle.

First claim

What is claimed is:

1 . A modular drive system, comprising:
a gearbox housing comprising: a motor mount configured for mounting of an electric motor; a first space within the gearbox housing capable of receiving an input gear capable of being coupled to the electric motor; a second space within the gearbox housing capable of receiving an output gear; at least one intermediate gear mounted within the first gearbox housing and configured to: mechanically interface with the input gear; and mechanically interface with the output gear; a first opening in a first side of the gearbox housing adjacent to the second space; and a second opening in a second side of the gearbox housing adjacent to the second space, wherein: the first side and the second side are opposite sides of the gearbox housing; the second opening is configured to enable an output shaft to pass through to drive a first wheel; the first opening comprises a mount configured for mounting of a differential housing and a cover plate; when the differential housing is mounted to the mount, the modular drive system is capable of driving two wheels; and when the cover plate is mounted to the mount, the modular drive system is capable of driving the first wheel.

2 . The modular drive system of claim 1 , wherein:
the at least one intermediate gear comprises a compound gear comprising a larger gear and a smaller gear; the larger gear is configured to mechanically interface with the input gear; and the smaller gear is configured to mechanically interface with the output gear.

3 . The modular drive system of claim 1 , wherein:
the gearbox housing is a first gearbox housing; the output shaft is a first output shaft having a first rotational axis; at least one of the cover plate and the gearbox housing is configured for attachment to a second gearbox housing; the second gearbox housing comprises a second output shaft having a second rotational axis; and when the second gearbox housing is attached to the first gearbox housing, the first rotational axis and the second rotational axis are aligned.

4 . The modular drive system of claim 3 , wherein:
the electric motor is a first electric motor; the second gearbox housing further comprises a motor mount configured for mounting of a second electric motor.

5 . The modular drive system of claim 4 , wherein the first gearbox housing and the second gearbox housing each provide a gear reduction between a corresponding motor shaft and corresponding output shaft.

6 . The modular drive system of claim 1 , wherein:
the gearbox housing further comprises an intermediate shaft; the at least one intermediate gear is mounted to the intermediate shaft; and the intermediate shaft is offset from a line considered to extend from a center of the input gear to a center of the output shaft.

7 . The modular drive system of claim 4 , wherein:
the first gearbox housing comprises an indentation to accommodate the second motor; and the second gearbox housing comprises an indentation to accommodate the first motor.

8 . The modular drive system of claim 4 , wherein the first output shaft rotates about a first drive axis, and wherein when the modular drive system is viewed perpendicular to the drive axis:
the first gearbox housing at least partially overlaps with the second motor; and the second gearbox housing at least partially overlaps with the first motor.

9 . The modular drive system of claim 8 , wherein:
the first gearbox housing comprises a first end proximate to a first motor shaft of the first motor and a second end proximate to the first output shaft; the second end of the first gearbox housing is located a first distance away from the first motor shaft, which is greater than a distance from the first motor shaft to an outer side surface of the first motor; the second gearbox housing comprises a first end proximate to a second motor shaft of the second motor and a second end proximate to the second output shaft; the second end of the second gearbox housing is located a second distance away from the second motor shaft, which is greater than a distance from the second motor shaft to an outer side surface of the second motor; and the second end of the first gearbox housing is adjacent to the second end of the second gearbox housing.

10 . The modular drive system of claim 9 , wherein the second end of the first gearbox housing is mechanically connected to the second end of the second gearbox housing.

11 . The modular drive system of claim 1 , wherein a motor shaft of the electric motor extends from the electric motor in a first direction and wherein the output shaft extends from the gearbox housing in the first direction.

12 . The modular drive system of claim 11 , further comprising an inverter configured to control the operation of the electric motor, wherein the inverter is aligned with the motor shaft and mechanically coupled to the gearbox housing.

13 . The modular drive system of claim 12 , wherein:
the gearbox housing is a first gearbox housing; the mount is further configured for mounting of a clutch assembly coupled to a second gearbox housing; the output shaft is a first output shaft having a first rotational axis; the second gearbox housing comprises a second output shaft having a second rotational axis; and when the clutch assembly coupled to the second gearbox housing is mounted to the mount, the first rotational axis and the second rotational axis are aligned.

14 . A method of configuring the modular drive system of claim 1 , the method comprising:
determining a desired drive configuration; mounting the differential housing to the mount when the desired configuration is a single drive configuration; and mounting the cover plate to the mount when the desired configuration is a dual drive configuration.

Assignees

• Rivian Ip Holdings Llc

Inventors

• Verbridge Mason
• Gloceri Gary

Classifications

• H02K7/003

  Couplings; Details of shafts (means for mounting rotors on shafts H02K1/28) · CPC title

• F16H57/033 Primary

  Series gearboxes, e.g. gearboxes based on the same design being available in different sizes or gearboxes using a combination of several standardised units · CPC title

• B60K1/00

  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

• B60K2001/001

  one motor mounted on a propulsion axle for rotating right and left wheels of this axle · CPC title

• H02K7/116 Primary

  with gears · CPC title