Compact electrically powered axle assembly

Patent metadata

Field	Value
Publication number	US-9783035-B1
Application number	US-201615223784-A
Country	US
Kind code	B1
Filing date	Jul 29, 2016
Priority date	Jul 29, 2016
Publication date	Oct 10, 2017
Grant date	Oct 10, 2017

Abstract

A vehicle axle assembly including an electric motor, an electric power source, a mode shift gearset, an actuator and a differential within a housing. The motor can include a first output member. The mode shift gearset can include a second output member and a shift member. The shift member can transmit torque between the first and second output members when the shift member is in a second position. The actuator can be coupled to the shift member to move the shift member between first and second positions. The differential can include a differential case and a differential gearset. The differential case can be drivingly coupled to the second output member to receive rotary power therefrom. The differential gearset can transmit rotary power between the differential case and first and second output shafts.

First claim

What is claimed is:

1. An axle assembly for a vehicle, the axle assembly comprising:
a first output shaft;
a second output shaft;
a housing;
an electric motor disposed within the housing and including a first output member;
an electric power source disposed within the housing and electrically coupled to the electric motor to provide electrical power thereto;
a mode shift gearset disposed within the housing and including a second output member and a shift member, the shift member being movable between a first position and a second position relative to the first and second output members, the shift member transmitting torque between the first and second output members when the shift member is in the second position;
an actuator disposed within the housing and coupled to the shift member, the actuator being configured to move the shift member between the first and second positions; and
a differential disposed within the housing and including a differential case and a differential gearset, the differential case being drivingly coupled to the second output member to receive rotary power therefrom, the differential gearset being configured to transmit rotary power between the differential case and the first and second output shafts.

2. The axle assembly of claim 1 , wherein the housing defines a second cavity and a third cavity separated from the second cavity, wherein the electric power source is disposed within the second cavity, and wherein the electric motor, the mode shift gearset, and the actuator are disposed within the third cavity.

3. The axle assembly of claim 2 , wherein the housing includes a first case and a second case that is fixedly mounted to the first case, wherein the first case defines the second cavity and the second case defines the third cavity.

4. The axle assembly of claim 3 , wherein the second case defines a fourth cavity that is separated from the second and third cavities, and wherein the differential is disposed within the fourth cavity.

5. The axle assembly of claim 1 , wherein the differential case is supported for rotation relative to the housing about a first axis, and the first and second output members are supported for rotation relative to the housing about a second axis that is parallel and offset from the first axis.

6. The axle assembly of claim 5 , further comprising an intermediate member disposed within the housing and supported for rotation relative to the housing about a third axis that is parallel to and offset from the first axis, the intermediate member being drivingly coupled between the second output member and the differential case to transmit rotary power therebetween.

7. The axle assembly of claim 1 , wherein the mode shift gearset includes a first input member non-rotatably coupled to the first output member, wherein the first input member includes a second set of teeth and the second output member includes a fourth set of teeth, wherein when the shift member is in the second position, the shift member engages the second and fourth sets of teeth to couple the first input member and the second output member for common rotation.

8. The axle assembly of claim 7 , wherein when the shift member is in the first position, the shift member is disengaged from either the second set of teeth or the fourth set of teeth and torque is not transmitted between the first input member and the second output member.

9. The axle assembly of claim 7 , wherein the mode shift gearset includes a third output member that is rotatable relative to the first input member and is coupled to the first input member to receive rotary power from the first input member, wherein the third output member includes a third set of teeth, and wherein when the shift member is in the first position, the shift member engages the third set of teeth and the fourth set of teeth to couple the third output member and the second output member for common rotation.

10. The axle assembly of claim 9 , wherein the mode shift gearset includes a planetary reduction gearset including a sun gear, a plurality of planet gears, and a planet carrier, wherein the first input member is non-rotatably coupled to the sun gear and the third output member is non-rotatably coupled to the planet carrier.

11. The axle assembly of claim 10 , wherein actuator is configured to move the shift member between the first position, the second position, and a third position, wherein when the shift member is in the third position, the shift member is disengaged from at least two of the second set of teeth, the third set of teeth, or the fourth set of teeth and torque is not transmitted between the first input member and the second output member.

12. An axle assembly for a vehicle, the axle assembly comprising:
a first output shaft rotatable about a first axis;
a second output shaft rotatable about the first axis;
a mode shift unit including:
a first input member rotatable about the second axis and including a first set of teeth and a second set of teeth;
a second input member rotatable about the second axis and including a third set of teeth;
a gearset coupling the first input member to the second input member such that rotation of the first input member drives rotation of the second input member at a rotational speed that is different from a rotational speed of the first input member;
an output member rotatable about the second axis and including a fourth set of teeth; and
a shift member rotatable about the second axis and axially movable along the second axis between a first axial position and a second axial position, the shift member being configured to matingly engage the second, third, and fourth sets of teeth, wherein when the shift member is in the first axial position, the shift member is disengaged from at least two of the second, third, and fourth sets of teeth, wherein when the shift member is in the second axial position, the shift member matingly engages the second and fourth sets of teeth to couple the first input member and the output member for common rotation, and wherein when the shift member is in the third axial position, the shift member matingly engages the third and fourth sets of teeth to couple the second input member and the output member for common rotation;

a linear motor coupled to the shift member and configured to move the shift member between the first, second and third axial positions; and
a differential including a differential case and a differential gearset, the differential case being drivingly coupled to the output member to receive rotary power therefrom, the differential gearset being configured to transmit rotary power between the differential case and the first and second output shafts.

13. The axle assembly of claim 12 , wherein when the shift member is in the first position, the shift member is disengaged from the second and third sets of teeth and is engaged with the fourth set of teeth.

14. The axle assembly of claim 12 , wherein when the shift member is in the first position, the shift member is disengaged from the third and fourth sets of teeth and is engaged with the second set of teeth.

15. The axle assembly of claim 12 , wherein the second, third, and fourth sets of teeth are external teeth.

16. The axle assembly of claim 15 , wherein the shift member includes a first set of internal teeth and a second set of internal teeth that are axially spaced apart from the first set of internal teeth, the first set of internal teeth being configured to engage the third set of external teeth, and the second set of internal teeth being configured to engage the fourth set of external teeth

Assignees

• American Axle & Mfg Inc

Inventors

• Huang Zugang
• Downs James P

Classifications

• F16H2200/2035

  with two engaging means · CPC title

• B60K17/16

  of differential gearing · CPC title

• F16H63/304

  the final output mechanisms comprising elements moved by electrical or magnetic force (band brake actuating mechanisms F16H63/3003) · CPC title

• B60K17/04 Primary

  characterised by arrangement, location or kind of gearing · 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