U.S. patent application number 16/594702 was filed with the patent office on 2021-04-08 for axle assembly having a multi-speed countershaft transmission.
This patent application is currently assigned to ArvinMeritor Technology, LLC. The applicant listed for this patent is ArvinMeritor Technology, LLC. Invention is credited to Chetankumar Ghatti, Christopher Keeney, Mark Smith, Rodrigo Soffner.
Application Number | 20210102609 16/594702 |
Document ID | / |
Family ID | 1000004428680 |
Filed Date | 2021-04-08 |
![](/patent/app/20210102609/US20210102609A1-20210408-D00000.png)
![](/patent/app/20210102609/US20210102609A1-20210408-D00001.png)
![](/patent/app/20210102609/US20210102609A1-20210408-D00002.png)
![](/patent/app/20210102609/US20210102609A1-20210408-D00003.png)
![](/patent/app/20210102609/US20210102609A1-20210408-D00004.png)
![](/patent/app/20210102609/US20210102609A1-20210408-D00005.png)
United States Patent
Application |
20210102609 |
Kind Code |
A1 |
Ghatti; Chetankumar ; et
al. |
April 8, 2021 |
AXLE ASSEMBLY HAVING A MULTI-SPEED COUNTERSHAFT TRANSMISSION
Abstract
An axle assembly having a countershaft transmission. A rotor
shaft may extend through a drive pinion and may operatively connect
an electric motor to a countershaft transmission. The countershaft
transmission may have a first countershaft subassembly that is
rotatable about a first countershaft axis and a second countershaft
subassembly that is rotatable about a second countershaft axis.
Inventors: |
Ghatti; Chetankumar; (Troy,
MI) ; Soffner; Rodrigo; (Osasco, BR) ; Keeney;
Christopher; (Troy, MI) ; Smith; Mark; (Troy,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ArvinMeritor Technology, LLC |
Troy |
MI |
US |
|
|
Assignee: |
ArvinMeritor Technology,
LLC
Troy
MI
|
Family ID: |
1000004428680 |
Appl. No.: |
16/594702 |
Filed: |
October 7, 2019 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16H 2200/20 20130101;
F16H 3/097 20130101; F16H 2200/0039 20130101; F16H 37/0813
20130101; B60K 2001/001 20130101; B60K 1/00 20130101; F16H 37/042
20130101; F16H 2702/04 20130101 |
International
Class: |
F16H 37/08 20060101
F16H037/08; F16H 3/097 20060101 F16H003/097; B60K 1/00 20060101
B60K001/00; F16H 37/04 20060101 F16H037/04 |
Claims
1. An axle assembly comprising: an electric motor having a rotor
that is rotatable about a first axis; a drive pinion that is
rotatable about the first axis; a rotor shaft that extends through
the drive pinion and is operatively connected to the rotor; a
countershaft transmission that operatively connects the rotor shaft
to the drive pinion, the countershaft transmission having a first
countershaft subassembly that is rotatable about a first
countershaft axis and a second countershaft subassembly that is
rotatable about a second countershaft axis; and differential
assembly that is rotatable about a second axis, wherein the
differential assembly is positioned between the electric motor and
the countershaft transmission such that the electric motor and the
countershaft transmission are positioned on opposite sides of the
second axis.
2. The axle assembly of claim 1 wherein the differential assembly
is operatively connected to the drive pinion.
3. The axle assembly of claim 9 wherein a differential assembly
that is rotatable about a second axis is positioned between the
electric motor and the countershaft transmission such that the
electric motor and the countershaft transmission are positioned on
opposite sides of the second axis.
4. The axle assembly of claim 1 wherein the rotor shaft is
operatively connected to a first gear of the countershaft
transmission.
5. The axle assembly of claim 4 wherein the drive pinion has a gear
portion and a shaft portion that extends from the gear portion,
wherein the first gear is disposed along the first axis and faces
toward an end of the shaft portion that is disposed opposite the
gear portion.
6. The axle assembly of claim 4 further comprising a first clutch
that selectively couples the first gear to the drive pinion,
wherein torque is transmitted between the electric motor and the
drive pinion via the first gear when the first clutch couples the
first gear to the drive pinion such that the first gear rotates
about the first axis with the drive pinion.
7. The axle assembly of claim 4 wherein the first countershaft
subassembly includes a first countershaft and a first countershaft
gear that are rotatable about the first countershaft axis, the
second countershaft subassembly includes a second countershaft and
a first countershaft gear that are rotatable about the second
countershaft axis, and the first gear meshes with the first
countershaft gear of the first countershaft subassembly and the
first countershaft gear of the second countershaft subassembly.
8. The axle assembly of claim 7 further comprising a second gear
through which the drive pinion and the rotor shaft extend, wherein
the second gear is selectively couplable to the drive pinion.
9. An axle assembly comprising: an electric motor having a rotor
that is rotatable about a first axis; a drive pinion that is
rotatable about the first axis; a rotor shaft that extends through
the drive pinion and is operatively connected to the rotor; a
countershaft transmission that operatively connects the rotor shaft
to the drive pinion, the countershaft transmission having a first
countershaft subassembly that is rotatable about a first
countershaft axis and a second countershaft subassembly that is
rotatable about a second countershaft axis, wherein the first
countershaft subassembly includes a first countershaft and a first
countershaft gear that are rotatable about the first countershaft
axis, the second countershaft subassembly includes a second
countershaft and a first countershaft gear that are rotatable about
the second countershaft axis; a first gear that is operatively
connected to the rotor shaft and that meshes with the first
countershaft gear of the first countershaft subassembly and the
first countershaft gear of the second countershaft subassembly, and
a second gear through which the drive pinion and the rotor shaft
extend, wherein the second gear is selectively couplable to the
drive pinion and the second gear is positioned along the first axis
between the first gear and the electric motor.
10. The axle assembly of claim 8 wherein the first countershaft
subassembly includes a second countershaft gear that is rotatable
about the first countershaft axis, the second countershaft
subassembly includes a second countershaft gear that is rotatable
about the second countershaft axis, and the second gear meshes with
the second countershaft gear of the first countershaft subassembly
and the second countershaft gear of the second countershaft
subassembly.
11. The axle assembly of claim 10 further comprising a first clutch
that selectively couples the second gear to the drive pinion,
wherein torque is transmitted between the electric motor and the
drive pinion via the second gear when the first clutch does not
couple the first gear to the drive pinion and the first clutch
couples the second gear to the drive pinion such that the second
gear rotates about the first axis with the drive pinion.
12. The axle assembly of claim 10 further comprising a first clutch
that selectively couples the first gear to the drive pinion, and a
second clutch that selectively couples the second gear to the drive
pinion, wherein torque is transmitted between the electric motor
and the drive pinion via the second gear when the first clutch does
not couple the first gear to the drive pinion and the second clutch
couples the second gear to the drive pinion such that the second
gear rotates about the first axis with the drive pinion.
13. The axle assembly of claim 8 further comprising a third gear
through which the drive pinion and the rotor shaft extend, wherein
the third gear is selectively couplable to the drive pinion.
14. An axle assembly comprising: an electric motor having a rotor
that is rotatable about a first axis; a drive pinion that is
rotatable about the first axis; a rotor shaft that extends through
the drive pinion and is operatively connected to the rotor; a
countershaft transmission that operatively connects the rotor shaft
to the drive pinion, the countershaft transmission having a first
countershaft subassembly that is rotatable about a first
countershaft axis and a second countershaft subassembly that is
rotatable about a second countershaft axis, wherein the first
countershaft subassembly includes a first countershaft and a first
countershaft gear that are rotatable about the first countershaft
axis, the second countershaft subassembly includes a second
countershaft and a first countershaft gear that are rotatable about
the second countershaft axis; a first gear that is operatively
connected to the rotor shaft and the meshes with the first
countershaft gear of the first countershaft subassembly and the
first countershaft gear of the second countershaft subassembly; a
second gear through which the drive pinion and the rotor shaft
extend; and a third gear through which the drive pinion and the
rotor shall extend, wherein the third gear is positioned closer to
the electric motor than the second gear and the second gear is
positioned along the first axis between the first gear and the
third gear.
15. The axle assembly of claim 13 wherein the first countershaft
subassembly includes a third countershaft gear that is rotatable
about the first countershaft axis, the second countershaft
subassembly includes a third countershaft gear that is rotatable
about the second countershaft axis, and the third gear meshes with
the third countershaft gear of the first countershaft subassembly
and the third countershaft gear of the second countershaft
subassembly.
16. The axle assembly of claim 15 wherein a first gear ratio is
provided when the first gear is coupled to the drive pinion, a
second gear ratio is provided when the second gear is coupled to
the drive pinion, and a third gear ratio is provided when the third
gear is coupled to the drive pinion, wherein the first gear ratio
differs from the second gear ratio and the third gear ratio, and
the second gear ratio differs from the third gear ratio.
17. An axle assembly comprising: an electric motor haying a rotor
that is rotatable about a first axis; a drive pinion that is
rotatable about the first axis; a rotor shaft that extends through
the drive pinion and is operatively connected to the rotor; a
countershaft transmission that operatively connects the rotor shaft
to the drive pinion, the countershaft transmission having a first
countershaft subassembly that is rotatable about a first
countershaft axis and a second countershaft subassembly that is
rotatable about a second countershaft axis, wherein the first
countershaft subassembly includes a first countershaft and a first
countershaft gear that are rotatable about the first countershaft
axis the second countershaft subassembly includes a second
countershaft and a first countershaft gear that are rotatable about
the second countershaft axis; a first gear that is operatively
connected to the rotor shaft and that meshes with the first
countershaft gear of the first countershaft subassembly and the
first countershaft gear of the second countershaft subassembly; a
second gear through which the drive pinion and the rotor shaft
extend; a third gear through which the drive pinion and the rotor
shaft extend; a first clutch that selectively couples the first
gear to the drive pinion; and a second clutch that selectively
couples the third gear to the drive pinion, wherein torque is
transmitted between the electric motor and the drive pinion via the
third gear when the first clutch does not couple the first gear to
the drive pinion and the second clutch couples the third gear to
the drive pinion such that the third gear rotates about the first
axis with the drive pinion.
18. The axle assembly of claim 17 wherein torque is not transmitted
between the electric motor and the drive pinion when the first
clutch is in a neutral position in which the first gear is
rotatable about the first axis with respect to the drive pinion and
the second clutch is in a neutral position in which the second gear
and the third gear are rotatable about the first axis with respect
to the drive pinion.
19. The axle assembly of claim 17 wherein the first clutch is
axially positioned between the first gear and the second gear and
the second clutch is axially positioned between the second gear and
the third gear, wherein the first clutch receives the drive pinion
and is rotatable about the first axis with the drive pinion and the
second clutch receives the drive pinion and is rotatable about the
first axis with the drive pinion.
20. The axle assembly of claim 17 wherein a first actuator actuates
the first clutch along the first axis and a second actuator
actuates the second clutch along the first axis.
Description
TECHNICAL FIELD
[0001] This disclosure relates to an axle assembly having a
multi-speed countershaft transmission that may operatively connect
an electric motor to a drive pinion. A rotor shaft may extend
through the drive pinion.
BACKGROUND
[0002] An axle assembly having an electric motor module is
disclosed in Patent Publication No. 2019/0054816.
SUMMARY
[0003] In at least one embodiment, an axle assembly is provided.
The axle assembly may include an electric motor, a drive pinion, a
rotor shaft, and a countershaft transmission. The electric motor
may have a rotor that may be rotatable about the first axis. The
drive pinion may be rotatable about the first axis. The rotor shaft
may extend through the drive pinion and may be operatively
connected to the rotor. The countershaft transmission may
operatively connect the rotor shaft to the drive pinion. The
countershaft transmission may have a first countershaft subassembly
that is rotatable about a first countershaft axis and a second
countershaft subassembly that is rotatable about a second
countershaft axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] FIG. 1 shows an example of an axle assembly having a
countershaft transmission in a neutral position.
[0005] FIG. 2 illustrates the axle assembly with a first gear ratio
engaged.
[0006] FIGS. 3A and 3B illustrate the axle assembly with a second
gear ratio engaged.
[0007] FIG. 4 illustrates the axle assembly with a third gear ratio
engaged.
DETAILED DESCRIPTION
[0008] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention that
may be embodied in various and alternative forms. The figures are
not necessarily to scale; some features may be exaggerated or
minimized to show details of particular components. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting, hut merely as a representative basis
for teaching one skilled in the art to variously employ the present
invention.
[0009] Referring to FIG. 1, an example of an axle assembly 10 is
shown. The axle assembly 10 may be provided with a motor vehicle
like a car, truck, bus, farm equipment, mining equipment, military
transport or weaponry vehicle, or cargo loading equipment for land,
air, or marine vessels. The motor vehicle may include a trailer for
transporting cargo in one or more embodiments.
[0010] The axle assembly 10 may provide torque to one or more
traction wheel assemblies that may include a tire 12 mounted on a
wheel 14. One or more axle assemblies may be provided with the
vehicle. In at least one configuration, the axle assembly 10 may
include a housing assembly 20, an electric motor 22, a drive pinion
24, a rotor shaft 26, a countershaft transmission 28, a
differential assembly 30, at least one axle shall 32, and a control
system 34.
[0011] The housing assembly 20 may facilitate mounting of the axle
assembly 10 to the vehicle. In addition, the housing assembly 20
may receive various components of the axle assembly 10. For
example, the housing assembly 20 may receive and support the
electric motor 22, the drive pinion 24, the rotor shaft 26, the
countershaft transmission 28, the differential assembly 30, the
axle shafts 32, or combinations thereof In at least one
configuration, the housing assembly 20 may include an axle housing
40 that may have a center portion 42 and one or more arm portions
44.
[0012] The center portion 42 may be disposed proximate the center
of the housing assembly 20. The center portion 42 may at least
partially define a cavity that may receive the differential
assembly 30. The center portion 42 may be made of one or more
components and may facilitate mounting of a differential carrier
that supports the differential assembly 30. A lower region of the
center portion 42 may at least partially define a sump portion that
may contain lubricant that may be splashed to lubricate internal
components of the axle assembly 10, such as the differential
assembly 30 and associated bearings. The center portion 42 may also
facilitate mounting of various external components. For instance,
the center portion 42 may facilitate mounting of the electric motor
22 and the countershaft transmission 28 to the housing assembly
20.
[0013] One or more arm portions 44 may extend from the center
portion 42. For example, two arm portions 44 may extend in opposite
directions from the center portion 42 and away from the
differential assembly 30. The arm portions 44 may have
substantially similar configurations. For example, the arm portions
44 may each have a hollow configuration or tubular configuration
that may extend around a corresponding axle shaft 32 and may help
separate or isolate the axle shaft 32 from the surrounding
environment. An arm portion 44 or a portion thereof may be
integrally formed with the center portion 42. Alternatively, an arm
portion 44 may be separate from the center portion 42. In such a
configuration, each arm portion 44 may be attached to the center
portion 42 in any suitable manner, such as by welding or with one
or more fasteners. Each arm portion 44 may define an arm cavity
that may receive a corresponding axle shaft 32. It is also
contemplated that the arm portions 44 may be omitted.
[0014] The electric motor 22 may provide torque to the differential
assembly 30 via the rotor shaft 26, the countershaft transmission
28, and the drive pinion 24. In addition, the electric motor 22 may
be electrically connected to an electrical power source 50, such as
a battery, capacitor, or the like. An inverter may electrically
connect the electric motor 22 and the electrical power source 50.
The electric motor 22 may have any suitable configuration. In at
least one configuration, the electric motor 22 may include a stator
52 and a rotor 54.
[0015] The stator 52 may be fixedly positioned with respect to the
housing assembly 20. For example, the stator 52 may extend around a
first axis 60 and may not rotate about the first axis 60. The
stator 52 may include windings that may be electrically connected
to the electrical power source 50.
[0016] The rotor 54 may extend around the first axis 60 and may be
received inside the stator 52. The rotor 54 may be rotatable about
the first axis 60 with respect to the stator 52. For example, the
rotor 54 may be spaced apart from the stator 52 and may include
magnets or ferromagnetic material that may facilitate the
generation of electrical current. The rotor 54 may be operatively
connected to the countershaft transmission 28 via, the rotor shaft
26 as will be discussed in more detail below.
[0017] The drive pinion 24 may be at least partially received in
the housing assembly 20. The drive pinion 24 may be selectively
connected to the electric motor 22. As such, the drive pinion 24
may help operatively connect the electric motor 22 to components of
the axle assembly 10 like the differential assembly 30. The drive
pinion 24 may extend along and may be rotatable about a first axis
60. The drive pinion 24 may be indirectly connected to the electric
motor 22 via the rotor shaft 26 and the countershaft transmission
28. In at least one configuration, the drive pinion 24 may include
a gear portion 70, a shaft portion 72, and a through hole 74.
[0018] The gear portion 70 may be disposed at or near an end of the
drive pinion 24. The gear portion 70 may have a plurality of teeth
that may mate or mesh with corresponding teeth on a ring gear of
the differential assembly 30 as will be discussed in more detail
below. As such, the drive pinion 24 may provide torque from the
electric motor 22 to the ring gear.
[0019] The shall portion 72 may extend along and may be rotatable
about the first axis 60 with the gear portion 70. The shaft portion
72 may be operatively connected to the countershaft transmission 28
and may extend from the gear portion 70 in a direction that may
extend away from the electric motor 22 and that may extend toward
the countershaft transmission 28. The shaft portion 72 may be
integrally formed with the gear portion 70 or may be provided as a
separate component that may be fixedly coupled to the gear portion
70.
[0020] The through hole 74 may extend through the drive pinion 24.
The through hole 74 may be defined by the gear portion 70 and the
shaft portion 72 and may extend from a first end of the drive
pinion 24 to a second end of the drive pinion 24 that may be
disposed opposite the first end. The through hole 74 may extend
along the first axis 60. In addition, the through hole 74 may be
centered about the first axis 60.
[0021] The rotor shaft 26 may operatively connect the electric
motor 22 to the countershaft transmission 28. For example, the
rotor shaft 26 may extend from the rotor 54 or may be operatively
connected to the rotor 54 such that the rotor 54 and the rotor
shaft 26 may be rotatable together about the first axis 60. The
rotor shaft 26 may be fixedly coupled to the rotor 54 at or
proximate a first end, may extend into or through the through hole
74 of the drive pinion 24, and may be fixedly coupled to the
countershaft transmission 28 at a second end that may be disposed
opposite the first end.
[0022] The countershaft transmission 28 may operatively connect the
electric motor 22 to the drive pinion 24. The countershaft
transmission 28 may be spaced apart from the electric motor 22 such
that the differential assembly 30 may be positioned along the first
axis 60 between the countershaft transmission 28 and the
differential assembly 30. In at least one configuration, the
countershaft transmission 28 may include a set of drive pinion
gears 80, a first countershaft subassembly 82, and a second
countershaft subassembly 84.
[0023] The set of drive pinion gears 80 may include a plurality of
gears that may be selectively coupled to the drive pinion 24. In
the configuration shown, the set of drive pinion gears 80 includes
a first gear 92, a second gear 94, and a third gear 96; however, it
is to be understood that a greater or lesser number of gears may be
provided. A member of the set of drive pinion gears 80 may be
rotatable about the first axis 60 with the drive pinion 24 When
that gear is coupled to the drive pinion 24. Conversely, the drive
pinion 24 may be rotatable about the first axis 60 with respect to
a member of the set of drive pinion gears 80 that is decoupled from
or not coupled to the drive pinion 24. A member of the set of drive
pinion gears 80 may be selectively coupled to the drive pinion 24
in any suitable manner, such as with a clutch as will be discussed
in more detail below. In at least one configuration, no more than
one gear of the set of drive pinion gears 80 may be coupled to the
drive pinion 24 at the same time when the drive pinion 24 rotates
about the first axis 60.
[0024] The first gear 92 may be disposed proximate an end of the
drive pinion 24 that faces away from electric motor 22. For
instance, the first gear 92 may be disposed proximate the end of
the shaft portion 72 of the drive pinion 24 that is disposed
opposite the gear portion 70 of the drive pinion 24. The first gear
92 may face toward the end of the shaft portion 72 and may or may
not receive the shaft portion 72. In at least one configuration,
the first gear 92 may not have a through hole through which the
shall portion 72 may extend and may intersect the first axis 60.
The first gear 92 may have a plurality of teeth that may be
arranged around and may face away from the first axis 60. The teeth
of the first gear 92 may contact and may mate or mesh with teeth of
a first countershaft gear that may be provided with the first
countershaft subassembly 82 and the second countershaft subassembly
84 as will be discussed in more detail below. The first gear 92 may
be operatively connected to the rotor 54 of the electric motor 22
such that the rotor 54, the rotor shaft 26, and the first gear 92
are rotatable together about the first axis 60. For example, the
first gear 92 may be fixedly coupled to the rotor shaft 26 such
that the first gear 92 does not rotate about the first axis 60 with
respect to the rotor shaft 26. In at least one configuration, the
first gear 92 may be axially positioned along the first axis 60
such that the first gear 92 is positioned further from the electric
motor 22 and the differential assembly 30 than some or all of the
other members of the set of drive pinion gears 80.
[0025] The second gear 94 may receive the shaft portion 72 of the
drive pinion 24. For example, the second gear 94 may have a through
hole through which the shaft portion 72 may extend. The second gear
94 may extend around the first axis 60 and the shaft portion 72 and
may have a plurality of teeth that may be arranged around and may
face away from the first axis 60. The teeth of the second gear 94
may contact and may mate or mesh with teeth of a second
countershaft gear that may be provided with the first countershaft
subassembly 82 and the second countershaft subassembly 84 as will
be discussed in more detail below. The second gear 94 may have a
different diameter than the first gear 92 and the third gear 96.
For example, the second gear 94 may have a larger diameter than the
first gear 92 and a smaller diameter than the third gear 96. In at
least one configuration, the second gear 94 may be axially
positioned along the first axis 60 between the first gear 92 and
the third gear 96.
[0026] The third gear 96 may receive the shaft portion 72 of the
drive pinion 24. For example, the third gear 96 may have a through
hole through which the shaft portion 72 may extend. The third gear
96 may extend around the first axis 60 and the shaft portion 72 and
may have a plurality of teeth that may be arranged around and may
face away from the first axis 60. The teeth of the third gear 96
may contact and may mate or mesh with teeth of a third countershaft
gear that may be provided with the first countershaft subassembly
82 and the second countershaft subassembly 84 as will be discussed
in more detail below. The third gear 96 may have a different
diameter than the first gear 92 and the second gear 94. For
example, the third gear 96 may have a larger diameter than the
first gear 92 and the second gear 94. In at least one
configuration, the third gear 96 be axially positioned along the
first axis 60 closer to the electric motor 22 and the differential
assembly 30 than the first gear 92 and the second gear 94.
[0027] Optionally, a bearing such as a roller bearing may receive
the shaft portion 72 and may rotatably support a corresponding
gear. For instance, a bearing may be received between the second
gear 94 and the shaft portion 72 and/or a bearing between the third
gear 96 and the shaft portion 72 to facilitate rotation of the
drive pinion 24 with respect to a gear when the gear is not coupled
to the drive pinion 24.
[0028] The first countershaft subassembly 82 may be at least
partially received in the housing assembly 20. The first
countershaft subassembly 82 may be rotatable about a first
countershaft axis 100. The first countershaft axis 100 may be
disposed parallel or substantially parallel to the first axis 60 in
one or more embodiments. The first countershaft subassembly 82 may
include a first countershaft 110 and a plurality of gears. In the
configuration shown, the plurality of gears of the first
countershaft subassembly 82 include a first countershaft gear 112,
a second countershaft gear 114, and a third countershaft gear 116;
however, it is contemplated that a greater number of gears or a
lesser number of gears may be provided.
[0029] The first countershaft 110 may be rotatable about the first
countershaft axis 100. For instance, the first countershaft 110 may
be rotatably supported on the housing assembly 20 by one or more
roller bearing assemblies. As an example, a roller bearing assembly
may be located near opposing first and second ends the first
countershaft 110. The roller bearing assembly may have any suitable
configuration. For instance, the roller bearing assembly may
include a plurality of rolling elements that may be disposed
between an inner race and an outer race. The inner race may be
mounted to the first countershaft 110 and may extend around and may
receive the first countershaft 110. The outer race may extend
around the inner race and may be mounted to the housing assembly
20. The first countershaft 110 may support the first countershaft
gear 112, the second countershaft gear 114, and the third
countershaft gear 116.
[0030] The first countershaft gear 112 may be fixedly disposed on
the first countershaft 110 or fixedly mounted to the first
countershaft 110. As such, the first countershaft gear 112 may
rotate about the first countershaft axis 100 with the first
countershaft 110. For example, the first countershaft gear 112 may
have a hole that may receive the first countershaft 110 and may be
fixedly coupled to the first countershaft 110. The first
countershaft gear 112 may extend around the first countershaft axis
100 and may have a plurality of teeth that may be arranged around
and may face away from the first countershaft axis 100. The teeth
of the first countershaft gear 112 may contact and may mate or mesh
with the teeth of the first gear 92. In at least one configuration,
the first countershaft gear 112 may be axially positioned along the
first countershaft axis 100 further from the electric motor 22 and
the differential assembly 30 than the second countershaft gear 114
and the third countershaft gear 116 of the first countershaft
subassembly 82.
[0031] The second countershaft gear 114 may be fixedly disposed on
the first countershaft 110 or fixedly mounted to the first
countershaft 110. As such, the second countershaft gear 114 may
rotate about the first countershaft axis 100 with the first
countershaft 110. For example, the second countershaft gear 114 may
have a hole that may receive the first countershaft 110 and may be
fixedly coupled to the first countershaft 110. The second
countershaft gear 114 may extend around the first countershaft axis
100 and may have a plurality of teeth that may be arranged around
and may face away from the first countershaft axis 100. The teeth
of the second countershaft gear 114 may contact and may mate or
mesh with the teeth of the second gear 94. The second countershaft
gear 114 may have a different diameter than the first countershaft
gear 112 and the third countershaft gear 116. In at least one
configuration, the second countershaft gear 114 may be axially
positioned along the first countershaft axis 100 between the first
countershaft gear 112 of the first countershaft subassembly 82 and
the third countershaft gear 116 of the first countershaft
subassembly 82.
[0032] The third countershaft gear 116 may be fixedly disposed on
the first countershaft 110 or fixedly mounted to the first
countershaft 110. As such, the third countershaft gear 116 may
rotate about the first countershaft axis 100 with the first
countershaft 110. For example, the third countershaft gear 116 may
have a hole that may receive the first countershaft 110 and may be
fixedly coupled to the first countershaft 110. The third
countershaft gear 116 may extend around the first countershaft axis
100 and may have a plurality of teeth that may be arranged around
and may face away from the first countershaft axis 100. The teeth
of the third countershaft gear 116 may contact and may mate or mesh
with the teeth of the third gear 96. The third countershaft gear
116 may have a different diameter than the first countershaft gear
112 and the second countershaft gear 114. In at least one
configuration, the third countershaft gear 116 may be axially
positioned along the first countershaft axis 100 between the second
countershaft gear 114 of the first countershaft subassembly 82 and
the electric motor 22.
[0033] The second countershaft subassembly 84 may be at least
partially received in the housing assembly 20 and may be rotatable
about a second countershaft axis 100'. The second countershaft axis
100' may be disposed parallel or substantially parallel to the
first countershaft axis 100 in one or more embodiments. The second
countershaft subassembly 84 may be spaced apart from the
differential assembly 30 such that the differential assembly 30 may
be positioned along the first axis 60 between the second
countershaft subassembly 84 and the electric motor 22. The second
countershaft subassembly 84 may generally be disposed on an
opposite side of the first axis 60 from the first countershaft
subassembly 82 or may be disposed directly opposite the first
countershaft subassembly 82. Moreover, the second countershaft
subassembly 84 may have substantially the same configuration as the
first countershaft subassembly 82. For example, the second
countershaft subassembly 84 may include a second countershaft 110'
that may be analogous to or may have the same structure as the
first countershaft 110. In addition, the second countershaft
subassembly 84 may include a plurality of gears. In the
configuration shown, the plurality of gears of the second
countershaft subassembly 84 include a first countershaft gear 112',
a second countershaft gear 114', and a third countershaft gear
116'; however, it is contemplated that a greater number of gears or
a lesser number of gears may be provided. The first countershaft
gear 112', a second countershaft gear 114', and a third
countershaft gear 116' of the second countershaft subassembly 84
may be analogous to or may have the same structure as the first
countershaft gear 112, a second countershaft gear 114, and a third
countershaft gear 116, respectively, of the first countershaft
subassembly 82 and may be arranged along second countershaft axis
100' rather than the first countershaft axis 100 and may be fixed
to the second countershaft 110' rather than the first countershaft
110.
[0034] The first gear 92 and the first countershaft gears 112, 112'
may provide a different gear ratio than the second gear 94 and the
second countershaft gears 114, 114' and may provide a different
gear ratio than the third gear 96 and the third countershaft gears
116, 116'. As a non-limiting example, the first gear 92 and the
first countershaft gears 112, 112' may provide a gear ratio of more
than 2:1, the second gear 94 and the second countershaft gears 114,
114' may provide a gear ratio from 1:1 to 2:1, and the third gear
96 and the third countershaft gears 116, 116' may provide a gear
ratio of 1:1 or less. For instance, the first countershaft gears
112, 112' may have a larger diameter than the first gear 92, the
second countershaft gears 114, 114', and the third countershaft
gears 116, 116'. The second countershaft gears 114, 114' may have a
larger diameter than the second gear 94 and the third countershaft
gears 116, 116'. The third gear 96 may have the same diameter as
the third countershaft gears 116, 116'.
[0035] It is also contemplated that other gear configurations may
be provided. As one example, the first gear 92 may have a larger
diameter than the second gear 94 and the third gear 96. As another
example, gears or gear pairings may be arranged in different
sequences along their respective axes. As another example, multiple
meshing gear pairings or no gear pairings may provide "overdrive"
gear ratios of less than 1:1. As another example, multiple meshing
gear pairings may provide gear ratios of greater than 1:1. As such,
gear ratios may be provided that are greater than 1:1, less than
1:1, equal (i.e., 1:1), or combinations thereof.
[0036] The teeth of the countershaft transmission gears may be of
any suitable type. As a non-limiting example, the meshing teeth of
the members of the set of drive pinion gears 80 and the gears of
the first countershaft subassembly 82 and the second countershaft
subassembly 84 may have a helical configuration.
[0037] The differential assembly 30 may be at least partially
received in the center portion 42 of the housing assembly 20. The
differential assembly 30 may transmit torque to the vehicle
traction wheel assemblies and permit the traction wheel assemblies
to rotate at different velocities. For example, the differential
assembly 30 may be operatively connected to the axle shafts 32 and
may permit the axle shafts 32 to rotate at different rotational
speeds about a second axis 120. The second axis 120 may be disposed
perpendicular or substantially perpendicular to the first axis 60.
Moreover, the electric motor 22 may be positioned on an opposite
side of the differential assembly 30, the second axis 120, or both
from the drive pinion 24, the countershaft transmission 28, or
both. In at least one configuration, the differential assembly 30
may include a differential case 130, a ring gear 132, a first
differential gear 134, a second differential gear 136, and at least
one pinion gear 138.
[0038] The differential case 130 may be configured to receive
components of the differential assembly 30. In addition, the
differential case 130 may be rotatable about the second axis 120.
For example, the differential case 130 may be rotatably supported
by a pair of roller bearing assemblies, which in turn may be
mounted to a portion of the housing assembly 20, such as a
differential carrier. The differential case 130 may at least
partially define a cavity that may at least partially receive the
first differential gear 134, second differential gear 136, and
pinion gear(s) 138.
[0039] The ring gear 132 may be fixedly disposed on the
differential case 130 or fixedly mounted to the differential case
130. As such, the ring gear 132 may rotate about the second axis
120 with the differential case 130. The ring gear 132 may extend
around the second axis 120 and may have a plurality of teeth that
may be arranged around and may face away from the second axis 120.
The teeth of the ring gear 132 may contact and mate or mesh with
teeth of the gear portion 70 of the drive pinion 24. As such,
torque may be transmitted between the countershaft transmission 28
and the differential assembly 30 via the meshing teeth of the drive
pinion 24 and the ring gear 132.
[0040] The first differential gear 134 may be disposed in the
differential ease 130. In addition, the first differential gear 134
may be coupled to an axle shaft 32 such that the axle shaft 32 and
the first differential gear 134 are rotatable together about the
second axis 120. The first differential gear 134 may be coupled to
the axle shaft 32 in any suitable manner. For instance, the first
differential gear 134 may have a hole that may receive the axle
shaft 32 and the axle shaft 32 and first differential gear 134 may
be coupled with mating splines, a weld, fastener, or the like. The
first differential gear 134 may also have gear portion that may
have a set of teeth that may be arranged around the second axis 120
and that may mate or mesh with teeth on one or more pinion gears
138.
[0041] The second differential gear 136 may be disposed in the
differential case 130. The second differential gear 136 may be
spaced apart from the first differential gear 134 and may have a
similar or identical configuration as the first differential gear
134. As such, the second differential gear 136 may be coupled to
another axle shaft 32 in any suitable manner such that the axle
shaft 32 and the second differential gear 136 are rotatable
together about the second axis 120. The second differential gear
136 may also have gear portion that may have a set of teeth that
may be arranged around the second axis 120 and that may mate or
mesh with teeth on one or more pinion gears 138.
[0042] At least one pinion gear 138 may be received in the
differential case 130. A pinion gear 138 may include a set of teeth
that mate or mesh with teeth on the first differential gear 134 and
teeth on the second differential gear 136. In addition, a pinion
gear 138 may be rotatable with respect to the differential case 130
or rotatably mounted on the differential case 130. For instance, a
pinion gear 138 may receive and may be rotatable about a shaft or a
spider that may extend from or may be mounted to the differential
case 130 such that the shaft or spider is rotatable about the
second axis 120 with the differential case 130.
[0043] The axle shafts 32 may transmit torque from the differential
assembly 30 to corresponding traction wheel assemblies. For
example, two axle shafts 32 may be provided such that each axle
shaft 32 extends into or through a different arm portion 44 of
housing assembly 20. The axle shafts 32 may extend along and may be
rotatable about the second axis 120. Each axle shaft 32 may have a
first end and a second end. The first end may be operatively
connected to the differential assembly 30. The second end may be
disposed opposite the first end and may be operatively connected to
a corresponding wheel end assembly that may have a wheel hub that
may support a wheel 14. Optionally, gear reduction may be provided
between an axle shaft 32 and a wheel 14, such as with a gear
reduction unit 140 having any suitable configuration. For instance,
the gear reduction unit 140 may be configured with bevel gears or a
planetary gear set in a manner known by those skilled in the
art.
[0044] The control system 34 may control operation of the axle
assembly 10. The control system 34 may include one or more
electronic controllers, such as a microprocessor-based controller,
that may monitor and/or control operation of various components of
the axle assembly 10, such as the electric motor 22 and the
electrical power source 50. In addition, the control system 34 may
control coupling and decoupling of the gears of the set of drive
pinion gears 80 to and from the drive pinion 24. For instance, the
control system 34 may control operation of one or more clutches
that may couple/decouple at least one member of the set of drive
pinion gears 80 to/from the drive pinion 24.
[0045] A clutch may have any suitable configuration. The clutch may
be configured as a disc clutch that may include friction discs that
may be selectively engaged to couple a gear to a corresponding
shaft. Alternatively, the clutch may be configured as a dog clutch
or clutch collar that may receive, rotate with, and slide along a
corresponding shaft to selectively couple and decouple one or more
members of the set of drive pinion gears 80 to the drive pinion 24.
For example, a clutch that is configured as a dog clutch or a
clutch collar may have a through hole that may receive the shaft
portion 72 of the drive pinion 24 and may rotate about the first
axis 60 with the shaft portion 72. For instance, the clutch and
shall portion 72 may have mating splines that inhibit rotation of
the clutch with respect to the shaft portion 72 while allowing the
clutch to slide in an axial direction along the first axis 60 with
respect to the shall portion 72 to engage or disengage a member of
the set of drive pinion gears 80. Such a clutch may have a tooth or
teeth that may be configured to selectively mate or mesh with
corresponding teeth on a member of the set of drive pinion gears 80
to couple the gear to the shaft portion 72 such that the gear
rotates about the first axis 60 with the drive pinion 24. The tooth
or teeth of the clutch may be configured as a face gear that may be
disposed along a lateral side of the clutch or may be configured
like a spline and may be received inside a hole of a member of the
set of drive pinion gears 80. Clutches will primarily be described
below as having a dog clutch or clutch collar configuration;
however, it is to be understood that a clutch may have a different
configuration and may not be configured as a dog clutch or a clutch
collar, that a different number of clutches may be provided, and
that clutches may be associated with a single member of the set of
drive pinion gears 80 rather than multiple drive pinion gears or
vice versa.
[0046] In at least one configuration, a first clutch 150 and a
second clutch 152 may be provided. The first clutch 150 may be
axially positioned along the first axis 60 between the first gear
92 and the second gear 94 while the second clutch 152 may be
axially positioned between the second gear 94 and the third gear
96. The first clutch 150 and the second clutch 152 may be
configured to selectively couple a single gear or multiple gears to
the drive pinion 24 as will be discussed in more detail below. It
is contemplated that a single actuator may be provided to actuate
multiple clinches, like the first clutch 150 and the second clutch
152 or that different actuators may actuate different clutches.
[0047] The first clutch 150 may be operatively connected to a first
actuator 160 that may be configured to move the first clutch 150
along the first axis 60. For example, a linkage 162, such as a
shift fork, may operatively connect the first clutch 150 to the
first actuator 160. The first actuator 160 may be of any suitable
type. For example, the first actuator 160 may be an electrical,
electromechanical, pneumatic, or hydraulic actuator. In at least
one configuration, such as when the first clutch 150 is a clutch
collar or dog clutch, the first actuator 160 may move the first
clutch 150 along the first axis 60 and may execute a shift when the
rotational speed of the first clutch 150 and a corresponding member
of the set of drive pinion gears 80 are sufficiently synchronized
to complete a shift so that the teeth of the first clutch 150 may
mesh with teeth on a drive pinion gear or so that the teeth of the
first clutch 150 gear may disengage from teeth on a drive pinion
gear. The control system 34 may monitor and/or control operation of
the first actuator 160.
[0048] The second clutch 152 may be operatively connected to a
second actuator 170 that may be configured to move the second
clutch 152 along the first axis 60. It is also contemplated that a
single actuator may be provided to actuate multiple clutches, like
the first clutch 150 and the second clutch 152. For example, a
linkage 172, such as a shift fork, may operatively connect the
second clutch 152 to the second actuator 170. The second actuator
170 may be of any suitable type. For example, the second actuator
170 may be an electrical, electromechanical, pneumatic, or
hydraulic actuator. In at least one configuration, such as when the
second clutch 152 is a clutch collar or dog clutch, the second
actuator 170 may move the second clutch 152 along the first axis 60
and may execute a shift when the rotational speed of the second
clutch 152 and a corresponding member of the set of drive pinion
gears 80 are sufficiently synchronized to complete a shift so that
the teeth of the second clutch 152 may mesh with teeth on a drive
pinion gear or so that the teeth of the second clutch 152 gear may
disengage from teeth on a drive pinion gear. The control system 34
may monitor and/or control operation of the second actuator
170.
[0049] Sufficient synchronization to permit shifting or movement of
a clutch, like the first clutch 150 or the second clutch 152, may
be attained using a gear synchronizer, by controlling the
rotational speed of the rotor 54, or combinations thereof. Such
synchronization components or control actions may be omitted with
different clutch configurations, such as a clutch that is a disc
clutch.
[0050] Referring to FIGS. 1-4, examples of different clutch
positions are shown. The control system 34 may actuate the first
clutch 150 and the second clutch 152 to a desired position based on
an operator input or an automated shift control routine. The first
countershaft 110, second countershaft 110', and countershaft
transmission gears that are coupled to the first countershaft 110
and the second countershaft 110' may rotate about their respective
countershaft axes when the first gear 92 rotates about the first
axis 60 in the clutch positions described below.
[0051] Referring to FIG. 1, the first clutch 150 and the second
clutch 152 are shown in neutral positions. The first clutch 150 may
not couple a gear of the set of drive pinion gears 80 to the drive
pinion 24 when the first clutch 150 is in the neutral position. For
instance, the first clutch 150 may not couple the first gear 92 or
the second gear 94 to the drive pinion 24 when the first clutch 150
is in the neutral position. Likewise, the second clutch 152 may not
couple a gear of the set of drive pinion gears 80 to the drive
pinion 24 when the second clutch 152 is in the neutral position.
For instance, the second clutch 152 may not couple the second gear
94 or the third gear 96 to the drive pinion 24 when the second
clutch 152 is in the neutral position. The drive pinion 24 may be
free to rotate about the first axis 60 with respect to at least one
member of the set of drive pinion gears 80 when a clutch is in the
neutral position and may be free to rotate about the first axis 60
with respect to all members of the set of drive pinion gears 80
when all clutches are in their respective neutral positions. Thus,
torque is not transmitted between the electric motor 22 and the
drive pinion 24 when the first clutch 150 and the second clutch 152
are in their respective neutral positions.
[0052] As an overview of the configurations shown in FIGS. 24,
torque may be transmitted between the electric motor 22 and the
drive pinion 24 when one member of the set of drive pinion gears 80
is coupled to the drive pinion 24 by a corresponding clutch and the
other members of the set of drive pinion gears 80 are decoupled
from the drive pinion 24 such that the drive pinion 24 is five to
rotate about the first axis 60 with respect to a decoupled drive
pinion gear. The straight arrowed lines in FIGS. 2-4 that are not
shown in FIG. 1 depict the torque transmission path from the
electric motor 22 to the drive pinion 24, and hence to the
differential assembly 30; however, it is to be understood that the
torque transmission path may be reversed in each of these figures
and torque may be transmitted from the differential assembly 30 to
the drive pinion 24 and then to the electric motor 22 via the
countershaft transmission 28 and the rotor shaft 26.
[0053] Referring to FIG. 2, the first clutch 150 is shown in a
first position and the second clutch 152 is shown in the neutral
position. The first clutch 150 may be moved to the first position
by the first actuator 160. In the first position, the first clutch
150 may couple the first gear 92 to the drive pinion 24 such that
the first gear 92 rotates about the first axis 60 with the drive
pinion 24. Thus, the rotor 54, the rotor shaft 26, the first gear
92, and the drive pinion 24 are rotatable together about the first
axis 60. The second gear 94 and the third gear 96 are not coupled
to the drive pinion 24 by a clutch. Accordingly, rotation of the
first gear 92 may cause the first countershaft 110 and the second
countershaft 110' to rotate about the first countershaft axis 100
and the second countershaft axis 100', respectively, but torque may
not be transmitted to or from the drive pinion 24 via the second
gear 94 or the third gear 96 since these gears are decoupled from
the drive pinion 24. Thus, torque may be transmitted between the
electric motor 22 and the drive pinion 24 via the first gear 92
when the first clutch 150 couples the first gear 92 to the drive
pinion 24 such that the first gear 92 rotates about the first axis
60 with the drive pinion 24. A first gear ratio is provided when
the first gear 92 is coupled to the drive pinion 24.
[0054] Referring to FIGS. 3A and 3B, two different examples are
shown that illustrate the transmission of torque via the second
gear 94. In FIGS. 3A and 3B, a second gear ratio is provided when
the second gear 94 is coupled to the drive pinion 24. The second
gear ratio may differ from the first gear ratio.
[0055] In FIG. 3A, the first clutch 150 is shown in a second
position and the second clutch 152 is shown in the neutral
position. The first clutch 150 may be moved to the second position
by the first actuator 160. In the second position, the first clutch
150 couples the second gear 94 to the drive pinion 24 such that the
second gear 94 rotates about the first axis 60 with the drive
pinion 24. Accordingly, rotation of the first gear 92 may cause the
first countershaft 110 and the second countershaft 110' to rotate
about the first countershaft axis 100 and the second countershaft
axis 100', respectively, and torque may be transmitted to or from
the drive pinion 24 via the second countershaft gears 114, 114',
the first clutch 150, and the second gear 94. The first gear 92 and
the third gear 96 are not coupled to the drive pinion 24 via the
first clutch 150 or the second clutch 152. Thus, torque may not be
transmitted to or from the drive pinion 24 via the first gear 92
and the third gear 96 since these gears are decoupled from the
drive pinion 24. Therefore, torque is transmitted between the
electric motor 22 and the drive pinion 24 via the second gear 94
when the first clutch 150 does not couple the first gear 92 to the
drive pinion 24 and the first clutch 150 couples the second gear 94
to the drive pinion 24 such that the second gear 94 rotates about
the first axis 60 with the drive pinion 24.
[0056] In FIG. 3B, the second clutch 152 is shown in a first
position and the first clutch 150 is shown in the neutral position.
The second clutch 152 may be moved to the first position by the
second actuator 170. In the first position, the second clutch 152
couples the second gear 94 to the drive pinion 24 such that the
second gear 94 rotates about the first axis 60 with the drive
pinion 24. Accordingly, rotation of the first gear 92 may cause the
first countershaft 110 and the second countershaft 110' to rotate
about the first countershaft axis 100 and the second countershaft
axis 100', respectively, and torque may be transmitted to or from
the drive pinion 24 via the second countershaft gears 114, 114',
the second clutch 152, and the second gear 94. The first gear 92
and the third gear 96 are not coupled to the drive pinion 24 via
the first clutch 150 or the second clutch 152. Thus, torque may not
be transmitted to or from the drive pinion 24 via the first gear 92
and the third gear 96 since these gears are decoupled from the
drive pinion 24. Therefore, torque is transmitted between the
electric motor 22 and the drive pinion 24 via the second gear 94
when the first clutch 150 does not couple the first gear 92 to the
drive pinion 24 and the second clutch 152 couples the second gear
94 to the drive pinion 24 such that the second gear 94 rotates
about the first axis 60 with the drive pinion 24.
[0057] In FIG. 4, the second clutch 152 is shown in a second
position and the first clutch 150 is shown in the neutral position.
The second clutch 152 may be moved to the second position by the
second actuator 170. In the second position, the second clutch 152
couples the third gear 96 to the drive pinion 24 such that the
third gear 96 rotates about the first axis 60 with the drive
pillion 24. Accordingly, rotation of the first gear 92 may cause
the first countershaft 110 and the second countershaft 110' to
rotate about the first countershaft axis 100 and the second
countershaft axis 100', respectively, and torque may be transmitted
to or from the drive pinion 24 via the third countershaft gears
116, 116', the second clutch 152, and the third gear 96. The first
gear 92 and the second gear 94 are not coupled to the drive pinion
24 via the first clutch 150 or the second clutch 152. Thus, torque
may not be transmitted to or from the drive pinion 24 via the first
gear 92 and the second gear 94 since these gears are decoupled from
the drive pinion 24. Therefore, torque is transmitted between the
electric motor 22 and the drive pinion 24 via the third gear 96
when the first clutch 150 does not couple the first gear 92 or the
second gear 94 to the drive pinion 24 and the second clutch 152
couples the third gear 96 to the drive pinion 24 such that the
third gear 96 rotates about the first axis 60 with the drive pinion
24. A third gear ratio is provided when the third gear 96 is
coupled to the drive pinion 24. The third gear ratio may differ
from the first gear ratio and the second gear ratio.
[0058] The axle assembly configurations discussed above may provide
an axle assembly configuration in which the electric motor and
countershaft transmission are arranged on opposite sides of a
differential assembly and a center portion of an axle housing. Such
a configuration may help thermally separate the electric motor and
heat generated by the fast-spinning rotor roller bearings (which
may rotate at speeds greater than 50,000 rpm) from other components
of the axle assembly, such as the countershaft transmission and
lubricant of the axle assembly. This thermal separation may improve
thermal management of the axle assembly and may reduce lubricant
heating, which may help improve lubricant life. In addition, such
an arrangement may provide better weight distribution by locating
the center of mass of the axle assembly closer to the axle shafts
as compared to a configuration in which the electric motor and
countershaft transmission extend from the same side of the housing
assembly. As a result, the "standout" or distance the housing
assembly extends from the axle shafts may be reduced and housing
structural integrity may be improved as compared to a configuration
in which the electric motor and countershaft transmission extend
from the same side of the housing assembly. The axle assembly may
accommodate a wide range of gear ratios, including gear ratios less
than 1:1, greater than 4:1 or both. The configurations described
above may also allow a modular countershaft transmission to be
provided with multiple gears mounted to a corresponding
countershaft without independent bearings for associated gears.
[0059] While exemplary embodiments are described above, it is not
intended that these embodiments describe all possible forms of the
invention. Rather, the words used in the specification are words of
description rather than limitation, and it is understood that
various changes may be made without departing from the spirit and
scope of the invention. Additionally, the features of various
implementing embodiments may be combined to form further
embodiments of the invention.
* * * * *