Dana Heavy Vehicle Systems Group, LLC

Deere & Company

Dana Automotive Systems Group, LLC

Darren J Ziskovsky

Jordan M Houser

Jeffrey S Turner

Mark A Davis

Aaron D Gries

Austin B Stephens

Steven R Fliearman

Kyle K McKinzie

Michael D Cook

Jeffrey M David

Steven Vanhee

Langston H Corn

Clayton George Janasek

Mark W Leber

William F Waltz

Louis Lambourg

Maximilian Hombsch

Martin D Fairchild

Gustav Johnson

Timothy D Rice

Methods and systems are provided for an electric axle. The electric axle system includes, in one example, an electric machine and a multi-speed transmission that is rotationally coupled to the electric machine and rotationally coupled to two output shafts. The transmission includes a differential rotationally coupled and positioned coaxial to a mode planetary gear set. In the electric axle system, the mode planetary gear set is a meshed planet compound planetary gear set and a mode clutch in the transmission is configured to selectively shift the mode planetary gear set between a first mode and a second mode.

Electric axle

Various methods are provided for an electric motor including a coolant jacket molded to a stator. In one embodiment, the method comprises flowing a coolant to an annular coolant passage formed between a stator and a coolant jacket molded directly to the stator, and spraying the coolant toward the stator from a nozzle formed in a spray ring molded integrally with the coolant jacket.

Systems and method for an electric motor with molded coolant jacket and spray ring

A cooling system for an electric machine is provided that includes a housing at least partially enclosing a rotor, a stator, and a coolant jacket, the coolant jacket including a plurality of coolant channels that receive coolant from a coolant inlet. In the cooling system two or more materials that form boundaries of the plurality of coolant channels are configured to thermally expand at different rates and form a bypass flow passage of at least one of the plurality of coolant channels when the two or more materials are below a threshold temperature or within a lower temperature range.

Electric machine with coolant jacket

Various systems and methods are provided for an electric motor of a vehicle, and particularly to an electric motor including a coolant spray ring. In one example, a method of manufacture comprises forming, via injection molding, a unitary motor spray ring including a plurality of axial grooves joined to a plurality of nozzle orifices.

Systems and method for an electric motor with spray ring

In one example, a line of transmissions is provided comprising, a first transmission and a second transmission. Each transmission includes an input shaft with a first pair of gears arranged thereon and a first clutch positioned therebetween designed to selectively rotationally couple at least one of a first gear and a second gear of the first pair of gears to the input shaft. Each transmission includes a layshaft with a second pair of gears fixedly coupled thereto. Each transmission includes an output shaft with a third pair of gears arranged thereon and a second clutch positioned therebetween designed to selectively rotationally couple at least one of a third gear and a fourth gear in the third pair of gears to the output shaft. The first transmission has the second gear fixed to the input shaft. The second transmission has the fourth gear fixed to the output shaft.

Line of transmissions and method for operating the transmissions

An electric motor cooling jacket enclosing a surface of an electric motor stator and having protuberances adapted for contact with the surface of the stator, with fluid passageways formed by the cooling jacket body, the protuberances, and the surface of the electric motor stator, wherein the fluid passageways are arranged to permit a cooling fluid to flow in a serpentine path across the surface of the stator to remove heat from the stator. Spray rings are fluidly coupled with the fluid passageways so as to permit the cooling fluid to flow into the fluid passageways, across the outer circumference of the electric motor stator, and out from orifices in the spray rings to cool the windings of the stator. The protuberances are formable using a pair of mold halves aligned anti-symmetrically with one another so that a serpentine fluid path is formed when casting the cooling jacket body.

Electric axle assembly

Methods and systems for an electric drive assembly are provided herein. In one example, an electric drive system is provided that includes two multi-motor drive units with associated planetary gear reductions that have asymmetric gear ratios. The planetary gear reduction in each drive unit includes a ring gear and a sun gear that are rotationally coupled to a pair of motors and a carrier rotationally coupled to an output gear that interfaces with a gear reduction of an axle assembly.

Electric drive axle system and operating method

Various systems and methods are provided for an electric motor of a vehicle, and particularly to an electric motor including a coolant spray ring. In one example, a spray ring for an electric motor comprises an outer circumferential surface including a plurality of axial grooves, an inner circumferential surface including a plurality of nozzle orifices in fluidic communication with the plurality of axial grooves, and a plurality of nozzle guide surfaces formed through the spray ring and extending from the plurality of axial grooves to the plurality of nozzle orifices in a direction toward a central opening of the spray ring.

Methods and systems for an electric drive assembly are provided herein. In one example, a method for operation of an electric drive system is provided that includes coordinating operation of a first electric drive unit and a second electric drive unit based on a first power request. In the system, each of the first and second electric drive units include a planetary gear reduction that delivers power from a pair of motors to a set of axle shafts, and the planetary gear reductions have asymmetric gear ratios.

Various methods and systems are provided for an electric motor including a coolant jacket molded to a stator. In one embodiment, an electric motor comprises a stator, and a coolant jacket molded as a single, unitary piece in sealing engagement against an outer perimeter of the stator, with a first end of the coolant jacket forming a first integrated spray ring.

Systems are provided for an electric motor housing. In one example, a system comprising a phase connection enclosure comprising a bus bar assembly sealed between a motor lead and a plurality of phase cable connections. The phase connection enclosure is integrally arranged within a cooling jacket of the electric motor housing.

Electric motor cooling jacket

Methods and systems for an electric motor system are provided. In one example, a motor system is provided which comprises a first electric machine rotationally coupled to a second electric machine by a planetary gear set that has three components: a ring gear, a sun gear, and a carrier with a plurality of planet gears. In the system, the first electric machine varies in size from the second electric machine and one of the planetary assembly components is permanently grounded.

Electric motor system

An electric axle assembly having dual motors and dual disconnects allowing for selectably disconnecting either one of the motors so that either motor may operate as the primary drive motor. Each of the dual motors is coupled to a layshaft, and each disconnect is positioned between a gear reduction at the output of the motor and a gear reduction connected to the layshaft. The layshaft is coupled to a differential via a clutch and gear set, the gear set providing a two-speed transmission for power delivered from the layshaft to the differential.

Methods and systems are provided for an electric axle assembly having dual motors and dual disconnects allowing for selectably disconnecting either one of the motors so that either motor may operate as the primary drive motor. In one example, an electric axle assembly comprises: a first motor in communication with a first shaft; a second motor in communication with a second shaft; a first gear set operably coupled to the first shaft; a second gear set operably coupled to the second shaft; and a clutch assembly selectively coupled to the first gear set and the second gear set and operably coupled to an output shaft, wherein the clutch assembly comprises a shift collar and a shift fork, the clutch assembly having a first configuration, a second configuration, and a third configuration, wherein in the first configuration the first motor and the second motor are coupled to the output shaft, in the second configuration the first motor is coupled to the output shaft, and in the third configuration the second motor is coupled to the output shaft.

Methods and systems are provided for lubrication of a transmission. In one example, the transmission system may include a pair of shielded bearings attached to a first transmission shaft, each of the shielded bearings including at least one shield that forms a restriction between the shield and a race of the bearing and a cavity positioned axially between the pair of shielded bearings, wherein the restrictions tune lubricant pressurization in the cavity. The transmission system further includes a radial passage in the first transmission shaft in fluidic communication with the cavity and a lubricated transmission component.

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Bowling Green, OH, United States of America

Darren J Ziskovsky