Dana Automotive Systems Group, LLC

Nissan North America, Inc.

Ford Global Technolgoies, LLC

Eric M Engerman

Andy Perakes

Ryan D Nelms

Rick C Sigmon

Mitchell R Lawson

Matthew P Simister

Travis J Miller

Ned W Wright

Charles B Lohr, Iii

Amar Nivarthi

Gordon M McIndoe

Gowrisankar Devaraj

Ronald B Morrow

Brian Shepard

George Henry Gasahl, Iv

Zachary Stoklosa

An electric axle is provided. The electric axle includes, in one example, an electric machine rotationally coupled to a layshaft via a first gear reduction and a differential rotationally coupled to the first gear reduction, a first axle shaft, and a second axle shaft. In the electric axle, the electric machine is positioned laterally between at least two drive wheels that are rotationally coupled to the first axle shaft and the second axle shaft and a rotational axis of the electric machine is axially offset from rotational axes of the at least two drive wheels.

Electric axle with compact electric machine and gear train layout

An electric axle is provided. The electric axle includes, in one example, a first electric machine directly coupled to a first planetary gear set, a second electric machine directly coupled to a second planetary gear set and a housing. The housing includes a first section that encloses the first electric machine and the first planetary gear set, a second section that encloses the second electric machine and the second planetary gear set, and a decreased diameter section that extends between the first section and the second section.

Electric axle with compact electric machine and gearbox arrangement

Methods and systems for an electric drive axle of a vehicle are provided. An electric drive axle system includes, in one example, a gear train configured to rotationally attach to an electric motor-generator. The gear train includes an output shaft rotationally coupled to a first planetary gear assembly axially offset from an input shaft rotationally coupled to the electric motor-generator, the first planetary gear assembly configured to removably couple to a differential arranged co-axial with an axle.

Electric drive axle system with removable planetary gear assembly

Methods and systems for a clutch assembly in an electric drive axle of a vehicle are provided. In one example, a clutch assembly in a gear train is provided that includes a locking clutch. The locking clutch includes a gear including a plurality of teeth having at least one tooth with a tapered end, an indexing shaft rotationally connected to an output shaft, a shift collar mounted on the indexing shaft, configured to translate on the indexing shaft into an engaged and disengaged configuration, and including a plurality of teeth on a face, where at least one tooth in the plurality of teeth in the shift collar includes a tapered end, and an indexing mechanism coupled to the shift collar and the indexing shaft and configured to accommodate for indexing between the indexing shaft and the shift collar during shift collar engagement.

Electric drive axle system with a self-indexing clutch and method for operation of said clutch

Systems and methods for a lockable electric axle are provided. The electric axle includes a first electric machine coupled to a first drive wheel via a first gear set. The electric axle further includes a second electric machine coupled to a second drive wheel via a second gear set, and a locking clutch designed to selectively lock the rotation of a first rotor shaft and a second rotor shaft in the first and second electric machines, respectively.

Electric axle with multiple electric machines and locking clutch

Methods and systems for an electric drive axle of a vehicle are provided. A gear train in an electric drive axle system includes, in one example, an input shaft configured to rotationally couple to an electric motor-generator and including a first gear and an intermediate shaft including a second gear rotationally coupled to the first gear and a third gear and a fourth gear each configured to rotationally couple to a separate gear on an output shaft. In this example, the second gear, the third gear, and the fourth gear have different sizes, the third gear includes an axial extension having at outer surface, and an interior surface of the second gear circumferentially surrounds at least a portion of the outer surface of the axial extension.

Electric drive axle gear train and method for manufacturing said gear train

Methods and systems for a vehicle transmission are provided. A transmission system includes, in one example, an intermediate shaft rotationally coupled to an input shaft and an output shaft, wherein the input shaft is configured to receive rotational input from an electric machine. The system further includes a first gear coupled to the intermediate shaft, and a plurality of clutches coupled to the input shaft and the output shaft and configured to in a first mode, transfer power directly between a second gear coupled to the input shaft, the first gear, and a third gear coupled to the output shaft, and in a second mode, transfer power indirectly between the second gear, the first gear, and/or the third gear.

Vehicle system with multi-speed transmission

An electric drive axle in a vehicle is provided. The electric drive axle includes, in one example, a housing configured to enclose an electric motor-generator and a gearbox. In the electric drive axle, the housing includes a first section that is removably coupled to a second section, the second section at least partially encloses the gearbox, the first section includes a first axle shaft opening, and the second section includes a second axle shaft opening that is laterally aligned with the first axle shaft opening.

Electric drive axle in a vehicle

An electric drive axle in a vehicle is provided. The electric drive axle includes, in one example, an electric motor-generator, a gearbox, and a differential. The gearbox comprises a planetary gear set that includes a sun gear configured to rotate on a sun gear shaft directly coupled to a rotor of the electric motor-generator and an intermediate shaft that includes an idler gear rotationally coupled to a pinion gear that is rotationally coupled to the carrier.

Vehicle electric drive axle

An electric drive axle of a vehicle includes an electric motor having an output shaft. A compound idler assembly is connected to the electric motor. The compound idler assembly includes at least one gear-clutch assembly in driving engagement with the output shaft of the electric motor. A differential is connected to the compound idler assembly, and in selective driving engagement with the compound idler assembly.

Multi-speed gearbox with a gear-clutch assembly

Methods and systems for an electric drive axle are provided. An electric drive axle, in one example, includes an electric machine rotationally coupled to a gearbox which includes a higher range planetary gear set coupled to a lower range planetary gear set via a clutch. The clutch is configured to selectively rotationally couple an input gear to a sun gear in each of the higher range planetary gear set and the lower range planetary gear set in different positions or selectively rotationally couple a carrier in the higher range planetary gear set to a carrier and a sun gear in the lower range planetary gear set in different positions.

Electric drive axle with a gearbox and gearbox operating method

An electric drive axle of a vehicle includes an electric motor having an output shaft. An idler assembly is drivingly coupled to the electric motor and a differential. The idler assembly includes a first gear-clutch assembly to facilitate a first gear ratio and a second gear-clutch assembly to facilitate a second gear ratio.

Multi-speed gearbox and the drive axle made therewith

Multi-speed gearbox systems and methods. A multi-speed gearbox, in one example, includes a planetary assembly with a first gear set rotationally coupled to a second gear set. The multi-speed gearbox further includes a first clutch configured to selectively couple a first sun gear of the first gear set to an input shaft configured to rotationally couple to an electric machine and a second clutch configured to selectively couple a first sun gear of the second gear set to an output shaft.

Multi-speed gearbox and gearbox operating method

A line of vehicle transmissions is provided. The vehicle line includes a first multi-stage gear train assembly with at least two stages, a second multi-stage gear train assembly with at least three stages, and a housing including a first section removably attached to a second section. The second housing section is configured to receive the first and second multi-stage gear train assemblies in different product arrangements.

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Novi, MI, United States of America

Eric M Engerman