Dana Automotive Systems Group, LLC

Dana Heavy Vehicle Systems Group, LLC

Dana Belgium N.v.

Thibault G Devreese

Steven Vanhee

Joachim Druant

Luke Miller

Kenneth E Cooper

George A Willford

Steven J Wesolowski

Nicholas W Laforce

Robert L Vailliencourt

Ned W Wright

Carl Trudel

Benoit Vandevoorde

Frederik Desmet

Jaywant S Pawar

Wouter W A Galoppin

Wouter Wa Galoppin

Lewis H Nickell

Systems are provided for an electronic drive unit. In one example, the electronic drive unit comprises a cooling passage integrally arranged therein, wherein the cooling passage is sealed via laminations of the stator. The laminations are further shaped to jet oil from the cooling passage onto end-windings.

Systems for electric motor cooling

Systems are described for integrating a gearbox and an electric motor in a same housing. In one example, a system may include enclosing a gearbox containing an idler gear configured to drive an accessory gear coupled to a differential.

Integrated gearbox in electric motor systems

Methods and systems are provided to cool an electric machine. In one embodiment, an electric machine includes a rotor assembly that includes a rotor shaft and a stack of rotor laminations. The rotor assembly further includes one or more nozzles designed to receive pressurized coolant from a rotor shaft coolant passage and deliver the coolant to a set of open coolant channels in the stack of rotor laminations, wherein the set open coolant channels includes outlets that are profiled to direct the coolant towards a groove in a balancing plate that is coupled to the rotor assembly.

Methods and systems for cooling an electric machine

Systems and methods for cooling an electric motor in an electric drive unit are provided. In one example, the electric drive unit includes electric motor with a housing with a water jacket arranged therein, a stator that includes a plurality of stator laminations positioned within the housing, and an oil inlet mounted to and extending through the housing. The plurality of stator laminations includes a radial opening that is designed to receive oil from the oil inlet and direct oil to one or more oil ducts that axially extend through at least a portion of the plurality of stator laminations.

Electric motor with water jacket and oil-cooled stator and method for operation of the electric motor

Systems and methods for cooling an electric motor in an electric drive unit are provided. In one example, the electric motor includes a stator and an inverter power module positioned within a motor housing. The inverter power module forms an interface with a peripheral surface of an outer section of stator laminations of the stator, and the stator laminations include a plurality of cutouts forming axially extending oil ducts.

Cooling system for an electric machine

Systems and methods for a sun gear, counter bearing parts, and bearing arrangements. The gear comprising a helical toothing and a first and a second thrust surface which are configured to axially support the sun gear at a first and a second counter thrust surface, respectively, wherein the first and the second thrust surface have a thrust generating geometry that is configured to build up a lubrication fluid film between the first thrust surface and the first counter thrust surface and between the second thrust surface and the second counter thrust surface during rotation of the sun gear. The counter bearing part for axially supporting a sun gear, and to a bearing arrangement for axially supporting a sun gear.

Sun gear for use in a planetary gear system, counter bearing part, bearing arrangement and planetary gear system

Various methods and systems are provided for a system for cooling an electric motor. The cooling system includes a primary coolant passage through a rotor shaft linked to a plurality of secondary passages though lamination stacks of a rotor configured to receive coolant at a central region of the lamination stacks.

Methods and systems for oil cooled rotor laminations

Methods and systems for an electric axle assembly are provided herein. The electric axle assembly includes, in one example, an electric machine with a rotor shaft having an output gear thereon. The electric axle assembly further includes a planetary gearset with a carrier coupled to a pair of axle shafts, a first ring gear with external teeth that are rotationally coupled to the output gear; and a sun gear meshing with a plurality of planet gears that rotate on the carrier, where, in the axle assembly, internal teeth of the ring gear are rotationally coupled to the plurality of planet gears, and where, in the axle assembly, the sun gear or the carrier are grounded by a housing of the electric axle assembly.

Electric axle assembly and operating method

Methods and systems are provided for integrating a gearbox into an electric motor. In one example, a system may include enclosing a gearbox containing a planetary gear set and a differential within an envelope of a rotor of the electric motor.

An electric drive axle having first and second axle shafts operatively connected by a differential apparatus, and an electric motor having a driving shaft coupled with a rotor of the electric motor is provided. A driving shaft may be coupled for rotation with a rotor of the electric motor, and disposed parallel with the first axle shaft. A first driving gear may be disposed on the driving shaft. A driven shaft having a first driven gear and a second driven gear, wherein the first driven gear meshes with the first driving gear. A layshaft disposed parallel with the first axle shaft may comprise a first layshaft gear coupled therewith and meshed with the second driven gear. A second layshaft gear disposed on the layshaft may be in meshed engagement with a first drive gear coupled with the differential apparatus case.

Electric drive axle powerpath and the drive axle made therewith

A modular electric axle head assembly for a vehicle. An axle assembly of the vehicle includes a banjo portion with a first opening extending from an inner surface to an outer surface of an inboard side of the banjo portion. At least a portion of a differential assembly disposed within at the banjo portion of the axle assembly and is drivingly connected to at least a portion of a gear assembly. The gear assembly is also drivingly connected to a motor output shaft. At least a portion of the gear assembly is disposed within a hollow portion of a gear assembly housing. An outboard portion of the gear assembly housing has a mounting flange that is integrally connected to the inboard side of the banjo portion. A first and second protruding portion extends from the axle assembly mounting flange and provides rotational support for the differential assembly.

Modular head assembly for an electric axle

A drive unit having motor output shaft that is connected to a sun gear is connected to one or more planetary gears that are connected to a planetary gear housing. The housing is connected to planetary gear assembly pinion gear, which is connected to a ring gear. A first side of the ring gear is connected to a first clutch drum and the second side of the ring gear is connected to a second clutch drum. Connected to the first clutch drum is a first plurality of clutch plates interleafed with a second plurality of clutch plates connected to a first clutch can. The first clutch can is connected to a first shaft. Connected to the second clutch drum is a third plurality of clutch plates interleafed with a fourth plurality of clutch plates connected to a second clutch can. The second clutch can is connected to a second shaft.

Drive unit assembly with power boost and torque vectoring

A planetary gear system including a first gear coupled to a shaft, a plurality of second gears in rotational engagement with the first gear, a fluid supply apparatus spaced apart from the second gears, and a carrier. The carrier includes an annular portion having a flow channel configured to receive a fluid deposited onto the carrier by the fluid supply apparatus. A pinion shaft is disposed through each of the second gears and includes a primary fluid conduit in fluid communication with the flow channel and at least one secondary fluid conduit in fluid communication with the primary fluid conduit. The primary fluid conduit and the at least one secondary fluid conduit facilitate a flow of the fluid from the flow channel to at least one bearing disposed on each of the pinion shafts and at least one thrust plate interposed between the second gears and the carrier.

Planetary gear system

Provided herein is a dual clutch transmission including a reverse countershaft that is selectively engaged with at least one primary shaft and provides speed ratio changes without torque interruption and a compact axial arrangement.

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Ghent, Belgium

Thibault G Devreese