Axle assembly with a transmission module

Abstract

An axle assembly includes a housing assembly, an electric motor module, and a transmission module. A first lubricant passageway can convey lubricant from the housing assembly to a transmission housing cavity of the transmission module. The first lubricant passageway can extend through a motor housing, a motor cover, and a first transmission housing.

Description

Technical Field

[0001] This disclosure relates to an axle assembly having a transmission module and a lubricant distribution associated with the transmission module. Background

[0002] An axle assembly having an electric motor module is disclosed in U.S. Patent Publication No. 2019 / 0054816.

[0003] Overview

[0004] In at least one embodiment, an axle assembly is provided. The axle assembly can include a housing assembly, an electric motor module, and a transmission module. The housing assembly can receive a differential assembly and can at least partially define a cavity having a reservoir portion for receiving lubricant. The electric motor module can include a motor housing and a motor cover. The motor housing can be mounted to the housing assembly and can at least partially define a motor housing cavity within which an electric motor is received. The motor cover can be mounted to an end of the motor housing opposite the housing assembly. The transmission module can include a first transmission housing and a second transmission housing. The first transmission housing can be mounted to the motor cover. The second transmission housing can be mounted to the first transmission housing. The first transmission housing and the second transmission housing can cooperate to define a transmission housing cavity that receives a transmission that can be operatively connected to the electric motor. A first lubricant passage can convey lubricant from the housing assembly to the transmission housing cavity. The first lubricant passage can extend through the motor housing, the motor cover, and the first transmission housing and can be separated from the motor housing cavity.

[0005] In at least one embodiment, an axle assembly is provided. The axle assembly can include a housing assembly, an electric motor module, and a transmission module. The housing assembly can receive a differential assembly and can at least partially define a cavity having a reservoir portion that can receive lubricant. The electric motor module can be mounted to the housing assembly. The transmission module can include a first transmission housing and a second transmission housing. The first transmission housing can be mounted to the electric motor module and can be fluidly connected to the housing assembly via a first lubricant passage. The second transmission housing can be mounted to the first transmission housing. The first transmission housing and the second transmission housing can cooperate to define a transmission housing cavity that can receive a transmission. A lubricant trap can be received in the transmission housing cavity. The lubricant trap can be mounted to the second transmission housing and can extend from the second transmission housing toward the first transmission housing. Brief Description of the Drawings

[0006] Figure 1 is a perspective view of an example of the axle assembly.

[0007] Figure 2 It is a cross-sectional view of the axle assembly along section line 2-2.

[0008] Figure 3 It is an end view of the axle assembly, with the cover at this end of the axle assembly removed.

[0009] Figure 4 and Figure 5 It is an exploded view showing the motor housing, motor cover and first transmission housing of the axle assembly.

[0010] Figure 6 It is a side view of this part of the axle assembly including the first transmission housing.

[0011] Figure 7 is Figure 6 A side view of this part of the axle assembly shown in , where a baffle and bearing assembly are arranged on the first transmission housing.

[0012] Figure 8 It is a side view of a part of the axle assembly, showing the second transmission housing, a lubricant trap mounted to the second transmission, and a part of the transmission of the axle assembly.

[0013] Figure 9 It is an exploded view of the second transmission housing and the lubricant trap.

[0014] Figure 10 It is a top cross-sectional view of a part of the axle assembly along section line 10-10.

[0015] Figure 11 It is a top cross-sectional view of the axle assembly along section line 11-11, with the differential carrier omitted for clarity.

[0016] Figure 12 It is a side view of a part of the axle assembly, showing the first lubricant passage.

[0017] Figure 13 is Figure 12 A side view of the opposite side of this part of the axle assembly shown in , showing the second lubricant passage.

[0018] Figure 14 is Figure 2 An enlarged view of a part of the axle assembly shown in . Detailed Description

[0019] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely examples of the present invention that can be implemented in various forms and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Accordingly, the specific structural and functional details disclosed herein are not to be construed as limiting, but rather as a representative basis for teaching those skilled in the art to employ the present invention in various ways.

[0020] Referring Figure 1 , an example of an axle assembly 10 is shown. The axle assembly 10 can be provided for a motor vehicle, such as a heavy-duty truck, a passenger vehicle, a farm equipment, a mining equipment, a military transport or an armed vehicle, or a cargo loading device for a land, air, or marine vessel. In one or more embodiments, the motor vehicle can include a trailer for transporting cargo.

[0021] The axle assembly 10 can provide torque to one or more drive wheel assemblies, which can include tires mounted on wheels. The wheels can be mounted to hubs that can rotate about a wheel axis.

[0022] One or more axle assemblies can be provided to the vehicle. As shown best in Figure 1 and Figure 2 , the axle assembly 10 can include a housing assembly 20, a differential assembly 22, at least one half shaft 24, an electric motor module 26, and a transmission module 28 and a drive pinion 30. As shown best in Figure 12 and Figure 13 , the axle assembly 10 can include a first lubricant passage 32, a second lubricant passage 34, a shift mechanism 36, or a combination thereof.

[0023] Housing assembly

[0024] Referring Figure 1 , the housing assembly 20 can receive the various components of the axle assembly 10. Additionally, the housing assembly 20 can assist in mounting the axle assembly 10 to the vehicle. In at least one configuration, the housing assembly 20 can include an axle housing 40 and a differential carrier 42.

[0025] The axle housing 40 can receive and support the half shafts 24. In at least one configuration, the axle housing 40 can include a central portion 50 and at least one arm portion 52.

[0026] The central portion 50 can be disposed near the center of the axle housing 40. As shown in Figure 2As best shown, the central portion 50 can define a cavity 54 that can at least partially receive the differential assembly 22. The lower region of the central portion 50 can at least partially define a reservoir portion 56 that can hold or collect lubricant 58. The lubricant 58 in the reservoir portion 56 can be splashed by the ring gear 82 of the differential assembly 22 and distributed to lubricate various components that may or may not be received within the housing assembly 20. For example, some of the splashed lubricant 58 can lubricate components received within the cavity 54 (such as the differential assembly 22, the bearing assembly that rotatably supports the differential assembly 22, the drive pinion 30, etc.), while some of the splashed lubricant 58 can be delivered out of the cavity 54 via the first lubricant passage 32 (as shown best in Figure 12 ), to lubricate components located outside the housing assembly 20 (such as components associated with the transmission module 28, the shift mechanism 36, or both), which will be discussed in more detail below.

[0027] See Figure 1 and Figure 2 , one or more arm portions 52 can extend from the central portion 50. For example, two arm portions 52 can extend from the central portion 50 in opposite directions and away from the differential assembly 22. The arm portions 52 can have substantially similar configurations. For example, the arm portions 52 can each have a hollow configuration or a tubular configuration that can extend around the respective half shafts 24 and can receive the respective half shafts, and can help to isolate or separate the half shafts 24 or portions thereof from the surrounding environment. The arm portions 52 or portions thereof can be integrally formed with or without the central portion 50. It is also contemplated that the arm portions 52 can be omitted.

[0028] The differential carrier 42 can be mounted to the central portion 50 of the axle housing 40. The differential carrier 42 can support the differential assembly 22 and can facilitate the mounting of the electric motor module 26. For example, the differential carrier 42 can include one or more bearing supports that can support bearings, such as a rolling bearing assembly that can rotatably support the differential assembly 22. In at least one configuration, the differential carrier 42 can include a mounting flange 60 and / or a bearing support wall 62.

[0029] Refer to Figure 2 , the mounting flange 60 can facilitate the mounting of the electric motor module 26. As an example, the mounting flange 60 can be configured as a ring that can extend outwardly and away from the axis 70 and can extend around the axis 70. In at least one configuration, the mounting flange 60 can include a set of fastener holes that can be configured to receive fasteners (such as bolts or studs) that can secure the electric motor module 26 to the mounting flange 60.

[0030] The bearing support wall 62 can support bearings that can rotatably support other components of the axle assembly 10. For example, the bearing support wall 62 can support a bearing that can rotatably support the drive pinion 30, a bearing that can rotatably support the rotor of the electric motor module 26, or both. The bearing support wall 62 can extend in an axial direction away from the axle housing 40 and can extend around an axis 70. The bearing support wall 62 can define a hole that can extend along or around the axis 70 and that receives the drive pinion 30 and the bearing that rotatably supports the drive pinion 30. The bearing support wall 62 can be integrally formed with the differential carrier 42 or can be a separate component that is fixed or fastened to the differential carrier 42.

[0031] Differential assembly, drive pinion and half shaft

[0032] Reference Figure 2 , the differential assembly 22 can be at least partially received in the central portion 50 of the housing assembly 20. The differential assembly 22 can be rotatable about a differential axis 80 and can transmit torque to the half shafts 24 and the wheels. The differential assembly 22 can be operatively connected to the half shafts 24 and can allow the half shafts 24 to rotate at different rotational speeds in a manner known to those skilled in the art. The differential assembly 22 can have a ring gear 82 that can have teeth that mate or engage with the teeth of the gear portion of the drive pinion 30. Accordingly, the differential assembly 22 can receive torque from the drive pinion 30 via the ring gear 82 and transmit the torque to the half shafts 24.

[0033] The drive pinion 30 can operatively connect the transmission module 28 to the differential assembly 22. Thus, the drive pinion 30 can transmit torque between the differential assembly 22 and the transmission module 28. In at least one configuration, the drive pinion 30 can be rotatable about the axis 70 and can be rotatably supported within another component (such as the bearing support wall 62).

[0034] Reference Figure 1 , the half shafts 24 can transmit torque from the differential assembly 22 to the corresponding wheel hubs and wheels. Two half shafts 24 can be provided such that each half shaft 24 extends through a different arm portion 52 of the axle housing 40. The half shafts 24 can extend along an axis (such as the differential axis 80) and can be rotatable about that axis. Each half shaft 24 can have a first end and a second end. The first end can be operatively connected to the differential assembly 22. The second end can be arranged opposite the first end and can be operatively connected to the wheel. Optionally, a gear reduction can be provided between the half shaft 24 and the wheel.

[0035] Electric motor module

[0036] ReferenceFigure 2 The electric motor module 26 (which may also be referred to as an electric motor) can be mounted to the differential carrier 42 and can be operatively connected to the differential assembly 22. For example, the electric motor module 26 can provide torque to the differential assembly 22 via the transmission module 28 and the drive pinion 30, as will be discussed in more detail below. The electric motor module 26 can be mainly disposed outside the differential carrier 42. Additionally, the electric motor module 26 can be axially positioned between the axle housing 40 and the transmission module 28. In at least one configuration, the electric motor module 26 can include a motor housing 100, a coolant jacket 102, a stator 104, a rotor 106, at least one rotor bearing assembly 108, and a motor cover 110.

[0037] Reference Figure 2 、 Figure 4 and Figure 5 and, the motor housing 100 can extend between the differential carrier 42 and the motor cover 110. The motor housing 100 can be mounted to the differential carrier 42 and the motor cover 110. For example, the motor housing 100 can extend from the mounting flange 60 of the differential carrier 42 to the motor cover 110. The motor housing 100 can extend around an axis 70 and can define a motor housing cavity 120. The motor housing cavity 120 can be disposed inside the motor housing 100 and can have a generally cylindrical configuration. The bearing support wall 62 of the differential carrier 42 can be located inside the motor housing cavity 120. Additionally, the motor housing 100 can continuously extend around the bearing support wall 62 and can be spaced apart from the bearing support wall. In at least one configuration, the motor housing 100 can have an outer side 122, an inner side 124, a first end surface 126, and a second end surface 128.

[0038] The outer side 122 can face away from the axis 70 and can define the outer surface or the outer side surface of the motor housing 100.

[0039] The inner side 124 can be arranged opposite to the outer side 122 and can face the axis 70. In one or more configurations, the inner side 124 can be arranged at a substantially constant radial distance from the axis 70.

[0040] The first end surface 126 can extend between the outer side 122 and the inner side 124. The first end surface 126 can be disposed at the end of the motor housing 100 that can face the differential carrier 42. For example, the first end surface 126 can be arranged adjacent to the mounting flange 60 of the differential carrier 42 and can engage or contact the mounting flange 60.

[0041] The second end surface 128 may be arranged opposite the first end surface 126. Thus, the second end surface 128 may be disposed at the end of the motor housing 100 that may face the motor cover 110 and may engage or contact the motor cover 110.

[0042] Reference Figure 2 , the coolant jacket 102 may help cool the stator 104 or remove heat from the stator. The coolant jacket 102 may be received in the motor housing cavity 120 of the motor housing 100 and may engage the inner side 124 of the motor housing 100. The coolant jacket 102 may extend axially (e.g., in the direction along the axis 70) between the differential carrier 42 and the motor cover 110. For example, the coolant jacket 102 may extend axially from the differential carrier 42 to the motor cover 110. Additionally, the coolant jacket 102 may extend around the axis 70 and around the stator 104. Accordingly, the stator 104 may be at least partially received in the coolant jacket 102 and may be surrounded by the coolant jacket. The coolant jacket 102 may extend in the radial direction from the stator 104 to the inner side 124 of the motor housing 100. In at least one configuration, the coolant jacket 102 may include a plurality of channels through which coolant may flow.

[0043] The stator 104 may be received in the motor housing cavity 120. The stator 104 may be fixedly positioned relative to the coolant jacket 102. For example, the stator 104 may extend around the axis 70 and may include a stator winding that may be received inside the coolant jacket 102 and may be fixedly positioned relative to the coolant jacket.

[0044] The rotor 106 may extend around the axis 70 and may be rotatable about the axis. Additionally, the rotor 106 may extend around the bearing support wall 62 and may be supported by the bearing support wall. The rotor 106 may be received inside the stator 104, the coolant jacket 102, and the motor housing cavity 120 of the motor housing 100. The rotor 106 may be rotatable about the axis 70 relative to the differential carrier 42 and the stator 104. Additionally, the rotor 106 may be spaced apart from the stator 104 but may be arranged adjacent to the stator 104. The rotor 106 may include a magnet or ferromagnetic material that may facilitate current generation or may be induction-based.

[0045] One or more rotor bearing assemblies 108 may rotatably support rotor 106. For example, rotor bearing assembly 108 may extend around and receive bearing support wall 62 of differential carrier 42 and may be received within rotor 106. Rotor 106 may be operatively connected to drive pinion 30. For example, a coupling (such as rotor output flange 150) may operatively connect rotor 106 to transmission module 28, which in turn may be operatively connectable to drive pinion 30.

[0046] Reference Figure 2 、 Figure 4 and Figure 5 ,With reference to Figure 2 , Figure 4 , and Figure 5 , motor cover 110 may be mounted to motor housing 100 and may be disposed opposite axle housing 40 and differential carrier 42. For example, motor cover 110 may be mounted to second end surface 128 of motor housing 100. Motor cover 110 may be spaced from differential carrier 42 and may not engage the differential carrier. Motor cover 110 may be provided in various configurations. In at least one configuration, motor cover 110 may include first side 160 and second side 162. First side 160 may face motor housing 100 and may engage the motor housing. Second side 162 may be disposed opposite first side 160. Second side 162 may face away from motor housing 100. Motor cover 110 may also include motor cover opening 164 through which drive pinion 30 may extend.

[0047] Transmission module

[0048] Main reference Figure 2 、 Figure 10 and Figure 11 With reference to Figure 2 , Figure 10 , and Figure 11 , transmission module 28 may transfer torque between electric motor module 26 and differential assembly 22. Thus, transmission module 28 may be operatively connectable to electric motor module 26 and differential assembly 22. In at least one configuration, transmission module 28 may include first transmission housing 200, second transmission housing 202, and transmission 204. First transmission housing 200 and second transmission housing 202 may cooperate to define transmission housing cavity 206 that may receive transmission 204.

[0049] Main reference Figure 2 and Figures 4 to 7 With reference to Figure 2 and Figures 4 to 7 , first transmission housing 200 may be mounted to electric motor module 26. For example, first transmission housing 200 may be mounted to second side 162 of motor cover 110. Thus, motor cover 110 may separate first transmission housing 200 from motor housing 100. In at least one configuration and as Figure 5As best shown, the first transmission housing 200 may define a central bore 210, an outlet 502 of the first lubricant passage 32, and an inlet 550 of the second lubricant passage 34. As referenced Figure 6 As best shown, the first transmission housing 200 may include a first recess 220, a first connecting passage 222, a first outlet passage 224, a first channel 226, a second recess 230, a second connecting passage 232, a second outlet passage 234, a second channel 236, a deflector 238, or a combination thereof. Note that Figure 7 the arrow lines in represent the flow of lubricant 58 that may be associated with these features.

[0050] Primarily referring to Figures 5 to 7 , the central bore 210 may be a through-bore that extends around or along an axis 70. In at least one configuration, the central bore 210 may receive a drive pinion 30.

[0051] The first recess 220 may be configured as a depression or cavity in the first transmission housing 200 that extends toward the motor cover 110 and away from the second transmission housing 202. As Figure 7 best shown, the first recess 220 may receive a bearing assembly 240 that may rotatably support a first countershaft of the transmission 204. The first recess 220 may have a generally circular or cylindrical configuration and may be spaced apart from the central bore 210. As Figure 6 best shown, the first recess 220 or a portion thereof may be positioned below the outlet 502. Additionally, the first recess 220 may be laterally positioned closer to the central bore 210 compared to the positioning of the outlet 502 relative to the central bore 210.

[0052] The first connecting passage 222 may extend from the outlet 502 of the first lubricant passage 32 to the first recess 220. Thus, the first connecting passage 222 may convey lubricant from the outlet 502 to the first recess 220 and the bearing assembly 240 received in the first recess 220. The first connecting passage 222 may be configured as a depression or cavity in the first transmission housing 200. The first connecting passage 222 may extend downwardly toward the first recess 220 to facilitate the flow of lubricant 58 from the outlet 502 to the first recess 220 under the force of gravity. In one or more embodiments, the first connecting passage 222 may be linear.

[0053] The first outlet passage 224 may extend from the first recess 220 in a direction that may deviate from the outlet 502, the first connection passage 222, or both. The first outlet passage 224 may be configured as a depression or cavity in the first transmission housing 200. The first outlet passage 224 may extend downwardly from the first recess 220 to facilitate the flow of lubricant by gravity from the first recess 220 into the transmission housing cavity 206. The first connection passage 222 and the first outlet passage 224 may extend from opposite sides of the first recess 220.

[0054] The first passage 226 may convey some of the lubricant 58 exiting the outlet 502 around the first recess 220. The first passage 226 may be configured as a depression or cavity in the first transmission housing 200 that may extend toward the motor cover 110 and away from the second transmission housing 202. Additionally, the first passage 226 may be spaced from the first recess 220 and may extend partially around the first recess 220. For example, the first passage 226 may extend from the outlet 502 of the first lubricant passage 32 to the first passage end 250. The first passage end 250 may be disposed below the first recess 220 or closer to the bottom of the first transmission housing 200 than the first recess 220. For example, the first passage end 250 may be disposed below the axis 70, the central bore 210, or a combination thereof.

[0055] Reference Figure 7 , the first baffle 260 may deflect the lubricant 58 exiting the outlet 502 of the first lubricant passage 32 into the first passage 226. The first baffle 260 may have any suitable configuration. For example, the first baffle 260 may be configured as a generally flat plate that may extend over the outlet 502 and a portion of the first passage 226. The first baffle 260 may be fixedly disposed on the first transmission housing 200. For example, the first baffle 260 or a portion thereof may be received within the first passage 226 and may be fastened to the first transmission housing 200 with one or more fasteners such as screws. The first baffle 260 may not cover the first passage end 250, thereby allowing the lubricant 58 to exit the first passage 226 at the first passage end 250 and enter the transmission housing cavity 206.

[0056] Reference Figure 6 and Figure 7, the second recess 230 can be configured as a depression or cavity in the first transmission housing 200 that extends toward the motor cover 110 and away from the second transmission housing 202. The second recess 230 can receive a bearing assembly 240 that rotatably supports a second countershaft of the transmission 204. The second recess 230 can have a generally circular or cylindrical configuration and can be spaced from the central hole 210. The central hole 210 can be positioned between the first recess 220 and the second recess 230. The second recess 230 or a portion thereof can be positioned above the inlet 550 of the second lubricant passage 34. Additionally, the second recess 230 can be laterally positioned closer to the central hole 210 compared to the positioning of the inlet 550 relative to the central hole 210.

[0057] The second connecting passage 232 can extend from the second channel 236 to the second recess 230. Thus, the second connecting passage 232 can convey lubricant 58 from the second channel 236 to the second recess 230 and the bearing assembly 240 received in the second recess 230. The second connecting passage 232 can be configured as a depression or cavity in the first transmission housing 200. The second connecting passage 232 can extend downward from the second channel 236 toward the second recess 230 to facilitate the flow of lubricant 58 from the second channel 236 to the second recess 230 under the force of gravity. In one or more embodiments, the second connecting passage 232 can be linear.

[0058] The second outlet passage 234 can extend from the second recess 230 in a direction that can be away from the second connecting passage 232. The second outlet passage 234 can be configured as a depression or cavity in the first transmission housing 200. The second outlet passage 234 can extend downward from the second recess 230 to facilitate the flow of lubricant 58 from the second recess 230 to the transmission housing cavity 206 under the force of gravity. The second connecting passage 232 and the second outlet passage 234 can extend from opposite sides of the second recess 230.

[0059] The second channel 236 can convey some lubricant 58 around the second recess 230 to the inlet 550 of the second lubricant passage 34. The second channel 236 can be configured as a depression or cavity in the first transmission housing 200 that extends toward the motor cover 110 and away from the second transmission housing 202. Additionally, the second channel 236 can be spaced from the second recess 230 and can partially surround the second recess 230. For example, the second channel 236 can extend from an enlarged end 270 of the second channel 236 to the inlet 550 of the second lubricant passage 34. The enlarged end 270 can be located above the axis 70 and the central hole 210.

[0060] Reference Figure 7, the second baffle 280 can deflect or direct the lubricant 58 from the second passage 236 into the inlet 550. The second baffle 280 can have any suitable configuration. For example, a portion of the second baffle 280 can be configured as a substantially flat plate that can extend over the inlet 550 and a portion of the second passage 236. The second baffle 280 can be fixedly arranged on the first transmission housing 200. For example, a portion of the second baffle 280 can be received within the second passage 236 and can be fastened to the first transmission housing 200 with one or more fasteners (such as screws). In at least one configuration, the second baffle 280 can include a spoon-shaped portion 282.

[0061] The spoon-shaped portion 282 can project from the first transmission housing 200 into the transmission housing cavity 206 and can be configured to capture the lubricant 58, such as the lubricant that may be splashed by the transmission 204 when the transmission 204 rotates within the transmission housing cavity 206. The spoon-shaped portion 282 can be arranged above the axis 70 and can be arranged above the central hole 210. The spoon-shaped portion 282 can be generally aligned with the enlarged end 270 of the second passage 236 and can be open in an upward direction that can be away from the axis 70, such that the spoon-shaped portion 282 can capture or collect the splashed lubricant 58 and cooperate with the first transmission housing 200 to direct or convey the lubricant 58 into the second passage 236. Optionally, the spoon-shaped portion 282 can engage the deflector 238, can be fastened to the deflector 238, or both.

[0062] The deflector 238 may be disposed above the axis 70 and may extend from the first transmission housing 200 toward the second transmission housing 202. In this way, the deflector 238 may extend into the transmission housing cavity 206. The deflector 238 may direct the lubricant 58 into the enlarged end 270 and / or the scoop 282. For example, the deflector 238 may extend from the inner top side of the first transmission housing 200 in a downward direction toward the axis 70 and may be at least partially defined by opposing first surface 290 and second surface 292. The first surface 290 and the second surface 292 may extend along an arc and may direct the lubricant 58 into the enlarged end 270 and / or the scoop 282. The deflector 238 and its first surface 290 and second surface 292 may help to disrupt or redirect the lubricant 58 such that when the transmission 204 rotates, at least some of the lubricant 58 does not circulate in a loop along the inner surface 294 of the first transmission housing 200. For example, the countershaft gears of the transmission 204 may rotate in a common direction of rotation. This rotation may cause the lubricant to circulate along the inner surface 294 of the first transmission housing 200 and reduce the amount of lubricant 58 entering the inlet 550 of the second lubricant passage 34. The deflector 238 may disrupt the lubricant circulation along the inner surface 294 such that more lubricant 58 may enter the second passage 236 and exit the transmission housing cavity 206 via the inlet 550 and the second lubricant passage 34, which may help to reduce churning losses that may occur when an excess of lubricant 58 is present in the transmission housing cavity 206 and may help to improve the operating efficiency of the axle assembly and may reduce energy consumption or power losses.

[0063] Main reference Figures 8 to 11 , shows the second transmission housing 202. Figure 8 and Figure 9 along the axis 70 away from the first transmission housing 200 and the electric motor module 26 and thus is in an opposite direction along the axis 70 as viewed from the Figure 6 and Figure 7 angles shown. The second transmission housing 202 may be mounted to the first transmission housing 200. For example, the first transmission housing 200 may be mounted to and may engage or contact the side of the first transmission housing 200 that may face away from the motor cover 110. In this way, the first transmission housing 200 may separate the second transmission housing 202 from the motor cover 110. In at least one configuration and as best shown in Figure 9 , the second transmission housing 202 may define a central hole 310 and a lubricant outlet hole 312. Referring to Figure 8 and Figure 9, the second transmission housing 202 may further include a first recess 320, a first inlet slot 322, a first outlet slot 324, a second recess 330, a second inlet slot 332, a second outlet slot 334, a shoulder 336, or a combination thereof. A lubricant trap 340 may be provided in the second transmission housing 202.

[0064] Main reference Figure 9 , the central hole 310 may be a through hole that extends around or along the axis 70. In at least one configuration, the central hole 310 may receive the drive pinion 30 or an extension of the drive pinion 30, such as the connecting member 420, as best shown in Figure 14 .

[0065] The lubricant outlet hole 312 may be configured as a through hole that extends through the wall of the second transmission housing 202. The lubricant outlet hole 312 may direct the lubricant 58 trapped by the lubricant trap 340 into the shift mechanism housing cavity 600, as best shown in Figure 14 . For example, the lubricant outlet hole 312 may be fluidly connected to a pipe or conduit 338 that conveys the lubricant 58 from the lubricant outlet hole 312 to a desired location within the shift mechanism housing cavity 600.

[0066] Reference Figure 8 and 9 , the first recess 320 may be configured as a depression or cavity in the second transmission housing 202 that extends away from the first transmission housing 200. As best shown in Figure 8 , the first recess 320 may receive a bearing assembly 240 that rotatably supports the first countershaft of the transmission 204. As best shown in Figure 9 , the first recess 320 may have a generally circular or cylindrical configuration and may be spaced from the central hole 310. The first recess 320 or a portion thereof may be positioned below the lubricant outlet hole 312. Additionally, the first recess 320 may be aligned with the first recess 220 of the first transmission housing 200 and may be coaxially arranged with that first recess.

[0067] The first inlet slot 322 can convey lubricant 58 to the first recess 320 and the bearing assembly 240 received by the first recess. The first inlet slot 322 can be configured as a depression or a recess in the second transmission housing 202, and the depression or the recess can extend away from the first transmission housing 200. The first inlet slot 322 can extend from the outer circumference of the first recess 320. In at least one configuration, the first inlet slot 322 can extend between the shoulder 336 and the first recess 320. The first inlet slot 322 can extend downwardly toward the first recess 320 to facilitate the flow of lubricant 58 from the shoulder 336 to the first recess 320 under the action of gravity. In one or more embodiments, the first inlet slot 322 can be linear.

[0068] The first outlet slot 324 can allow lubricant 58 to leave the first recess 320 and the bearing assembly 240 received by the first recess. The first outlet slot 324 can be configured as a depression or a recess in the second transmission housing 202. The first outlet slot 324 can extend or project outwardly from the outer circumference of the first recess 320. In at least one configuration, the first outlet slot 324 can extend from the first recess 320 in a direction that can extend away from the central bore 310. The first outlet slot 324 can be spaced apart from the first inlet slot 322 and can be positioned closer to the bottom of the second transmission housing 202 than the first inlet slot 322 to facilitate the flow of lubricant 58 from the first recess 320 into the transmission housing cavity 206 under the action of gravity.

[0069] The second recess 330 can be configured as a depression or a recess in the second transmission housing 202, and the depression or the recess can extend away from the first transmission housing 200. The second recess 330 can receive a bearing assembly 240, and the bearing assembly can rotatably support the second countershaft of the transmission 204. The second recess 330 can have a generally circular or cylindrical configuration and can be spaced apart from the central bore 310. The second recess 330 or a portion thereof can be positioned below the lubricant outlet hole 312. Additionally, the second recess 330 can be aligned with the second recess 230 of the first transmission housing 200 and can be coaxially arranged with the second recess.

[0070] The second inlet slot 332 can convey lubricant 58 to the second recess 330 and the bearing assembly 240 received by the second recess. The second inlet slot 332 can be configured as a depression or a recess in the second transmission housing 202, which can extend away from the first transmission housing 200. The second inlet slot 332 can extend from the outer circumference of the second recess 330. In at least one configuration, the second inlet slot 332 can extend between the shoulder 336 and the second recess 330. The second inlet slot 332 can extend downwardly toward the second recess 330 to facilitate the flow of the lubricant 58 from the shoulder 336 to the second recess 330 under the action of gravity. In one or more embodiments, the second inlet slot 332 can be linear.

[0071] The second outlet slot 334 can allow the lubricant 58 to leave the second recess 330 and the bearing assembly 240 received by the second recess. The second outlet slot 334 can be configured as a depression or a recess in the second transmission housing 202. The second outlet slot 334 can extend or protrude outwardly from the outer circumference of the second recess 330. In at least one configuration, the second outlet slot 334 can extend from the second recess 330 in a direction that can extend away from the central bore 310. The second outlet slot 334 can be spaced apart from the second inlet slot 332 and can be positioned closer to the bottom of the second transmission housing 202 than the second inlet slot 332 to facilitate the flow of the lubricant 58 from the second recess 330 to the transmission housing cavity 206.

[0072] Reference Figure 9 , the shoulder 336 can extend away from the first transmission housing 200. In at least one configuration, the shoulder 336 can include one or more substantially horizontal surfaces that can extend from the central bore 310 or a ring that can surround the central bore 310. The shoulder 336 can be disposed below the lubricant trap 340.

[0073] Reference Figures 8 to 10 , the lubricant trap 340 can be configured to trap the lubricant 58 that may be splashed by the transmission 204 when the transmission 204 rotates in the transmission housing cavity 206. The lubricant trap 340 can extend from the second transmission housing 202 toward the first transmission housing 200 such that the lubricant trap 340 is spaced apart from the first transmission housing 200. Thus, the lubricant trap 340 can protrude from the second transmission housing 202 into the transmission housing cavity 206. In at least one configuration, the lubricant trap 340 can be disposed above the axis 70 and can be disposed above the central bore 310 of the second transmission housing 202.

[0074] Reference Figure 8 ,Figure 10 and Figure 11 ,the lubricant trap 340 can extend across or over at least one of the gear sets 400 of the drive pinion of the transmission 204. For example, the lubricant trap 340 can extend across or over at least a portion of the fourth gear 416 of the gear set 400 of the drive pinion. The lubricant trap 340 or a portion thereof can extend over a member of the first countershaft gear set 402 of the transmission 204, a member of the second countershaft gear set 404 of the transmission 204, or a combination thereof. In Figure 8 , the lubricant trap 340 is shown extending over the fourth countershaft gear 466 of the first countershaft gear set 402 and the fourth countershaft gear 466' of the second countershaft gear set 404.

[0075] The lubricant trap 340 can be open in an upward direction that can be away from the axis 70, such that the lubricant trap 340 can cooperate with the second transmission housing 202 to capture or collect the lubricant 58 and direct or convey the lubricant 58 into the lubricant outlet hole 312. The lubricant trap 340 can be a component separate from the second transmission housing 202, and the component can be attached to the second transmission housing 202 in any suitable manner. For example, the lubricant trap 340 can be received in one or more slots 350, as best shown in Figure 9 , and the one or more slots can be provided for the second transmission housing 202. Alternatively or additionally, the lubricant trap 340 can be attached to the second transmission housing 202 with one or more fasteners. The fasteners can or can not be integrally formed with the lubricant trap 340. In at least one configuration, and as best shown with reference to Figure 8 and Figure 10 , the lubricant trap 340 can at least partially define a central slot 360, a first end slot 362, a second end slot 364, or a combination thereof.

[0076] The central slot 360 can extend laterally along the second transmission housing 202. In at least one configuration, the second transmission housing 202 and the lubricant trap 340 can cooperate to define the central slot 360. The lubricant 58 captured by the lubricant trap 340 can be conveyed to the lubricant outlet hole 312.

[0077] The first end slot 362 can extend from the central slot 360 toward the first transmission housing 200 to help capture more lubricant 58 than the central slot 360 can capture. The lubricant 58 captured by the first end slot 362 can be delivered to the central slot 360. The first end slot 362 can be spaced from the top of the second transmission housing 202 and can be disposed above one or more gears of the transmission 204. For example, the first end slot 362 can be disposed above a member of the pinion gear set 400, a member of the first countershaft gear set 402, or both. In at least one configuration, the second transmission housing 202 and the lubricant trap 340 can cooperate to define the first end slot 362.

[0078] The second end slot 364 can be spaced from the first end slot 362. The second end slot 364 can extend from the central slot 360 toward the first transmission housing 200 to help capture more lubricant 58 than the central slot 360 can capture. In at least one configuration, the second end slot 364 can be disposed at an opposite end of the central slot 360 from the first end slot 362. Thus, a member (such as the fourth gear 416) in the pinion gear set 400 of the drive pinion can be received between the first end slot 362 and the second end slot 364. The lubricant 58 captured by the second end slot 364 can be delivered to the central slot 360. The second end slot 364 can be spaced from the top of the second transmission housing 202 and can be disposed above one or more gears of the transmission 204. For example, the second end slot 364 can be disposed above a member of the pinion gear set 400, a member of the second countershaft gear set 404, or both. In at least one configuration, the second transmission housing 202 and the lubricant trap 340 can cooperate to define the second end slot 364.

[0079] Reference Figure 10 and Figure 11 , the transmission 204 can be operatively connected to an electric motor. In at least one configuration, the transmission 204 can be configured as a countershaft transmission that can include a pinion gear set 400, a first countershaft gear set 402, and a second countershaft gear set 404.

[0080] The pinion gear set 400 can be received in the transmission housing cavity 206 and can be disposed along the axis 70 between the first transmission housing 200 and the second transmission housing 202. The pinion gear 400 can include a plurality of gears, some of which can be selectively coupled to the drive pinion 30. In the illustrated configuration, the pinion gear set 400 includes a first gear 410, a second gear 412, a third gear 414, and a fourth gear 416; however, it should be understood that more or fewer gears can be provided.

[0081] The first gear 410 can extend about an axis 70 and can be disposed near the first transmission housing 200. In at least one configuration, the first gear 410 can have a through-hole that can receive the drive pinion 30, an extension of the drive pinion 30 (such as the connecting member 420), or both. The first gear 410 can have a plurality of teeth that can be arranged about the axis 70 and can extend away from the axis. The teeth of the first gear 410 can contact and cooperate or mesh with the teeth of the first countershaft gear, which can be provided for the first countershaft gear set 402 and the second countershaft gear set 404, as will be discussed in more detail below. The first gear 410 can be operatively connected to the rotor 106 of the electric motor module 26 such that the rotor 106 and the first gear 410 are rotatable together about the axis 70. For example, the first gear 410 can be fixedly positioned relative to the rotor 106 or fixedly coupled to the rotor 106 such that the first gear 410 cannot rotate relative to the rotor 106 about the axis 70. It is contemplated that the first gear 410 can be fixedly mounted to the rotor output flange 150 or integrally formed with the rotor output flange. Additionally, the first gear 410 can be continuously disengaged from the drive pinion 30 and can be rotatable relative to the drive pinion 30. Thus, the clutch does not connect the first gear 410 to the drive pinion 30 or the connecting member 420. The connecting member 420 (if provided) can be received within the first gear 410 and can be spaced apart from the first gear 410. In at least one configuration, the first gear 410 can be axially positioned along the axis 70 between the second gear 412 and the electric motor module 26.

[0082] The second gear 412 can extend about the axis 70. In at least one configuration, the second gear 412 can have a through-hole that can receive the drive pinion 30, the connecting member 420, or both. The second gear 412 can have a plurality of teeth that can be arranged about the axis 70 and can extend away from the axis. The teeth of the second gear 412 can contact and cooperate or mesh with the teeth of the second countershaft gear, which can be provided for the first countershaft gear set 402 and the second countershaft gear set 404, as will be discussed in more detail below. The second gear 412 can have a different diameter than the first gear 410. For example, the second gear 412 can have a larger diameter than the first gear 410. In at least one configuration, the second gear 412 can be axially positioned along the axis 70 between the first gear 410 and the third gear 414. In one or more configurations, the connecting member 420 can be received within the second gear 412 and can be spaced apart from the second gear 412.

[0083] The third gear 414 can extend about an axis 70. In at least one configuration, the third gear 414 can have a through-hole that can receive the drive pinion 30, the connecting member 420, or both. The third gear 414 can have a plurality of teeth that can be arranged about the axis 70 and can extend away from the axis. The teeth of the third gear 414 can contact and can cooperate or mesh with the teeth of a third countershaft gear that can be provided for the first countershaft gear set 402 and the second countershaft gear set 404, as will be discussed in more detail below. The third gear 414 can have a diameter different from that of the first gear 410 and the second gear 412. For example, the third gear 414 can have a larger diameter than the first gear 410 and the second gear 412. In at least one configuration, the third gear 414 is axially positioned along the axis 70 between the second gear 412 and the fourth gear 416. In one or more configurations, the connecting member 420 can be received within the third gear 414 and can be spaced apart from the third gear 414.

[0084] The fourth gear 416 can extend about an axis 70. In at least one configuration, the fourth gear 416 can have a through-hole that can receive the drive pinion 30, the connecting member 420, or both. The fourth gear 416 can have a plurality of teeth that can be arranged about the axis 70 and can extend away from the axis. The teeth of the fourth gear 416 can contact and can cooperate or mesh with the teeth of a fourth countershaft gear that can be provided for the first countershaft gear set 402 and the second countershaft gear set 404, as will be discussed in more detail below. The fourth gear 416 can have a diameter different from that of the first gear 410, the second gear 412, and the third gear 414, such as a larger diameter. In at least one configuration, the fourth gear 416 is axially positioned along the axis 70 farther from the electric motor module 26 than the first gear 410, the second gear 412, and the third gear 414. Thus, the fourth gear 416 can be axially positioned closer to or adjacent to the second transmission housing 202. In one or more configurations, the connecting member 420 can be received within the fourth gear 416 and can be spaced apart from the fourth gear 416.

[0085] Optionally, a thrust bearing 430 can be provided between members of the gear set 400 of the drive pinion, between the first transmission housing 200 and the gear set 400 of the drive pinion, between the second transmission housing 202 and the gear set 400 of the drive pinion (or combinations thereof). For example, a first thrust bearing 430 can be axially positioned between the first transmission housing 200 and the first gear 410, a second thrust bearing 430 can be axially positioned between the first gear 410 and the second gear 412, a third thrust bearing 430 can be axially positioned between the second gear 412 and the third gear 414, a fourth thrust bearing 430 can be axially positioned between the third gear 414 and the fourth gear 416, and a fifth thrust bearing 430 can be axially positioned between the fourth gear 416 and the second transmission housing 202.

[0086] The first countershaft gear set 402 can be received in the transmission housing cavity 206 and can be in meshing engagement with the gear set 400 of the drive pinion. The first countershaft gear set 402 can be rotatable about a first countershaft axis 440. In one or more embodiments, the first countershaft axis 440 can be arranged parallel or substantially parallel to the axis 70. The first countershaft gear set 402 can include a first countershaft 450 and a plurality of gears. In the illustrated configuration, the plurality of gears of the first countershaft gear set 402 includes a first countershaft gear 460, a second countershaft gear 462, a third countershaft gear 464, and a fourth countershaft gear 466; however, it is contemplated that a greater number or a smaller number of countershaft gears can be provided.

[0087] The first countershaft 450 can be rotatable about the first countershaft axis 440. For example, the first countershaft 450 can be rotatably supported on the first transmission housing 200 and the second transmission housing 202 by respective bearing assemblies 240. For example, the first bearing assembly and the second bearing assembly 240 can be located near opposite first and second ends of the first countershaft 450, respectively. The first countershaft 450 can support the first countershaft gear 460, the second countershaft gear 462, the third countershaft gear 464, and the fourth countershaft gear 466 and can rotate therewith.

[0088] The first countershaft gear 460 can be fixedly arranged on or fixedly mounted to the first countershaft 450. In this way, the first countershaft gear 460 can rotate about the first countershaft axis 440 with the first countershaft 450 and can not be rotatable relative to the first countershaft 450. For example, the first countershaft gear 460 can have a hole that can receive the first countershaft 450 and can be fixedly coupled to the first countershaft 450. The first countershaft gear 460 can extend about the first countershaft axis 440 and can have a plurality of teeth that can be arranged about the first countershaft axis 440 and can extend away from the first countershaft axis. The teeth of the first countershaft gear 460 can contact the teeth of the first gear 410 and can cooperate or mesh therewith. In at least one configuration, the first countershaft gear 460 can be axially positioned along the first countershaft axis 440 between the second countershaft gear 462 of the first countershaft gear set 402 and the first transmission housing 200.

[0089] The second countershaft gear 462 can be fixedly arranged on or fixedly mounted to the first countershaft 450. In this way, the second countershaft gear 462 can rotate about the first countershaft axis 440 with the first countershaft 450 and can not be rotatable relative to the first countershaft 450. For example, the second countershaft gear 462 can have a hole that can receive the first countershaft 450 and can be fixedly coupled to the first countershaft 450. The second countershaft gear 462 can extend about the first countershaft axis 440 and can have a plurality of teeth that can be arranged about the first countershaft axis 440 and can extend away from the first countershaft axis. The teeth of the second countershaft gear 462 can contact the teeth of the second gear 412 and can cooperate or mesh therewith. The second countershaft gear 462 can have a diameter different from that of the second countershaft gear 462 and the third countershaft gear 464. In at least one configuration, the second countershaft gear 462 can be axially positioned along the first countershaft axis 440 between the first countershaft gear 460 of the first countershaft gear set 402 and the third countershaft gear 464 of the first countershaft gear set 402.

[0090] The third countershaft gear 464 can be fixedly arranged on or fixedly mounted to the first countershaft 450. In this way, the third countershaft gear 464 can rotate with the first countershaft 450 about the first countershaft axis 440 and may not be rotatable relative to the first countershaft 450. For example, the third countershaft gear 464 can have a hole that can receive the first countershaft 450 and can be fixedly coupled to the first countershaft 450. The third countershaft gear 464 can extend about the first countershaft axis 440 and can have a plurality of teeth that can be arranged about the first countershaft axis 440 and can extend away from the first countershaft axis. The teeth of the third countershaft gear 464 can contact the teeth of the third gear 414 and can cooperate or mesh therewith. The third countershaft gear 464 can have a different diameter from the first countershaft gear 460 and the second countershaft gear 462. In at least one configuration, the third countershaft gear 464 can be axially positioned along the first countershaft axis 440 between the second countershaft gear 462 and the fourth countershaft gear 466 of the first countershaft gear set 402.

[0091] The fourth countershaft gear 466 can be fixedly arranged on or fixedly mounted to the first countershaft 450. In this way, the fourth countershaft gear 466 can rotate with the first countershaft 450 about the first countershaft axis 440 and may not be rotatable relative to the first countershaft 450. For example, the fourth countershaft gear 466 can have a hole that can receive the first countershaft 450 and can be fixedly coupled to the first countershaft 450 or can be integrally formed with the first countershaft 450. The fourth countershaft gear 466 can extend about the first countershaft axis 440 and can have a plurality of teeth that can be arranged about the first countershaft axis 440 and can extend away from the first countershaft axis. The teeth of the fourth countershaft gear 466 can contact the teeth of the fourth gear 416 and can cooperate or mesh therewith. The fourth countershaft gear 466 can have a different diameter from the first countershaft gear 460, the second countershaft gear 462, and the third countershaft gear 464. In at least one configuration, the fourth countershaft gear 466 can be axially positioned along the first countershaft axis 440 farther from the electric motor module 26 than the third countershaft gear 464 of the first countershaft gear set 402.

[0092] The second countershaft gear set 404 can be received in the transmission housing cavity 206 and can be rotatable about the second countershaft axis 440'. In one or more embodiments, the second countershaft axis 440' can be arranged parallel or substantially parallel to the axis 70 and the first countershaft axis 440. The second countershaft gear set 404 can generally be arranged on the opposite side of the axis 70 from the first countershaft gear set 402, or can be arranged such that the first countershaft axis 440 and the second countershaft axis 440' can be arranged at a common radial distance from the axis 70.

[0093] The second countershaft gear set 404 may have the same or substantially the same configuration as the first countershaft gear set 402. For example, the second countershaft gear set 404 may include a second countershaft 450', which may be similar to the first countershaft 450 or may have the same structure as the first countershaft. Additionally, the second countershaft gear set 404 may include a plurality of gears that rotate with the second countershaft 450'. In the illustrated configuration, this plurality of gears of the second countershaft gear set 404 includes a first countershaft gear 460', a second countershaft gear 462', a third countershaft gear 464', and a fourth countershaft gear 466'; however, it is contemplated that a greater number of gears or a smaller number of gears may be provided. The first countershaft gear 460', the second countershaft gear 462', the third countershaft gear 464', and the fourth countershaft gear 466' of the second countershaft gear set 404 may be respectively similar to the first countershaft gear 460, the second countershaft gear 462, the third countershaft gear 464, and the fourth countershaft gear 466 of the first countershaft gear set 402, or may respectively have the same structure as them. The first countershaft gear 460', the second countershaft gear 462', the third countershaft gear 464', and the fourth countershaft gear 466' may be arranged along the second countershaft axis 440' rather than the first countershaft axis 440', and may rotate about the second countershaft axis rather than the first countershaft axis, and may be fixed to the second countershaft 450' rather than the first countershaft 450.

[0094] The first gear 410 and the first countershaft gears 460, 460' may provide a different gear ratio than the second gear 412 and the second countershaft gears 462, 462', the third gear 414 and the third countershaft gears 464, 464', and the fourth gear 416 and the fourth countershaft gears 466, 466'. Gear ratios greater than 1:1, less than 1:1, equal (i.e., 1:1), or combinations thereof may be provided.

[0095] The teeth of the drive pinion and the countershaft gears may be of any suitable type. As a non-limiting example, the mating teeth of the members of the gear set 400 of the drive pinion, the gears of the first countershaft gear set 402, and the gears of the second countershaft gear set 404 may have a helical configuration.

[0096] First and second lubricant passages

[0097] Reference Figure 12 , a side view of a portion of the axle assembly 10 is shown, in which an example of the first lubricant passage 32 is shown in hidden lines. The first lubricant passage 32 may convey the lubricant 58 from the housing assembly 20 to the transmission housing cavity 206 to lubricate components disposed outside the housing assembly 20.

[0098] The first lubricant passage 32 can be at least partially defined by through-holes in the differential carrier 42, the motor housing 100, the motor cover 110, and the first transmission housing 200, which can be fluidly connected to each other. In this way, the first lubricant passage 32 can extend through the motor housing 100, the motor cover 110, and the first transmission housing 200. The first lubricant passage 32 can be at least partially defined in the outer walls of the motor housing 100, the motor cover 110, and the first transmission housing 200. This configuration can allow the lubricant 58 to be conveyed away from the axis 70 and around the stator 104 and the rotor 106 to transport the lubricant 58 from the housing assembly 20 to the transmission housing cavity 206, rather than transporting the lubricant 58 through the motor housing cavity 120 of the motor housing 100, through the motor cover opening 164 of the motor cover 110, or both. In at least one configuration, the first lubricant passage 32 can be entirely disposed above the axis 70. The first lubricant passage 32 can have at least one inlet 500 and at least one outlet 502.

[0099] The inlet 500 can be disposed near the housing assembly 20. The inlet 500 can receive the lubricant 58 splashed, for example, by the differential assembly 22 when the differential assembly 22 rotates about the differential axis 80 (as previously discussed). In at least one configuration, the inlet 500 can be provided for the differential carrier 42. The inlet 500 can be positioned above the outlet 502, or arranged to be further above the axis 70 than the outlet 502. In this way, the first lubricant passage 32 or a portion thereof can slope downward from the inlet 500 toward the outlet 502.

[0100] As previously discussed, the outlet 502 can be provided for the first transmission housing 200.

[0101] Reference Figure 4 and Figure 5 , show the portion of the first lubricant passage 32 defined by the motor housing 100, the motor cover 110, and the first transmission housing 200. In these figures, the lubricant flow is indicated by dashed arrows.

[0102] The portion 510 of the first lubricant passage 32 defined by the motor housing 100 can be disposed between the outer side 122 and the inner side 124 of the motor housing 100, and can be spaced from the outer side and the inner side. In this way, the portion 510 can be radially positioned farther from the axis 70 than the stator 104, the coolant jacket 102, and the inner side 124. The portion 510 can extend between an inlet port 512 and an outlet port 514. The inlet port 512 can face the differential carrier 42 and can be fluidly connected to the inlet 500. The outlet port 514 can be arranged opposite the inlet port 512 and can be arranged adjacent to the motor cover 110.

[0103] The portion 520 of the first lubricant passage 32 defined by the motor cover 110 may be disposed between the outer and inner sides of the motor cover 110 and may be spaced from the outer and inner sides. Thus, the portion 520 may be radially positioned farther from the axis 70 than the motor cover opening 164. The portion 520 may extend between an inlet port 522 and an outlet port 524. The inlet port 522 may face the motor housing 100 and may be fluidly connected to the outlet port 514. The outlet port 524 may be disposed opposite the inlet port 522 and may be adjacent to the first transmission housing 200.

[0104] The portion 530 of the first lubricant passage 32 defined by the first transmission housing 200 may extend between an inlet port 532 and an outlet 502. The inlet port 532 may face the motor cover 110 and may be fluidly connected to the outlet port 524. The outlet 502 may be disposed opposite the inlet port 532.

[0105] Reference Figure 13 , a side view of a portion of the axle assembly 10 is shown, in which an example of the second lubricant passage 34 is shown in hidden lines. The second lubricant passage 34 may return lubricant to the reservoir portion 56 of the housing assembly 20. For example, the second lubricant passage 34 may convey lubricant 58 from the transmission housing cavity 206 to the housing assembly 20 and may allow a common type of lubricant 58 or a common reservoir portion 56 to be provided to the axle assembly 10. The second lubricant passage 34 may be spaced from the first lubricant passage 32. In the illustrated configuration, the second lubricant passage 34 and the first lubricant passage 32 are disposed on opposite sides of the axle assembly 10.

[0106] The second lubricant passageway 34 may be at least partially defined by through - holes in the first transmission housing 200, the motor cover 110, the motor housing 100, and the differential carrier 42, and these through - holes may be fluidly connected to each other. Thus, the second lubricant passageway 34 may extend through the first transmission housing 200, the motor cover 110, and the motor housing 100. The second lubricant passageway 34 may be at least partially defined in the outer walls of the first transmission housing 200, the motor cover 110, and the motor housing 100. This configuration may allow the lubricant 58 to be conveyed away from the axis 70 and around the stator 104 and the rotor 106 to transport the lubricant 58 from the transmission housing cavity 206 to the housing assembly 20, rather than transporting the lubricant 58 through the motor housing cavity 120 of the motor housing 100, through the motor cover opening 164 of the motor cover 110, or both. In at least one configuration, the second lubricant passageway 34 may be at least partially disposed below the first lubricant passageway 32. For example, the second lubricant passageway 34 or a portion thereof may be disposed below the axis 70. The second lubricant passageway 34 may have at least one inlet 550 and at least one outlet 552.

[0107] The inlet 550 may be defined by the first transmission housing 200. The inlet 500 may receive the lubricant 58 that is splashed, for example, when the transmission 204 rotates (as previously discussed) by the transmission 204. The inlet 550 may be disposed above the outlet 552. Thus, the second lubricant passageway 34 or a portion thereof may slope downward from the inlet 550 toward the outlet 552 or to the outlet.

[0108] The outlet 552 may be provided for the differential carrier 42.

[0109] Reference Figure 4 and Figure 5 shows the portion of the second lubricant passageway 34 defined by the first transmission housing 200, the motor cover 110, and the motor housing 100.

[0110] The portion 560 of the second lubricant passageway 34 defined by the first transmission housing 200 may extend between the inlet 550 and the outlet port 574. The inlet 550 may face the transmission housing cavity 206 and may be fluidly connected to the transmission housing cavity. The outlet port 574 may be disposed opposite the inlet 550.

[0111] The portion 580 of the second lubricant passage 34 defined by the motor cover 110 may be disposed between an outer side and an inner side of the motor cover 110 and may be spaced apart from the outer side and the inner side. Accordingly, the portion 580 may be radially positioned farther from the axis 70 than the motor cover opening 164. The portion 580 may extend between an inlet port 582 and an outlet port 584. The inlet port 582 may face the first transmission housing 200 and may be fluidly connected to the outlet port 574. The outlet port 584 may be disposed opposite the inlet port 582 and may be disposed adjacent to the motor housing 100.

[0112] The portion 590 of the second lubricant passage 34 defined by the motor housing 100 may be disposed between an outer side 122 and an inner side 124 of the motor housing 100 and may be spaced apart from the outer side and the inner side. In this way, the portion 590 may be radially positioned farther from the axis 70 than the stator 104, the coolant jacket 102, and the inner side 124. The portion 590 may extend between an inlet port 592 and an outlet port 594. The inlet port 592 may face the motor cover 110 and may be fluidly connected to the outlet port 584. The outlet port 594 may be disposed opposite the inlet port 512 and may be disposed adjacent to the differential carrier 42 and may be fluidly connected to the outlet 552 of the second lubricant passage 34.

[0113] Shift mechanism

[0114] Reference Figure 3 and Figure 13 , the shift mechanism 36 may cooperate with the transmission module 28 to provide a desired gear reduction ratio, thereby changing the torque provided from the electric motor module 26 to the differential assembly 22 and thus to the half shafts 24 of the axle assembly 10. In at least one configuration, the shift mechanism 36 may operatively connect a member of the pinion gear set 400 of the drive pinion to the drive pinion 30 such that the connected drive pinion may rotate with the drive pinion 30. More specifically, the shift mechanism 36 may couple a member of the pinion gear set 400 of the drive pinion to the drive pinion 30 one at a time to provide different drive gear ratios.

[0115] The shift mechanism 36 may be received in or partially received in the shift mechanism housing cavity 600, as best shown in Figure 3 and Figure 14 . The shift mechanism housing cavity 600 may be partially defined by the second transmission housing 202 and may be disposed near one end of the axle assembly 10.

[0116] The shift mechanism 36 can have any suitable configuration. For example, the shift mechanism 36 can include one or more clutches of any suitable type. In the illustrated configuration, the shift mechanism 36 includes a shift collar 610 that can be moved along an axis 70 to selectively connect members of a gear set 400 of the drive pinion to the drive pinion 30 such that the connected gears can rotate about the axis 70 with the drive pinion 30.

[0117] An actuator 612 can actuate the shift mechanism 36. The actuator 612 can be of any suitable type, such as an electric actuator, an electromechanical actuator, or a mechanical actuator.

[0118] While the foregoing describes exemplary embodiments, these embodiments are not intended to describe all possible forms of the invention. Rather, the words used in this specification are words of description rather than limitation, and it should be understood that various changes may be made without departing from the spirit and scope of the invention. In addition, the features of the various embodiments to be implemented may be combined to form additional embodiments of the invention.

Claims

1. A axle assembly, comprising: A housing assembly that receives a differential assembly and at least partially defines a cavity having a reservoir portion for receiving a lubricant; An electric motor module, the electric motor module comprising: A motor housing that is mounted to the housing assembly and defines a motor housing cavity for receiving an electric motor; and A motor cover that is mounted to an end of the motor housing opposite the housing assembly; A transmission module, the transmission module comprising: A first transmission housing that is mounted to the motor cover; and A second transmission housing that is mounted to the first transmission housing, wherein the first transmission housing and the second transmission housing cooperate to define a transmission housing cavity that receives a transmission operatively connected to the electric motor; and A first lubricant passage that conveys lubricant from the housing assembly to the transmission housing cavity, wherein the first lubricant passage extends through the motor housing, the motor cover, and the first transmission housing and is separated from the motor housing cavity.

2. The axle assembly according to claim 1, wherein, The first transmission housing defines a first recess and a first connection passage, the first recess receiving a bearing assembly that rotatably supports a first countershaft, and the first connection passage extending from an outlet of the first lubricant passage to the first recess.

3. The axle assembly according to claim 1, wherein, The first transmission housing defines a first recess that receives a bearing assembly that rotatably supports a first countershaft, a first passage spaced from the first recess and extending from an outlet of the first lubricant passage, and a first baffle extending over the outlet and deflecting lubricant leaving the outlet into the first passage.

4. The axle assembly according to claim 3, wherein, The first passage extends from the outlet to a first passage end disposed below a central hole of the first transmission housing that receives a drive pinion, wherein the first baffle does not cover the first passage end to allow lubricant to leave the first passage at the first passage end.

5. The axle assembly according to claim 3, wherein, The first baffle is received within the first passage.

6. The axle assembly according to claim 1, further comprising: A second lubricant passage that conveys lubricant from the transmission housing cavity to the housing assembly, wherein the second lubricant passage extends through the first transmission housing, the motor cover, and the motor housing and is separated from the first lubricant passage and the motor housing cavity.

7. The axle assembly according to claim 6, wherein, The first transmission housing defines a second passage extending from an inlet of the second lubricant passage, a second recess receiving a bearing assembly that rotatably supports a second countershaft, and a second connection passage extending from the second passage to the second recess.

8. The axle assembly according to claim 6, wherein, The first transmission housing defines a second recess that receives a bearing assembly that rotatably supports a second countershaft, a second passage spaced from the second recess and extending from an inlet of the second lubricant passage, and a second baffle extending over a portion of the second passage and deflecting lubricant into an inlet of the second lubricant passage.

9. The axle assembly according to claim 8, wherein, The first transmission housing defines a central hole that extends along an axis and receives a drive pinion, and wherein the second baffle has a spoon-shaped portion disposed above the axis, the spoon-shaped portion being configured to capture lubricant splashed by the transmission in the transmission housing cavity and convey the lubricant to the second passage.

10. The axle assembly according to claim 9, further comprising: A deflector disposed above the axis and extending from the first transmission housing into the transmission housing cavity and toward the second transmission housing, wherein the deflector directs lubricant into the spoon-shaped portion.

11. The axle assembly according to claim 10, wherein, The second baffle is mounted to the deflector.

12. An axle assembly comprising: A housing assembly that receives a differential assembly and at least partially defines a cavity having a reservoir portion for receiving lubricant; An electric motor module mounted to the housing assembly; A transmission module including: A first transmission housing mounted to the electric motor module and fluidly connected to the housing assembly via a first lubricant passage; and A second transmission housing mounted to the first transmission housing, wherein the first transmission housing and the second transmission housing cooperate to define a transmission housing cavity for receiving a transmission, and a lubricant trap is received in the transmission housing cavity, the lubricant trap being mounted to the second transmission housing and extending from the second transmission housing toward the first transmission housing, wherein the first lubricant passage conveys lubricant from the housing assembly to the transmission housing cavity; and wherein the lubricant trap is configured to capture lubricant splashed by the transmission when the transmission rotates in the transmission housing cavity.

13. The axle assembly according to claim 12, wherein, The second transmission housing defines a central hole that extends along an axis, the transmission includes a gear set of a drive pinion disposed between the first transmission housing and the second transmission housing along the axis, and wherein at least a portion of the lubricant trap extends over at least one member of the gear set of the drive pinion.

14. The axle assembly according to claim 13, wherein, The lubricant trap at least partially defines a central groove extending along the second transmission housing and a first end groove extending from the central groove toward the first transmission housing, the first end groove being disposed above a member of the gear set of the drive pinion.

15. The axle assembly according to claim 14, wherein, The lubricant trap at least partially defines a second end groove extending from the central groove toward the first transmission housing and spaced from the first end groove, wherein the member of the gear set of the drive pinion is received between the first end groove and the second end groove.

16. The axle assembly according to claim 15, wherein, The second transmission housing and the lubricant trap cooperate to define at least one of the central groove, the first end groove, and the second end groove, and the lubricant trap is spaced from the first transmission housing.

17. The axle assembly according to claim 15, wherein, The transmission includes a first countershaft gear set rotatable about a first countershaft axis and a second countershaft gear set rotatable about a second countershaft axis, and wherein the lubricant trap extends over members of the first countershaft gear set and members of the second countershaft gear set.

18. The axle assembly according to claim 12, wherein, The second transmission housing defines a first recess that receives a bearing assembly rotatably supporting the first countershaft, a first inlet slot that projects from an outer circumference of the first recess, and a first outlet slot that is spaced from the first inlet slot and projects outward from the outer circumference of the first recess, wherein the first inlet slot facilitates flow of lubricant into the first recess and the first outlet slot facilitates flow of lubricant out of the first recess.

19. The axle assembly according to claim 18, wherein, The second transmission housing defines a shoulder that is disposed below the lubricant trap, wherein the first inlet slot extends from the shoulder.

20. The axle assembly according to claim 12, wherein, The second transmission housing has a lubricant outlet hole that is a through hole extending through the second transmission housing, and wherein lubricant trapped by the lubricant trap is conveyed to the lubricant outlet hole.

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