Axle assembly with a gear reduction module having multiple gear sets

Abstract

Disclosed is an axle assembly having a gear reduction unit configured to operatively connect an electric motor to a drive pinion. The gear reduction unit includes at least two gear sets. A shift collar is rotatable with the drive pinion and movable along the drive pinion to couple the gear sets to the drive pinion.

Description

Technical Field

[0001] The present disclosure relates to an axle assembly having a plurality of gear sets that operatively connect a rotor to a drive pinion. 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 an electric motor, a drive pinion, a gear reduction unit, and a shift collar. The electric motor can have a rotor rotatable about an axis. The drive pinion can extend through the rotor and be rotatable about the axis. The gear reduction unit can include a first gear set and a second gear set. The first gear set can have a first sun gear, a first ring gear, a first set of planet gears, and a first planet gear carrier. The first sun gear can be operatively connected to the rotor and be rotatable about the axis. The first ring gear can be fixedly positioned such that the first ring gear is not rotatable about the axis. The first set of planet gears can mesh with the first sun gear and the first ring gear. The first planet gear carrier can rotatably support the first set of planet gears. The second gear set can have a second sun gear, a second ring gear, a second set of planet gears, and a second planet gear carrier. The second sun gear can be rotatable about the axis. The second set of planet gears can mesh with the second sun gear and be rotatably supported on the first planet gear carrier. The components of the second set of planet gears can have a smaller diameter than the components of the first set of planet gears. The shift collar can be rotatable about the axis with the drive pinion. The shift collar can be movable along the axis between a first position and a second position. In the first position, the shift collar can couple the first planet gear carrier to the drive pinion without coupling the first sun gear or the second sun gear to the drive pinion. In the second position, the shift collar can couple the second sun gear to the drive pinion without coupling the first sun gear or the first planet gear carrier to the drive pinion.

[0005] In at least one embodiment, an axle assembly is provided. The axle assembly can include an electric motor, a drive pinion, a gear reduction unit, and a shift collar. The electric motor can have a rotor rotatable about an axis. The drive pinion can extend through the rotor and be rotatable about the axis. The gear reduction unit can include a first gear set, a second gear set, and an epicyclic gear set. The first gear set can have a first sun gear, a first ring gear, a first set of planet gears, and a first planet gear carrier. The first sun gear can be operatively connected to the rotor and be rotatable about the axis. The first ring gear can be fixedly positioned such that the first ring gear is not rotatable about the axis. The first set of planet gears can mesh with the first sun gear and the first ring gear. The first planet gear carrier can rotatably support the first set of planet gears. The second gear set can have a second set of planet gears rotatably supported on the first planet gear carrier. The members of the second set of planet gears can have a smaller diameter than the members of the first set of planet gears. The epicyclic gear set can have an epicyclic sun gear, an epicyclic ring gear, a set of epicyclic planet gears, and an epicyclic plane gear carrier. The epicyclic sun gear can be fixedly positioned relative to the first planet gear carrier such that the epicyclic sun gear does not rotate relative to the first planet gear carrier. The epicyclic ring gear can be fixedly positioned such that the epicyclic ring gear is not rotatable about the axis. The set of epicyclic planet gears can mesh with the epicyclic sun gear and the epicyclic ring gear. The epicyclic planet gear carrier can rotatably support the set of epicyclic planet gears. The shift collar can be rotatable about the axis with the drive pinion. The shift collar can be movable along the axis between a first position and a second position. In the first position, the shift collar can couple the epicyclic planet gear carrier to the drive pinion without coupling the first sun gear or the epicyclic sun gear to the drive pinion. In the second position, the shift collar can couple the epicyclic sun gear to the drive pinion without coupling the first sun gear or the epicyclic planet gear carrier to the drive pinion.

[0006] In at least one embodiment, an axle assembly is provided. The axle assembly can include an electric motor, a drive pinion, a gear reduction unit, and a shift collar. The electric motor can have a rotor rotatable about an axis. The drive pinion can extend through the rotor and be rotatable about the axis. The gear reduction unit can include an epicyclic gear set, a first gear set, and a second gear set. The epicyclic gear set can have an epicyclic sun gear, an epicyclic ring gear, a set of epicyclic planet gears, and an epicyclic planet gear carrier. The epicyclic sun gear can be operatively connected to the rotor and be rotatable about the axis. The epicyclic ring gear can be rotatable about the axis. The set of epicyclic planet gears can mesh with the epicyclic sun gear and the epicyclic ring gear. The epicyclic planet gear carrier can rotatably support the set of epicyclic planet gears and be fixedly positioned such that the epicyclic planet gear carrier is not rotatable about the axis. The first gear set can have a first sun gear, a first ring gear, a first set of planet gears, and a first planet gear carrier. The first sun gear can be fixedly positioned relative to the epicyclic ring gear such that the first sun gear does not rotate relative to the epicyclic ring gear. The first ring gear can be fixedly positioned such that the first ring gear is not rotatable about the axis. The first set of planet gears can mesh with the first sun gear and the first ring gear. The first planet gear carrier can rotatably support the first set of planet gears. The second gear set can have a second sun gear and a second set of planet gears. The second sun gear can be rotatable about the axis. The second set of planet gears can mesh with the second sun gear and be rotatably supported on the first planet gear carrier. The members of the second set of planet gears can have a smaller diameter than the members of the first set of planet gears. The shift collar can rotate about the axis with the drive pinion. The shift collar can be movable along the axis between a first position and a second position. In the first position, the shift collar can couple the first planet gear carrier to the drive pinion without coupling the first sun gear, the second sun gear, or the epicyclic sun gear to the drive pinion. In the second position, the shift collar can couple the second sun gear to the drive pinion without coupling the epicyclic sun gear, the first sun gear, or the first planet gear carrier to the drive pinion.

[0007] In at least one embodiment, an axle assembly is provided. The axle assembly can include an electric motor, a drive pinion, a gear reduction unit, and a shift collar. The electric motor can have a rotor rotatable about an axis. The drive pinion can be received within the rotor and can be rotatable about the axis. The gear reduction unit can include an epicyclic gear set, a first gear set, and a second gear set. The epicyclic gear set can have an epicyclic sun gear, an epicyclic ring gear, a set of epicyclic planet gears, and an epicyclic planet gear carrier. The epicyclic sun gear can be fixedly positioned such that the epicyclic sun gear cannot rotate about the axis. The epicyclic ring gear can be operatively connected to the rotor and can be rotatable about the axis with the rotor. The set of epicyclic planet gears can mesh with the epicyclic sun gear and the epicyclic ring gear. The epicyclic planet gear carrier can rotatably support the set of epicyclic planet gears. The first gear set can have a first sun gear, a first ring gear, a first set of planet gears, and a first planet gear carrier. The first sun gear can be fixedly positioned relative to the epicyclic planet gear carrier such that the first sun gear does not rotate relative to the epicyclic planet gear carrier. The first ring gear can be fixedly positioned such that the first ring gear cannot rotate about the axis. The first set of planet gears can mesh with the first sun gear and the first ring gear. The first planet gear carrier can rotatably support the first set of planet gears. The second gear set can have a second sun gear and a second set of planet gears. The second sun gear can be rotatable about the axis. The second set of planet gears can mesh with the second sun gear and can be rotatably supported on the first planet gear carrier. The members of the second set of planet gears can have a smaller diameter than the members of the first set of planet gears. The shift collar can be rotatable about the axis with the drive pinion. The shift collar can be movable along the axis between a first position and a second position. In the first position, the shift collar can couple the first planet gear carrier to the drive pinion without coupling the first sun gear, the second sun gear, or the epicyclic sun gear to the drive pinion. In the second position, the shift collar can couple the second sun gear to the drive pinion without coupling the epicyclic sun gear, the first sun gear, or the first planet gear carrier to the drive pinion. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a perspective view of an example of the axle assembly.

[0009] Figure 2 is Figure 1 a cross-sectional view of the axle assembly taken along section line 2-2.

[0010] Figure 3 is an enlarged view of a portion of Figure 2 showing the gear reduction unit and the shift collar in the first position.

[0011] Figure 4Shows the shift collar in the second position.

[0012] Figure 5 Is an enlarged view showing a second configuration of the gear reduction unit, where the shift collar is in the first position.

[0013] Figure 6 and Figure 7 Show the shift collar in the second and third positions, respectively.

[0014] Figure 8 Is an enlarged view showing a third configuration of the gear reduction unit, where the shift collar is in the first position.

[0015] Figure 9 and Figure 10 Show the shift collar in the second and third positions, respectively.

[0016] Figure 11 Is an enlarged view showing a fourth configuration of the gear reduction unit, where the shift collar is in the first position.

[0017] Figure 12 and Figure 13 Show the shift collar in the second and third positions, respectively. Detailed Description

[0018] As required, detailed embodiments of the present invention are disclosed herein; however, it should 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 specific components. Therefore, the specific structural and functional details disclosed herein should not be construed as limiting, but only as a representative basis for teaching those skilled in the art to practice the present invention in various ways.

[0019] Reference Figure 1 , shows an example of the axle assembly 10. The axle assembly 10 can be provided for a motor vehicle, such as a truck, bus, farm equipment, mining equipment, military transport or armored vehicle, or for cargo loading equipment for land, air, or marine vessels. In one or more embodiments, the motor vehicle can include a trailer for transporting cargo.

[0020] 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.

[0021] One or more axle assemblies can be provided for a vehicle. As referenced Figure 1 and Figure 2Best shown, the axle assembly 10 can include a housing assembly 20, a differential assembly 22, at least one half shaft 24, and an electric motor module 26. As Figure 2 Best shown, the axle assembly 10 can include a gear reduction module 30 and a shift mechanism 32.

[0022] Housing assembly

[0023] Reference Figure 1 , the housing assembly 20 can house 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.

[0024] The axle housing 40 can house and can 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.

[0025] The central portion 50 can be disposed near the center of the axle housing 40. The central portion 50 can define a cavity that can at least partially house the differential assembly 22. As Figure 2 Best shown, a lower region of the central portion 50 can at least partially define an oil pan portion 54 that can hold or collect lubricant 56. The lubricant 56 in the oil pan portion 54 can be splashed by the ring gear of the differential assembly 22 and distributed to lubricate various components.

[0026] Reference Figure 2 , the central portion 50 can include a bracket mounting surface 58. The bracket mounting surface 58 can assist in mounting the differential carrier 42 to the axle housing 40. For example, the bracket mounting surface 58 can face and can engage the differential carrier 42, and can have a set of holes that can align with corresponding holes on the differential carrier 42. Each hole can receive a fastener, such as a bolt or stud, that can couple the differential carrier 42 to the axle housing 40.

[0027] Reference Figure 1 , 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 a corresponding half shaft 24 and can receive the corresponding half shaft, and can assist in separating or isolating the half shaft 24 or a portion thereof from the surrounding environment. The arm portions 52 or a portion thereof can be integrally formed with the central portion 50, or can not be integrally formed with the central portion. It is also contemplated that the arm portions 52 can be omitted.

[0028] Reference Figure 1 and Figure 2 Figure 2 , 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 can include one or more bearing supports that can support bearings, such as a roller bearing assembly, that can rotatably support the differential assembly 22. The differential carrier 42 can also include a mounting flange 60 and a bearing support wall 62.

[0029] Reference Figure 2 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 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 84, 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 the axis 70. The bearing support wall 62 can define a hole that can extend along or around the axis 70 and receive the drive pinion 84 and bearings that rotatably support the drive pinion 84. 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 Figure 2 , the differential assembly 22 can be at least partially received within the central portion 50 of the housing assembly 20. The differential assembly 22 can be rotatable about a differential axis 80 and can transfer 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 84. Accordingly, the differential assembly 22 can receive torque from the drive pinion 84 via the ring gear 82 and transfer the torque to the half shafts 24.

[0033] The drive pinion 84 can provide torque to the ring gear 82. In an axle assembly including the gear reduction module 30, the drive pinion 84 can operatively connect the gear reduction module 30 to the differential assembly 22. In at least one configuration, the drive pinion 84 can be rotatable about an axis 70 and can be rotatably supported within another component, such as a bearing support wall 62).

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

[0035] Electric motor module

[0036] Reference Figure 2 , the electric motor module 26 (which can also be referred to as an electric motor) can be mounted to the differential carrier 42 and can be operatively connectable to the differential assembly 22. For example, the electric motor module 26 can provide torque to the differential assembly 22 via the drive pinion 84 and the gear reduction module, as will be discussed in more detail below. The electric motor module 26 can be primarily disposed outside the differential carrier 42. Additionally, the electric motor module 26 can be axially positioned between the axle housing 40 and the gear reduction module 30. 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 cover 110.

[0037] The motor housing 100 can extend between the differential carrier 42 and the cover 110. The motor housing 100 can be mounted to the differential carrier 42 and the cover 110. For example, the motor housing 100 can extend from a mounting flange 60 of the differential carrier 42 to the cover 110. The motor housing 100 can extend around the axis 70 and can define a motor housing cavity 120. The motor housing cavity 120 can be disposed within the motor housing 100 and can have a generally cylindrical configuration. The bearing support wall 62 of the differential carrier 42 can be located within the motor housing cavity 120. Additionally, the motor housing 100 can extend continuously around the bearing support wall 62 and can be spaced therefrom. In at least one configuration, the motor housing 100 can have an outer side 122, an inner side 124, a first end surface 126, a second end surface 128, and one or more ports 130.

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

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

[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 arranged 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. The motor housing 100 and the first end surface 126 can be received inside the mounting flange 60, or may not be received inside the mounting flange.

[0041] The second end surface 128 can be arranged opposite to the first end surface 126. Thus, the second end surface 128 can be arranged at the end of the motor housing 100 that can face and can engage the cover 110. The second end surface 128 can extend between the outer side 122 and the inner side 124, and can be received inside the cover 110, or may not be received inside the cover.

[0042] One or more ports 130 can extend through the motor housing 100. The port 130 can be configured as a through-hole that can extend from the outer side 122 to the inner side 124. The port 130 can allow coolant (such as a fluid, such as water, a water / antifreeze mixture, etc.) to flow into and out of the coolant jacket 102, as will be discussed in more detail below.

[0043] Reference Figure 2 , the coolant jacket 102 can help cool the stator 104 or remove heat from the stator. The coolant jacket 102 can be received in the motor housing cavity 120 of the motor housing 100 and can engage the inner side 124 of the motor housing 100. The coolant jacket 102 can extend axially between the differential carrier 42 and the cover 110. For example, the coolant jacket 102 can extend axially from the differential carrier 42 to the cover 110. Additionally, the coolant jacket 102 can extend around the axis 70 and the stator 104. Thus, the stator 104 can be at least partially received in the coolant jacket 102 and can be surrounded by the coolant jacket. Furthermore, the coolant jacket 102 can 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 can include a plurality of channels 140.

[0044] The passage 140 can extend around the axis 70 and can be arranged opposite to the stator 104. The passage 140 can be configured to have an open side that can face away from the axis 70 and towards the inner side 124 of the motor housing 100. Coolant can be supplied to the coolant jacket 102 via the first port 130 and the coolant jacket 102 can be drained via the second port 130. For example, the coolant can flow from the first port 130 into the passage 140, receive heat from the stator 104 as the coolant flows through the passage 140, and be discharged at the second port 130. One or more baffles can be provided with the coolant jacket 102, which can reverse or change the coolant flow direction to assist in delivering the coolant from the first port 130 to the second port 130.

[0045] The stator 104 can be received in the motor housing 100. For example, the stator 104 can be received in the motor housing cavity 120. The stator 104 can be fixedly positioned relative to the coolant jacket 102. For example, the stator 104 can extend around the axis 70 and can include stator windings that can be received inside the coolant jacket 102 and can be fixedly positioned relative to the coolant jacket.

[0046] The rotor 106 can extend around the axis 70 and can be rotatable about the axis. The rotor 106 can be received inside the stator 104, the coolant jacket 102, and the motor housing cavity 120 of the motor housing 100. The rotor 106 can be rotatable about the axis 70 relative to the differential carrier 42 and the stator 104. Additionally, the rotor 106 can be spaced apart from the stator 104, but can be arranged adjacent to the stator 104. The rotor 106 can include magnets or ferromagnetic materials that can facilitate current generation or can be based on induction. The rotor 106 can extend around the bearing support wall 62 and can be supported by the bearing support wall.

[0047] One or more rotor bearing assemblies 108 can rotatably support the rotor 106. For example, the rotor bearing assembly 108 can receive the bearing support wall 62 of the differential carrier 42 and can be received inside the rotor 106. The rotor 106 can be operatively connected to the drive pinion 84. For example, a coupling (such as the rotor output flange 150) can operatively connect the rotor 106 to the gear reduction module 30, which in turn can be operatively connectable to the drive pinion 84.

[0048] Reference Figure 2, the cover 110 can be mounted to the motor housing 100 and can be arranged to be opposite to the axle housing 40 and the differential carrier 42. For example, the cover 110 can be mounted to the end or end surface of the motor housing 100, such as the second end surface 128, which can be arranged to be opposite to the differential carrier 42. In this way, the cover 110 can be spaced apart from the differential carrier 42 and can be non-engaging with the differential carrier. The cover 110 can be provided in different configurations. In at least one configuration, the cover 110 can include a first side 160 and a second side 162. The first side 160 can face the motor housing 100 and can engage the motor housing. The second side 162 can be arranged to be opposite to the first side 160. The second side 162 can face away from the motor housing 100 and can be arranged to be opposite to the motor housing 100. The cover 110 can also include or define a motor cover opening, which can be a through hole through which the drive pinion 84 can extend.

[0049] Gear reduction module and shift mechanism

[0050] Reference Figure 2 , an example of the gear reduction module 30 is shown. The gear reduction module 30 can transmit torque between the electric motor module 26 and the differential assembly 22. In this way, the gear reduction module 30 can be operatively connected to the electric motor module 26 and the differential assembly 22.

[0051] The gear reduction module 30 can be arranged outside the differential carrier 42, and can be mainly arranged outside the electric motor module 26, or can be integrally arranged outside the electric motor module 26, so as to provide a modular structure that can be mounted to the electric motor module 26 when gear reduction is desired. For example, the gear reduction module 30 can include a gear reduction module housing 170, which can accommodate the gears of the gear reduction module 30. The gear reduction module housing 170 can be provided in various configurations. For example, the gear reduction module housing 170 can be a separate component mounted to the cover 110, or can be integrally formed with the cover 110. The gear reduction module housing 170 can extend from the second side 162 of the cover 110 in a direction away from the electric motor module 26. A gear reduction module cover 172 can be arranged on the gear reduction module housing 170 and can be removable to provide access to the components located inside the gear reduction module housing 170.

[0052] The gear reduction module can be provided in various configurations and can include multiple gear sets operatively connected to each other. These gear sets can be configured as epicyclic gear sets, where one or more planet gears can revolve or rotate around a central sun gear. Each planet gear can be rotatable about a corresponding axis, which can be positioned at a constant or substantially constant radial distance from the axis about which the central sun gear rotates. A particular gear set may or may not have a planet ring gear that extends around and meshes with the planet gears. For clarity, each gear set is designated by a different name in the following discussion.

[0053] Four main configurations 30, 30’, 30”, 30”’ of the gear reduction module are described below and are best shown in Figures 3 to 13 It should be understood that each gear reduction module configuration can be provided for an axle assembly as described above (i.e., provided for an axle assembly having a housing assembly 20, a differential assembly 22, at least one half shaft 24, an electric motor module 26, a shift mechanism 32, a drive pinion 84, and a gear reduction module housing 170). Accordingly, an enlarged view is shown in Figures 3 to 13 to better depict each gear reduction module configuration rather than the rest of the axle assembly. Each enlarged view is a cross-sectional view along axis 70. In these figures, the torque transmission path between the electric motor module 26 and the drive pinion 84 is represented by thickened, straight, unnumbered double-dashed lines. The torque transmission path can be bidirectional.

[0054] Referring to Figure 3 and Figure 4 , a first configuration of the gear reduction module 30 is shown. The gear reduction module 30 can include a first gear set 200 and a second gear set 202.

[0055] The first gear set 200 can be axially positioned along axis 70 between the electric motor module 26 and the second gear set 202. The first gear set 200 can be configured as an epicyclic gear set. For example, the first gear set 200 can include a first sun gear 210, a first set of planet gears 212, a first planet ring gear 214, and a first planet gear carrier 216.

[0056] The first sun gear 210 can be operatively connected to the rotor 106. For example, the first sun gear 210 can be operatively connected to the rotor 106 via the rotor output flange 150. Thus, the first sun gear 210 can be rotatable about axis 70 with the rotor 106 and the rotor output flange 150. Optionally, the first sun gear 210 can extend around the drive pinion 84 and can receive the drive pinion.

[0057] The first set of planetary gears 212 may be rotatably disposed between the first sun gear 210 and the first planetary ring gear 214. Each first planetary gear 212 may have teeth that may engage the teeth of the first sun gear 210 that extend away from the axis 70, and the teeth of the first planetary ring gear 214 that may extend toward the axis 70. Additionally, each first planetary gear 212 may be rotatable about a corresponding planetary gear axis 218.

[0058] The first planetary ring gear 214 may extend about the axis 70 and may receive the first set of planetary gears 212. The first planetary ring gear 214 may be fixedly positioned such that the first planetary ring gear 214 is not rotatable about the axis 70. For example, the first planetary ring gear 214 may be received within the gear reduction module housing 170 and may be fixedly coupled to the gear reduction module housing such that the first planetary ring gear 214 is not rotatable about the axis 70.

[0059] The first planetary gear carrier 216 may rotatably support the first set of planetary gears 212. Additionally, the first planetary gear carrier 216 may be rotatable about the axis 70. The first planetary gear carrier 216 may extend toward the second gear set 202 and may be operatively connected to the second gear set. In at least one configuration, the first planetary gear carrier 216 may include a support portion 220, a flange portion 222, and a gear portion 224.

[0060] The support portion 220 may rotatably support the first set of planetary gears 212. The support portion 220 may have any suitable configuration. For example, the support portion 220 may include a plurality of pins that may extend along each planetary gear axis 218 and may be received within holes in each first planetary gear 212. Bearings, such as roller bearing assemblies, may be received within the holes in each first planetary gear 212 and may extend around each pin to help rotatably support each first planetary gear 212.

[0061] The flange portion 222 may extend from an end of the support portion 220 toward the axis 70. The flange portion 222 may be axially positioned along the axis 70 between the gear reduction module cover 172 and the gears of the second gear set 202.

[0062] The gear portion 224 may extend from the flange portion 222 toward the axis 70. The gear portion 224 may include a plurality of teeth that may be arranged in a repeating pattern about the axis 70. The teeth of the gear portion 224 may extend toward the axis 70 and may be arranged to be substantially parallel to the axis 70. The teeth of the gear portion 224 may be selectively engaged by a shift collar 250, as will be discussed in more detail below.

[0063] The support bearing assembly 226 can rotatably support the first planetary gear carrier 216. The support bearing assembly 226 can extend from the gear reduction module housing 170 to the first planetary gear carrier 216. For example, the support bearing assembly 226 can be received inside the gear reduction module housing 170, and the first planetary gear carrier 216 can be received inside the support bearing assembly 226. The support bearing assembly 226 can be disposed adjacent to the flange portion 222 of the first planetary gear carrier 216 and can be axially positioned between the second gear set 202 and the gear reduction module cover 172. In this way, the second gear set 202 can be axially positioned along the axis 70 between the first gear set 200 and the support bearing assembly 226.

[0064] The second gear set 202 can be operatively connected to the first gear set 200. Despite the first planetary gear carrier 216, the second gear set 202 can be spaced apart from the first gear set 200. The second gear set 202 can include a second sun gear 230 and a second set of planetary gears 232. In one or more configurations, the planetary ring gear can be omitted from the second gear set 202.

[0065] The second sun gear 230 can be rotatable about the axis 70. The second sun gear 230 can extend around the shift collar 250 and can receive the shift collar. Additionally, the second sun gear 230 can include a set of internal teeth 234. The set of internal teeth 234 can be disposed within a bore defined by the second sun gear 230 and can extend toward the axis 70. The set of internal teeth 234 can include a plurality of teeth that can be arranged in a repeating pattern around the axis 70. The internal teeth 234 can extend toward the axis 70 and can be arranged to be substantially parallel to the axis 70. The set of internal teeth 234 can be selectively engaged by the shift collar 250, as will be discussed in more detail below.

[0066] The second set of planetary gears 232 may be rotatably disposed on the second sun gear 230. Each second planetary gear 232 may have teeth that may engage the teeth of the second sun gear 230 that extend away from the axis 70. Each second planetary gear 232 may be rotatable about a corresponding planetary gear axis that may be set parallel to the planetary gear axis 218. In at least one configuration, the components of the second set of planetary gears 232 may have a smaller diameter than the components of the first set of planetary gears 212. The support portion 220 may rotatably support the components of the first set of planetary gears 212 and the components of the second set of planetary gears 232, such that the planetary gears may be rotationally fixed such that the first planetary gear 212 and the corresponding second planetary gear 232 may be rotatable about the same planetary rotation gear axis 218. For example, each first planetary gear 212 may be coupled to a corresponding second planetary gear 232 to form a compound planetary gear, where the first planetary gear 212 and the second planetary gear 232 rotate together rather than relative to each other. The second set of planetary gears 232 may be rotatably supported on the first planetary gear carrier 216. Each second planetary gear 232 may be axially positioned between the components of the first gear set 200 or the first set of planetary gears 212 and the flange portion 222 of the first planetary gear carrier 216. When the planetary ring gear is not provided with the second gear set 202, the teeth of the second set of planetary gears 232 may only engage the teeth of the second sun gear 230.

[0067] Reference Figure 2 , the shift mechanism 32 may cooperate with the gear reduction module 30 to provide a desired gear reduction ratio to change the torque transmitted between the electric motor module 26 and the differential assembly 22 and thus transmitted to or from the half shafts 24 of the axle assembly 10. The shift mechanism 32 may have any suitable configuration. For example, the shift mechanism 32 may include an actuator 240 (best shown in Figure 1 ) and a shift collar 250.

[0068] Reference Figure 1 , the actuator 240 may be configured to move the shift collar 250 along the axis 70 to selectively couple the gear set of the gear reduction module 30 to the drive pinion 84 or decouple the gear set from the drive pinion 84. The actuator 240 may be of any suitable type and may be coupled to the shift collar 250 in any suitable manner, such as by a linkage, such as a shift fork.

[0069] Reference Figure 3, the shift collar 250 is movable along an axis 70 to selectively couple the gear set to the drive pinion 84. For example, the shift collar 250 may be disposed on the drive pinion 84 such that the shift collar 250 is rotatable about the axis 70 with the drive pinion 84 and is movable in the axial direction or along the axis 70 relative to the drive pinion 84. The shift collar 250 may be received within the first sun gear 210 and the second sun gear 230. The shift collar 250 may include teeth 252 that extend away from the axis 70, and these teeth may selectively engage corresponding teeth of the gear portion 224 of the first planet carrier 216 or the internal teeth 234 of the second sun gear 230 to assist in transmitting torque between the electric motor module 26 and the differential assembly 22 at a desired torque ratio. Although a single set of teeth 252 is shown, it is contemplated that multiple sets of teeth 252 may be provided on the shift collar 250 for selectively engaging the gear set.

[0070] The shift collar 250 is movable along the axis 70 between a first position and a second position.

[0071] Reference Figure 3 , the shift collar 250 is shown in the first position. When in the first position, the shift collar 250 may couple the first planet carrier 216 to the drive pinion 84, thereby providing a first drive gear ratio. When in the first position, the teeth 252 of the shift collar 250 may engage and mesh with the teeth of the gear portion 224 of the first planet carrier 216. When the shift collar 250 is in the first position, torque may be transmitted, for example, from the rotor 106 to the first sun gear 210 via the rotor output flange 150, from the first sun gear 210 to the first planet carrier 216 via the first set of planet gears 212, and then from the first planet carrier 216 to the drive pinion 84 via the shift collar 250. When in the first position, the shift collar 250 may not couple the first sun gear 210 or the second sun gear 230 to the drive pinion 84. Thus, when the shift collar 250 is in the first position, the first sun gear 210 and the second sun gear 230 may be rotatable about the axis 70 relative to the drive pinion 84.

[0072] Reference Figure 4, the shift collar 250 is shown in the second position. When in the second position, the shift collar 250 can couple the second sun gear 230 to the drive pinion 84, thereby providing a second drive gear ratio that can be different from the first drive gear ratio. As a non-limiting example, the first gear ratio can be approximately 2.5, while the second gear ratio can be approximately 1.4. When in the second position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 234 of the second sun gear 230. When the shift collar 250 is in the second position, torque can be transmitted, for example, from the rotor 106 to the first sun gear 210 via the rotor output flange 150, from the first sun gear 210 to the first planet gear carrier 216 via the first set of planetary gears 212, from the first planet gear carrier 216 to the second sun gear 230 via the second set of planetary gears 232, and then from the second sun gear 230 to the drive pinion 84 via the shift collar 250. When in the second position, the shift collar 250 can not couple the first sun gear 210 or the first planet gear carrier 216 to the drive pinion 84. Thus, when the shift collar 250 is in the second position, the first sun gear 210 and the first planet gear carrier 216 can be rotatable about the axis 70 relative to the drive pinion 84.

[0073] Reference Figures 5 to 7 , a second configuration of the gear reduction module 30' is shown. In this configuration, the gear reduction module 30' can include a first gear set 200, a second gear set 202, and an epicyclic gear set 304. The epicyclic gear set 304 can be axially positioned along the axis 70 between the electric motor module 26 and the first gear set 200. The first gear set 200 can be axially positioned along the axis 70 between the epicyclic gear set 304 and the second gear set 202.

[0074] The first gear set 200 and the second gear set 202 can be the same as the first and second gear sets described above, although having the following items.

[0075] First, the first sun gear 210 can be coupled to the epicyclic gear set 304 instead of being operatively connected to the rotor 106 via the rotor output flange 150.

[0076] Second, the first sun gear 210 can be provided with a set of internal teeth 264 that can be selectively engaged by the shift collar 250. The set of internal teeth 264 can include a plurality of teeth that can be arranged in a repeating pattern around the axis 70. The internal teeth 264 can extend towards the axis 70 and can be arranged substantially parallel to the axis 70.

[0077] The epicyclic gear set 304 can be axially positioned along axis 70 between the electric motor module 26 and the first gear set 200. The epicyclic gear set 304 can be configured as a planetary gear set. For example, the epicyclic gear set 304 can include an epicyclic sun gear 310, a set of epicyclic planet gears 312, an epicyclic planet ring gear 314, and an epicyclic planet carrier 316.

[0078] The epicyclic sun gear 310 can be operatively connected to the rotor 106. For example, the epicyclic sun gear 310 can be operatively connected to the rotor 106, such as via the rotor output flange 150. In this way, the epicyclic sun gear 310 can rotate about axis 70 with the rotor 106 and the rotor output flange 150. The epicyclic sun gear 310 can extend around the drive pinion 84, the shift collar 250, or both, and can receive the drive pinion, the shift collar, or both.

[0079] The set of epicyclic planet gears 312 can be rotatably disposed between the epicyclic sun gear 310 and the epicyclic planet ring gear 314. Each epicyclic planet gear 312 can have teeth that can mesh with the teeth of the epicyclic sun gear 310 that extend away from axis 70 and the teeth of the epicyclic planet ring gear 314 that extend toward axis 70. Each epicyclic planet gear 312 can rotate about a corresponding planet gear axis 218, or can rotate about a planet gear axis offset from the planet gear axis 218. In at least one configuration, the members of the set of epicyclic planet gears 312 can have a smaller diameter than the members of the first set of planet gears 212, a larger diameter than the members of the second set of planet gears 232, or both.

[0080] The epicyclic ring gear 314 can extend about an axis 70 and can receive the set of epicyclic planet gears 312. The epicyclic ring gear 314 can be rotatable about the axis 70. For example, the epicyclic ring gear 314 can be received internally and can be rotatable about the axis 70 relative to the gear reduction module housing 170. The epicyclic ring gear 314 can be rotatably supported by an epicyclic support bearing assembly 318. The epicyclic support bearing assembly 318 can be received internally and can extend from the gear reduction module housing 170 to the epicyclic ring gear 314. The epicyclic ring gear 314 can be fixedly positioned relative to the first sun gear 210 such that the first sun gear 210 and the epicyclic ring gear 314 can be rotatable together about the axis 70 and can not rotate relative to each other. The first sun gear 210 and the epicyclic ring gear 314 can be integrally formed as a common part or can be an assembly of separate parts. In the illustrated configuration, the epicyclic ring gear 314 is connected to the first sun gear 210 by a connecting portion 320. The connecting portion 320 can be axially positioned between the epicyclic gear set 304 and the first gear set 200 and can extend from an end of the epicyclic ring gear 314 to an end of the first sun gear 210.

[0081] The epicyclic planet carrier 316 can rotatably support the set of epicyclic planet gears 312. Additionally, the epicyclic planet carrier 316 can be fixedly positioned such that the epicyclic planet carrier 316 can not rotate about the axis 70. For example, the epicyclic planet carrier 316 can be fixedly positioned relative to the gear reduction module housing 170 and the cover 110 of the electric motor module 26. The epicyclic planet carrier 316 can extend from the cover 110, the gear reduction module housing 170, or both. In at least one configuration, the epicyclic planet carrier 316 can include a support portion 330.

[0082] The support portion 330 can rotatably support the set of epicyclic planet gears 312. The support portion 330 can have any suitable configuration. For example, the support portion 330 can include a plurality of pins that can be received in holes in each epicyclic planet gear 312. A roller bearing assembly can be received in the holes in each epicyclic planet gear 312 and can extend around each pin to help rotatably support each epicyclic planet gear 312. Each pin can extend along a corresponding planet gear axis, which can be or can not be the planet gear axis 218.

[0083] The shift collar 250 can be movable along the axis 70 between a first position, a second position, and a third position.

[0084] Reference Figure 5, the shift collar 250 is shown in a first position. When in the first position, the shift collar 250 can couple the first planetary carrier 216 to the drive pinion 84, thereby providing a first drive gear ratio. When in the first position, the teeth 252 of the shift collar 250 can engage and mesh with the teeth of the gear portion 224 of the first planetary carrier 216. When the shift collar 250 is in the first position, torque can be transmitted from the rotor 106 to the epicyclic sun gear 310, for example via the rotor output flange 150, from the epicyclic sun gear 310 to the epicyclic planet ring gear 314 and the first sun gear 210 via the set of epicyclic planet gears 312, from the first sun gear 210 to the first planetary carrier 216 via the first set of planetary gears 212, and then from the first planetary carrier 216 to the drive pinion 84 via the shift collar 250. When in the first position, the shift collar 250 may not couple the first sun gear 210, the second sun gear 230, or the epicyclic sun gear 310 to the drive pinion 84. Thus, when the shift collar 250 is in the first position, the first sun gear 210, the second sun gear 230, and the epicyclic sun gear 310 may be rotatable about the axis 70 relative to the drive pinion 84.

[0085] Reference Figure 6 , the shift collar 250 is shown in a second position. When in the second position, the shift collar 250 can couple the second sun gear 230 to the drive pinion 84, thereby providing a second drive gear ratio that may be different from the first drive gear ratio. When in the second position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 234 of the second sun gear 230. When the shift collar 250 is in the second position, torque can be transmitted from the rotor 106 to the epicyclic sun gear 310, for example via the rotor output flange 150, from the epicyclic sun gear 310 to the epicyclic planet ring gear 314 and the first sun gear 210 via the set of epicyclic planet gears 312, from the first sun gear 210 to the first planetary carrier 216 via the first set of planetary gears 212, from the first planetary carrier 216 to the second sun gear 230 via the second set of planetary gears 232, and then from the second sun gear 230 to the drive pinion 84 via the shift collar 250. When in the second position, the shift collar 250 may not couple the first sun gear 210, the epicyclic sun gear 310, or the first planetary carrier 216 to the drive pinion 84. Thus, when the shift collar 250 is in the second position, the first sun gear 210, the epicyclic sun gear 310, and the first planetary carrier 216 may be rotatable about the axis 70 relative to the drive pinion 84.

[0086] Reference Figure 7, the shift collar 250 is shown in the third position. When in the third position, the shift collar 250 can couple the first sun gear 210 to the drive pinion 84, thereby providing a third drive gear ratio that can be different from the first and second drive gear ratios. As a non-limiting example, the drive gear ratios can be approximately 1.7, 3.1, and 5.9, respectively. When in the third position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 264 of the first sun gear 210. When the shift collar 250 is in the third position, torque can be transmitted, for example, from the rotor 106 to the epicyclic sun gear 310 via the rotor output flange 150, from the epicyclic sun gear 310 to the epicyclic planet ring gear 314 and the first sun gear 210 via the set of epicyclic planet gears 312, and then from the first sun gear 210 to the drive pinion 84 via the shift collar 250. When in the third position, the shift collar 250 may not couple the epicyclic sun gear 310, the second sun gear 230, or the first planet carrier 216 to the drive pinion 84. Thus, when the shift collar 250 is in the third position, the epicyclic sun gear 310, the second sun gear 230, and the first planet carrier 216 can be rotatable about the axis 70 relative to the drive pinion 84.

[0087] Reference Figures 8 to 10 , a third configuration of the gear reduction module 30” is shown. In this configuration, the gear reduction module 30” can include a first gear set 200, a second gear set 202, and an epicyclic gear set 304. As in the previous configuration, the first gear set 200 can be axially positioned between the epicyclic gear set 304 and the second gear set 202, while the epicyclic gear set 304 can be axially positioned between the electric motor module 26 and the first gear set 200.

[0088] As an overview, Figures 8 to 10 the configuration in Figures 5 to 7 is similar to the configuration in Figures 5 to 7 , but the first sun gear 210 is connected to the epicyclic planet carrier 316 instead of the epicyclic planet ring gear 314. For example, the epicyclic gear set 304 can be the same as the epicyclic gear set described above with respect to Figures 5 to 7 , except for the following items.

[0089] First, the epicyclic sun gear 310 can be fixedly positioned such that the epicyclic sun gear 310 cannot rotate about the axis 70. For example, the epicyclic sun gear 310 can be fixedly coupled to a bearing support wall 62 of the differential carrier 42. In the illustrated configuration, the epicyclic sun gear 310 extends along the axis 70 into the electric motor module 26 and is coupled to the bearing support wall 62 near the distal end of the bearing support wall 62, the distal end of which is located opposite the axle housing 40. In at least one configuration, the epicyclic sun gear 310 can be received inside the bearing support wall 62 and can be coupled to the bearing support wall 62 inside the bearing support wall 62.

[0090] Second, the epicyclic ring gear 314 can be operatively connected to or provided with the rotor 106 and can thus rotate about the axis 70 with the rotor 106. For example, the rotor 106 can be provided with a greater axial length and can receive or incorporate the epicyclic ring gear 314. Alternatively, the rotor output flange 150 can be provided with a greater diameter than in previous configurations and can extend from the rotor 106 and receive or incorporate the epicyclic ring gear 314. In either configuration, the epicyclic ring gear 314 can be considered to be received inside the rotor 106.

[0091] Third, the epicyclic planet carrier 316 can rotate about the axis 70. Additionally, the epicyclic planet carrier 316 and the first sun gear 210 can be fixedly positioned relative to each other such that the first sun gear 210 does not rotate relative to the epicyclic planet carrier 316.

[0092] Fourth, the epicyclic support bearing assembly 318 can be omitted.

[0093] It should also be noted that in one or more configurations, the set of epicyclic planet gears 312 can have a smaller diameter than the members of the first set of planet gears 212 and a larger diameter than the members of the second set of planet gears 232.

[0094] The shift collar 250 can be movable along the axis 70 between a first position, a second position, and a third position.

[0095] Reference Figure 8, the shift collar 250 is shown in a first position. When in the first position, the shift collar 250 can couple the first planetary carrier 216 to the drive pinion 84, thereby providing a first drive gear ratio. When in the first position, the teeth 252 of the shift collar 250 can engage and mesh with the teeth of the gear portion 224 of the first planetary carrier 216. When the shift collar 250 is in the first position, torque can be transmitted from the rotor 106 and the epicyclic ring gear 314 through the set of epicyclic planetary gears 312 to the epicyclic planetary carrier 316 and the first sun gear 210, from the first sun gear 210 through the first set of planetary gears 212 to the first planetary carrier 216, and then from the first planetary carrier 216 through the shift collar 250 to the drive pinion 84. When in the first position, the shift collar 250 can not couple the first sun gear 210, the second sun gear 230, or the epicyclic sun gear 310 to the drive pinion 84. Thus, when the shift collar 250 is in the first position, the first sun gear 210 and the second sun gear 230 can be rotatable about the axis 70 relative to the drive pinion 84.

[0096] Reference Figure 9 , the shift collar 250 is shown in a second position. When in the second position, the shift collar 250 can couple the second sun gear 230 to the drive pinion 84, thereby providing a second drive gear ratio that can be different from the first drive gear ratio. When in the second position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 234 of the second sun gear 230. When the shift collar 250 is in the second position, torque can be transmitted from the rotor 106 and the epicyclic ring gear 314 through the set of epicyclic planetary gears 312 to the epicyclic planetary carrier 316 and the first sun gear 210, from the first sun gear 210 through the first set of planetary gears 212 to the first planetary carrier 216, from the first planetary carrier 216 through the second set of planetary gears 232 to the second sun gear 230, and then from the second sun gear 230 through the shift collar 250 to the drive pinion 84. When in the second position, the shift collar 250 can not couple the first sun gear 210, the epicyclic sun gear 310, or the first planetary carrier 216 to the drive pinion 84. Thus, when the shift collar 250 is in the second position, the first sun gear 210, the epicyclic sun gear 310, and the first planetary carrier 216 can be rotatable about the axis 70 relative to the drive pinion 84.

[0097] Reference Figure 10, the shift collar 250 is shown in the third position. When in the third position, the shift collar 250 can couple the first sun gear 210 to the drive pinion 84, thereby providing a third drive gear ratio that can be different from the first and second drive gear ratios. As a non-limiting example, the drive gear ratios can be approximately 1.6, 3.0, and 5.6, respectively. When in the third position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 264 of the first sun gear 210. When the shift collar 250 is in the third position, torque can be transmitted from the rotor 106 and the epicyclic ring gear 314 through the set of epicyclic planet gears 312 to the epicyclic planet carrier 316 and the first sun gear 210, and then from the first sun gear 210 to the drive pinion 84 via the shift collar 250. When in the third position, the shift collar 250 can decouple the epicyclic sun gear 310, the second sun gear 230, or the first planet carrier 216 from the drive pinion 84. Thus, when the shift collar 250 is in the third position, the epicyclic sun gear 310, the second sun gear 230, and the first planet carrier 216 can be rotatable about the axis 70 relative to the drive pinion 84.

[0098] Reference Figures 11 to 13 , a fourth configuration of the gear reduction module 30''' is shown. In this configuration, the gear reduction module 30''' can include a first gear set 200, a second gear set 202, and an epicyclic gear set 304. This configuration is similar to Figure 3 and Figure 4 the configuration shown, but attaches the epicyclic gear set 304 to the second gear set 202. For example, the first gear set 200 and the second gear set 202 can be the same as the first and second gear sets described above with respect to Figure 3 and Figure 4 except that the epicyclic sun gear 310 can be operatively connected to the first planet carrier 216. The first gear set 200 can remain axially positioned along the axis 70 between the electric motor module 26 and the second gear set 202, but the second gear set 202 can be axially positioned along the axis 70 between the first gear set 200 and the epicyclic gear set 304.

[0099] The epicyclic gear set 304 is similar to Figures 5 to 7 the configuration shown, with the following modifications.

[0100] First, the epicyclic sun gear 310 can be coupled to the first planetary gear carrier 216. For example, the epicyclic sun gear 310 can be integrally formed with or attached to the first planetary gear carrier 216. The epicyclic sun gear 310 and the first planetary gear carrier 216 can be positioned relative to each other in a fixed manner such that the epicyclic sun gear 310 does not rotate relative to the first planetary gear carrier 216, and the epicyclic sun gear 310 and the first planetary gear carrier 216 can rotate together about the axis 70. Additionally, the epicyclic sun gear 310 can include a set of internal teeth 324 that can be selectively engaged by the shift collar 250. The set of internal teeth 324 can include a plurality of teeth and repeating patterns that can be arranged around the axis 70. The internal teeth 324 can extend towards the axis 70 and can be arranged substantially parallel to the axis 70.

[0101] Second, the epicyclic ring gear 314 cannot rotate about the axis 70. For example, the epicyclic ring gear 314 can be fixedly mounted to the gear reduction module housing 170.

[0102] Third, the epicyclic planetary gear carrier 316 can rotate about the axis 70. The epicyclic planetary gear carrier 316 can still rotatably support the set of epicyclic planetary gears 312, but can also include a set of internal teeth 334 that can be selectively engaged by the shift collar 250. The set of internal teeth 334 can include a plurality of teeth and repeating patterns that can be arranged around the axis 70. The internal teeth 334 can extend towards the axis 70 and can be arranged substantially parallel to the axis 70.

[0103] Fourth, the epicyclic support bearing assembly 318 that rotatably supports the epicyclic ring gear 314 in Figures 5 to 7 can be omitted.

[0104] Fifth, a support bearing assembly 336 can be provided to rotatably support the epicyclic planetary gear carrier 316. The support bearing assembly 336 can extend from the gear reduction module housing 170 to the epicyclic planetary gear carrier 316. For example, the support bearing assembly 336 can be received inside the gear reduction module housing 170, and the epicyclic planetary gear carrier 316 can be received inside the support bearing assembly 336. The support bearing assembly 336 can be axially positioned between the epicyclic gear set 304 and the gear reduction module cover 172.

[0105] The shift collar 250 can be movable along the axis 70 between a first position, a second position, and a third position.

[0106] Reference Figure 11, the shift collar 250 is shown in a first position. When in the first position, the shift collar 250 can couple the epicyclic carrier 316 to the drive pinion 84, thereby providing a first drive gear ratio. When in the first position, the teeth 252 of the shift collar 250 can engage and mesh with the set of internal teeth 334 of the epicyclic carrier 316. When the shift collar 250 is in the first position, torque can be transmitted, for example, from the rotor 106 via the rotor output flange 150 to the first sun gear 210, from the first sun gear 210 via the first set of planetary gears 212 to the first planetary carrier 216 and the epicyclic sun gear 310, from the epicyclic sun gear 310 via the set of epicyclic planetary gears 312 to the epicyclic carrier 316, and from the epicyclic carrier 316 via the shift collar 250 to the drive pinion 84. When in the first position, the shift collar 250 may not couple the first sun gear 210, the first planetary carrier 216, the second set of planetary gears 232, or the epicyclic sun gear 310 to the drive pinion 84. Thus, when the shift collar 250 is in the first position, the first sun gear 210, the first planetary carrier 216, the second set of planetary gears 232, and the epicyclic sun gear 310 may be rotatable about the axis 70 relative to the drive pinion 84.

[0107] Reference Figure 12 , the shift collar 250 is shown in a second position. When in the second position, the shift collar 250 can couple the first planetary carrier 216 / epicyclic sun gear 310 to the drive pinion 84, thereby providing a second drive gear ratio that may be different from the first drive gear ratio. When in the second position, the teeth 252 of the shift collar 250 can engage and mesh with the internal teeth 324 of the epicyclic sun gear 310. When the shift collar 250 is in the second position, torque can be transmitted, for example, from the rotor 106 via the rotor output flange 150 to the first sun gear 210, from the first sun gear 210 via the first set of planetary gears 212 to the first planetary carrier 216 and the epicyclic sun gear 310, and then from the first planetary carrier 216 and the epicyclic sun gear 310 via the shift collar 250 to the drive pinion 84. When in the second position, the shift collar 250 may not couple the first sun gear 210, the second set of planetary gears 232, or the epicyclic carrier 316 to the drive pinion 84. Thus, when the shift collar 250 is in the second position, the first sun gear 210, the second set of planetary gears 232, and the epicyclic carrier 316 may be rotatable about the axis 70 relative to the drive pinion 84.

[0108] Reference Figure 13, the shift collar 250 is shown in the third position. When in the third position, the shift collar 250 can couple the second set of planetary gears 232 to the drive pinion 84, thereby providing a third drive gear ratio that can be different from the first and second drive gear ratios. As a non-limiting example, the drive gear ratios can be approximately 1.6, 3.4, and 8.1, respectively. When in the third position, the teeth 252 of the shift collar 250 can engage and mesh with the teeth of the second set of planetary gears 232. When the shift collar 250 is in the third position, torque can be transmitted from the rotor 106 to the first sun gear 210, for example via the rotor output flange 150, from the first sun gear 210 to the first planetary carrier 216 via the first set of planetary gears 212, from the first planetary carrier 216 to the second set of planetary gears 232, and then from the second set of planetary gears 232 to the drive pinion 84 via the shift collar 250. When in the third position, the shift collar 250 may not couple the epicyclic carrier 316, the epicyclic sun gear 310, the first sun gear 210, or the first planetary carrier 216 to the drive pinion 84. Thus, when the shift collar 250 is in the third position, the epicyclic carrier 316, the epicyclic sun gear 310, the first sun gear 210, and the first planetary carrier 216 may be rotatable about the axis 70 relative to the drive pinion 84.

[0109] Reference Figure 1 , the axle assembly 10 may optionally include an isolator support 400. The isolator support 400 can help support the end of the axle assembly 10 that is disposed farthest from the axle housing 40 and the differential axis 80. In at least one configuration, the isolator support 400 can extend from the gear reduction module housing 170 or the gear reduction module cover 172 to a crossmember 402, which can be part of the vehicle chassis. For example, the crossmember 402 can extend between two frame rails of the vehicle in the lateral direction. The isolator support 400 can include a first portion 404 and a second portion 406, the first portion can be mounted on the gear reduction module housing 170 or the gear reduction module cover 172, and the second portion can be mounted to the crossmember 402. The isolator support 400 can allow the first portion 404 to pivot relative to the second portion 406 about an isolator mounting axis 408 and can help limit movement and acceleration of the gear reduction module housing 170. For example, it is contemplated that a portion of the isolator support 400 can include an elastic member that can be received in a hole in the first portion 404, the second portion 406, or both. It is also contemplated that the first portion 404 or the second portion 406 can be configured as a shock absorber. The isolator support 400 can be provided in any of the configurations previously discussed.

[0110] An axle assembly having a gear set configuration as described above can provide multiple gear ratios or multiple speeds while providing a more compact packaging space. Additionally, compared to a two-speed single planetary gear configuration, these gear set configurations can allow for a reduction in the difference between gear ratios, which can help improve the efficiency of the gear reduction unit and the driving performance of the vehicle. Further, the above configurations can allow each gear ratio to be a gear reduction relative to the rotor speed, which can help reduce the rotational speed of the gear set and help reduce the heat generation of the roller bearing assembly associated with the gear set, and increase bearing life.

[0111] While the above 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. Additionally, the features of the various implemented embodiments may be combined to form further embodiments of the invention.

Claims

1. An axle assembly, comprising: an electric motor having a rotor rotatable about an axis; a drive pinion extending through the rotor and rotatable about the axis; a gear reduction unit including: a first gear set having a first sun gear, a first ring gear, a first set of planet gears and a first planet gear carrier, the first sun gear being operatively connected to the rotor and rotatable about the axis, the first ring gear being fixedly positioned such that the first ring gear is not rotatable about the axis, the first set of planet gears meshing with the first sun gear and the first ring gear, the first planet gear carrier rotatably supporting the first set of planet gears; and a second gear set having a second sun gear rotatable about the axis and a second set of planet gears meshing with the second sun gear and rotatably supported on the first planet gear carrier, wherein the members of the second set of planet gears have a smaller diameter than the members of the first set of planet gears; and a shift collar rotatable about the axis with the drive pinion and movable along the axis between a first position and a second position, in the first position, the shift collar couples the first planet gear carrier to the drive pinion without coupling the first sun gear or the second sun gear to the drive pinion, and in the second position, the shift collar couples the second sun gear to the drive pinion without coupling the first sun gear or the first planet gear carrier to the drive pinion.

2. The axle assembly according to claim 1, wherein, the first gear set is axially positioned along the axis between the electric motor and the second gear set.

3. The axle assembly according to claim 1, wherein, the shift collar receives the drive pinion, and the shift collar is received inside the first sun gear and the second sun gear.

4. The axle assembly according to claim 1, wherein, the teeth of the second set of planet gears mesh only with the teeth of the second sun gear.

5. The axle assembly according to claim 1, wherein, the first planet gear carrier is received inside a support bearing assembly that rotatably supports the first planet gear carrier, and wherein the second gear set is axially positioned along the axis between the first gear set and the support bearing assembly.

6. An axle assembly, comprising: an electric motor having a rotor rotatable about an axis; a drive pinion extending through the rotor and rotatable about the axis; a gear reduction unit including: A first gear set having a first sun gear, a first ring gear, a first set of planet gears, and a first planet carrier, the first sun gear being operatively connected to the rotor and rotatable about the axis, the first ring gear being fixedly positioned such that the first ring gear is non-rotatable about the axis, the first set of planet gears meshing with the first sun gear and the first ring gear, and the first planet carrier rotatably supporting the first set of planet gears; A second gear set having a second set of planet gears rotatably supported on the first planet carrier, wherein the members of the second set of planet gears have a smaller diameter than the members of the first set of planet gears; and An epicyclic gear set having an epicyclic sun gear, an epicyclic ring gear, a set of epicyclic planet gears, and an epicyclic planet carrier, the epicyclic sun gear being fixedly positioned relative to the first planet carrier such that the epicyclic sun gear does not rotate relative to the first planet carrier, the epicyclic ring gear being fixedly positioned such that the epicyclic ring gear is non-rotatable about the axis, the set of epicyclic planet gears meshing with the epicyclic sun gear and the epicyclic ring gear, and the epicyclic planet carrier rotatably supporting the set of epicyclic planet gears; and A shift collar rotatable about the axis with the drive pinion and movable axially along the axis between a first position and a second position, in the first position the shift collar coupling the epicyclic planet carrier to the drive pinion without coupling the first sun gear or the epicyclic sun gear to the drive pinion, and in the second position the shift collar coupling the epicyclic sun gear to the drive pinion without coupling the first sun gear or the epicyclic planet carrier to the drive pinion.

7. The axle assembly according to claim 6, wherein, the shift collar is movable to a third position, in which the shift collar couples the second set of planet gears to the drive pinion without coupling the first sun gear, the epicyclic sun gear, or the epicyclic planet carrier to the drive pinion.

8. The axle assembly according to claim 6, wherein, the second gear set is axially positioned along the axis between the first gear set and the epicyclic gear set, and the first gear set is axially positioned along the axis between the electric motor and the second gear set.

9. The axle assembly according to claim 6, wherein, the shift collar receives the drive pinion, and the shift collar is received inside the first sun gear, the second set of planet gears, and the epicyclic sun gear, and the members of the set of epicyclic planet gears have a smaller diameter than the members of the first set of planet gears and a larger diameter than the members of the second set of planet gears.

10. The axle assembly according to claim 6, wherein, The epicyclic planet gear carrier is received within an epicyclic support bearing assembly that rotatably supports the epicyclic planet gear carrier, wherein the epicyclic gear set is axially positioned along the axis between the second gear set and the epicyclic support bearing assembly.

11. An axle assembly, comprising: an electric motor having a rotor rotatable about an axis; a drive pinion extending through the rotor and rotatable about the axis; a gear reduction unit comprising: an epicyclic gear set having an epicyclic sun gear, an epicyclic planet ring gear, a set of epicyclic planet gears, and an epicyclic planet gear carrier, the epicyclic sun gear being operatively connected to the rotor and rotatable about the axis, the epicyclic planet ring gear being rotatable about the axis, the set of epicyclic planet gears meshing with the epicyclic sun gear and the epicyclic planet ring gear, the epicyclic planet gear carrier rotatably supporting the set of epicyclic planet gears and being fixedly positioned such that the epicyclic planet gear carrier is non-rotatable about the axis; a first gear set having a first sun gear, a first planet ring gear, a first set of planet gears, and a first planet gear carrier, the first sun gear being fixedly positioned relative to the epicyclic planet ring gear such that the first sun gear does not rotate relative to the epicyclic planet ring gear, the first planet ring gear being fixedly positioned such that the first planet ring gear is non-rotatable about the axis, the first set of planet gears meshing with the first sun gear and the first planet ring gear, the first planet gear carrier rotatably supporting the first set of planet gears; a second gear set having a second sun gear rotatable about the axis and a second set of planet gears meshing with the second sun gear and rotatably supported on the first planet gear carrier, wherein the members of the second set of planet gears have a smaller diameter than the members of the first set of planet gears; and a shift collar rotatable about the axis with the drive pinion and movable along the axis between a first position and a second position, in the first position, the shift collar coupling the first planet gear carrier to the drive pinion without coupling the first sun gear, the second sun gear, or the epicyclic sun gear to the drive pinion, in the second position, the shift collar coupling the second sun gear to the drive pinion without coupling the epicyclic sun gear, the first sun gear, or the first planet gear carrier to the drive pinion.

12. The axle assembly of claim 11, wherein, the shift collar is movable to a third position, in the third position, the shift collar coupling the first sun gear to the drive pinion without coupling the epicyclic sun gear, the second sun gear, or the first planet gear carrier to the drive pinion.

13. The axle assembly of claim 11, wherein, The first gear set is axially positioned along the axis between the epicyclic gear set and the second gear set, and the epicyclic gear set is axially positioned along the axis between the electric motor and the first gear set.

14. The axle assembly according to claim 11, wherein, the shift collar receives the drive pinion, and the shift collar is received inside the first sun gear, the second sun gear, and the epicyclic sun gear, and the members of the set of epicyclic planet gears have a smaller diameter than the members of the first set of planet gears and a larger diameter than the members of the second set of planet gears.

15. The axle assembly according to claim 11, wherein, the epicyclic ring gear is received inside an epicyclic support bearing assembly that rotatably supports the epicyclic ring gear, and the first planet gear carrier is received inside a support bearing assembly that rotatably supports the first planet gear carrier, wherein the second gear set is axially positioned along the axis between the first gear set and the support bearing assembly.

16. An axle assembly, comprising: an electric motor having a rotor rotatable about an axis; a drive pinion received inside the rotor and rotatable about the axis; a gear reduction unit including: an epicyclic gear set having an epicyclic sun gear, an epicyclic ring gear, a set of epicyclic planet gears, and an epicyclic planet gear carrier, the epicyclic sun gear being fixedly positioned such that the epicyclic sun gear is not rotatable about the axis, the epicyclic ring gear being operatively connected to the rotor and rotatable with the rotor about the axis, the set of epicyclic planet gears meshing with the epicyclic sun gear and the epicyclic ring gear, the epicyclic planet gear carrier rotatably supporting the set of epicyclic planet gears; a first gear set having a first sun gear, a first ring gear, a first set of planet gears, and a first planet gear carrier, the first sun gear being fixedly positioned relative to the epicyclic planet gear carrier such that the first sun gear does not rotate relative to the epicyclic planet gear carrier, the first ring gear being fixedly positioned such that the first ring gear is not rotatable about the axis, the first set of planet gears meshing with the first sun gear and the first ring gear, the first planet gear carrier rotatably supporting the first set of planet gears; a second gear set having a second sun gear rotatable about the axis, and a second set of planet gears meshing with the second sun gear and rotatably supported on the first planet gear carrier, wherein the members of the second set of planet gears have a smaller diameter than the members of the first set of planet gears; and A shift collar that is rotatable about the axis with the drive pinion and movable axially along the axis between a first position and a second position. In the first position, the shift collar couples the first planetary gear carrier to the drive pinion without coupling the first sun gear, the second sun gear, or the orbiting sun gear to the drive pinion. In the second position, the shift collar couples the second sun gear to the drive pinion without coupling the orbiting sun gear, the first sun gear, or the first planetary gear carrier to the drive pinion.

17. The axle assembly according to claim 16, wherein, the shift collar is movable to a third position, in which the shift collar couples the first sun gear to the drive pinion without coupling the orbiting sun gear, the second sun gear, or the first planetary gear carrier to the drive pinion.

18. The axle assembly according to claim 16, wherein, the first gear set is axially positioned along the axis between the epicyclic gear set and the second gear set, and the epicyclic gear set is axially positioned along the axis between the electric motor and the first gear set.

19. The axle assembly according to claim 16, wherein, the shift collar receives the drive pinion, and the shift collar is received within the first sun gear, the second sun gear, and the orbiting sun gear.

20. The axle assembly according to claim 16, wherein, the orbiting planetary ring gear is received within the rotor, and the members of the set of orbiting planetary gears have a smaller diameter than the members of the first set of planetary gears and a larger diameter than the members of the second set of planetary gears.

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