Axle assembly having a gear reduction module with multiple gear sets

Abstract

An axle assembly is disclosed 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 and at least one clutch engagable to provide a torque path between the electric motor and the drive pinion.

Description

Technical Field

[0001] The present disclosure relates to an axle assembly having a plurality of gear sets that can operatively connect a rotor to a drive pinion. background

[0002] An axle assembly with 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 may include an electric motor, a drive pinion, a gear reduction unit, a first clutch, and a second clutch. The electric motor may have a rotor that is rotatable about an axis. The drive pinion may extend through the rotor and be rotatable about the axis. The gear reduction unit may include a first gear set and a second gear set. The first gear set may include a first sun gear, a first planetary ring gear, a first set of planetary gears, and a first planetary gear carrier. The first sun gear may be operatively connected to the rotor and may rotate with the rotor about the axis. The first planetary ring gear may be fixedly positioned so that the first planetary ring gear cannot rotate about the axis. The first set of planetary gears may mesh with the first sun gear and the first planetary ring gear. The first planetary gear carrier may rotatably support the first set of planetary gears. The second gear set may include a second sun gear, a second planetary ring gear, a second set of planetary gears, and a second planetary gear carrier. The second planetary ring gear may be coupled to the first planetary gear carrier so that the first and second planetary ring gears rotate together about the axis. The second set of planetary gears may mesh with the second sun gear and the second planetary ring gear. The second planetary gear carrier may rotatably support the second set of planetary gears and may rotate about the axis. The first clutch can selectively couple the first planetary gear carrier to the drive pinion gear.The second clutch can selectively couple the first planetary gear carrier to the second gear set.

[0005] In at least one embodiment, an axle assembly is provided. The axle assembly may include an electric motor, a drive pinion, a gear reduction unit, and a first clutch. The electric motor may have a rotor that is rotatable about an axis. The drive pinion may extend through the rotor and be rotatable about the axis. The gear reduction unit may include a first planetary gear set and a second planetary gear set. The first planetary gear set may include a first sun gear, a first planetary ring gear, a first set of planetary gears, and a first planetary gear carrier. The first sun gear may be operatively connected to the rotor and may rotate with the rotor about the axis. The first planetary ring gear may be fixedly positioned so that the first planetary ring gear cannot rotate about the axis. The first set of planetary gears may mesh with the first sun gear and the first planetary ring gear. The first planetary gear carrier may rotatably support the first set of planetary gears. The second planetary gear set may include a second sun gear, a second planetary ring gear, a second set of planetary gears, and a second planetary gear carrier. The second set of planetary gears may mesh with the second sun gear and the second planetary ring gear. The second planetary gear carrier may rotatably support the second set of planetary gears and may rotate about the axis. The first clutch may selectively couple the rotor to the second sun gear. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0007] Figure 2 yes Figure 1 A cross-sectional view of the axle assembly along section line 2-2.

[0008] Figure 3 yes Figure 2 An enlarged view of a portion of FIG. 1 is shown, illustrating the gear reduction unit and the torque path associated with the first gear ratio.

[0009] Figure 4 Shown Figure 2 A gear reduction unit and a torque path associated with a second gear ratio.

[0010] Figure 5 is an enlarged view showing a second configuration of the gear reduction unit and the torque path associated with the first gear ratio.

[0011] Figure 6 Shown Figure 5 A gear reduction unit and a torque path associated with a second gear ratio.

[0012] Figure 7 Shown Figure 5 A gear reduction unit and a torque path associated with a third gear ratio.

[0013] Figure 8is an enlarged view showing a third configuration of the gear reduction unit and the torque path associated with the first gear ratio.

[0014] Figure 9 Shown Figure 8 A gear reduction unit and a torque path associated with a second gear ratio.

[0015] Figure 10 Shown Figure 8 A gear reduction unit and a torque path associated with a third gear ratio. DETAILED DESCRIPTION

[0016] 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 invention that may be embodied in various and alternative forms. The drawings are not necessarily to scale; some features may be exaggerated or minimized to illustrate details of particular components. Therefore, the specific structural and functional details disclosed herein should not be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0017] refer to Figure 1 , shows an example of an axle assembly 10. The axle assembly 10 may be provided for a motor vehicle, such as a truck, a bus, farm equipment, mining equipment, a military transport or armored vehicle, or cargo loading equipment for land, air, or marine vessels. In one or more embodiments, the motor vehicle may include a trailer for transporting cargo.

[0018] The axle assembly 10 can provide torque to one or more traction wheel assemblies, which can include tires mounted on wheels. The wheels can be mounted to hubs that can rotate about a wheel axis.

[0019] One or more axle assemblies may be provided for a vehicle. Figure 1 and Figure 2 As best shown, the axle assembly 10 may include a housing assembly 20, a differential assembly 22, at least one half-shaft 24, and an electric motor module 26. Figure 2 As best shown, the axle assembly 10 may include a gear reduction module 30 .

[0020] Housing assembly

[0021] refer to Figure 1 The housing assembly 20 can receive various components of the axle assembly 10. Additionally, the housing assembly 20 can facilitate installation of the axle assembly 10 to a vehicle. In at least one configuration, the housing assembly 20 can include an axle housing 40 and a differential carrier 42.

[0022] The axle housing 40 can receive and can support the half-shaft 24. In at least one configuration, the axle housing 40 can include a center portion 50 and at least one arm portion 52.

[0023] The center portion 50 may be positioned proximate the center of the axle housing 40. The center portion 50 may define a cavity that may at least partially receive the differential assembly 22. Figure 2 As best shown, a lower region of the center portion 50 may at least partially define an oil sump portion 54 that may contain or collect lubricant 56. The lubricant 56 in the oil sump portion 54 may splash through the ring gear of the differential assembly 22 and be distributed to lubricate various components.

[0024] refer to Figure 2 , the center portion 50 may include a carrier mounting surface 58. The carrier mounting surface 58 may facilitate mounting the differential carrier 42 to the axle housing 40. For example, the carrier mounting surface 58 may face and engage the differential carrier 42 and may have a set of holes that may align with corresponding holes on the differential carrier 42. Each hole may receive a fastener, such as a bolt or a stub, that may couple the differential carrier 42 to the axle housing 40.

[0025] refer to Figure 1 , one or more arm portions 52 can extend from the center portion 50. For example, two arm portions 52 can extend from the center 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 and receive a corresponding axle 24 and can help separate or isolate the axle 24 or a portion thereof from the surrounding environment. The arm portion 52 or a portion thereof can be integrally formed with the center portion 50, or can not be integrally formed with the center portion. It is also contemplated that the arm portion 52 can be omitted.

[0026] refer to Figure 1 and Figure 2 , a differential carrier 42 can be mounted to the center portion 50 of the axle housing 40. The differential carrier 42 can support the differential assembly 22 and can facilitate the installation of the electric motor module 26. For example, the differential carrier can include one or more bearing supports that can support bearings, such as roller bearing assemblies, 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.

[0027] refer to Figure 2, the mounting flange 60 can facilitate installation of the electric motor module 26. As an example, the mounting flange 60 can be configured as a ring that can extend outward 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.

[0028] 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 about the axis 70. The bearing support wall 62 can define a bore that can extend along or about the axis 70 and receive the drive pinion 84 and the bearing that rotatably supports 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.

[0029] Differential assembly, drive pinion, and axle shafts

[0030] refer to 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 rotate 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 permit 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 mesh with teeth of a gear portion of a drive pinion 84. Accordingly, the differential assembly 22 can receive torque from the drive pinion 84 via the ring gear 82 and transmit the torque to the half-shafts 24.

[0031] The drive pinion 84 can provide torque to the ring gear 82. In an axle assembly that includes 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 rotate about the axis 70 and can be rotatably supported within another component, such as the bearing support wall 62.

[0032] refer to Figure 1, the half shaft 24 can transfer torque from the differential assembly 22 to the corresponding wheel hub and wheel. Two half shafts 24 can be provided, so that each half shaft 24 extends through a different arm portion 52 of the axle housing 40. The half shaft 24 can extend along an axis (such as the differential axis 80) and can rotate about the 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 to 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.

[0033] Electric motor module

[0034] refer to Figure 2 The electric motor module 26 (also referred to as an electric motor) can be mounted to the differential carrier 42 and operatively connected 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 discussed in greater detail below. The electric motor module 26 can be primarily disposed external to the differential carrier 42. Furthermore, 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.

[0035] 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 the mounting flange 60 of the differential carrier 42 to the cover 110. The motor housing 100 can extend about the axis 70 and can define a motor housing cavity 120. The motor housing cavity 120 can be disposed within the interior of the motor housing 100 and can have a generally cylindrical configuration. The bearing support wall 62 of the differential carrier 42 can be positioned within the motor housing cavity 120. Furthermore, the motor housing 100 can extend continuously around the bearing support wall 62 and can be spaced apart therefrom. In at least one configuration, the motor housing 100 can have an exterior side 122, an interior side 124, a first end surface 126, a second end surface 128, and one or more ports 130.

[0036] The outer side 122 may face away from the axis 70 and may define an outer or outside surface of the motor housing 100 .

[0037] The inner side 124 can be disposed opposite the outer side 122. In one or more configurations, the inner side 124 can be disposed at a substantially constant radial distance from the axis 70.

[0038] 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 an end of the motor housing 100 that can face toward the differential carrier 42. For example, the first end surface 126 can be disposed adjacent to the mounting flange 60 of the differential carrier 42. The motor housing 100 and the first end surface 126 can be received within the mounting flange 60, or can be received outside the mounting flange.

[0039] The second end surface 128 can be disposed opposite the first end surface 126. As such, the second end surface 128 can be disposed at an end of the motor housing 100 that can face toward and engage the cover 110. The second end surface 128 can extend between the exterior side 122 and the interior side 124 and can be received within the interior of the cover 110 or not.

[0040] One or more ports 130 may extend through the motor housing 100. The ports 130 may be configured as through-holes that may extend from the exterior side 122 to the interior side 124. The ports 130 may allow coolant (e.g., 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.

[0041] refer to 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. In addition, the coolant jacket 102 can extend around the axis 70 and the stator 104. In this way, the stator 104 can be at least partially received in the coolant jacket 102 and can be surrounded by the coolant jacket. Moreover, the coolant jacket 102 can extend in a 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.

[0042] The passage 140 can extend about the axis 70 and can be disposed opposite the stator 104. The passage 140 can be configured with an open side that can face away from the axis 70 and toward the interior 124 of the motor housing 100. Coolant can be provided to the coolant jacket 102 via the first port 130 and can exit the coolant jacket 102 via the second port 130. For example, 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 exit at the second port 130. One or more baffles can be provided for the coolant jacket 102 that can reverse or change the coolant flow direction to help direct coolant from the first port 130 to the second port 130.

[0043] 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 about the axis 70 and can include stator windings that can be received within the coolant jacket 102 and can be fixedly positioned relative to the coolant jacket.

[0044] The rotor 106 can extend about the axis 70 and can rotate about the axis. The rotor 106 can be received within the stator 104, the coolant jacket 102, and the motor housing cavity 120 of the motor housing 100. The rotor 106 can rotate about the axis 70 relative to the differential carrier 42 and the stator 104. In addition, the rotor 106 can be spaced apart from the stator 104, but can be positioned in close proximity to the stator 104. The rotor 106 can include magnets or ferromagnetic materials that can facilitate current generation or can be induction-based. The rotor 106 can extend around the bearing support wall 62 and can be supported by the bearing support wall.

[0045] 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 a rotor output flange 150) can operatively connect the rotor 106 to the gear reduction module 30, which in turn can be operatively connected to the drive pinion 84.

[0046] refer to Figure 2The cover 110 can be mounted to the motor housing 100 and can be positioned opposite the axle housing 40 and the differential carrier 42. For example, the cover 110 can be mounted to an end or end surface of the motor housing 100 that can be positioned opposite the differential carrier 42, such as the second end surface 128. In this way, the cover 110 can be spaced apart from the differential carrier 42 and can not engage 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 toward and engage the motor housing 100. The second side 162 can be positioned opposite the first side 160. The second side 162 can face away from the motor housing 100 and can be positioned opposite 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.

[0047] Gear reduction modules and clutches

[0048] refer to Figure 2 , shows an example of a gear reduction module 30. The gear reduction module 30 can transfer torque between the electric motor module 26 and the differential assembly 22. In this way, the gear reduction module 30 can operatively connect the electric motor module 26 and the differential assembly 22.

[0049] The gear reduction module 30 can be disposed externally to the differential carrier 42 and can be primarily disposed externally to the electric motor module 26, or can be disposed entirely externally to the electric motor module 26, thereby providing a modular construction 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 that can receive the gears of the gear reduction module 30. The gear reduction module housing 170 can be provided in different 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 extending away from the electric motor module 26. A gear reduction module cover 172 can be disposed on the gear reduction module housing 170 and can be removable to provide access to components located within the gear reduction module housing 170.

[0050] The gear reduction module can be provided in different configurations and can include multiple gear sets operatively connected to each other. These gear sets can be configured as epicyclic gear sets, in which one or more planetary gears can revolve or rotate around a central sun gear. Each planetary gear can rotate about a corresponding axis, which can be located at a constant or substantially constant radial distance from the axis about which the central sun gear rotates. For clarity, each gear set is designated by a different name below.

[0051] The following describes and Figures 3 to 10 Three main configurations of gear reduction modules 30, 30', 30" are best shown. It should be understood that each gear reduction module configuration can be provided for an axle assembly having the components described above (e.g., an axle assembly having a housing assembly 20, a differential assembly 22, at least one half shaft 24, an electric motor module 26, a drive pinion 84, a gear reduction module housing 170, etc.). Accordingly, Figures 3 to 10 The enlarged views shown in the figures 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 transfer path between the electric motor module 26 and the drive pinion 84 is represented by a straight double dashed line. In the configurations described below, the torque transfer path is primarily described in the context of transferring torque from the electric motor module 26 to the drive pinion 84; however, the torque transfer path can be bidirectional and can facilitate the transfer of torque from the drive pinion 84 to the electric motor module 26 under various operating conditions (such as during regenerative braking).

[0052] refer to Figure 3 and Figure 4 , showing a first configuration of the gear reduction module 30 . The gear reduction module 30 may include a first gear set 200 and a second gear set 202 .

[0053] The first gear set 200 can be positioned axially along the axis 70 between the electric motor module 26 and the second gear set 202. The first gear set 200 can be configured as a planetary gear set. For example, the first gear set 200 can include a first sun gear 210, a first set of planetary gears 212, a first planetary ring gear 214, and a first planetary gear carrier 216.

[0054] 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. As such, the first sun gear 210 can rotate with the rotor 106 and the rotor output flange 150 about the axis 70. Alternatively, the first sun gear 210 can extend around the drive pinion 84 and can receive the drive pinion.

[0055] A first set of planet gears 212 can be rotatably disposed between the first sun gear 210 and the first planet ring gear 214. Each first planet gear 212 can have teeth that can mesh with teeth of the first sun gear 210, which can extend away from the axis 70, and with teeth of the first planet ring gear 214, which can extend toward the axis 70. Each first planet gear 212 can rotate about a corresponding planet gear axis 218.

[0056] The first planet ring gear 214 can extend about the axis 70 and can receive the first set of planet gears 212. The first planet ring gear 214 can be fixedly positioned such that the first planet ring gear 214 cannot rotate about the axis 70. For example, the first planet ring gear 214 can be received inside the gear reduction module housing 170 and can be fixedly coupled thereto such that the first planet ring gear 214 cannot rotate about the axis 70.

[0057] The first planet gear carrier 216 can rotatably support the first set of planet gears 212. Furthermore, the first planet gear carrier 216 can rotate about the axis 70. The first planet gear carrier 216 can extend toward the second gear set 202 and can be operatively connected to the second gear set. In at least one configuration, the first planet gear carrier 216 can include a support portion 220, a first flange portion 222, and a connecting portion 224.

[0058] The support portion 220 can rotatably support the first set of planet gears 212. The support portion 220 can have any suitable configuration. For example, the support portion 220 can include a plurality of pins that can extend along each planet gear axis 218 and can be received within a hole in each first planet gear 212. A bearing (such as a rolling element bearing assembly) can be received within a hole in each first planet gear 212 and can extend around each pin to help rotatably support each first planet gear 212.

[0059] The first flange portion 222 may extend from an end of the support portion 220 toward the axis 70. The first flange portion 222 may be positioned axially along the axis 70 between the first set of planetary gears 212 and the second gear set 202.

[0060] The connecting portion 224 can extend from an end of the first flange portion 222. In at least one configuration, the connecting portion 224 can extend generally parallel to the axis 70. The connecting portion 224 can be disposed closer to the axis 70 than the support portion 220.

[0061] The support bearing assembly 226 can rotatably support the first planet gear carrier 216. The support bearing assembly 226 can extend from a support structure, such as the gear reduction module housing 170, to the first planet gear carrier 216. For example, the support bearing assembly 226 can be received within the gear reduction module housing 170, and the first planet gear carrier 216 can be received within the support bearing assembly 226. The support bearing assembly 226 can be disposed proximate to the connecting portion 224 of the first planet gear carrier 216 and can be axially positioned between the first flange portion 222 and the second gear set 202. As such, the support bearing assembly 226 can be axially positioned along the axis 70 between the various components of the first gear set 200 and the second gear set 202.

[0062] The second gear set 202 can be operatively connected to the first gear set 200. Despite the presence of the first planet gear carrier 216, the second gear set 202 can be spaced apart from the first gear set 200. In at least one configuration, the second gear set 202 can include a second sun gear 230, a second set of planet gears 232, a second planetary ring gear 234, and a second planet gear carrier 236.

[0063] The second sun gear 230 can be fixedly positioned such that the second sun gear 230 cannot rotate about the axis 70. For example, the second sun gear 230 can be received inside the gear reduction module housing 170 and can be fixedly coupled thereto such that the second sun gear 230 cannot rotate about the axis 70.

[0064] The second set of planet gears 232 can be rotatably disposed on the second sun gear 230. Each second planet gear 232 can have teeth that can mesh with teeth of the second sun gear 230, which can extend away from the axis 70, and with teeth of the second planet ring gear 234, which can extend toward the axis 70. Each second planet gear 232 can rotate about a corresponding planet gear axis, which can be disposed at the same distance from the axis 70 as or at a different distance from the planet gear axis 218 associated with the first set of planet gears 212. In at least one configuration, the members of the second set of planet gears 232 can have a larger diameter than the members of the first set of planet gears 212. The second set of planet gears 232 can be rotatably supported on a second planet gear carrier 236. Each second planet gear 232 can be axially positioned between the first gear set 200 and the gear reduction module cover 172.

[0065] The second planetary ring gear 234 can extend about the axis 70 and can receive the second set of planetary gears 232. The second planetary ring gear 234 can rotate about the axis 70 relative to the gear reduction module housing 170. In at least one configuration, the second planetary ring gear 234 can include a connecting flange portion 240. The connecting flange portion 240, or a portion thereof, can extend toward the axis 70 and the connecting portion 224 of the first planetary gear carrier 216.

[0066] The second support bearing assembly 242 can rotatably support the second planet ring gear 234. The second support bearing assembly 242 can extend from a support structure, such as the gear reduction module housing 170, to the second planet ring gear 234. For example, the second support bearing assembly 242 can be received inside the gear reduction module housing 170, and the second planet ring gear 234 can be received inside the second support bearing assembly 242.

[0067] The second planetary gear carrier 236 can rotatably support the second set of planetary gears 232. Furthermore, the second planetary gear carrier 236 can rotate with the drive pinion 84 about the axis 70. The second planetary gear carrier 236 can be connected to the drive pinion 84 in any suitable manner. For example, the second planetary gear carrier 236 can include a flange portion 250 that extends from a support member 252 that can rotate about the axis 70. The flange portion 250 can be coupled to the support member 252 or formed integrally therewith. The flange portion 250 can be positioned axially between the connecting flange portion 240 of the second planetary ring gear 234 and the second set of planetary gears 232.

[0068] The support member 252 can be directly or indirectly coupled to the drive pinion 84. In at least one configuration, the support member 252 can be disposed within the second sun gear 230 and can be rotatably supported by one or more bearings 256. For example, the bearings 256 can extend around the support member 252 and from the support member 252 to the second sun gear 230. It is also contemplated that the support member 252 can be omitted, such as by increasing the length of the shaft portion of the drive pinion 84. It is also contemplated that the support member 252 can be a single, unitary component or can be constructed from multiple components.

[0069] In the configuration described below, one or more clutches can cooperate with the gear reduction module 30 to provide a desired gear reduction ratio and change the torque transmitted between the electric motor module 26 and the differential assembly 22 and therefore transmitted to or from the half-shaft 24 of the axle assembly 10. The clutch can control the rotation of one component relative to another. For example, the clutch can connect and disconnect two components (such as a driving component and a driven component). The clutch can have any suitable configuration. For example, the clutch can be configured as a friction clutch, an electromagnetic clutch, a hydraulic clutch, etc. The clutch can be configured as a slip clutch or a non-slip clutch. The slip clutch can be provided in different configurations, an example of which is a multi-plate clutch.

[0070] In the accompanying drawings, a clutch is represented by a box extending between two components. When the clutch is engaged to couple, connect, or lock the two components to each other, the box is marked with an X. When the clutch is disengaged and the two components are decoupled, disconnected, or unlocked from each other, the box is empty and unmarked. Two rotatable components can rotate together when the clutch connects the two components, but cannot rotate together when the clutch is not coupling or connecting the two rotatable components. The clutch can inhibit rotation of the rotatable component when connecting the rotatable component to a stationary or non-rotatable component, and can rotate relative to the stationary or non-rotatable component when the clutch is not coupling or connecting the two components. These boxes can represent separate clutches or clutches that can share common components. For example, a clutch configured as a shift collar can have teeth that can mesh with teeth on different components depending on the axial position of the shift collar. Thus, one box can represent the approximate position of the shift collar in which the shift collar can be coupled to or decoupled from a first component, while a second box can represent the approximate position of the shift collar in which the shift collar can be coupled to or decoupled from a second component. The clutch may be operated or actuated by any suitable type of actuator in a manner known to those skilled in the art.

[0071] refer to Figure 3 , two clutches are shown. These clutches may be referred to as a first clutch 260 and a second clutch 262.

[0072] A first clutch 260 can selectively couple the first planetary gear carrier 216 to the drive pinion 84. For example, when the first clutch 260 is engaged, the first clutch 260 can connect the first planetary gear carrier 216 to the drive pinion 84, either directly or via the support member 252, such that the first planetary gear carrier 216 and the drive pinion 84 can rotate together about the axis 70. Conversely, the first clutch 260 can be disengaged to permit relative rotation between the first planetary gear carrier 216 and the drive pinion 84. The first clutch 260 is illustrated as extending between the connecting portion 224 of the first planetary gear carrier 216 and the support member 252; however, other configurations and positionings are also contemplated. For example, the support member 252 can be omitted, and the first clutch 260 can extend from the drive pinion 84.

[0073] A second clutch 262 can selectively couple the first planet gear carrier 216 to the second gear set 202. For example, when the second clutch 262 is engaged, the second clutch 262 can connect the first planet gear carrier 216 to the second planet ring gear 234, allowing the first planet gear carrier 216 and the second planet ring gear 234 to rotate together about the axis 70. Conversely, the second clutch 262 can be disengaged to permit relative rotation between the first planet gear carrier 216 and the second planet ring gear 234. The second clutch 262 is shown extending between the connecting portion 224 of the first planet gear carrier 216 and the connecting flange portion 240 of the second planet ring gear 234; however, other configurations and positionings are also contemplated. For example, a connecting flange portion can be provided for the first planet gear carrier 216, and the second clutch 262 can be positioned further away from the axis 70, so that the second clutch 262 can connect or disconnect the connecting flange portion and the second planet ring gear 234.

[0074] refer to Figure 3 , showing the clutches providing a first gear ratio. The first clutch 260 is disengaged, while the second clutch 262 is engaged. Torque can be transferred 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 planet gear carrier 216 via the first set of planet gears 212, from the first planet gear carrier 216 to the second planet ring gear 234 via the second clutch 262, from the second planet ring gear 234 to the second planet gear carrier 236 via the second set of planet gears 232, and from the second planet gear carrier 236 to the drive pinion 84 via the support member 252 (if provided). Thus, when the first gear ratio is provided, the first sun gear 210 and the first planet gear carrier 216 can rotate relative to the drive pinion 84 about the axis 70.

[0075] refer to Figure 4, showing the clutches that provide the second gear ratio. First clutch 260 is engaged, while second clutch 262 is disengaged. Torque can be transferred from rotor 106 to first sun gear 210, for example, via rotor output flange 150, from first sun gear 210 to first planet gear carrier 216 via first set of planet gears 212, and from first planet gear carrier 216 to drive pinion 84 via first clutch 260 and support member 252 (if provided). Thus, torque cannot be transferred between first gear set 200 and second gear set 202 via second clutch 262.

[0076] refer to Figures 5 to 7 , shows a second configuration of the gear reduction module 30'. In this configuration, the gear reduction module 30' can include a first gear set 200, a second gear set 202, and a third gear set 304. The third gear set 304 can be positioned axially along the axis 70 between the second gear set 202 and the gear reduction module cover 172. Thus, the first gear set 200 can be positioned axially along the axis 70 between the electric motor module 26 and the second gear set 202, and the second gear set 202 can be positioned axially between the first gear set 200 and the third gear set 304.

[0077] The first gear set 200 may be the same as the first gear set described previously.

[0078] The second gear set 202 can be the same as the second gear set described above, except that the second sun gear 230 can be selectively coupled to a stationary component such as the gear reduction module housing 170 .

[0079] The third gear set 304 can be configured as a planetary gear set. For example, the third gear set 304 can include a third sun gear 310 , a third set of planetary gears 312 , a third planetary ring gear 314 , and a third planetary gear carrier 316 .

[0080] The third sun gear 310 can be fixedly positioned relative to the second sun gear 230. As such, the third sun gear 310 and the second sun gear 230 cannot rotate relative to each other. The third sun gear 310 can extend around and receive the support member 252.

[0081] The third set of planet gears 312 can be rotatably disposed between the third sun gear 310 and the third planet ring gear 314. Each of the third planet gears 312 can have teeth that can mesh with teeth of the third sun gear 310, which can extend away from the axis 70, and with teeth of the third planet ring gear 314, which can extend toward the axis 70. The members of the third set of planet gears 312 can have the same or different diameters as the members of the second set of planet gears 232. In the illustrated configuration, the second set of planet gears 232 and the third set of planet gears 312 are shown as having the same diameter and being rotatable about an axis that can be located at a common radial distance from the axis 70.

[0082] The third planetary ring gear 314 can extend about the axis 70 and can receive the third set of planetary gears 312. The third planetary ring gear 314 can rotate about the axis 70. For example, the third planetary ring gear 314 can be received internally and can rotate about the axis 70 relative to the gear reduction module housing 170.

[0083] The third support bearing assembly 318 can rotatably support the third planet ring gear 314. The third support bearing assembly 318 can extend from a support structure, such as the gear reduction module housing 170, to the third planet ring gear 314. For example, the third support bearing assembly 318 can be received inside the gear reduction module housing 170, and the third planet ring gear 314 can be received inside the third support bearing assembly 318.

[0084] The third planet gear carrier 316 can rotatably support the third set of planet gears 312. In addition, the third planet gear carrier 316 can be selectively coupled to a stationary component, such as the gear reduction module housing 170. In at least one configuration, the third planet gear carrier 316 can include a support portion 330 and a third flange portion 332.

[0085] The support portion 330 can rotatably support the third set of 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 within a hole in each of the third planet gears 312. A roller bearing assembly can be received within a hole in each of the third planet gears 312 and can extend around each pin to help rotatably support each of the third planet gears 312. Each pin can extend along a corresponding planet gear axis.

[0086] A third flange portion 332 may extend from an end of the support portion 330. For example, the third flange portion may extend away from the axis 70. The third flange portion 332 may be positioned axially along the axis 70 between the second gear set 202 and the third set of planetary gears 312. The third flange portion 332 may be omitted in different configurations.

[0087] refer to Figure 5 , five clutches are shown. These clutches may be referred to as a first clutch 360 , a second clutch 362 , a third clutch 364 , a fourth clutch 366 , and a fifth clutch 368 .

[0088] The first clutch 360 can selectively couple the first planet gear carrier 216 to the drive pinion 84 in the same manner as the previously described first clutch 260, such as via the support member 252. As such, when the first clutch 360 is engaged, the first planet gear carrier 216 and the drive pinion 84 can rotate together about the axis 70. Conversely, the first clutch 360 can be disengaged to permit relative rotation between the first planet gear carrier 216 and the drive pinion 84.

[0089] The second clutch 362 can selectively couple the first planet gear carrier 216 to the second gear set 202 in the same manner as the previously described second clutch 262. Thus, when the second clutch 262 is engaged, the first planet gear carrier 216 and the second planet ring gear 234 can rotate together about the axis 70. Conversely, the second clutch 262 can be disengaged to permit relative rotation between the first planet gear carrier 216 and the second planet ring gear 234.

[0090] The third clutch 364 can selectively couple the second gear set 202, the third gear set 304, or both to the drive pinion 84. For example, the support member 252 can be divided into two parts, such as a first support member part 370 and a second support member part 372, and the third clutch 364 can selectively connect the first support member part 370 to the second support member part 372. The first support member part 370 can be fixedly coupled to the third planetary ring gear 314 and can rotate therewith, while the second support member part 372 can be coupled to the drive pinion 84 and can rotate therewith. Thus, when the third clutch 364 is engaged, the third clutch 364 can connect the first support member part 370 to the second support member part 372, allowing the first support member part 370 and the second support member part 372 to rotate together about the axis 70. Conversely, the third clutch 364 can be disengaged to permit relative rotation between the first support member part 370 and the second support member part 372. The third clutch 364 is shown as being positioned generally between the first gear set 200 and the second gear set 202 ; however, other configurations and positionings are also contemplated. For example, the third clutch 364 can be positioned further away from the drive pinion 84 .

[0091] The fourth clutch 366 can selectively couple the second sun gear 230 and the third sun gear 310 to a stationary member. For example, the fourth clutch 366 can connect the second sun gear 230 and the third sun gear 310 to the gear reduction module housing 170 so that the second sun gear 230 and the third sun gear 310 can be inhibited from rotating about the axis 70. Conversely, the fourth clutch 366 can be disengaged to permit the second sun gear 230 and the third sun gear 310 to rotate together about the axis 70 relative to the gear reduction module housing 170. The fourth clutch 366 is shown as being disposed near the gear reduction module housing 170; however, the fourth clutch 366 can be disposed in other locations, such as closer to the axis 70.

[0092] The fifth clutch 368 can selectively couple the third planetary gear carrier 316 to a stationary component. For example, the fifth clutch 368 can connect the third planetary gear carrier 316 to the gear reduction module housing 170 so that the third planetary gear carrier 316 is inhibited from rotating about the axis 70. Conversely, the fifth clutch 368 can be disengaged to permit the third planetary gear carrier 316 to rotate relative to the gear reduction module housing 170 about the axis 70. The fifth clutch 368 is shown as being positioned near the gear reduction module housing 170; however, the fifth clutch 368 can be positioned elsewhere, such as closer to the axis 70.

[0093] refer to Figure 5 , showing a clutch providing a first gear ratio. In at least one configuration, the first gear ratio can be a low speed gear ratio. The first clutch 360 and the fourth clutch 366 can be disengaged, while the second clutch 362, the third clutch 364, and the fifth clutch 368 can be engaged. Torque can be transferred 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 planet gear carrier 216 via the first set of planet gears 212, from the first planet gear carrier 216 to the second planet ring gear 234 via the second clutch 362, from the second planet ring gear 234 to the second planet gear carrier 236, the second sun gear 230, and the third sun gear 310 via the second set of planet gears 232, from the third sun gear 310 to the third planet ring gear 314 via the third set of planet gears 312, and from the second planet gear carrier 236 and the third planet ring gear 314 to the drive pinion 84 via the first support member portion 370, the third clutch 364, and the second support member portion 372. Thus, when the first gear ratio is provided, the second sun gear 230 and the third sun gear 310 can rotate relative to the drive pinion 84 about the axis 70.

[0094] refer to Figure 6, showing a clutch providing a second gear ratio. In at least one configuration, the second gear ratio can be a medium or intermediate speed gear ratio that can be different from the first gear ratio. The first clutch 360 and the fifth clutch 368 can be disengaged, while the second clutch 362, the third clutch 364, and the fourth clutch 366 can be engaged. Torque can be transferred 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 planet gear carrier 216 via the first set of planet gears 212, from the first planet gear carrier 216 to the second planet ring gear 234 via the second set of planet gears 232, from the second planet ring gear 234 to the second planet gear carrier 236, and from the second planet gear carrier 236 to the drive pinion 84 via the first support member portion 370, the third clutch 364, and the second support member portion 372. Thus, when the second gear ratio is provided, torque cannot be transmitted through the third gear set 304 and the third planetary gear carrier 316 can rotate relative to the drive pinion 84 about the axis 70 .

[0095] refer to Figure 7 , showing a clutch that provides a third gear ratio. In at least one configuration, the third gear ratio can be a high-speed gear ratio that can be different from the first and second gear ratios. First clutch 360 can be engaged, while second clutch 362, third clutch 364, fourth clutch 366, and fifth clutch 368 can be disengaged. Torque can be transmitted from rotor 106 to first sun gear 210, for example, via rotor output flange 150, from first sun gear 210 to first planet gear carrier 216 via first set of planet gears 212, and from first planet gear carrier 216 to drive pinion 84 via first clutch 360 and second support member portion 372. Thus, when providing the third gear ratio, torque cannot be transmitted through second gear set 202 and third gear set 304.

[0096] Also envisioned is Figures 5 to 7 The configuration in can be provided with fewer clutches. For example, the second clutch 362 and the third clutch 364 can be replaced by a rigid connection. However, this will result in additional planetary gears rotating in the high gear ratio or when the third gear ratio is engaged, which may increase energy use.

[0097] refer to Figures 8 to 10 , shows a third configuration of the gear reduction module 30 ″. In this configuration, the gear reduction module 30 ″ may include a first planetary gear set 400 and a second planetary gear set 402 .

[0098] The first planetary gear set 400 can be positioned axially along axis 70 between the electric motor module 26 and the second planetary gear set 402. In at least one configuration, the first planetary gear set 400 can include a first sun gear 410, a first set of planet gears 412, a first planetary ring gear 414, and a first planet gear carrier 416.

[0099] The first sun gear 410 can be operatively connected to the rotor 106. For example, the first sun gear 410 can be operatively connected to the rotor 106 via the rotor output flange 150. As such, the first sun gear 410 can rotate with the rotor 106 and the rotor output flange 150 about the axis 70. The first sun gear 410 can extend around the drive pinion 84 and can receive the drive pinion 84 depending on the length of the drive pinion 84.

[0100] A first set of planet gears 412 can be rotatably disposed between the first sun gear 410 and the first planet ring gear 414. Each first planet gear 412 can have teeth that can mesh with teeth of the first sun gear 410, which can extend away from the axis 70, and with teeth of the first planet ring gear 414, which can extend toward the axis 70. Furthermore, each first planet gear 412 can rotate about a corresponding planet gear axis 418.

[0101] The first planet ring gear 414 can extend about the axis 70 and can receive the first set of planet gears 412. The first planet ring gear 414 can be fixedly positioned such that the first planet ring gear 414 cannot rotate about the axis 70. For example, the first planet ring gear 414 can be received inside a stationary component, such as the gear reduction module housing 170, and can be fixedly coupled to the stationary component such that the first planet ring gear 414 cannot rotate about the axis 70.

[0102] The first planet gear carrier 416 can rotatably support the first set of planet gears 412. Furthermore, the first planet gear carrier 416 can rotate about the axis 70. The first planet gear carrier 416 can extend toward the second planetary gear set 402 and can be operatively connected thereto.

[0103] The second planetary gear set 402 can be positioned axially farther from the electric motor module 26 than the first planetary gear set 400 along axis 70. In at least one configuration, the second planetary gear set 402 can include a second sun gear 420, a second set of planet gears 422, a second planetary ring gear 424, and a second planet gear carrier 426.

[0104] The second sun gear 420 can be selectively coupled to a stationary member via a fifth clutch, as will be discussed below.

[0105] The second set of planet gears 422 can be rotatably disposed between the second sun gear 420 and the second planet ring gear 424. Each second planet gear 422 can have teeth that can mesh with teeth of the second sun gear 420, which can extend away from the axis 70, and with teeth of the second planet ring gear 424, which can extend toward the axis 70. Furthermore, each second planet gear 422 can rotate about a corresponding planet gear axis, which can be different from the planet gear axis 418 associated with the first set of planet gears 412.

[0106] The second planetary ring gear 424 can extend about the axis 70 and can receive the second set of planetary gears 422. The second planetary ring gear 424 can be selectively coupled to a stationary component, such as the gear reduction module housing 170.

[0107] The second planet gear carrier 426 can rotatably support the second set of planet gears 422. Furthermore, the second planet gear carrier 426 can rotate about the axis 70. The second planet gear carrier 426 can be fixedly coupled to the support member 252 or formed integrally therewith.

[0108] refer to Figure 8 , five clutches are shown. These clutches may be referred to as a first clutch 430 , a second clutch 432 , a third clutch 434 , a fourth clutch 436 , and a fifth clutch 438 .

[0109] The first clutch 430 can selectively couple the first sun gear 410 to the second sun gear 420. As such, the first clutch 430 can be used to selectively couple the rotor 106 to the second sun gear 420. For example, when the first clutch 430 is engaged, the first clutch 430 can connect the first sun gear 410 to the second sun gear 420 so that the first sun gear 410 and the second sun gear 420 can rotate together about the axis 70. Conversely, the first clutch 430 can be disengaged to permit relative rotation between the first sun gear 410 and the second sun gear 420.

[0110] The second clutch 432 can selectively couple the first planet gear carrier 416 to the second sun gear 420. For example, when the second clutch 432 is engaged, the second clutch 432 can connect the first planet gear carrier 416 to the second sun gear 420 so that the first planet gear carrier 416 and the second sun gear 420 can rotate together about the axis 70. Conversely, the second clutch 432 can be disengaged to permit relative rotation between the first planet gear carrier 416 and the second sun gear 420.

[0111] The third clutch 434 can selectively couple the first planet gear carrier 416 to the second planet ring gear 424. For example, when the third clutch 434 is engaged, the third clutch 434 can connect the first planet gear carrier 416 to the second planet ring gear 424 so that the first planet gear carrier 416 and the second planet ring gear 424 can rotate together about the axis 70. Conversely, the third clutch 434 can be disengaged to permit relative rotation between the first planet gear carrier 416 and the second planet ring gear 424.

[0112] The fourth clutch 436 can control the rotation of the second planetary ring gear 424 about the axis 70. For example, when the fourth clutch 436 is engaged, the fourth clutch 436 can connect the second planetary ring gear 424 to a stationary component (such as the gear reduction module housing 170) so that the second planetary ring gear 424 cannot rotate about the axis 70. Conversely, the fourth clutch 436 can be disengaged to permit the second planetary ring gear 424 to rotate about the axis 70 relative to the gear reduction module housing 170.

[0113] The fifth clutch 438 can control the rotation of the second sun gear 420 about the axis 70. For example, when the fifth clutch 438 is engaged, the fifth clutch 438 can connect the second sun gear 420 to a stationary component (such as the gear reduction module housing 170) so that the second sun gear 420 cannot rotate about the axis 70. Conversely, the fifth clutch 438 can be disengaged to permit the second sun gear 420 to rotate about the axis 70 relative to the gear reduction module housing 170.

[0114] refer to Figure 8 , showing a clutch providing a first gear ratio. In at least one configuration, the first gear ratio can be a low speed gear ratio. The first clutch 430, the third clutch 434, and the fifth clutch 438 can be disengaged, while the second clutch 432 and the fourth clutch 436 can be engaged. Torque can be transferred from the rotor 106 to the first sun gear 410, for example, via the rotor output flange 150, from the first sun gear 410 to the first planet gear carrier 416 via the first set of planet gears 412, from the first planet gear carrier 416 to the second sun gear 420 via the second clutch 432, from the second sun gear 420 to the second planet gear carrier 426 via the second set of planet gears 422, and from the second planet gear carrier 426 to the drive pinion 84 via the support member 252, noting that the support member 252 can be formed integrally with the second planet gear carrier 426 or attached as a separate component. As such, when providing the first gear ratio, the first sun gear 410 and the second sun gear 420 can rotate relative to the drive pinion 84 about the axis 70 and can rotate at different speeds relative to each other.

[0115] refer to Figure 9 , showing a clutch that provides a second gear ratio. In at least one configuration, the second gear ratio can be a medium or intermediate speed gear ratio that can be different from the first gear ratio. The third clutch 434 and the fifth clutch 438 can be engaged, while the first clutch 430, the second clutch 432, and the fourth clutch 436 can be disengaged. Torque can be transferred from the rotor 106 to the first sun gear 410, for example, via the rotor output flange 150, from the first sun gear 410 to the first planet gear carrier 416 via the first set of planet gears 412, from the first planet gear carrier 416 to the second planet ring gear 424 via the third clutch 434, from the second planet ring gear 424 to the second planet gear carrier 426 via the second set of planet gears 422, and from the second planet gear carrier 426 to the drive pinion 84 via the support member 252. Thus, when the second gear ratio is provided, the first sun gear 410, but not the second sun gear 420, can rotate relative to the drive pinion 84 about the axis 70.

[0116] refer to Figure 10 , showing a clutch that provides a third gear ratio. In at least one configuration, the third gear ratio can be a high-speed gear ratio that can be different from the first and second gear ratios. The first clutch 430 and the fourth clutch 436 can be engaged, while the second clutch 432, the third clutch 434, and the fifth clutch 438 can be disengaged. Torque can be transferred from the rotor 106 to the first sun gear 410, for example, via the rotor output flange 150, from the first sun gear 410 to the second sun gear 420 via the first clutch 430, from the second sun gear 420 to the second planet gear carrier 426 via the second set of planet gears 422, and from the second planet gear carrier 426 to the drive pinion 84 via the support member 252. Thus, when the third gear ratio is provided, the first sun gear 410 and the second sun gear 420 can rotate at the same speed about the axis 70 relative to the drive pinion 84.

[0117] refer to Figure 1The axle assembly 10 may optionally include an isolator support 500. The isolator support 500 can help support the end of the axle assembly 10 that is positioned farthest from the axle housing 40 and the differential axis 80. In at least one configuration, the isolator support 500 can extend from the gear reduction module housing 170 or the gear reduction module cover 172 to a cross member 502, which can be part of the vehicle chassis. For example, the cross member 502 can extend in a transverse direction between two frame rails of the vehicle. The isolator support 500 can include a first portion 504, which can be mounted to the gear reduction module housing 170 or the gear reduction module cover 172, and a second portion 506, which can be mounted to the cross member 502. The isolator support 500 can allow the first portion 504 to pivot relative to the second portion 506 about an isolator mounting axis 508 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 500 may include a resilient member that may be received in a hole in the first portion 504, the second portion 506, or both. It is also contemplated that the first portion 504 or the second portion 506 may be configured as a shock absorber. The isolator support 500 may be provided for any of the previously discussed configurations.

[0118] Axle assemblies having gear set configurations as described above can provide multiple gear ratios or speeds while providing a more compact package. Furthermore, these gear set configurations can reduce the difference between gear ratios compared to a two-speed single planetary gear configuration, which can help improve the efficiency of the gear reduction unit and the drivability of the vehicle. Furthermore, 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 heating of the roller bearing assembly associated with the gear set, thereby improving bearing life.

[0119] While exemplary embodiments have been described above, these embodiments are not intended to describe all possible forms of the present invention. Rather, the terms used in this specification are illustrative rather than restrictive, and it should be understood that various changes may be made without departing from the spirit and scope of the present invention. Furthermore, the features of various implemented embodiments may be combined to form additional embodiments of the present 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, comprising: a first gear set having a first sun gear, a first planetary ring gear, a first set of planetary gears, and a first planetary gear carrier, the first sun gear being operatively connected to the rotor and rotatable with the rotor about the axis, the first planetary ring gear being fixedly positioned so as to be non-rotatable about the axis, the first set of planetary gears meshing with the first sun gear and the first planetary ring gear, and the first planetary gear carrier rotatably supporting the first set of planetary gears; and a second gear set having a second sun gear, a second planetary ring gear, a second set of planetary gears, and a second planetary gear carrier, the second planetary ring gear being coupleable to the first planetary gear carrier such that the first planetary gear carrier and the second planetary ring gear are rotatable together about the axis, the second set of planetary gears being meshed with the second sun gear and the second planetary ring gear, the second planetary gear carrier rotatably supporting the second set of planetary gears and being rotatable about the axis; a first clutch that selectively couples the first planetary gear carrier to the drive pinion; and a second clutch selectively coupling the first planetary gear carrier to the second gear set; and A support member is coupled to the drive pinion, wherein the support member is disposed inside the second sun gear and is rotatably supported by one or more bearings.

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

3. The axle assembly of claim 1, wherein: Members of the first set of planetary gears have a smaller diameter than members of the second set of planetary gears.

4. The axle assembly of claim 1, wherein: The second planet gear carrier is operatively connected to the drive pinion such that the second planet gear carrier does not rotate relative to the drive pinion.

5. The axle assembly of claim 1, wherein: When the second clutch couples the first planetary gear carrier to the second gear set, the first clutch does not couple the first planetary gear carrier to the drive pinion, and when the first clutch couples the first planetary gear carrier to the drive pinion, the second clutch does not couple the first planetary gear carrier to the second gear set.

6. The axle assembly of claim 1, wherein: The second sun gear is fixedly positioned such that the second sun gear is non-rotatable about the axis.

7. The axle assembly of claim 1, wherein: The second clutch selectively couples the first planet gear carrier to the second planet ring gear.

8. 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: a first gear set having a first sun gear, a first planetary ring gear, a first set of planetary gears, and a first planetary gear carrier, the first sun gear being operatively connected to the rotor and rotatable with the rotor about the axis, the first planetary ring gear being fixedly positioned so as to be non-rotatable about the axis, the first set of planetary gears meshing with the first sun gear and the first planetary ring gear, and the first planetary gear carrier rotatably supporting the first set of planetary gears; and a second gear set having a second sun gear, a second planetary ring gear, a second set of planetary gears, and a second planetary gear carrier, the second planetary ring gear being coupleable to the first planetary gear carrier such that the first planetary gear carrier and the second planetary ring gear are rotatable together about the axis, the second set of planetary gears being meshed with the second sun gear and the second planetary ring gear, the second planetary gear carrier rotatably supporting the second set of planetary gears and being rotatable about the axis; a first clutch that selectively couples the first planetary gear carrier to the drive pinion; and a second clutch selectively coupling the first planetary gear carrier to the second gear set; and A third gear set, the third gear set comprising: a third sun gear fixedly positioned relative to the second sun gear; a third planetary ring gear, the third planetary ring gear being rotatable about the axis; a third set of planetary gears meshing with the third sun gear and the third planetary ring gear; and A third planet gear carrier rotatably supports the third set of planet gears and is selectively rotatable about the axis.

9. The axle assembly of claim 8, further comprising: a third clutch selectively connecting the third planetary ring gear to the drive pinion; a fourth clutch, the fourth clutch controlling rotation of the second sun gear and the third sun gear about the axis; as well as A fifth clutch controls rotation of the third planetary gear carrier about the axis.

10. The axle assembly of claim 9, wherein: When the second clutch couples the first planetary gear carrier to the second gear set, the third clutch connects the third planetary ring gear to the drive pinion, and the fifth clutch locks the third planetary gear carrier so that the third planetary gear carrier does not rotate about the axis, torque is transferred between the electric motor and the drive pinion via the first gear set and the second gear set.

11. The axle assembly of claim 10, wherein: The first clutch does not connect the first planetary gear carrier to the drive pinion, and the fourth clutch unlocks the second sun gear and the third sun gear so that the second sun gear and the third sun gear can rotate about the axis.

12. The axle assembly of claim 9, wherein: When the second clutch connects the first planetary gear carrier to the second gear set, the third clutch connects the third planetary ring gear to the drive pinion, and the fourth clutch locks the second sun gear and the third sun gear so that the second sun gear and the third sun gear do not rotate about the axis, torque is transmitted between the electric motor and the drive pinion via the first gear set and the second gear set.

13. The axle assembly of claim 12, wherein: The first clutch does not connect the first planetary gear carrier to the drive pinion, and the fifth clutch permits the third planetary gear carrier to rotate about the axis.

14. The axle assembly of claim 9, wherein: When the first clutch couples the first planetary gear carrier to the drive pinion, torque is transferred between the electric motor and the drive pinion via the first gear set.

15. The axle assembly of claim 14, wherein: The second clutch does not couple the first planetary gear carrier to the second gear set, and the third clutch does not connect the third planetary ring gear to the drive pinion.

16. 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: a first planetary gear set having a first sun gear, a first planetary ring gear, a first set of planetary gears, and a first planetary gear carrier, the first sun gear being operatively connected to the rotor and rotatable with the rotor about the axis, the first planetary ring gear being fixedly positioned so as to be non-rotatable about the axis, the first set of planetary gears meshing with the first sun gear and the first planetary ring gear, and the first planetary gear carrier rotatably supporting the first set of planetary gears; and a second planetary gear set having a second sun gear, a second planetary ring gear, a second set of planetary gears, and a second planetary gear carrier, the second set of planetary gears being meshed with the second sun gear and the second planetary ring gear, the second planetary gear carrier rotatably supporting the second set of planetary gears and being rotatable about the axis; and A first clutch selectively couples the first sun gear to the second sun gear.

17. The axle assembly of claim 16, further comprising: a second clutch selectively connecting the first planetary gear carrier to the second sun gear; a third clutch selectively connecting the first planet gear carrier to the second planet ring gear; a fourth clutch, the fourth clutch controlling rotation of the second planetary ring gear about the axis; as well as A fifth clutch controls rotation of the second sun gear about the axis.

18. The axle assembly of claim 17, wherein: When the second clutch connects the first planetary gear carrier to the second sun gear and the fourth clutch locks the second planetary ring gear so that it cannot rotate about the axis, torque is transferred between the electric motor and the drive pinion at a first gear ratio.

19. The axle assembly of claim 17, wherein: When the third clutch connects the first planetary gear carrier to the second planetary ring gear and the fifth clutch locks the second sun gear so that it cannot rotate about the axis, torque is transferred between the electric motor and the drive pinion at a second gear ratio.

20. The axle assembly of claim 17, wherein: When the first clutch couples the rotor to the second sun gear, torque is transferred between the electric motor and the drive pinion in a third gear ratio.

Images