An electric drive axle assembly and a vehicle with the same

Abstract

The application discloses an electric drive axle assembly and a vehicle with the same, which comprises a clutch, a gear ring, a planetary gear, a first shift element, a second driving gear and a third driving gear; the gear ring can be combined with or disconnected from the clutch, and the gear ring is engaged with the planetary gear; the first shift element can be combined with or disconnected from the second driving gear, and the first shift element can be combined with or disconnected from the third driving gear; when the gear position is changed, the clutch and the gear ring are combined to be in first gear; the first shift element is combined with the second driving gear to be in second gear; and the first shift element is combined with the third driving gear to be in third gear. The application has the advantages of compact system structure, few parts, light weight, small volume, satisfaction of the chassis space requirement of a leaf spring and an air suspension arrangement, appropriate increase of the number of speed ratios, full exertion of the efficiency of a driving motor, improvement of the transmission efficiency of each speed ratio, improvement of the electric drive axle system efficiency, effective reduction of energy consumption, prolongation of driving mileage and saving of transportation cost for users.

Description

Technical Field

[0001] This invention belongs to the field of electric drive axle assembly technology, and relates to an electric drive axle assembly and a vehicle equipped with the electric drive axle assembly. Background Technology

[0002] With the continuous development of new energy drive technology, highly integrated electric drive axles are gradually being used in commercial vehicles. The development challenge of electric drive axle systems lies in arranging a reduction gear mechanism with as many gears as possible within the limited space of the axle housing, while simultaneously considering lightweight design, hill-climbing requirements, and high-speed driving requirements.

[0003] Currently, the road load spectrum data collected by the tractor at high speed standard load, taking two gears as an example, shows that the first gear ratio (maximum gear ratio) is mainly used for fully loaded climbing steep slopes, starting, and crawling in traffic jams, accounting for less than 1 / 10 of the total effective driving time. In other situations, the highest gear is mainly used.

[0004] Patent CN214492504U provides an electric drive axle with wheel-side reducers. The drive motor power is connected to a two-speed shift module on the axle through a transmission module, and then distributed to the two half-shafts through a planetary reducer and differential, and finally transmitted to the wheels through the wheel-side reducer. Patent CN217574828U provides a two-speed electric drive axle system in which the motor output shaft is directly connected to the planetary gear reducer mechanism. After shifting, the two wheels are respectively connected to the second planetary gear set and the third planetary gear set. Patent CN218805002U provides an electric axle assembly in which the gearbox includes a gear train, a drive shaft, a balance shaft and a differential coupled in sequence. The entire transmission includes six parallel shafts.

[0005] The aforementioned electric drive axle structure still has some drawbacks when applied to heavy-duty trucks: heavy-duty trucks have large load capacities and high torque requirements. Although using planetary gear reducers can increase the overall speed ratio, power still needs to pass through the planetary gear set during operation, resulting in low transmission efficiency. Parallel shaft transmissions are highly efficient, but the excessive number of transmission stages not only increases the envelope size of the electric drive axle, making the overall vehicle layout difficult, but also reduces the overall transmission efficiency.

[0006] Currently, most electric drive axles use two gears (two different speed ratios), resulting in a relatively small number of speed ratios. This is detrimental to improving the overall vehicle's fuel economy and leads to rapid power consumption. There are two reasons for this: 1. If the speed ratio range is large enough to balance both climbing ability and high-speed driving capability, the difference between the two speed ratios becomes too large, preventing the motor from operating in its efficient range under complex conditions. 2. If the speed ratio range is small, while the large speed ratio satisfies climbing capability, the small speed ratio will be too high. At high speeds, the motor rotates at high speeds, placing stringent demands on the gearbox bearings and seals. If the small speed ratio is adjusted to a suitable value, the large speed ratio cannot meet the high wheel-end torque requirements. Summary of the Invention

[0007] To address the problems existing in the prior art, the present invention provides an electric drive axle assembly and a vehicle equipped with the electric drive axle assembly, thereby solving the technical problems of poor vehicle economy and high power consumption caused by the low speed ratio of the electric drive axle in the prior art.

[0008] This invention is achieved through the following technical solution:

[0009] An electric drive axle assembly includes a power input unit and a power output unit;

[0010] The first gear control component includes a clutch, a ring gear, and planetary gears. The ring gear can be engaged or disengaged from the clutch. The ring gear meshes with the planetary gears. The planetary gears are connected to both the power input unit and the power output unit.

[0011] The second gear control component includes a first shift element and a second drive gear. The first shift element can be engaged or disengaged from the second drive gear. The first shift element is connected to the power input unit, and the second drive gear is connected to the power output unit.

[0012] The third gear control component includes a third drive gear, and the first shifting element can be engaged or disengaged from the third drive gear; the third drive gear is connected to the power output unit.

[0013] When shifting gears, the clutch and the gear ring engage to achieve first gear shifting; when the first shifting element engages with the second drive gear, second gear shifting is achieved; when the first shifting element engages with the third drive gear, third gear shifting is achieved.

[0014] Preferably, the power input unit includes an input shaft, with a drive motor and an input shaft drive gear fixedly connected to both ends of the input shaft; an intermediate shaft driven gear meshes with the input shaft drive gear, the intermediate shaft driven gear is fixedly mounted on the intermediate shaft, a first drive gear is also fixedly mounted on the intermediate shaft, a first driven gear meshes with the first drive gear, the first driven gear is connected to a sun gear, and the sun gear meshes with planet gears; the first shifting element is fixedly mounted on the intermediate shaft.

[0015] Preferably, the power output unit includes a first half-shaft and a second half-shaft; one end of the first half-shaft and the second half-shaft are both connected to a wheel, and the other end is fixedly connected to a differential; the planetary gear, the second drive gear and the third drive gear are all connected to the differential.

[0016] Preferably, the electric drive axle assembly further includes a second driven gear, which is fixedly connected to the differential; the second driving gear meshes with the second driven gear, and the second driving gear is connected to the differential through the second driven gear.

[0017] Preferably, the electric drive axle assembly further includes a third driven gear, which is fixedly connected to the differential; the third driving gear meshes with the third driven gear, and the third driving gear is connected to the differential through the third driven gear.

[0018] Preferably, the electric drive bridge assembly further includes a planetary carrier, and the planetary gears are connected to a third driven gear via the planetary carrier.

[0019] Preferably, the first drive gear is engaged with a planetary gear ring gear, which in turn engages with planetary gears and a sun gear in sequence; the sun gear is engaged with a second shifting element, which can be engaged or disengaged from the transmission housing.

[0020] Preferably, the first shifting element and the second shifting element are any one of a sliding sleeve, a synchronizer, and a clutch.

[0021] Preferably, the electric drive bridge assembly includes two sets of power input units arranged symmetrically.

[0022] Vehicles equipped with the aforementioned electric drive axle assembly.

[0023] Compared with the prior art, the present invention has the following beneficial technical effects:

[0024] This invention discloses an electric drive axle assembly. Through a rational structural arrangement, it features three speed ratios, a wide speed ratio range, and easy adjustment of the speed ratio differences between adjacent gears. The electric drive axle exhibits high overall performance. The first gear, the highest speed ratio, employs a planetary gear set and a three-stage gear transmission, resulting in a large transmission ratio. This reduces the motor torque requirement and size, lowers motor and electronic control costs, and outputs high wheel-end torque, significantly improving climbing performance. The intermediate speed ratios, second and third gears, utilize a two-stage parallel shaft transmission, offering high transmission efficiency and improving fuel economy under various operating conditions and at high speeds, significantly enhancing vehicle range. The system of this invention has a compact structure, fewer components, is lightweight, and small in size, meeting the chassis space requirements for leaf spring and air suspension arrangements. The appropriate increase in the number of speed ratios allows for full utilization of the drive motor's efficiency, improves the transmission efficiency of each speed ratio, thereby enhancing the efficiency of the electric drive axle system, effectively reducing energy consumption, extending driving range, and saving transportation costs for users.

[0025] Furthermore, the electric drive axle assembly includes two symmetrically arranged power input units with a dual-motor layout, enabling uninterrupted gear shifting and improving driving comfort, vehicle economy, and power. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the structure of an electric drive bridge assembly according to the present invention;

[0028] Figure 2 This is a schematic diagram of another structure of a section in this invention;

[0029] Figure 3 This is a schematic diagram of the dual-motor structure of the electric drive bridge assembly in this invention.

[0030] The components are: 1. Drive motor; 2. Input shaft; 3. Third drive gear; 4. Input shaft drive gear; 5. Intermediate shaft driven gear; 6. Intermediate shaft; 7. First drive gear; 8. First driven gear; 9. First shifting element; 10. Second drive gear; 11. Second driven gear; 12. Differential; 13. Wheel; 141. First half-shaft; 142. Second half-shaft; 15. Third driven gear; 16. Gear ring; 17. Clutch; 18. Planetary gears; 19. Sun gear; 20. Planetary gear set large gear ring; 21. Second shifting element; 100. Transmission housing; 200. Axle housing. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0032] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0033] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0034] In the description of the embodiments of the present invention, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of the invention is in use, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the present invention. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0035] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0036] In the description of the embodiments of the present invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention according to the specific circumstances.

[0037] The present invention will now be described in further detail with reference to the accompanying drawings:

[0038] like Figure 1 As shown, the present invention provides an electric drive bridge assembly, including a power input unit and a power output unit;

[0039] The first gear control component includes a clutch 17, a gear ring 16, and a planetary gear 18. The gear ring 16 can be engaged or disengaged from the clutch 17. The gear ring 16 meshes with the planetary gear 18. The planetary gear 18 is connected to both the power input unit and the power output unit.

[0040] The second gear control component includes a first shift element 9 and a second drive gear 10. The first shift element 9 can be engaged or disengaged from the second drive gear 10. The first shift element 9 is connected to the power input unit, and the second drive gear 10 is connected to the power output unit.

[0041] The third gear control component includes a third drive gear 3, and the first shifting element 9 can be engaged or disengaged from the third drive gear 3; the third drive gear 3 is connected to the power output unit.

[0042] When shifting gears, the clutch 17 and the gear ring 16 are engaged to achieve first gear shift; when the first shifting element 9 is engaged with the second drive gear 10, second gear shift is achieved; when the first shifting element 9 is engaged with the third drive gear 3, third gear shift is achieved.

[0043] Specifically, the power input unit includes an input shaft 2, with a drive motor 1 and an input shaft drive gear 4 fixedly connected to both ends of the input shaft 2; an intermediate shaft driven gear 5 meshes with the input shaft drive gear 4, the intermediate shaft driven gear 5 is fixedly mounted on an intermediate shaft 6, a first drive gear 7 is also fixedly mounted on the intermediate shaft 6, a first driven gear 8 meshes with the first drive gear 7, the first driven gear 8 is connected to a sun gear 19, and the sun gear 19 meshes with planet gears 18; and a first shifting element 9 is fixedly mounted on the intermediate shaft 6.

[0044] The power output unit includes a first half-shaft 141 and a second half-shaft 142; one end of the first half-shaft 141 and the second half-shaft 142 are connected to the wheel 13, and the other end is fixedly connected to the differential 12; the planetary gear 18, the second drive gear 10 and the third drive gear 3 are all connected to the differential 12.

[0045] The power input unit and the power output unit are arranged inside the transmission housing 100 and the axle housing 200. The axle housing 200 is divided into left and right parts and is connected to the middle transmission housing 100.

[0046] In another preferred embodiment of the present invention, the electric drive axle assembly further includes a second driven gear 11, which is fixedly connected to the differential 12; the second drive gear 10 meshes with the second driven gear 11, and the second drive gear 10 is connected to the differential 12 through the second driven gear 11.

[0047] Furthermore, the electric drive axle assembly also includes a third driven gear 15 and a planetary carrier; the third driven gear 15 is fixedly connected to the differential 12; the third driving gear 3 meshes with the third driven gear 15, and the third driving gear 3 is connected to the differential 12 through the third driven gear 15; the planetary gear 18 is connected to the third driven gear 15 through the planetary carrier.

[0048] In the specific implementation of this invention, the drive motor 1 is connected to the transmission housing 100 in the middle position, and the two axle housings 200 on both sides are connected to the transmission housing 100. After the power of the drive motor 1 is reduced in speed and increased in torque by the transmission, it is transmitted to the two wheels 13 on both sides through the differential 12, the first half-shaft 141 and the second half-shaft 142 to drive the vehicle.

[0049] The drive motor 1 is connected to the input shaft 2. The input shaft 2 is equipped with the input shaft drive gear 4. The intermediate shaft 6 is fixed with the intermediate shaft driven gear 5, the first drive gear 7, and the first shifting element 9. The third drive gear 3 and the second drive gear 10 are loosely fitted on the intermediate shaft 6. The input shaft drive gear 4 meshes with the intermediate shaft driven gear 5. The first drive gear 7 meshes with the first driven gear 8. The first driven gear 8, the sun gear 19, and the third driven gear 15 are all loosely fitted on the second half-shaft 142. The first driven gear 8 is connected to the sun gear 19. The planetary gear 18 is connected to the third driven gear 15 through the planetary carrier. The third driven gear 15 and the second driven gear 11 are fixed together on the differential 12. The planetary gear 18 meshes with the sun gear 19 and the ring gear 16 respectively. The third driven gear 15 meshes with the third drive gear 3. The second driven gear 11 meshes with the second drive gear 10. The first half-shaft 141 and the second half-shaft 142 are both fixedly connected to the differential 12.

[0050] When clutch 17 engages with gear ring 16, the movement of gear ring 16 is constrained, and the transmission is in first gear, i.e., the maximum speed ratio state, which can provide the maximum wheel end torque; when the first shift element 9 engages with the leftward movement and the second drive gear 10, the transmission is in second gear, i.e., the intermediate speed ratio state; when the first shift element 9 engages with the rightward movement and the third drive gear 3, the transmission is in third gear, i.e., the minimum speed ratio state, which can provide the maximum wheel end speed.

[0051] When the clutch 17 is not engaged with the gear ring 16 and the first shift element 9 is not engaged with the gears on both sides, the transmission is in neutral. When the transmission is in neutral, the drive motor 1 connected to it stops working.

[0052] like Figure 2As shown, the first gear in this invention can also be arranged in another way. Preferably, a planetary gear set large ring gear 20 meshes with the first driving gear 7, and the planetary gear set large ring gear 20 meshes with planet gears 18 and sun gear 19 in sequence. A second shift element 21 meshes with the sun gear 19, and the second shift element 21 can be engaged or disengaged from the transmission housing 100. Specifically, the first driving gear 7 meshes with the external teeth of the planetary gear set large ring gear 20, the planet gears 18 mesh with the large ring gear 20 and the sun gear 19 respectively, and are connected to the third driven gear 15 through the planet carrier. The sun gear 22 is connected to the second shift element 21 and loosely fitted on the second half-shaft 142. When the second shift element 21 moves to the right and connects with the transmission housing 100, the movement of the sun gear 22 is constrained, and the transmission operates in first gear, i.e., at the maximum speed ratio.

[0053] like Figure 3 As shown, this invention can also include two drive motors 1 to achieve dual-motor drive, with the two drive motors 1 arranged symmetrically. Specifically, the drive motors 1 and the internal transmission components of the gearbox are arranged symmetrically. The dual power sources ensure uninterrupted power during gear shifting, improving driving comfort and safety. In the dual-motor arrangement, the power of the front and rear drive motors can be the same or different.

[0054] In this invention, the electric drive axle assembly is installed inside the transmission housing 100 and the axle housing 200. The transmission is modularly arranged according to the actual needs of the vehicle. The left and right segmented axle housings 200 have strong versatility, which significantly reduces the production costs of product development and subsequent upgrades.

[0055] In a further preferred embodiment, the first shifting element 9 and the second shifting element 21 in this invention can also be replaced by other shifting elements, such as synchronizers, clutches, electromagnetic shifters, etc., all of which fall within the protection scope of this invention.

[0056] The clutch 17 described in this invention can also be replaced by components such as brakes or sliding sleeves, all of which fall within the protection scope of this invention.

[0057] The bridge housing 200 described in this invention can be a stamped and welded bridge housing, a cast bridge housing, or an alloy bridge housing such as an aluminum alloy bridge housing.

[0058] This invention provides a multi-speed ratio high transmission efficiency electric drive axle assembly. Based on the actual operating time of each speed ratio, a planetary gear set mechanism is used to meet the high speed ratio requirement of first gear in commercial vehicles. For the lower speed ratio gears second and third gears, which are used for most of the time, two-stage parallel shaft transmission is used, so that the system efficiency of the electric drive axle assembly is optimal.

[0059] To address the technical problems of existing electric drive axle products, this invention provides a multi-speed ratio, high-efficiency electric drive axle assembly. This assembly improves system efficiency through a rationally arranged multi-speed ratio structure, meeting the design requirements of high economy and high power for new energy commercial vehicles. This invention features three speed ratios with a wide range and easily adjustable speed ratio differences between adjacent gears, resulting in high overall performance of the electric drive axle. The first gear, the highest speed ratio, uses a planetary gear set and a three-stage gear pair transmission, offering a large transmission ratio that reduces motor torque requirements and size, lowers motor and electronic control costs, and outputs high wheel-end torque, significantly improving climbing performance. The intermediate speed ratios, second and third gears, employ a two-stage parallel shaft transmission, offering high transmission efficiency and improving economy under comprehensive operating conditions and at high speeds, significantly enhancing vehicle range. The system has a compact structure, fewer components, is lightweight, and small in size, meeting the chassis space requirements for leaf spring and air suspension arrangements. Preferably, the system can be arranged with dual motors, enabling uninterrupted gear shifting, improving ride comfort and overall vehicle economy and power. The gearbox and axle platform design in this invention are modular and have good product portability, making it easy to match products and upgrade them.

[0060] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electric drive bridge assembly, characterized in that, Includes a power input unit and a power output unit; The first gear control component includes a clutch (17), a gear ring (16), and a planetary gear (18). The gear ring (16) can be engaged or disengaged from the clutch (17). The gear ring (16) meshes with the planetary gear (18). The planetary gear (18) is connected to both the power input unit and the power output unit. The second gear control component includes a first shift element (9) and a second drive gear (10). The first shift element (9) can be engaged or disengaged from the second drive gear (10). The first shift element (9) is connected to the power input unit, and the second drive gear (10) is connected to the power output unit. The third gear control component includes a third drive gear (3), and the first shifting element (9) can be engaged or disengaged from the third drive gear (3); the third drive gear (3) is connected to the power output unit. When shifting gears, the clutch (17) and the gear ring (16) are engaged to achieve first gear shift; when the first shifting element (9) is engaged with the second drive gear (10), second gear shift is achieved; when the first shifting element (9) is engaged with the third drive gear (3), third gear shift is achieved. The power input unit includes an input shaft (2), with a drive motor (1) and an input shaft drive gear (4) fixedly connected to both ends of the input shaft (2); an intermediate shaft driven gear (5) meshes with the input shaft drive gear (4), the intermediate shaft driven gear (5) is fixedly mounted on the intermediate shaft (6), and a first drive gear (7) is also fixedly mounted on the intermediate shaft (6), with a first driven gear (8) meshing with the first drive gear (7), the first driven gear (8) being connected to a sun gear (19), and the sun gear (19) meshing with a planet gear (18); the first shifting element (9) is fixedly mounted on the intermediate shaft (6), and the second drive gear (10) and the third drive gear (3) are loosely mounted on the intermediate shaft (6); The power output unit includes a first half-shaft (141) and a second half-shaft (142); one end of the first half-shaft (141) and the second half-shaft (142) are connected to the wheel (13), and the other end is fixedly connected to the differential (12); the planetary gear (18), the second drive gear (10) and the third drive gear (3) are all connected to the differential (12); The electric drive axle assembly also includes a second driven gear (11), which is fixedly connected to the differential (12); the second driving gear (10) meshes with the second driven gear (11), and the second driving gear (10) is connected to the differential (12) through the second driven gear (11); The electric drive axle assembly also includes a third driven gear (15), which is fixedly connected to the differential (12); the third driving gear (3) meshes with the third driven gear (15), and the third driving gear (3) is connected to the differential (12) through the third driven gear (15); The electric drive bridge assembly also includes a planetary carrier, through which the planetary gears (18) are connected to a third driven gear (15).

2. The electric drive bridge assembly according to claim 1, characterized in that, The first drive gear (7) is meshed with a planetary gear ring (20), which meshes with the planetary gear (18) and the sun gear (19) in sequence; the sun gear (19) is meshed with a second shift element (21), which can be engaged or disengaged from the transmission housing (100).

3. The electric drive bridge assembly according to claim 2, characterized in that, The first shifting element (9) and the second shifting element (21) are any one of the following: a sliding sleeve, a synchronizer, and a clutch.

4. The electric drive bridge assembly according to claim 1, characterized in that, The electric drive axle assembly includes two sets of power input units arranged symmetrically.

5. A vehicle equipped with the electric drive axle assembly according to any one of claims 1 to 4.

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