Multi-axis gear guide bracket for electric drive unit

Abstract

A number of variations disclosed may include a product that may include a carrier having guide features for assembling a plurality of gear drive devices for use in an electric drive unit of a vehicle. A number of variations disclosed may include a method of assembling a portion of an electric drive unit using a gear guide bracket having guide features for assembling a plurality of gear drive devices.

Description

Technical Field

[0001] The technical field generally relates to electric drive units for vehicles, components and assembly methods thereof. Background Art

[0002] Electric drive units for vehicles have many components, which makes their assembly challenging.

[0003] Therefore, it is desirable to provide an electric drive unit and its components that can be assembled in a more precise manner.Furthermore, other desirable features and characteristics of the variations disclosed herein will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the drawings and the foregoing disclosure. Summary of the invention

[0004] A number of variations may include a product that may include a bracket having guide features for assembling a plurality of gear drive devices for use in an electric drive unit of a vehicle.

[0005] A number of variations may include a method of assembling a portion of an electric drive unit using a gear guide bracket having guide features for assembling a plurality of gear driven devices. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Exemplary embodiments will be described below in conjunction with the following drawings, wherein like reference numerals denote like elements, and in the drawings:

[0007] Figure 1 is a functional block diagram of a vehicle according to a number of variations;

[0008] Figure 2 is used according to a number of variants Figure 1 A perspective view of an electric drive unit of a vehicle;

[0009] Figure 3A is a front perspective view showing a bracket according to a number of variations;

[0010] Figure 3B is a front perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0011] Figure 3C is a rear perspective view showing a bracket according to a number of variations;

[0012] Figure 3D is a rear perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0013] Figure 4A is a front perspective view showing a bracket according to a number of variations;

[0014] Figure 4B is a front perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0015] Figure 4C is a rear perspective view showing a bracket according to a number of variations;

[0016] Figure 4D is a rear perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0017] Figure 5A is a front perspective view showing a bracket according to a number of variations;

[0018] Figure 5B is a front perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0019] Fig. 6A is a rear perspective view showing a bracket according to a number of variations;

[0020] Figure 6B is a rear perspective view showing a bracket according to a number of variations, with portions shown in phantom to illustrate internal components;

[0021] Figure 6C is a rear perspective view showing a bracket according to a number of variations; and

[0022] Figure 7 is a front perspective view showing a bracket according to a number of modifications.

[0023] Figure 8 is a front view illustrating a bracket according to a number of variations, the bracket showing a first bearing cap and a second bearing cap.

[0024] Fig. 9 is a rear view showing a bracket according to a number of variations, the bracket showing a third bearing cap.

[0025] Fig.10 is an exploded perspective view illustrating a bracket according to a number of variations, the bracket showing at least one bearing cap. DETAILED DESCRIPTION

[0026] The following detailed description is merely illustrative in nature and is not intended to limit application and use. In addition, it is not intended to be bound by any express or implied theory presented in the aforementioned technical field, background technology, summary of the invention or the following detailed description. As used herein, the term module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated or group) and memory that executes one or more software or firmware programs, a combinational logic circuit and / or other suitable components that provide the described functions.

[0027] Figure 1 Several variations of the vehicle 10 are shown in the form of functional block diagrams. In several variations, the vehicle 10 may be an automobile. The vehicle 10 may be any of numerous different types of vehicles, such as, but not limited to, a sedan, a van, a van, a truck, or a sport utility vehicle (SUV), and may be two-wheel drive (e.g., rear-wheel drive or front-wheel drive), four-wheel drive or all-wheel drive, and / or various other types of vehicles in certain variations. In certain variations, the vehicle 10 may also include another type of mobile platform.

[0028] The vehicle 10 may include a body 12 that may be disposed on or integrated with a chassis. The body 12 may substantially surround the other components of the vehicle 10. The vehicle 10 may also include a plurality of wheels 14 and 16, which may be referred to as a left or driver's side wheel 14, and a right or passenger's side wheel 16. The wheels 14 and 16 may each be rotatably coupled to the chassis near a respective corner of the body 12 to facilitate movement of the vehicle 10. In a number of variations, the vehicle 10 may include four wheels 14 and 16, although this may vary in other variations, such as for trucks and certain other vehicles.

[0029] The drive system 18 can be installed in the vehicle 10 to drive the wheels 14 and 16, for example, via shafts 20, 22. In some variations, the drive system 18 can include a drive unit 24. In some variations, the drive unit 24 can include a power plant 26 coupled to the transmission system 28, such as an internal combustion engine and / or an electric motor / generator. In multiple variations, the power plant 26 can be an electric motor, which can also be configured as a generator. In multiple variations, the drive unit 24 can vary, and / or two or more drive unit systems 24 can be used in the vehicle. For example, the vehicle 10 can also include any one or combination of multiple different types of drive units 24, such as a combustion / electric hybrid engine.

[0030] The vehicle 10 may also include a braking system 30 and a steering system 32. In a number of variations, the braking system 30 controls braking of the vehicle 10 using a brake actuator 34, which may be controlled via input provided by a driver, such as through a brake pedal coupled to the brake actuator 34, and in a number of variations, via automatic control of a control system 36. The braking system 30 may include brakes, such as brake 38, at any of the plurality of wheels 14 and 16. In a number of variations, the steering system 32 controls steering of the vehicle 10 via a steering actuator 40, such as with input from a steering wheel 42 (e.g., in conjunction with a steering column coupled to the axle 20 and / or wheels 14 and 16), which is controlled via input provided by a driver, and in some variations, via automatic control of a controller system 36.

[0031] In various variations, the control system 36 may be coupled to various systems including the braking system 30 and the steering system 32 of the vehicle 10. In various variations, the control system 36 may also be coupled to one or more other systems and / or components of the vehicle 10, including, for example, the controller 44. The controller 44 and the powertrain controller 46 may be part of or include a computer system 47. The controller 44 may be different from the computer system 47 in other aspects. Figure 1 Controller 44 may be configured as any number of controllers and / or microcontrollers in communication with one another.

[0032] The controller 44 may be coupled to various actuators including the actuators 34, 40 and the drive unit 24. The controller 44 may also be coupled to various sensors that sense observable states of the vehicle 10. In a number of variations, the sensing devices may include, but are not limited to, brake sensors such as a pedal position sensor, steering angle sensors, acceleration sensors, and torque request sensors such as at an accelerator pedal or throttle.

[0033] In a number of variations, the controller 44 may be coupled to other devices, sensors, the braking system 30 , the steering system 32 , the drive unit 24 , and / or other system command devices or components of the vehicle 10 .

[0034] The controller 44 may provide control functions of the vehicle 10 to the drive unit 24. In a number of variations, a powertrain controller 46 may be coupled to the control system 36 and in a number of variations may be included in the controller 44. In a number of variations, the powertrain module 50 may reside in the powertrain controller 46, or may be included in the powertrain controller 46, or the powertrain controller may be provided as a separate control unit. The powertrain controller 46 may provide various functions for controlling the drive unit 24, such as operating the drive unit to propel the vehicle 10 by providing torque commands.

[0035] Figure 2 A number of variations are shown, which may include a portion of the drive unit 24, a portion of the powerplant 26, and a transmission system 28. The portion of the powerplant 26 may be an electric motor configured to provide motor torque, and may include a rotor 301 that rotates about a rotor axis 303. The rotor 301 may be interconnected with an input differential 600 that is configured to selectively split the motor torque into a first path 401 and a second path 402. The first path 401 extends from the input differential 600 to the wheels 14, and the second path 402 extends from the input differential 600 to the wheels 16.

[0036] The input differential 600 can be configured to selectively transfer torque from the rotor 301 to two pinion shafts or input drive shafts 90, each of which can be configured to rotate about the rotor axis 303. In addition, the input drive shafts 90 can be configured to rotate pinion gears 92. Each pinion gear 92 can be mounted on a corresponding input drive shaft 90. The pinion gears 92 can be configured to rotate about the rotor axis 303. Details of various arrangements of gears and their alignment are described below.

[0037] Each pinion gear 92 can be configured to transfer torque to two parallel transfer gear sets 64 and 72, which can be referred to as first transfer gear sets 64 and second transfer gear sets 72. In a number of variations, each first transfer gear set 64 can rotate about the rear axis 451, and each second transfer gear set 72 can rotate about the front axis 461.

[0038] Each first transfer gear set 64 may include a first transfer shaft 60, a large gear member 68, and a pinion gear member 66. In a number of variations, the large gear member 68 may be formed on or mounted to the corresponding first transfer shaft 60. In a number of variations, each pinion gear member 66 may be formed on or mounted to the corresponding gear shaft 60. As a result, each first transfer shaft 60, large gear member 68, and pinion gear member 66 may rotate about the rear axis 451.

[0039] Each second transmission gear set 72 may include a second transmission shaft 70, a large gear member 74, and a pinion gear member 76. In a number of variations, each large gear member 74 may be formed on or mounted to a corresponding second transmission shaft 70. In a number of variations, each pinion gear member 76 may be formed on or mounted to a corresponding second transmission shaft 70. As a result, each second transmission shaft 70, large gear member 74, and pinion gear member 76 may rotate about the front axis 461.

[0040] Each pair of parallel transfer gear sets 64 and 72 can be configured to transfer torque to a corresponding final drive gear 94. Each final drive gear 94 can be configured to rotate about a drive axis 481. Specifically, each final drive gear 94 can be coupled or mounted to a drive shaft or output shaft 96.

[0041] exist Figure 3A , Figure 3B , Figure 3C and Figure 3D, which may include a bracket 52 having a guide feature 57. The bracket 52 may include a front or first face 54, which may include the guide feature 57. A cover portion 78 may extend generally perpendicularly from the first face 54. In a number of variations, the guide feature 57 may include a first through hole 56 and a spaced-apart second through hole 58, both of which are formed in the first face 54 of the bracket. The first face 54 and the cover 78 may be constructed and arranged to surround at least a portion of the first transfer gear set 64 and the spaced-apart second transfer gear set 72, as well as a pinion gear 92 (such as a pinion gear 92 mounted on or formed on an input or drive shaft 90) Figure 2 ). The first transmission gear set 64 may include a first large gear member 68 and a first small gear member 66, both of which are mounted on the first transmission shaft 60 or reshaped on the first transmission shaft 60. The second transmission gear set 72 may include a large gear member 74 and a small gear member 76, both of which are mounted on the second transmission shaft 70. Both the first transmission gear set 64 and the second transmission gear set 72 may be stepped gear sets. The bracket 52 may include a second face 80, the second face 80 may engage the second edge of the cover 78, and the second face 80 may extend generally perpendicularly from the cover 78. In a number of variations, the second face 80 may have a first spline 81, the first spline 81 may include a first arcuate flange portion 82 extending generally perpendicularly from the second face 80, and the first arcuate flange portion 82 has a plurality of spaced apart teeth 84 formed on its outer surface. In a number of variations, the second face 80 can have a second spline 83 that can include a second arcuate flange portion 86 extending generally perpendicularly from the second face 80 and having a plurality of spaced apart teeth 88 formed on an outer surface thereof. A final drive gear 94 can be provided and positioned to mesh with the first pinion gear member 66 and the second pinion gear member 76. An output drive shaft 96 can be coupled to the final drive gear 94, and a first output shaft annular 98 bearing can be coupled to the output drive shaft 96.

[0042] refer to Figure 3C and Figure 3D In a number of variations, a hollow cylindrical protrusion 100 may extend from the second face 80 of the bracket 52 and may be constructed and arranged to receive an input shaft bearing 102 and a portion of the input drive shaft 90. A second output shaft bearing 104 may be coupled to an output shaft extension 106 that protrudes from an output disk 108, which may carry the final drive gear 94. The bracket 52 may include a second set of guide features 130, which may include a first through hole 132 formed in the second face 80 (a variation best seen in the figure, but which is Figure 3C and Figure 3DIn some embodiments, the first transmission gear shaft 60 may be received in the first through hole 132 of the second face 80 and press-fit into the first through hole 56 formed in the first face 54 of the bracket 52. In some embodiments, the second transmission gear shaft 70 may be received in the second through hole 134 formed in the second face 80 and press-fit into the second through hole 58 formed in the first face 54 of the bracket 52. Transmission gear shaft bearings (not shown) may be provided in each through hole formed in the first face 54 and / or each through hole formed in the second face 80 so that the first transmission shaft 60 and the second transmission shaft 70 may rotate on the transmission shaft bearings. Providing a guide feature in at least one of the first face 54 or the second face 80 of the bracket 52 provides the advantage of being able to align the axis 451 of the first transmission shaft 60, the axis 461 of the second transmission shaft 70, and the axis 303 of the input drive shaft 90 relative to each other using the bracket. In a number of variations, axis 451 of first transmission shaft 60 , axis 461 of second transmission shaft 70 , and axis 303 of input drive shaft 90 may be aligned to be co-linear using guide features of bracket 52 .

[0043] exist Figure 4A , Figure 4B , Figure 4C and Figure 4D , which may include a bracket 52 having a first face 54 that does not include a spline extending therefrom. One or more bracket locating features 110 may be provided on at least the first face 54, which may be used to locate the bracket to the housing structure and react to any unbalanced load. In a number of variations, the one or more bracket locating features 110 may include two spaced apart elongated protrusions extending generally perpendicularly from the first face 54. The second face 80 of the bracket 52 may include an extension 112. The extension 112 may include an annular support 114. The second output shaft bearing 104 may be accommodated in the annular bearing support 114 to support the rotation of the output drive shaft 96 thereon. The second face 80 may include one or more bracket locating features 116, which may be used to locate the bracket to the housing structure and react to any unbalanced load. In a number of variations, the one or more bracket locating features 116 may include two spaced apart elongated protrusions extending generally perpendicularly from the second face 80.

[0044] exist Figure 5A and Figure 5B A number of variations are shown in FIG. 1 , wherein the baffle support structure 119 may be configured to surround at least a portion of the final drive gear 94 . Figure 5A and Figure 5BA number of variations are shown in which the baffle support structure 119 may be an extension of the first face 54 of the bracket 52. An opening 117 may be formed in the baffle support structure 119 to accommodate the final stage drive gear 94.

[0045] exist Fig. 6A , Figure 6B and Figure 6C 54, wherein the output drive shaft support 120 may be bolted to the first face 54 of the bracket 52. The output drive shaft support may include a mounting flange 121 having a plurality of bolt holes 122 formed therein for attachment to the first face 54. The second annular bearing support 99 may extend downwardly from the mounting flange 121. The second output shaft bearing 98 may be housed in the annular bearing support 99. The baffle support structure 119 may include a baffle mounting flange 126 having a plurality of bolt holes 128 formed therein for bolting to the first face 54 of the bracket 52. The baffle support structure 119 may have a portion covering a portion of the output drive shaft support 120. The baffle 118 may extend downwardly from the baffle mounting flange 126 of the baffle support structure 119 and may be constructed and arranged to surround or cover at least a portion of the final drive gear 94. Corresponding bolt holes (not shown) may be formed in the first face 54 for alignment with the bolt holes 122 formed in the output drive shaft support 120 and the bolt holes 128 formed in the fender support structure 119. In a number of variations, the output drive support 120 and the fender support structure 119 may be attached or coupled to the first face 54 of the bracket 52, either directly or indirectly.

[0046] exist Figure 7 , which may include a first face 54 having at least a first extension 136 extending beyond the cover 78. The extension 136 may have a plurality of bolt holes 128 formed therein for locating the bracket 52 and securing the bracket 52 to the housing structure with bolts (not shown) to react to any unbalanced loads. The locating feature 110 may be an elongated protrusion extending generally perpendicularly from the first face 54, which may be configured to locate the bracket 52 to the housing structure.

[0047] exist Figure 8 , Fig. 9 and Fig.10 A number of variations are shown in FIG. Figure 8, which may include one of a plurality of bearing caps 700, 703, 817, the bearing caps 700, 703, 817 may include a first bearing cap 700, the first bearing cap 700 may include a first protrusion 701 extending from the flat portion 81 of the second face 80 of the bracket 52. The first protrusion 701 may be stamped from the second face 80. In a plurality of variations, the first protrusion 701 may be defined in an opening for receiving the input shaft 90 (e.g., in Figure 3A-3B The first bearing cap 700 may be constructed and arranged to accommodate and retain the input shaft bearing 102.

[0048] A second bearing cap 703 may be provided. The second bearing cap 703 may include two portions 713 and 715, wherein the first portion 713 may include a second protrusion 705 extending from the flat surface 81 of the second face 80 of the bracket 52. The second protrusion 705 may be stamped out from the second face 80 or attached to the second face 80. In a number of variations, the second protrusion 705 may have a first arcuate portion 700b and a first mounting flange 702 extending from a first end of the first arcuate portion 700b and a second mounting flange 704 extending from a second end of the first arcuate portion 700b. The second portion 715 of the second bearing cap 703 may include a second arcuate portion 700c. A first mounting flange 706 extending from a first end of the second arcuate portion 700c and a second mounting flange 708 extending from a second end of the second arcuate portion 700c. The mounting flanges 702, 704, 706, 708 may have through holes formed therein, and bolts 710 may extend through the through holes and be held in place by nuts 712 to mount together the first and second portions 713, 715 of the second bearing cap 703. The second bearing cap 703 may be constructed and arranged to receive and retain the second output shaft bearing 104.

[0049] In several variations, such as Fig. 9As shown in, a third bearing cap 817 may be provided. The third bearing cap 817 may include two parts 813 and 815, wherein the first part 813 may include a third protrusion 805 extending from the flat surface 55 of the first face 54 of the bracket 52. The third protrusion 805 may be stamped out from the first face 54. The third protrusion 805 may be stamped out from the first face 54 or attached to the first face 54. In a number of variations, the second protrusion 805 may have a first arcuate portion 800b and a first mounting flange 802 extending from a first end of the first arcuate portion 800b and a second mounting flange 804 extending from a second end of the first arcuate portion 800b. The second part 815 of the second bearing cap 817 may include a second arcuate portion 800c. A first mounting flange 806 extending from a first end of the second arcuate portion 800c and a second mounting flange 808 extending from a second end of the second arcuate portion 800c. The mounting flanges 802, 804, 806, 808 may have through holes formed in each, and bolts 810 may extend through the through holes and be held in place by nuts 812 to mount together the first and second portions 813, 815 of the second bearing cap 817. The third bearing cap 813 may be constructed and arranged to receive and retain the first output shaft annular 98 bearing.

[0050] refer to Fig.10 In a number of variations, a first pin 718 may extend through a first through hole 56 in the first face 54 of the bracket 52 and may be received in a bearing 721, which may be received in the inner diameter of the first transfer gear shaft 60. A second pin 720 may extend through a second through hole 58 in the first face 54 of the bracket 52 and may be received in a bearing 719, which may be received in the inner diameter of the second transfer gear shaft 70. The first face 54, the second face 80 of the cover 78 may include a plurality of mounting flanges 714, each mounting flange 714 having a through hole formed therein for mounting the first face 54, the second face 80, and the cover 78 to each other or to another structure of the vehicle.

[0051] Although at least one illustrative variation has been proposed in the foregoing detailed description, it should be understood that there are a large number of variations. It should also be understood that an exemplary embodiment or multiple exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide a convenient roadmap for implementing an exemplary embodiment or multiple exemplary embodiments for those skilled in the art. It should be understood that various changes may be made to the function and arrangement of elements without departing from the scope of the present disclosure as set forth in the attached claims and their legal equivalents.

Claims

1. A product comprising: A gear guide bracket for use in an electric drive unit of a vehicle; The bracket includes a cover and at least one surface extending from the cover, the cover and the at least one surface being constructed and arranged to accommodate a first transmission gear mounted to or formed on a first transmission gear shaft and a second transmission gear mounted to or formed on a second transmission gear shaft, and wherein the cover and the at least one surface are constructed and arranged to surround or cover at least a portion of the first transmission gear mounted to or formed on the first transmission gear shaft and the second transmission gear mounted to or formed on the second transmission gear shaft, and the at least one surface has at least one guide feature to guide the first transmission gear shaft and the second transmission gear shaft to a position relative to the bracket and each other.

2. The product according to claim 1, wherein The at least one surface having at least one guide feature includes a first surface of the bracket, the first surface having a first through hole formed in the first surface and a second through hole formed in the first surface, wherein the first through hole formed in the first surface is spaced apart from the second through hole formed in the first surface, wherein the first through hole formed in the first surface is configured to accommodate the first transmission gear shaft, and wherein the second through hole formed in the first surface is configured to accommodate the second transmission gear shaft.

3. The product according to claim 2, wherein: The at least one face having at least one guide feature also includes a second face of the bracket extending from the cover, wherein a first through hole is formed in the second face and a second through hole is formed in the second face, wherein the first through hole formed in the second face is spaced apart from the second through hole formed in the second face, wherein the first through hole formed in the second face is configured to accommodate the first transmission gear shaft, and wherein the second through hole formed in the second face is configured to accommodate the second transmission gear shaft.

4. The product according to claim 3, wherein: A first imaginary axis extending through the first through hole formed in the first face and through the first through hole formed in the second face is parallel to and in the same plane as a second imaginary axis extending through the first through hole formed in the second face and through the second through hole formed in the second face.

5. The product according to claim 3, wherein: The at least one face of the bracket and the cover are constructed and arranged to at least partially surround or cover a pinion mounted to or formed on an input drive shaft, wherein the second face includes a third through hole formed therein, and the third through hole is constructed and arranged to accommodate the input drive shaft.

6. The product according to claim 1, wherein: The bracket includes features for engaging a housing structure constructed and arranged to react to an unbalanced load.

7. The product according to claim 6, wherein: The feature for engaging the housing structure includes at least one spline having a plurality of spaced apart teeth for engaging the housing structure.

8. The product according to claim 6, wherein: The feature for engaging the housing structure includes at least one elongated protrusion extending from the at least one face.

9. The product according to claim 1, wherein: The carrier includes an annular output shaft bearing support constructed and arranged to receive an output drive shaft bearing and support the output drive shaft.

10. A product as set forth in claim 3 further comprising at least one bearing cap including a protrusion extending from a flat portion of the first face or the second face of the bracket, wherein: The protrusion includes an annular portion of an arcuate portion, wherein the at least one bearing cap is constructed and arranged to receive and retain an input shaft bearing, a first output shaft bearing, or a second output shaft bearing.

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