Axle assembly with gearshift mechanism

Abstract

An axle assembly is disclosed having a shift mechanism and a drive pinion. The gear shifting mechanism comprises a gear shifting lantern ring, a linkage piece and an actuator. The linkage is coupled to the shift collar. An actuator is coupled to the linkage. The linkage is received in a drive pinion bore of the drive pinion.

Description

Technical Field

[0001] The invention relates to an axle assembly with a shift mechanism. background

[0003] An axle assembly having a shift mechanism is disclosed in US Pat. No. 11,441,657.

[0004] Overview

[0005] The present invention relates to an axle assembly. The axle assembly includes a drive pinion, a transmission, and a shift mechanism. The drive pinion can rotate around an axis. The drive pinion has a drive pinion hole. The drive pinion hole extends along the axis. The drive pinion hole extends from a first end of the drive pinion toward a second end of the drive pinion. The second end of the drive pinion is arranged opposite to the first end. The transmission has a set of gears. The shift mechanism includes a shift collar, a linkage, and an actuator. The shift collar can rotate around the axis with the drive pinion. The shift collar can move along the axis relative to the drive pinion. The linkage is connected to the shift collar. The linkage is received in the drive pinion hole of the drive pinion. The actuator is connected to the linkage. The actuator is configured to move the linkage and the shift collar along the axis to selectively connect the members of the set of gears to the drive pinion.

[0006] The linkage may extend along the axis. The linkage may rotate with the shift collar about the axis. The linkage may be disposed inside the shift collar. The linkage may be fixedly coupled to the shift collar.

[0007] The drive pinion may include a drive pinion extension. The drive pinion extension may rotate about an axis. The shift collar may be disposed on the drive pinion extension. The linkage may be received inside the drive pinion extension.

[0008] The drive pinion extension may have a groove. The groove may extend in an axial direction relative to the axis. The fastener may be received in the groove. The fastener may couple the linkage to the shift collar. The fastener may be fixedly coupled to the linkage and the shift collar. The fastener may move in the groove in an axial direction.

[0009] When the actuator moves the shift collar toward the actuator, the linkage, fastener, and the shift collar can move in a first direction along the axis. When the actuator moves the shift collar away from the actuator, the linkage, fastener, and the shift collar can move in a second direction along the axis, the second direction being opposite to the first direction.

[0010] The axle assembly may include an end cap. The end cap may be disposed at an end of the axle assembly. The end cap may define a recess. The support bearing may be received inside the recess. The support bearing may rotatably support the drive pinion. The fastener may be received in the recess.

[0011] The axle assembly may have an electric motor. The electric motor may include a rotor. The rotor may rotate about an axis. The rotor may surround a drive pinion. The drive pinion may surround a linkage.

[0012] The axle assembly may include an axle housing and a differential carrier. The axle housing and the differential carrier may cooperate to define an internal cavity. The differential assembly may be received inside the internal cavity. The actuator may be received inside the internal cavity. The actuator may be mounted to the differential carrier. The actuator may be mounted to the axle housing.

[0013] The differential assembly may rotate about a differential axis. The actuator may be positioned axially relative to the axis between the first end of the drive pinion and the differential axis.

[0014] The actuator may be positioned further from the drive pinion than the differential axis is positioned from the drive pinion.

[0015] The actuator may be disposed outside the interior cavity.The actuator may be mounted to the axle housing.

[0016] An actuator may be arranged along this axis.

[0017] The drive pinion can be rotatably coupled to the linkage. The linkage can rotate with the drive pinion around an axis. The linkage can move relative to the drive pinion along the axis.

[0018] The drive pinion can be rotatably coupled to a linkage in the drive pinion hole.The drive pinion and linkage can be rotatably coupled with mating splines.

[0019] The support shaft may extend along the axis. The support shaft may be surrounded by a linkage. The support shaft may be surrounded by a shift collar. The support shaft may rotate around the axis. The linkage may rotate with the support shaft around the axis. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a perspective view of an example of an axle assembly.

[0021] Figure 2 is a cross-sectional view of the axle assembly taken along section line 2-2.

[0022] Figure 3 is a cross-sectional view of a portion of the axle assembly along section line 3 - 3 , wherein the electric motor module is omitted for clarity.

[0023] Figure 4 is an exploded view of an example of a drive pinion extension, shift collar, and support bearing that may be provided for a shift mechanism of an axle assembly.

[0024] Figure 5 A partial plan view of a portion of an axle assembly illustrating an example of an actuator of a shift mechanism offset from the axis of rotation of a drive pinion.

[0025] Figure 6 is a cross-sectional view of a second configuration of the axle assembly along section line 2 - 2 .

[0026] Figure 7 is a cross-sectional view of the third configuration of the axle assembly along section line 2 - 2 .

[0027] Figure 8 is a cross-sectional view of a fourth configuration of the axle assembly along section line 2 - 2 .

[0028] Fig. 9 can be provided for Figure 8 A cross-sectional view of a portion of a drive pinion of an axle assembly.

[0029] Fig.10 yes Figure 8 Side view of the shift collar and linkage shown.

[0030] Fig.11 is a cross-sectional view of the fifth configuration of the axle assembly along section line 2 - 2 . DETAILED DESCRIPTION

[0031] As required, detailed embodiments of the present invention are disclosed herein; however, it should be understood that the disclosed embodiments are merely illustrative of the various and alternative forms in which the present invention may be implemented. The drawings are not necessarily to scale; some features may be exaggerated or minimized to show 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 those skilled in the art to employ the present invention in various ways.

[0032] It should also be understood that, although the terms first, second, etc. are used in some cases herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, without departing from the scope of the various embodiments described, the first element can be referred to as the second element, and similarly, the second element can be referred to as the first element. Both the first element and the second element are elements, but they are not the same element.

[0033] The terms used in the description of the various embodiments described are only for the purpose of describing specific embodiments, and are not intended to be limiting. As used in the description of the various embodiments described and the appended claims, the singular forms "one" and "an" and "the" are intended to also include plural forms, unless the context clearly indicates otherwise. It should also be understood that, as used herein, the term "and / or" refers to and encompasses any and all possible combinations of one or more listed related items. It should be further understood that, when used in this specification, the terms "comprising", "comprising", "including" and / or "including" indicate the presence of the narrated features, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, parts and / or their groups.

[0034] refer to Figure 1 , an example of an axle assembly 10 is shown. The axle assembly 10 may be provided for a motor vehicle, such as a truck, agricultural equipment, a military transport or armament vehicle, or a cargo loading device for a land, air, or undersea container. In one or more embodiments, the vehicle may include a trailer for transporting cargo.

[0035] The axle assembly 10 is a drive axle assembly. The drive axle assembly is configured to provide torque to one or more wheel assemblies. The wheel assembly can be rotatably supported on the axle assembly 10. The wheel assembly can include a tire disposed on the wheel. The wheel can be mounted to a wheel hub that can rotate around a wheel axis. The wheel hub can be rotatably disposed on the axle assembly 10.

[0036] In some configurations, the axle assembly 10 includes a housing assembly 20, a differential assembly 22, a pair of half shafts 24, an electric motor 26, a transmission 28, a drive pinion 30, and a shift mechanism 32. The positioning of the differential assembly 22, the electric motor 26, and / or the transmission 28 may be different than shown. For example, the differential assembly 22 may be positioned between the electric motor 26 and the transmission 28. It is also contemplated that in some configurations, the electric motor 26 may be positioned away from the axle assembly 10 and may not be a part of the axle assembly 10. For purposes of illustration, the axle assembly 10 will be primarily described in detail. Figures 1 to 3 The axle assembly 10 is described in the context of the illustrated configuration.

[0037] refer to Figure 1 , the housing assembly 20 receives various components of the axle assembly 10. In addition, the housing assembly 20 can facilitate installation of the axle assembly 10 to the vehicle. In some configurations, the housing assembly 20 includes an axle housing 40 and a differential carrier 42. In some configurations, the housing assembly 20 includes an electric motor housing 44, a transmission housing 46, an end cover 48, or a combination thereof.

[0038] refer to Figure 1 and Figure 2 The axle housing 40 may receive and support the half shaft 24. The axle housing 40 may include a center portion 50 and at least one arm portion 52.

[0039] The center portion 50 may be disposed proximate the center of the axle housing 40. The center portion 50 may help define an interior cavity 54 in which the differential assembly 22 may be received.

[0040] One or more arm portions 52 may extend from the center portion 50. For example, two arm portions 52 may extend from the center portion 50 in opposite directions and away from the differential assembly 22. The arm portions 52 may each have a hollow or tubular configuration that may extend around and receive a corresponding half-shaft 24 and may help separate or isolate the half-shaft 24 from the surrounding environment. The hub may be rotatably disposed on the arm portion 52 and may be connected to the half-shaft 24.

[0041] The differential carrier 42 is configured to be mounted to the axle housing 40. For example, the differential carrier 42 can be mounted to a center portion 50 of the axle housing 40. The differential assembly 22 can be rotatably supported on the differential carrier 42. The differential carrier 42 and the axle housing 40 can cooperate to define an interior cavity 54.

[0042] The electric motor housing 44 can extend around or around the electric motor 26. In some configurations, the electric motor housing 44 extends between the differential carrier 42 and the transmission case 46.

[0043] The transmission housing 46 can extend around or around the transmission 28. In some configurations, the transmission housing 46 extends between the electric motor housing 44 and the end cover 48.

[0044] The end cap 48 may be disposed at an end of the housing assembly 20. For example, the end cap 48 may be mounted to the end of the transmission housing 46 facing away from the differential assembly 22. The end cap 48 may define a recess 56, which is Figure 2 The recess 58 may be disposed along an axis 80 about which the drive pinion 30 may rotate, as will be discussed in greater detail below.

[0045] refer to Figure 2, the differential assembly 22 is disposed within the housing assembly 20. For example, the differential assembly 22 can be disposed in the interior cavity 54. The differential assembly 22 (which can also be referred to as an axle differential) can transfer torque to the half shafts 24 of the axle assembly 10 and permit the half shafts 24 and the wheel assembly to rotate at different speeds in a manner known to those skilled in the art. For example, the differential assembly 22 can have a ring gear 60 that can be fixedly mounted to the differential housing. The ring gear 60 and the differential housing can rotate about a differential axis 62. The differential housing can receive a differential gear that can be operatively connected to the half shafts 24.

[0046] The half shaft 24 is configured to transfer torque between the differential assembly 22 and the corresponding wheel hub. For example, 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 rotate about the wheel axis. The wheel axis can be the same as the differential axis 62 or can be different from the differential axis 62.

[0047] The electric motor 26 is configured to provide torque, such as propulsion torque or regenerative braking torque. The propulsion torque can be used to propel the vehicle, such as in a forward or backward direction. The propulsion torque can also be used to keep the vehicle in a stationary position or help reduce, limit, or prevent the vehicle from rolling back, such as when the vehicle is on an inclined surface. Regenerative braking can provide regenerative braking torque. When the electric motor 26 is used to brake the vehicle or slow down the speed of the vehicle, regenerative braking can capture kinetic energy. The recovered energy can be transferred from the wheel assembly to drive the electric motor 26. Therefore, the electric motor 26 can act as a generator and can be used to charge an electric power source (such as a battery). The electric motor 26 can be electrically connected to the electric power source via an inverter in a manner known to those skilled in the art.

[0048] The electric motor 26 includes a stator 70 and a rotor 72. The stator 70 may be fixedly positioned relative to the electric motor housing 44. The stator 70 may surround the rotor 72. The rotor 72 may rotate relative to the stator 70 about an axis 80. The rotor 72 may surround the drive pinion 30. The electric motor 26 may be mounted to the housing assembly 20 or positioned within it, such as within the electric motor housing 44.

[0049] The transmission 28 facilitates the transfer of torque between the electric motor 26 and the drive pinion 30. The torque transfer may be bidirectional. The transmission 28 may provide a gear reduction and multiple gear ratios between the rotor 72 and the drive pinion 30. The transmission 28 may be of any suitable type. For example, the transmission 28 may be a countershaft transmission, an epicyclic transmission (e.g., a transmission with a planetary gear set), etc. The countershaft transmission may include a single countershaft or multiple countershafts. Examples of axle assemblies with single countershaft transmissions are disclosed in U.S. Patent Nos. 11,002,352 and 11,209,072. Examples of axle assemblies with dual countershaft transmissions are disclosed in U.S. Patent Nos. 10,989,288, 11,207,976, and 11,220,176. Examples of axle assemblies with epicyclic transmissions are disclosed in U.S. Patent Nos. 11,038,396 and 11,428,297. The disclosures of the references in the preceding three sentences are incorporated herein by reference in their entirety.

[0050] Figure 2 and Figure 3 An example of a transmission 28 configured as a dual countershaft transmission is shown in FIG. However, it should be understood that the transmission 28 is not limited to a countershaft transmission and may be of any suitable type as discussed above. The transmission 28 includes one or more sets of gears. For example, in Figure 3 In the configuration shown, the transmission 28 may include a drive pinion gear set 90, a first countershaft gear set 92, and a second countershaft gear set 94. The gears of the first countershaft gear set 92 and the second countershaft gear set 94 may be disposed on a first countershaft 96 and a second countershaft 96', respectively, and may rotate therewith. In a single countershaft configuration, the second countershaft gear set 94 may be omitted. In other configurations, the drive pinion gear set 90, the first countershaft gear set 92, and the second countershaft gear set 94 may be replaced with one or more epicyclic gear sets or planetary gear sets.

[0051] exist Figure 3 , the gear set 90 of the drive pinion can include a plurality of gears, some or all of which can be selectively coupled to the drive pinion 30. The gears can rotate independently relative to each other. In the illustrated configuration, the gear set 90 of the drive pinion includes a first gear 100, a second gear 102, a third gear 104, and a fourth gear 106; however, it should be understood that more or fewer gears can be provided. The first gear 100 can mesh with one or more first countershaft gears 110, 110'. The second gear 102 can mesh with one or more second countershaft gears 112, 112'. The third gear 104 can mesh with one or more third countershaft gears 114, 114'. The fourth gear 106 can mesh with one or more fourth countershaft gears 116, 116'.

[0052] refer to Figure 2 , the drive pinion 30 operatively connects the transmission 28 to the differential assembly 22. In this way, the drive pinion 30 can transfer torque between the differential assembly 22 and the transmission 28. The drive pinion 30 can rotate about the axis 80. The drive pinion 30 is disposed inside the housing assembly 20 and can be rotatably supported on the differential carrier 42 via one or more roller bearing assemblies. The drive pinion 30 has a first end 120, a second end 122, a gear portion 124, a shaft portion 126, and a drive pinion hole 128. The drive pinion 30 may also include a drive pinion extension 130.

[0053] The first end 120 faces toward the differential assembly 22. The first end 120 may be part of a gear portion 124.

[0054] The second end 122 is disposed opposite the first end 120. As such, the second end 122 may face away from the differential assembly 22. The second end 122 may be part of a shaft portion 126.

[0055] The gear portion 124 includes a plurality of teeth that mate with corresponding teeth on the ring gear 60 of the differential assembly 22. The gear portion 124 may be disposed at or near an end of the shaft portion 126. The gear portion 124 may be integrally formed with the shaft portion 126, or may be provided as a separate component that may be fixedly disposed on the shaft portion 126.

[0056] The shaft portion 126 extends from the gear portion 124. For example, the shaft portion 126 can extend from the gear portion 124 to the second end 122. The shaft portion 126 can extend along or around the axis 80.

[0057] The drive pinion hole 128 is disposed in the drive pinion 30. The drive pinion hole 128 extends along the axis 80. The drive pinion hole 128 extends from the first end 120 toward the second end 122. In some configurations, the drive pinion hole 128 is a through hole. For example, the drive pinion hole 128 can extend from the first end 120 of the drive pinion 30 to the second end 122 of the drive pinion 30 along the axis 80. The drive pinion hole 128 can have any suitable configuration. For example, the drive pinion hole 128 can have a circular cross-section.

[0058] refer to Figures 2 to 4, the drive pinion extension 130 increases the axial length of the drive pinion 30. For example, the drive pinion extension 130 can be a separate component mounted to the shaft portion 126 so that the drive pinion extension 130 can rotate with the shaft portion 126 about the axis 80. For example, the drive pinion extension 130 can be mounted to the shaft portion 126 by a mating spline. The drive pinion extension 130 can extend from the second end 122 of the drive pinion 30 in a direction extending away from the gear portion 124. The drive pinion extension 130 can be fixedly positioned relative to the drive pinion 30 so that the drive pinion extension 130 cannot move relative to the shaft portion 126 along the axis 80. It is also contemplated that the drive pinion extension 130 can be formed integrally with the drive pinion 30. For ease of reference, the term "drive pinion" is used herein to refer to the drive pinion 30 with or without the drive pinion extension 130 unless otherwise specified.

[0059] Main references Figure 4 , the drive pinion extension 130 (if provided) defines a portion of the drive pinion aperture 128. In some configurations, the drive pinion extension 130 has a first extension end 140, a second extension end 142, one or more slots 144, and a spline 146. Optionally, the drive pinion extension 130 can include a socket 148.

[0060] The first extension end 140 faces the shaft portion 126 of the drive pinion 30. If the drive pinion extension 130 is integrally formed with the drive pinion 30 as a one-piece, unitary component, the first extension end 140 may be omitted.

[0061] The second extension end 142 is disposed opposite the first extension end 140. As such, the second extension end 142 faces away from the differential assembly 22. The portion of the drive pinion bore 128 disposed in the drive pinion extension 130 may extend from the first extension end 140 toward or to the second extension end 142. The second extension end 142 may be received within and rotatably supported by a support bearing 150 that rotatably supports the drive pinion extension 130. The support bearing 150 may be received in the recess 56 of the end cap 48, as shown. Figure 2 shown.

[0062] refer to Figure 2 and Figure 4, one or more grooves 144 may be provided for the drive pinion extension 130. The groove 144 may extend or be elongated in an axial direction relative to the axis 80 or in a direction extending along or parallel to the axis 80. The groove 144 may be a closed-end groove extending between a first groove end and a second groove end. The groove 144 may extend from the drive pinion hole 128 away from the axis 80. For example, the groove 144 may extend from the drive pinion hole 128 through the drive pinion extension 130 to an outer surface of the drive pinion extension 130 away from the axis 80. A groove 144 may be provided at the drive pinion hole 128. Figure 4 The two slots 144 are Figure 2 These grooves 144 are aligned with each other and are arranged on opposite sides of the axis 80.

[0063] Main references Figure 4 The spline 146 facilitates installation and axial movement of the shift collar, as will be discussed in more detail below. The spline 146 may include a plurality of teeth extending from the outside of the drive pinion extension 130 in a direction extending away from the axis 80 and the drive pinion hole 128. The spline 146 may be axially positioned between the first extension end 140 and the second extension end 142. For example, the spline 146 may be axially positioned between the first extension end 140 and the groove 144.

[0064] The socket 148 (if provided) receives the drive pinion 30. The socket 148 may extend from the first extension end 140. When the drive pinion extension 130 is provided as a separate part, the first end 120 of the drive pinion 30 may be disposed within the socket 148. The drive pinion 30 may be secured to the socket 148 in any suitable manner, such as by fasteners, threaded connections, mating splines, etc. It is also contemplated that a socket 148 may be provided for the drive pinion 30, and the drive pinion extension 130 may be received within the socket.

[0065] refer to Figure 2 , the shift mechanism 32 facilitates coupling the drive pinion 30 to the transmission 28. For example, the shift mechanism 32 is configured to selectively connect a gear of the transmission 28 (such as a member of the gear set 90 of the drive pinion) to the drive pinion 30. The shift mechanism 32 can couple one gear to the drive pinion 30 at a time. In some configurations, the gear coupled to the drive pinion 30 can rotate with the drive pinion 30 around the axis 80. The shift mechanism 32 can have any suitable configuration. In some configurations, the shift mechanism 32 includes a shift collar 160, a linkage 162, and an actuator 164. The shift mechanism 32 can also include a fastener 166.

[0066] Shift collar 160 (at Figure 41 and 1 , and the shift collar 160 is preferably shown in FIG. 1 and 1 , and can rotate with the drive pinion 30 about the axis 80. In addition, the shift collar 160 can move relative to the drive pinion 30 along the axis 80. The shift collar 160 can selectively connect a gear of the transmission 28 to the drive pinion 30. For example, the shift collar 160 can selectively connect a member of the drive pinion gear set 90 to the drive pinion 30, as will be discussed in more detail below. In at least one configuration, the shift collar 160 can include a first end 170, a second end 172, a shift collar hole 174, a shift collar spline 176, and a shift collar gear 178.

[0067] The first end 170 may face toward the drive pinion 30. The first end 170 may surround the axis 80.

[0068] The second end portion 172 is disposed opposite to the first end portion 170 . In this way, the second end portion 172 may face away from the driving pinion 30 .

[0069] The shift collar hole 174 may extend along the axis 80 between the first end 170 and the second end 172. The shift collar hole 174 may be configured as a through hole that may extend from the first end 170 to the second end 172. The drive pinion 30 or the drive pinion extension 130 may be received within the shift collar hole 174.

[0070] The shift collar splines 176 are configured to couple the shift collar 160 to the drive pinion 30, such as to the drive pinion extension 130 of the drive pinion 30. The shift collar splines 176 may be disposed in the shift collar aperture 174. The shift collar splines 176 may include teeth extending toward the axis 80. The shift collar splines 176 may mate with the splines 146. The mating splines may allow the shift collar 160 to move in an axial direction or along the axis 80 while limiting or inhibiting the shift collar 160 from rotating relative to the drive pinion 30 about the axis 80. Thus, when the shift collar splines 176 mate with the splines 146, the shift collar 160 may rotate with the drive pinion 30 about the axis 80.

[0071] The shift collar gear 178 may engage with a gear of the transmission 28. The shift collar gear 178 may be disposed between the first end 170 and the second end 172 of the shift collar 160. The shift collar gear 178 may be disposed opposite the shift collar aperture 174. The shift collar gear 178 may have teeth that may be arranged about the axis 80 and may extend away from the axis 80 and the shift collar aperture 174.

[0072] refer to Figure 2, the linkage 162 operatively connects the shift collar 160 and the actuator 164. The linkage 162 is received in the drive pinion hole 128. Thus, if a drive pinion extension 130 is provided, the linkage 162 can be received inside the drive pinion 30 and the drive pinion extension 130. The drive pinion 30, the drive pinion extension 130, or both can surround the linkage 162. The linkage 162 can extend along the axis 80. The linkage 162 is coupled to the shift collar 160. Thus, the linkage 162 can rotate with the shift collar 160 around the axis 80. The linkage 162 can be disposed inside the shift collar 160. The linkage 162 can be fixedly coupled to the shift collar 160. The linkage 162 can have any suitable configuration. For example, the linkage 162 can be configured as a shaft, a rod, etc.

[0073] The actuator 164 is configured to move the shift collar 160 along the axis 80. For example, the actuator 164 is configured to move the linkage 162 and the shift collar 160 along the axis 80 to selectively connect or selectively couple a gear of the transmission 28 to the drive pinion 30 or to decouple the shift collar 160 from the gear of the transmission 28. The actuator 164 is coupled to the linkage 162.

[0074] The actuator 164 can be disposed in different locations. In some configurations, the actuator 164 is disposed in or received in the interior cavity 54 of the housing assembly 20. For example, the actuator 164 can be disposed in the axle housing 40, the differential carrier 42, or both. Figure 2 In the configuration shown, the actuator 164 is disposed in the internal cavity 54 and in the differential carrier 42. The actuator 164 can be axially positioned between the first end 120 of the drive pinion 30 and the differential axis 62 relative to the axis 80. For example, the actuator 164 can be axially positioned along the axis 80 or relative to the axis between the first end 120 and the differential axis plane 168, which can be disposed substantially perpendicular to the axis 80. The term "substantially perpendicular" is used herein to refer to features or axes that are the same as or very close to perpendicular to perpendicular, and includes features that are within ±3° of perpendicular to each other. In this configuration, the actuator 164 can be mounted to the differential carrier 42.

[0075] exist Figure 6 In the configuration shown, the actuator 164 is arranged to be Figure 2The configuration shown is further from the first end 120 of the drive pinion 30. For example, the actuator 164 can be positioned further from the drive pinion 30 than the differential axis 62 is positioned from the drive pinion 30. For example, the actuator 164 can be positioned axially along the axis 80 or relative to the axis between the differential axis plane 168 and the end of the axle housing 40 or the bowl cover (e.g., from Figure 2 In this configuration, the actuator 164 can be disposed in the axle housing 40 and can be mounted to the axle housing 40.

[0076] exist Figure 7 In the illustrated configuration, the actuator 164 is not disposed within or received within the interior cavity 54 of the housing assembly 20. Alternatively, the actuator 164 or a portion thereof may be disposed outside of the interior cavity 54. Figure 7 In the embodiment shown in FIG. 1 , the actuator 164 is mounted to the axle housing 40 and disposed outside the axle housing 40 . In such a configuration, the linkage 162 may extend through a hole in the end or bowl cover of the axle housing 40 to facilitate coupling to the actuator 164 .

[0077] Main references Figure 2 , fasteners 166 couple linkage 162 to shift collar 160. Fasteners 166 may be of any suitable type, such as pins, dowels, threaded fasteners, etc. Fasteners 166 may be fixedly coupled to shift collar 160, linkage 162, or both. For example, fasteners 166 may protrude from linkage 162 into one or more fastener holes 180 in shift collar 160 that are located within the shift collar 160. Figure 4 1. The fastener 166 may be received in one or more slots 144 of the drive pinion 30 or the drive pinion extension 130. As such, the fastener 166 may be moved in an axial direction within the one or more slots 144. In some configurations, the fastener 166 may be received in the recess 56 of the end cap 48, such as when the shift collar 160 is actuated away from the drive pinion 30.

[0078] The shift collar 160, linkage 162, and fastener 166 can move together along the axis 80. The length of the slot 144 can limit the distance the shift collar 160, linkage 162, and fastener 166 can move along the axis 80. For example, when the fastener 166 engages or contacts the closed end of the slot 144, axial movement of the shift collar 160, linkage 162, and fastener 166 can be inhibited.

[0079] The shift collar 160, linkage 162, and fastener 166 are movable along axis 80 in a first direction 190 and in a second direction 192 disposed opposite to first direction 190. When actuator 164 moves shift collar 160 toward or away from actuator 164, Figure 2 , Figure 6 and Figure 7 As the perspective shown moves to the left, the shift collar 160, the linkage 162, and the fastener 166 can move in a first direction 190 along the axis 80. When the actuator 164 moves the shift collar 160 away from the actuator 164 or from the Figure 2 , Figure 6 and Figure 7 As the perspective shown moves to the right, the shift collar 160 , linkage 162 , and fastener 166 may move in a second direction 192 along the axis 80 .

[0080] exist Figure 2 , Figure 6 and Figure 7 In the configuration shown, the actuator 164 may or may not be disposed along or intersecting the axis 80. An actuator 164 disposed along or intersecting the axis 80 may be directly coupled to the linkage 162. As some non-limiting examples, the actuator 164 may be a linear actuator or a solenoid that may exert a force on the linkage 162 to move the linkage 162 along the axis 80. Figure 5 , shows an example of a partial plan view showing that the actuator 164 is offset from and does not intersect the axis 80. In this configuration, the actuator 164 can be coupled to the linkage 162 via a secondary linkage 200, which can connect the actuator to the linkage 162. The secondary linkage 200 can have any suitable configuration, such as a shaft, a cable (such as a push-pull cable), etc.

[0081] The actuator 164 can move the secondary linkage 200, the linkage 162, and the shift collar 160 along the axis 80. Figure 5 Leftward along axis 80 or in first direction 190 from Figure 2 and Figure 4 The illustrated positional movement may move the shift collar gear 178 out of engagement with the fourth gear 106 and into a first neutral position disposed between the fourth gear 106 and the third gear 104. Further actuation in the first direction 190 may move the shift collar gear 178 into engagement with the third gear 104, followed by a second neutral position between the third gear 104 and the second gear 102, and into engagement with the second gear 102.

[0082] refer to Figure 8, shows another configuration of the axle assembly. This configuration includes a housing assembly 20, a differential assembly 22, a pair of half shafts 24, an electric motor 26, and a transmission 28, as described above. The axle assembly also includes a drive pinion 30' and a shift mechanism 32'.

[0083] The drive pinion 30' is the same as the drive pinion 30 described above, but may have a shorter axial length. In addition, the drive pinion 30' has a mating feature 210', which Fig. 9 It is best shown in Fig. 9 Only a portion of the drive pinion 30 ′ is shown.

[0084] Main references Fig. 9 and Fig.10 , the mating feature 210' is configured to rotatably couple the drive pinion 30' to the linkage 162' of the shift mechanism 32', so that the drive pinion 30' and the linkage 162' can rotate together around the axis 80. The mating feature 210' allows the linkage 162' to move relative to the drive pinion 30' along the axis 80. The mating feature 210' can be disposed in the drive pinion hole 128. The mating feature 210' can have any suitable configuration. For example, the mating feature 210' can be configured to have a convex configuration, a concave configuration, or a combination thereof. As some examples, the mating feature 210' can be a pin, a key, one or more teeth, etc. In Fig. 9 , the mating feature 210' is depicted as one or more teeth, such as splines or spline teeth extending toward the axis 80. The mating feature 210' can be located inside the gear portion 124, the shaft portion 126, or both. In the illustrated configuration, the mating feature 210' is located inside the gear portion 124 of the drive pinion 30'.

[0085] refer to Figure 8 , the shift mechanism 32' facilitates coupling the drive pinion 30' to the transmission 28 and is configured to selectively connect a gear of the transmission 28 (such as a member of the drive pinion gear set 90) to the drive pinion 30', as previously discussed with respect to the shift mechanism 32. The shift mechanism 32 includes the actuator 164 as well as the shift collar 160', the linkage 162', and the support shaft 220' as previously discussed.

[0086] refer to Figure 8 and Fig.10, the shift collar 160' can rotate with the drive pinion 30' about the axis 80 and can move relative to the drive pinion 30' along the axis 80. The shift collar 160' can selectively connect a gear of the transmission 28 (such as a member of the drive pinion gear set 90) to the drive pinion 30', as previously discussed. In at least one configuration, the shift collar 160' is fixedly coupled to the linkage 162' or is integrally formed with the linkage and includes a shift collar aperture 174' and a shift collar gear 178, as previously described.

[0087] The shift collar hole 174' extends along the axis 80 and may be configured as a through hole. The support shaft 220' may be received inside the shift collar hole 174'.

[0088] The linkage 162' extends from the shift collar 160' and operatively connects the shift collar 160' to the drive pinion 30' and the actuator 164. The linkage 162' can rotate with the shift collar 160' about the axis 80. The linkage 162 is received in the drive pinion hole 128 and can protrude from the first end 120 to the outside of the drive pinion 30' and protrude from the second end 122 of the drive pinion 30'. In this way, the linkage 162' can have a greater axial length than the drive pinion 30'. In some configurations, the linkage 162' is configured as a hollow tube extending along the axis 80. The linkage 162' can surround the axis 80 and the support shaft 220'. In some configurations, the linkage 162' includes a linkage mating feature 222' and a shift block 224'.

[0089] The linkage mating feature 222' is configured to rotatably couple the linkage 162' to the drive pinion 30' and allow the linkage 162' to move relative to the drive pinion 30' along the axis 80. The linkage mating feature 222' can be disposed in the drive pinion hole 128. The linkage mating feature 222' engages the mating feature 210' of the drive pinion 30' and can have any suitable configuration that is compatible with the mating feature 210'. For example, the linkage mating feature 222' can be configured to have a convex configuration, a concave configuration, or a combination thereof. As some examples, the linkage mating feature 222' can be a recess, a pin, a key, one or more teeth, etc. In Fig.10In the illustrated configuration, the linkage mating feature 222' is depicted as one or more teeth (such as splines or spline teeth) that extend away from the axis 80 and are received between corresponding teeth of the mating feature 210' of the drive pinion 30' throughout the axial travel distance of the linkage 162'. The linkage mating feature 222' can have a greater axial length than the mating feature 210' of the drive pinion 30'. The linkage mating feature 222' can be located within the gear portion 124, the shaft portion 126, or both. In the illustrated configuration, at least a portion of the linkage mating feature 222' is located within the gear portion 124 of the drive pinion 30'.

[0090] The shift block 224' operatively connects the linkage 162' to the actuator 164. Depending on the size of the drive pinion hole 128, the shift block 224' may be integrally formed with the linkage 162' or may be a separate component secured to the linkage 162'. For example, the shift block 224' may be a separate component fixedly attached to the linkage 162' after the linkage 162' is inserted through the drive pinion hole 128. The shift block 224' is disposed at or near the end of the linkage 162' opposite the shift collar 160'. As such, the shift block 224' may be disposed within the interior of the axle housing 40, the differential carrier 42, or both. The shift block 224' may have any suitable configuration that is compatible with the actuator 164 and the linkage 162'. Figure 8 and Fig.11 , a simplified depiction of the actuator 164 is shown, wherein the shift block 224 ′ is movable along or parallel to the axis 80 .

[0091] The support shaft 220' supports the shift collar 160' and the linkage 162'. The support shaft 220' extends along the axis 80 and can be surrounded by the shift collar 160', the linkage 162', or both. The support shaft 220' can extend through the shift collar 160' and the linkage 162'. For example, the support shaft 220' can protrude from the end of the shift collar 160' and protrude from the end of the linkage 162'. The ends of the support shaft 220' can be supported by the housing assembly 20.

[0092] In some configurations, such as Figure 8 In the configuration shown, the support shaft 220' can rotate about the axis 80. In this configuration, the support shaft 220' is rotatably supported on a bearing 230', such as a roller bearing assembly. In the configuration shown, one bearing 230' is disposed on the axle housing 40 and the other bearing 230' is disposed on the transmission housing 46. The support shaft 220' may not translate along the axis 80.

[0093] In some configurations, the support shaft 220' can rotate with the shift collar 160' and the linkage 162' about the axis 80. In some configurations, the support shaft 220' can contact or engage the shift collar 160' and / or the linkage 162', but the shift collar 160' and the linkage 162' can be free to slide or translate relative to the support shaft 220' along the axis 80. For example, the support shaft 220' can be connected to the shift collar 160' and / or the linkage 162' by one or more mating features (such as keys, pins, teeth, mating splines, etc.).

[0094] In some configurations, the support shaft 220 ′ is not rotatable about the axis 80 . Fig.11 An example of such a configuration is shown in . In such a configuration, bearing 230' may be omitted and support shaft 220' is stationary. Shift collar 160' and linkage 162' may rotate relative to support shaft 220' about axis 80 and may move relative to support shaft 220' along axis 80. In some configurations, shift collar 160' and linkage 162' may be spaced apart from support shaft 220' such that a gap is provided therebetween.

[0095] One or more bearings 240' may be disposed between the support shaft 220' and the shift collar 160' and / or linkage 162' to facilitate rotation of the shift collar 160' and linkage 162' relative to the support shaft 220' and translation of the shift collar 160' and linkage 162' relative to the support shaft 220' along the axis 80. For example, the bearing 240' may include a plurality of bearing elements, such as ball bearings. Fig.11 In the embodiment, a single bearing 240' is shown, but it should be understood that additional bearings 240' may be provided. It is contemplated that the bearing 240' may move axially with the shift collar 160' and linkage 162', or the shift collar 160' and linkage 162' may move axially relative to the bearing 240'.

[0096] One or more bearings 242' may be disposed between the support shaft 220' and the shift block 224' to facilitate rotation of the shift collar 160' and linkage 162' relative to the shift block 224' and translation of the shift collar 160' and linkage 162' relative to the shift block 224' along the axis 80. In some configurations, the shift block 224' may surround the bearings 242', and the bearings 242' may surround the linkage 162' and may move axially with the linkage 162' and the shift block 224'. For example, the linkage 162', the shift block 224', and the bearings 242' may move leftward along the axis 80 from the position shown to move the shift collar 160' to a neutral position or to engage a different member of the gear set of the drive pinion.

[0097] It is envisaged that in Figure 8 and Fig.11 In the embodiment, the actuator 164 can be arranged closer to the drive pinion 30' than shown, such as closer to the differential axis plane 168, or arranged between the differential axis plane 168 and the drive pinion 30', similar to Figure 2 It is also contemplated that the actuator 164 may also be disposed externally to the housing assembly 20, similar to Figure 7 In this configuration, the support shaft 220' can be as shown. Figure 8 Rotatable or Fig.11 The actuator 164 may be non-rotatable in the linkage 162 ′, and an actuator shaft or another linkage may extend from the externally mounted actuator 164 into the interior cavity 54 of the housing assembly 20 to connect the actuator 164 to the linkage 162 ′.

[0098] The present invention can help reduce the stick-out or axial length of the axle assembly. For example, the present invention can allow the shift mechanism to be placed closer to the axle housing compared to a configuration in which the shift mechanism is positioned at the end of the axle assembly adjacent to the transmission. Positioning the shift mechanism at or near the end of the axle assembly adjacent to the transmission increases the stick-out or axial length of the axle assembly, increasing the space required to accommodate the axle assembly when installed on the vehicle. For example, in one or more configurations, the present invention can reduce the axial length by approximately 60 mm. In addition, positioning the shift mechanism at or near the end of the axle assembly requires the housing assembly to extend away from the axis (e.g., in a radial direction) to provide sufficient space to accommodate and package the shift mechanism. The present invention employs a hollow drive pinion that allows the shift mechanism to move closer to the opposite end of the axle assembly, which in turn allows an end cap to be provided that can be positioned closer to the axis and extends a shorter length along the axis.

[0099] Although exemplary embodiments are described above, these embodiments are not intended to describe all possible forms of the present invention. On the contrary, the words used in this specification are descriptive rather than restrictive, and it should be understood that various changes can be made without departing from the spirit and scope of the present invention. Additionally, the features of various implemented embodiments can be combined to form other embodiments of the present invention.

Claims

1. A vehicle axle assembly, comprising: a drive pinion gear rotatable about an axis and having a drive pinion gear hole extending along the axis from a first end of the drive pinion gear toward a second end of the drive pinion gear disposed opposite the first end; a transmission, the transmission comprising a set of gears; as well as A shift mechanism, the shift mechanism comprising: a shift collar rotatable with the drive pinion about the axis and movable relative to the drive pinion along the axis; a linkage coupled to the shift collar, wherein the linkage is received in a drive pinion bore of the drive pinion; and An actuator is coupled to the linkage and is configured to move the linkage and the shift collar along the axis to selectively connect a member of the set of gears to the drive pinion.

2. The axle assembly of claim 1, wherein: The linkage extends along the axis.

3. The axle assembly of claim 1, wherein: The linkage is rotatable with the shift collar about the axis.

4. The axle assembly of claim 1, wherein: The linkage member is arranged inside the shift collar.

5. The axle assembly of claim 1, wherein: The linkage is fixedly coupled to the shift collar.

6. The axle assembly of claim 1, wherein: The drive pinion includes a drive pinion extension rotatable about the axis, wherein the shift collar is disposed on the drive pinion extension and the linkage is received inside the drive pinion extension.

7. The axle assembly of claim 6, wherein: The drive pinion extension has a slot extending in an axial direction relative to the axis, and a fastener is received in the slot and couples the linkage to the shift collar.

8. The axle assembly of claim 7, wherein: The fastener is fixedly coupled to the linkage and the shift collar, and the fastener is movable in the axial direction within the groove.

9. The axle assembly of claim 7, wherein: When the actuator moves the shift collar toward the actuator, the linkage, the fastener, and the shift collar move in a first direction along the axis.

10. The axle assembly of claim 9, wherein: When the actuator moves the shift collar away from the actuator, the linkage, the fastener, and the shift collar move along the axis in a second direction, the second direction being disposed opposite the first direction.

11. The axle assembly of claim 7, wherein: The axle assembly includes an end cap disposed at an end of the axle assembly, wherein the end cap defines a recess in which a support bearing is received, the support bearing rotatably supporting the drive pinion, wherein the fastener is receivable in the recess.

12. The axle assembly of claim 1, wherein: The axle assembly has an electric motor including a rotor rotatable about the axis, the rotor surrounds the drive pinion, and the drive pinion surrounds the linkage.

13. The axle assembly of claim 1, wherein: The actuator is disposed along the axis.

14. The axle assembly of claim 1, wherein: The axle assembly includes an axle housing and a differential carrier that cooperate to define an internal cavity within which the differential assembly and the actuator are received.

15. The axle assembly of claim 14, wherein: The actuator is mounted to the differential carrier.

16. The axle assembly of claim 14, wherein: The differential assembly is rotatable about a differential axis, and the actuator is positioned axially relative to the axis between the first end of the drive pinion and the differential axis.

17. The axle assembly of claim 14, wherein: The actuator is mounted to the axle housing.

18. The axle assembly of claim 1, wherein: The axle assembly includes an axle housing and a differential carrier, the axle housing and differential carrier cooperating to define an internal cavity, the differential assembly and the actuator being received inside the internal cavity, the differential assembly being rotatable about a differential axis, and the actuator being positioned farther from the drive pinion than the differential axis is positioned from the drive pinion.

19. The axle assembly of claim 1, wherein: The axle assembly includes an axle housing and a differential carrier that cooperate to define an internal cavity within which a differential assembly is received, wherein the actuator is disposed outside of the internal cavity.

20. The axle assembly of claim 19, wherein: The actuator is mounted to the axle housing.

21. The axle assembly of claim 1, wherein: The drive pinion is rotatably coupled to the linkage such that the linkage is rotatable with the drive pinion about the axis and is movable along the axis relative to the drive pinion.

22. The axle assembly of claim 21, wherein: The drive pinion is rotatably coupled to the linkage in the drive pinion bore.

23. The axle assembly of claim 22, wherein: The drive pinion and the linkage are rotatably coupled with mating splines.

24. The axle assembly of claim 1 further comprising a support shaft extending along said axis and surrounded by said linkage and said shift collar.

25. The axle assembly of claim 24, wherein: The support shaft is rotatable about the axis.

26. The axle assembly of claim 25, wherein: The linkage is rotatable with the support shaft about the axis.

27. The axle assembly of claim 24, wherein: The support shaft is non-rotatable about the axis, and the linkage is rotatable about the axis relative to the support shaft.

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