Axle assembly for vehicle

Abstract

The shaft assembly includes first and second shaft housings, first and second wheel ends, first and second drive shafts, a gearbox, and a motor. First and second axle housings extending toward opposite sides of the frame, the axle housings aligned to define an axle axis; the first driving shaft and the second driving shaft are arranged in the first shaft shell and the second shaft shell; a gearbox having a first surface facing one side of the frame and a second surface facing the other side of the frame, the gearbox extending outwardly cantilevered with respect to the aligned axle housing to define a gearbox axis parallel to the longitudinal axis of the frame and transverse to the axle axis; the motor is connected to the second surface of the gearbox and extends toward the first side of the frame to define a motor axis that is parallel and offset from the axle axis, transverse to the gearbox axis, and transverse to the longitudinal axis.

Description

[0001] This application is a divisional application of a Chinese patent application with application number 201680073825.3, filing date December 16, 2016, entry date into the Chinese national phase June 15, 2018, and invention title "Axle Assembly for Vehicles".

[0002] Cross - Reference to Related Applications

[0003] This patent application claims the entire benefit and priority of U.S. Provisional Application No. US 62 / 268,852 filed on December 17, 2015 and U.S. Provisional Application No. US 62 / 333,032 filed on May 6, 2016. The entire contents of the applications US 62 / 268,852 and US 62 / 333,032 are incorporated herein by reference. Technical Field

[0004] The present disclosure generally relates to axles, and more particularly, to an axle assembly for a vehicle. Background Art

[0005] Axles are commonly used in vehicles having wheels, such as passenger cars and / or trucks, public transportation vehicles such as urban and / or commercial buses, agricultural vehicles, semi-trucks, trailers, and the like. Electric axles, i.e., axles having an electric motor, are becoming increasingly popular. However, due to the limited space under the vehicle floor, the proper and effective connection of the electric motor to the axle has become a challenge. The present disclosure aims to address the challenges pointed out above. Summary of the Invention

[0006] In one embodiment of the present disclosure, a vehicle includes: a frame having a front end, a rear end, and opposite first and second sides; a floor connected to the frame and extending between the front end and the rear end to define a longitudinal axis adapted to extend along the length of the vehicle, and the floor also extending at least between the first side and the second side to define a transverse axis adapted to extend along the width of the vehicle; a first axle housing and a second axle housing, each having a first housing end and a second housing end, the first housing end of the first axle housing extending toward the first side of the frame, and the first housing end of the second axle housing extending toward the second side of the frame, and the first axle housing and the second axle housing being aligned to define an axle axis parallel to the transverse axis; a first wheel end connected to the first housing end of the first axle housing adjacent to the first side of the frame; a second wheel end connected to the first housing end of the second axle housing adjacent to the second side of the frame; a first drive shaft at least partially disposed within the first axle housing and connected to the first wheel end; a second drive shaft at least partially disposed within the second axle housing and connected to the second wheel end; a gearbox having a housing with a first surface facing the first side of the frame and a second surface facing the second side of the frame, the first axle housing being connected to the first surface, the second axle housing being connected to the second surface, and the gearbox being outwardly suspended relative to the aligned first and second axle housings to define a gearbox axis parallel to the longitudinal axis and transverse to the axle axis; and an electric motor connected to the second surface of the gearbox and extending toward the first side of the frame to define a motor axis parallel to and offset from the axle axis, parallel to the transverse axis, transverse to the gearbox axis, and transverse to the longitudinal axis, wherein the electric motor is connected to the first drive shaft and the second drive shaft to rotate the first and second wheel ends.

[0007] In another embodiment of the present disclosure, a shaft assembly includes: a first shaft housing having a first housing end and a second housing end; a second shaft housing having a first housing end and a second housing end; a first wheel end connected to the first housing end of the first shaft housing; a second wheel end connected to the first housing end of the second shaft housing; a first drive shaft at least partially received within the first shaft housing and connected to the first wheel end; a second drive shaft at least partially received within the second shaft housing and connected to the second wheel end; a gearbox having a housing defining a perimeter, the housing having a first portion and a second portion defining a cavity, the first shaft housing being connected to the first portion and the second shaft housing being connected to the second portion such that the first shaft housing and the second shaft housing extend in opposite directions and the first shaft housing and the second shaft housing are aligned to define an axle axis, the gearbox being suspended relative to the aligned first shaft housing and second shaft housing to define a gearbox axis, the gearbox axis being transverse to the axle axis; and an electric motor connected to the first portion of the housing adjacent the first shaft housing and extending away from the first portion to define a motor axis parallel and offset from the axle axis and transverse to the gearbox axis; wherein the gearbox further includes: a flange extending outwardly from the perimeter of the housing and support ribs directly connecting the flange to the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Advantages of the present disclosure will be readily appreciated as it becomes better understood when considered in conjunction with the accompanying drawings. It should be understood that the drawings are merely illustrative and are not necessarily drawn to scale. It should also be understood that various features of the vehicle and / or shaft assembly are schematically illustrated in one or more of the drawings, at least for the purpose of simplifying the drawings.

[0009] Figure 1 is a semi-schematic side view of a portion of a vehicle showing a frame supporting a vehicle floorboard and a portion of an embodiment of a shaft assembly connected to the frame.

[0010] Figure 2 is a semi-schematic rear view of a portion of a vehicle showing a frame supporting a vehicle floorboard and the Figure 1 shaft assembly shown connected to the frame.

[0011] Figure 3 is Figure 1 and Figure 2 a perspective rear view of an embodiment of the shaft assembly shown, including a suspension and a steering assembly.

[0012] Figure 4 is Figure 1 and Figure 2 a perspective front view of the shaft assembly shown.

[0013] Figure 5 is a cross-sectional view of a part of the shaft assembly taken along the Figure 3 line 5-5 shown.

[0014] Figure 6 is Figure 4 an exploded view of a part of the shaft assembly shown.

[0015] Figure 7 is Figure 4 an exploded view of another part of the shaft assembly shown.

[0016] Figure 8 is an exploded view of a part of the shaft assembly shown from a different angle Figure 7 than that shown.

[0017] Figure 9 is a perspective rear view of another embodiment of the shaft assembly.

[0018] Figure 10 is Figure 9 a partial exploded view of the shaft assembly shown.

[0019] Figure 11 is a semi-schematic side view of a part of a vehicle, showing a frame supporting a vehicle floor and a part of another embodiment of a shaft assembly connected to the frame.

[0020] Figure 12 is a semi-schematic rear view of a part of a vehicle, showing a frame supporting a vehicle floor and the Figure 11 shaft assembly shown connected to the trailer frame.

[0021] Figure 13 is Figure 11 and Figure 12 a perspective front view of a shaft assembly for a vehicle shown.

[0022] Figure 14 is Figure 13 a top view of the shaft assembly shown.

[0023] Figure 15 is Figure 13 a rear view of the shaft assembly shown.

[0024] Figure 16 is Figure 13 a partial exploded view of the shaft assembly shown. DETAILED DESCRIPTION

[0025] With reference to the accompanying drawings, in which like reference numerals indicate corresponding parts throughout the several views, various embodiments of axle assemblies 100, 200 are shown in the drawings and are described in detail below. In certain embodiments, the axle assembly 100 is a drive steering axle for any type of vehicle 10. In other embodiments, the axle assembly 200 is a rigid axle for any type of vehicle 10. Non-limiting examples of the vehicle 10 include transit vehicles (such as city buses, commercial buses, trolleybuses, etc.), school buses, commercial semi-trucks and associated trailers, agricultural vehicles, passenger cars or trucks, and the like. If used on a trailer, the trailer can be connected to a semi-truck and can have multiple axle assemblies 200. In alternative embodiments, the axle assemblies 100, 200 can also include planetary gears, can be part of a tandem axle, and / or can have various additional features.

[0026] Figure 1 and Figure 2 A portion of the vehicle 10 including the axle assembly 100 is shown semi-schematically. The vehicle 10 includes a chassis having a frame 12. The frame 12 has a front end 14 and a rear end 16 and opposite first and second sides 18, 20. The vehicle 10 also includes a floor panel 22 that is connected to the frame 12 and extends between the front end 14 and the rear end 16 to define a longitudinal axis A adapted to extend along the length of the vehicle 10. L The floor panel 22 also extends at least between the first side 18 and the second side 20 to define a transverse axis A W , the transverse axis A W being adapted to extend along the width of the vehicle 10. The frame 12 and the floor panel 22 are shown schematically in Figure 1 and 2 such that the frame 12 can be larger or smaller in the width direction (i.e., along the transverse axis A W ). Thus, the floor panel 22 can extend between the first side 18 and the second side 20 of the frame 12 or can extend beyond the first side 18 and the second side 20 of the frame 12.

[0027] The axle assembly 100 for the vehicle 10 is a steerable or steering drive axle and includes a first axle housing 102 and a second axle housing 104, each of the axle housings 102, 104 having a first housing end 106 and a second housing end 108. As Figure 2As shown, the first housing end 106 of the first axle housing 102 extends toward the first side 18 of the vehicle frame 12, and the first housing end 106 of the second axle housing 104 extends toward the second side 20 of the vehicle frame 12. The second housing ends 108 of the first axle housing 102 and the second axle housing 104 are connected to the gearbox 110. The second housing ends 108 of the first axle housing 102 and the second axle housing 104 connected to the gearbox 110 are schematically shown in the figure, and the first axle housing 102 and the second axle housing 104 can be connected to the gearbox 110 in any suitable manner. In an embodiment, the first axle housing 102 and the second axle housing 104 are mirror images of each other. The axle housings 102, 104 can be made of or can include any suitable material.

[0028] The first axle housing 102 and the second axle housing 104 are aligned to define an axle axis A parallel to the transverse axis A W of the vehicle. A For example, as shown, the axle assembly 100 further includes a gearbox 110 having a first surface 112 and a second surface 114, wherein the first surface 112 faces the first side 18 of the vehicle frame 12 and the second surface 114 faces the second side 20 of the vehicle frame 12. In other words, the first surface 112 and the second surface 114 face each other. The second housing ends 108 of the first axle housing 102 and the second axle housing 104 are respectively connected to the first surface 112 and the second surface 114, such that the second housing ends 108 of the first axle housing 102 and the second axle housing 104 are aligned. The first axle housing 102 and the second axle housing 104 extend along the axle axis A A in opposite directions. For example, the first axle housing 102 extends in a direction toward the first side 18 of the vehicle frame 12, and the second axle housing 104 extends along the axle axis A A in a direction toward the second side 20 of the vehicle frame 12.

[0029] Each of the first axle housing 102 and the second axle housing 104 is a non-rotating housing; that is, the axle housings 102, 104 do not rotate during the operation of the vehicle 10. Therefore, the first axle housing 102 and the second axle housing 104 are fixed to the gearbox 110 in any suitable manner, for example, fixed to the gearbox 110 by one or more fasteners or the like.

[0030] In an embodiment, as Figure 3 shown, the axle assembly 100 may further include a stabilizer bar 115, and the ends of the stabilizer bar 115 are connected to the first axle housing 102 and the second axle housing 104 via brackets 117. The brackets 117 are configured to be connected to the steering column of the vehicle 10. Therefore, the stabilizer bar 115 extends between the brackets 117 and is substantially parallel to the axle axis A A .

[0031] The shaft assembly 100 further includes a first wheel end 116 and a second wheel end 118. The first wheel end 116 is connected to a first housing end 106 of the first axle housing 102 adjacent to the first side 18 of the vehicle frame 12, and the second wheel end 118 is connected to a first housing end 106 of the second axle housing 104 adjacent to the second side 20 of the vehicle frame 12. In an embodiment, the first wheel end 116 and the second wheel end 118 can be connected to the second housing end 108 through a hinge system. Each of the first wheel end 116 and the second wheel end 118 is connected to at least one wheel or tire 24. Each of the first wheel end 116 and the second wheel end 118 can also have a plurality of gears, such as a planetary gear set 120 having a gear ratio. The drive is applied to the wheels 24 by reducing at the gear ratio within the respective steering wheel ends 116, 118. Using the power generated by the electric motor 122, the first wheel end 116 and the second wheel end 118 rotate the wheels 24 forward to move the vehicle 10 forward, or rotate them backward to move the vehicle 10 backward. In an embodiment, each wheel end 116, 118 may further include a dry disc brake.

[0032] The shaft assembly 110 further includes a first drive shaft 124 and a second drive shaft 126. The first drive shaft 124 is at least partially disposed within the first axle housing 102 and is connected to the first wheel end 116, and the second drive shaft 126 is at least partially disposed within the second axle housing 104 and is connected to the second wheel end 118. For example, a portion of the first drive shaft 124 can be disposed to pass through the first axle housing 102, and the remaining portion of the first drive shaft 124 can be disposed within the gearbox 110. Similarly, a portion of the second drive shaft 126 can be disposed to pass through the second axle housing 104, and the remaining portion of the second drive shaft 126 can be disposed within the gearbox 110. As shown, each of the first drive shaft 124 and the second drive shaft 126 has a first shaft end 128 and a second shaft end 130. Each of the first shaft ends 128 is connected to a gear set 132 disposed within the gearbox 110, and each of the second shaft ends 130 is connected to the first wheel end 116 and the second wheel end 118, respectively. The drive shafts 124, 126 transmit the power (generated by the electric motor 122) from the gear set 132 in the gearbox 110 to the wheels 24 of the vehicle 10. Generally, when driven or started by the electric motor 122, the first drive shaft 124 and the second drive shaft 126 rotate within their respective first axle housing 102 and second axle housing 104 without engaging or otherwise rotating the axle housings 102, 104.

[0033] The first drive shaft 124 and the second drive shaft 126 can be any suitable drive shaft or transmission shaft. In an embodiment, each of the first drive shaft 124 and the second drive shaft 126 is a universal shaft. It should be understood that the drive shafts 124, 126 can be any mechanical component capable of appropriately transmitting torque and rotation and / or delivering power to the wheels 24, and are not limited to drive shafts or transmission shafts.

[0034] In an embodiment, the axle assembly 100 further includes a differential 134 disposed between the first drive shaft 124 and the second drive shaft 126. The differential 134 is connected to the drive shafts 124, 126 and allows each wheel end 116, 118 to rotate at different speeds. This facilitates the handling of the vehicle 10, for example making the vehicle 10 easier to steer. For example, when the vehicle 10 turns, the differential 134 allows the wheels 24 of the wheel ends 116, 118 connected to one side of the vehicle 10 to rotate faster than the wheels 24 of the other wheel ends 116, 118 connected to the other side of the vehicle 10.

[0035] In an embodiment, the axle assembly 100 further includes a first suspension member 136 and a second suspension member 138, which can be part of a suspension system, such as an air suspension system. The first suspension member 136 is connected to the first axle housing 102 and the frame 12, and the second suspension member 138 is connected to the second axle housing 102 and the frame 12. In an embodiment, the first suspension member 136 and the second suspension member 138 are elastically mounted to the frame 12 by springs, shock absorbers or other biasing components or devices. The suspension system stabilizes the vehicle, for example, by allowing relative movement between the frame 12 and the wheels 24 when the vehicle 10 is moving. In this way, the suspension system contributes to the handling and ride quality of the vehicle 10, because, even when driving over road bumps or potholes, etc., the suspension system can provide a smooth and comfortable ride for passengers.

[0036] As previously described, the axle assembly 100 further includes a gearbox 110 that houses a plurality of gears 132 commonly referred to as a gear set or a powertrain. In an embodiment, the differential 134 is at least partially disposed within the gearbox 110. The gearbox 110 can be located at or approximately at the center between the first wheel end 116 and the second wheel end 118. With this configuration, the gearbox 110 forms the central portion of the axle assembly 100. It should be understood that the gearbox 110 is shown schematically or semi-schematically in the drawings, and thus some features of the gearbox 110 are not shown.

[0037] The gearbox 110 has a housing 140. The housing 140 has a first surface 112 facing the first side 18 of the vehicle frame 12 and a second surface 114 facing the second side 20 of the vehicle frame 12. As shown, the first axle housing 102 is connected to the first surface 112 of the housing 140, and the second axle housing 104 is connected to the second surface 114 of the housing 140. In addition, the gearbox 110 extends outwardly relative to the aligned first and second axle housings 102 and 104 to define a gearbox axis A parallel to the longitudinal axis A L and transverse to the axle axis A A of the gearbox G . The gearbox 110 is also vertically spaced downwardly from the vehicle floor 22 of the vehicle 10 along a vertical axis A V , the vertical axis A V being perpendicular to and intersecting the axle axis A A and the gearbox axis A G .

[0038] In an embodiment, the housing 140 of the gearbox 110 may have multiple parts. The multiple parts of the gearbox 110 facilitate the assembly and / or maintenance of the multiple components of the shaft assembly 100, for example, facilitating the assembly and / or maintenance of the components inside the gearbox 100. In an embodiment, the housing 140 may have a first part 142 and a second part 144, and the parts 142, 144 define a cavity 146 for receiving the gear set 132. In Figures 1 - 8 the illustrated embodiment, one of the parts 142, 144 of the housing 140 may define the cavity 146, and the other part 142, 144 may define a cover 148 for covering the cavity 146. It is contemplated that the housing 140 of the gearbox 110 may have any suitable configuration, for example, the housing 140 may be substantially a single piece. It is also contemplated that the housing 140 of the gearbox 110 may be made of any suitable material, not limited to metal and / or metal alloy. More details of the gearbox 110 will be described below.

[0039] The housing 140 of the gearbox 110 may have any suitable shape. In an embodiment, the housing 140 has an oblong shape, which may be similar to an ellipse or a rectangular shape with soft or rounded edges. In a particular embodiment, the housing 140 has an oblong shape having a larger portion 150 (in terms of area and / or surface area), the larger portion 150 being joined to a smaller portion 152 (in terms of area and / or surface area). As shown, the first axle housing 102 and the second axle housing 104 are connected to the larger portion 150 of the housing 140, and the motor 122 is connected to the smaller portion 152 of the housing 140.

[0040] In an embodiment, one of the first portion 142 and the second portion 144 may define a base 154 and a continuous sidewall 156 integrally connected to the base 154. As Figure 6 shown, the first portion 142 defines the base 154 and the continuous sidewall 156. The base 154 and the sidewall 156 together define an inner surface 158 of the first portion 142, and the inner surface 158 defines a cavity 146 for receiving and accommodating the gear set 132. The cavity 146 may have any suitable depth for accommodating the gear set 132. The shape of the cavity 146 is not particularly limited. In an embodiment, the shape of the cavity 146 may simulate or be similar to the overall shape of the first portion 142 of the housing 140. Alternatively, the shape of the cavity 146 may be different from the shape of the first portion 142 of the housing 140.

[0041] The continuous sidewall 156 of the portion 142 also defines an outer surface 160 of the housing 140 of the gearbox 110. In an embodiment, the housing 140 has a plurality of corrugations 162, where the corrugations 162 are formed in or on the outer surface 160 of the housing 140. The corrugations 162 may have any shape, such as circular (similar to a semi-cylinder), polygonal (similar to a rectangle, semi-rectangle, triangle, semi-triangle, etc.), and / or a combination thereof. Each corrugation 162 generally extends between the first surface 112 and the second surface 114 of the gearbox 110. In an embodiment, the corrugations 162 are arranged adjacent to each other with no gap between the corrugations 162. Alternatively, the corrugations 162 may be spaced apart from each other. In an embodiment, the corrugations 162 are continuous along the entire outer surface 160 of the housing 140. In another embodiment, the corrugations 162 are discontinuous along the outer surface 160 of the housing 140. In the present embodiment, the corrugations 162 may be a single corrugation 162 or a group of corrugations 162 in a selected area or region of the outer surface 160 of the housing 140.

[0042] At least in terms of the width or diameter of each corrugation 162, the corrugations 162 may have any size. The corrugations 162 may also extend between the first surface 112 and the second surface 114 of the gearbox (i.e., along the entire height of the sidewall 156), or may extend along a portion of the distance between the first surface 112 and the second surface 114. Additionally, the corrugations 162 formed in or on the outer surface 160 of the housing 140 are substantially the same in terms of shape and size. Alternatively, the corrugations 162 may be different, where one or more corrugations 162 may be different from another corrugation 162 at least in terms of shape and size.

[0043] The housing 140 of the gearbox 110 also has a perimeter 164 defined by the outer surface 160 of the housing 140. Additionally, the gearbox 110 has a flange 166 extending outwardly from the perimeter 164 of the housing 140. In an embodiment, the flange 166 extends from the perimeter 164 of the housing 140, where the flange 166 has a larger surface area adjacent to the smaller portion 152 of the housing 140 and a smaller surface area adjacent to the larger portion 150 of the housing 140. In an alternative embodiment, the flange 166 extends only along the smaller portion 152 of the housing 140 from the perimeter 164 of the housing 140. The flange 166 having a larger surface area adjacent to the smaller portion 152 of the housing 140 provides additional strength to the gearbox 110, such that the gearbox 110 can properly hold and / or support the motor 122 suspended from the gearbox 110. In an embodiment, the combination of the flange 166 adjacent to the smaller portion 152 of the housing 140 and the corrugations 162 defined in or on the outer surface 160 of the housing 140 provides additional strength to the gearbox 110, such that the gearbox 110 can properly hold and / or support the motor 122 suspended from the gearbox 110.

[0044] As shown, the flange 166 has opposing first flange surface 168 and second flange surface 170, and the first flange surface 168 of the flange 166 is adjacent to the corrugations 162 formed in or on the sidewall 156 of the housing 140. The second flange surface 170 of the flange 166 provides a connection surface for the motor 122, and when assembled, the second flange surface 170 of the flange 166 is adjacent to the motor 122. The flange 166 can be made of or include any suitable material, not limited to metals and metal alloys. In an embodiment, the flange 166 is made of or includes the same material as the housing 140 of the gearbox 110.

[0045] The gearbox 110 also has support ribs 172 that directly connect the flange 166 to the housing 140. In another embodiment, the gearbox 110 also has a plurality of support ribs 172, each support rib 172 directly connecting the flange 166 to the housing 140. Each support rib 172 can have any suitable shape and size, and is typically larger in width (e.g., the effective diameter of the rib 172) than the corrugations 162. The support ribs 172 can extend between the first surface 112 and the second surface 114 of the gearbox 110 (i.e., along the entire height of the sidewall 156 of the housing 140). Optionally, the support ribs 172 can extend along a portion of the distance between the first surface 112 and the second surface 114 of the gearbox 110.

[0046] The support ribs 172 can be circular, polygonal, and / or a combination thereof. In one embodiment, one or more of the support ribs 172 have a tapered surface with a non-tapered end 174 adjacent to the flange 166 and a tapered end 176 adjacent to the second portion 144 of the housing 140. The support ribs 172 can be substantially the same or different in shape and size. If different, at least one of the support ribs 172 can be different from another support rib 172 in terms of shape and size. Additionally, the support ribs 172 can be distributed at selected positions along a portion of the perimeter 164 of the housing 140. In an alternative embodiment, the support ribs 172 are distributed at selected positions along the entire perimeter 164 of the housing 160.

[0047] As described above, the shaft assembly 100 further includes an electric motor 122. Although the term electric motor 122 is used, the electric motor 122 does not have to be electric and can be any suitable type of motor. It should be understood that the electric motor 122 is shown schematically or semi-schematically in the drawings, and thus certain features of the electric motor 122, such as the internal components of the electric motor 122, are not shown.

[0048] The electric motor 122 is connected to the first drive shaft 124 and the second drive shaft 126 to rotate the first wheel end 116 and the second wheel end 118. Additionally, the electric motor 122 is directly connected to the gearbox 110. The electric motor 122 can be directly connected to the gearbox 110 in any suitable manner, such as by using one or more fasteners. As shown, the electric motor 122 can have a housing 178 with an outer surface 179 and can have a generally cylindrical shape. The electric motor 122 also has internal motor components disposed within the housing 178, which are not shown. The electric motor 122 can also have a flange 180 extending outward from the housing 178. When assembled, the flange 180 of the housing 178 is aligned and connected to the flange 166 of the gearbox 110 in any suitable manner, such as by using one or more fasteners.

[0049] The electric motor 122 is also connected to the gearbox 110 through a gear set 132 disposed within the cavity 146 of the gearbox 110. In an embodiment, the shaft assembly 100 has a plurality of gears 181 that constitute the gear set 132. In one example, the gear set 132 has three gears 131, where one gear 181 is a pinion gear directly connected to the electric motor 122 through an output shaft 183, another gear 181 is part of the differential 134, and another gear 181 is an idler gear disposed between the pinion gear and the differential gear. The gears 181 are generally also parallel to the axle axis A A and parallel to the transverse axis A WArrangement. The gear 181 is configured to convert the energy generated by the electric motor 122 into rotational motion of the drive shafts 124, 126. For example, the gear 181 can be configured to convert the linear motion of the electric motor 122 into rotational motion of the drive shafts 124, 126 that achieves rotational motion of the wheels 24.

[0050] In another embodiment, as Figure 9 and Figure 10 shown, the shaft assembly 100 includes a motor housing 194 integrally connected to the flange 166 of the gearbox 110, and the electric motor 122 is disposed inside the motor housing 194. In the illustrated embodiment, the motor housing 194 has a main body 196 and a removable lid 198. When the lid 198 is removed, the electric motor 122 is placed inside the main body 196 of the motor housing 194. Then the lid 198 is fixed to the main body 196 to encapsulate the electric motor 122 inside the motor housing 194. The main body 196 of the motor housing 194 can have any suitable shape and size. In an embodiment, the main body 196 has generally the same shape as the electric motor 122. However, the main body 196 may be slightly larger than the electric motor 122 such that the electric motor 122 can be easily assembled inside the main body 196. The motor housing 194 can be made of or include any suitable rigid material, such as but not limited to, metal and / or metal alloy.

[0051] In an embodiment, the electric motor 122 (or the motor housing 194) is connected to the second surface 114 of the gearbox 110, specifically, to the second surface 170 of the flange 166 of the gearbox 110, extending toward the first side 18 of the vehicle frame 12 to define a motor axis A M . The motor axis A M is parallel and offset from the axle axis A A , and is parallel to the transverse axis A W . Further, the motor axis A M is transverse to the gearbox axis A G , and is transverse to the longitudinal axis A L , and the motor axis A M is also perpendicular to the vertical axis A V and the gearbox axis A G . Thus, as shown, the electric motor 122 (or the motor housing 194 that houses the electric motor 122) is suspended from the gearbox 110.

[0052] Due to the suspension, the electric motor 122 (or the motor housing 194) is connected to the flange 166 of the gearbox 110 and is not connected to the first axle housing 102. Accordingly, the outer surface 179 of the electric motor 122 (or the motor housing 194) is spaced apart from the first axle housing 102 and / or the vehicle frame 12. In addition, the electric motor 122 (or the motor housing 194) is spaced vertically downward from the vehicle floor 22 of the vehicle 10 and is spaced apart from the vehicle frame 12.

[0053] During operation, the electric motor 122 uses the internal gear 181 of the gear set 132 to supply power to the gearbox 110, and the internal gear 181 of the gear set 132 transmits the power to the first drive shaft 124 and the second drive shaft 126 through the differential 134. The first drive shaft 124 receives the power and rotates within the first axle housing 102 to effect rotation of the first wheel end 116. Similarly, the second drive shaft 126 receives the power and rotates within the second axle housing 104 to effect rotation of the second wheel end 118. The wheel ends 116, 118 then push and rotate the wheels 24 of the vehicle 10.

[0054] The following refers to Figures 11 - 16 Another embodiment of the axle assembly 200 is described. This embodiment of the axle assembly 200 is a rigid axle that can be used for a vehicle 10, such as a trailer towed by a semi-truck. As Figure 11 and 12 shown, the vehicle or trailer 10 includes a chassis having a vehicle frame 12. The vehicle frame 12 has a front end 14 and a rear end 16 and opposite first and second sides 18, 20. The vehicle or trailer 10 further includes a vehicle floor 22 that is connected to the vehicle frame 12 and extends between the front end 14 and the rear end 16 to define a longitudinal axis A adapted to extend along the length of the vehicle or trailer 10 L , and the vehicle floor 22 further extends between the first side 18 and the second side 20 to define a transverse axis A adapted to extend along the width of the vehicle or trailer 10 W .

[0055] The axle assembly 200 in this embodiment is a rigid axle. The axle assembly 200 has many of the same components as the axle assembly 100, including: a first axle housing 102 and a second axle housing 104, a first drive shaft 124 and a second drive shaft 126 disposed at least partially inside the respective first axle housing 102 and second axle housing 106, and an electric motor 122. The details of each of these components were described above for the axle assembly 100 and are shown in one or more of Figures 1 - 8 . It should be noted that for simplicity of the drawings, various features of the electric motor 122 and the gearbox 210 of this embodiment are shown schematically or semi-schematically in Figures 11 - 16 .

[0056] The shaft assembly further includes a first wheel end 216 and a second wheel end 218. The first wheel end 216 is connected to the first housing end 106 of the first shaft housing 102, and the second wheel end 218 is connected to the first housing end 106 of the second shaft housing 102. In this embodiment, since the shaft assembly 200 is a rigid shaft, the first wheel end 216 and the second wheel end 218 are not hinged. In addition, each of the first wheel end 216 and the second wheel end 218 may or may not include any gears or gear reduction devices.

[0057] The shaft assembly 200 further includes a gearbox 210 having a housing 240. The housing 240 has a first surface 212 facing the first side 18 of the frame 12 and a second surface 214 facing the second side 20 of the frame 12. As shown, the first shaft housing 102 is connected to the first surface 212 of the housing 240, and the second shaft housing 104 is connected to the second surface 214 of the housing 240. In addition, the gearbox 210 is externally suspended relative to the aligned first shaft housing 102 and second shaft housing 104 to define a gearbox axis A G , the gearbox axis A G is parallel to the longitudinal axis A L and transverse to the axle axis A A . The gearbox 210 is spaced vertically downward from the floor 22 of the vehicle or trailer 10 along a vertical axis A A that is perpendicular to and intersects the axle axis A G and the gearbox axis A V .

[0058] The housing 240 of the gearbox 210 has a plurality of parts. In this embodiment, the housing 240 has a first part 242 and a second part 244. As Figure 16 shown, the first part 242 and the second part 244 are substantially the same to define a cavity 246 for accommodating a gear set (not shown). In an embodiment, the cavity 246 receives a gear set similar to the gear set 132 described above. Each of the first part 242 and the second part 244 of the housing 140 defines the cavity 246, where a part of the cavity 246 is defined in the first part 242 and another part of the cavity 246 is defined in the second part 244. It is contemplated that the housing 240 of the gearbox 210 can be made of any suitable material, not limited to metals and / or metal alloys.

[0059] The housing 240 of the gearbox 210 can have any suitable shape. In an embodiment, the housing 240 has an oblong shape, which can be similar to an oval or a rectangular shape with soft or rounded edges. Additionally, each of the first portion 242 and the second portion 244 of the housing 240 defines a side wall 256 having an inner surface 258. The inner surfaces 258 of the first portion 242 and the second portion 244 together define a cavity 246 for receiving a gear set. The cavity 246 can have any suitable size / depth for receiving the gear set. There is no particular limitation on the shape of the cavity 246.

[0060] The side walls 256 of the first portion 242 and the second portion 244 define an outer surface 260 of the housing 240 of the gearbox 210. In an embodiment, the housing 240 has a plurality of housing ribs 263 formed on the outer surface 260 of the housing 240. Specifically, the housing ribs 263 are formed on the side walls 256 of the first portion 242 and the second portion 244 of the housing 240. The housing ribs 263 can have any shape, such as the wedge shape shown in the figure. Optionally, the housing ribs 263 can be circular, polygonal, and / or a combination thereof. The housing ribs 263 are spaced apart from each other and are distributed along the entire side wall 256 of each of the first portion 242 and the second portion 244. In an embodiment, the housing ribs 263 formed on the side wall 256 of the first part 242 are aligned with the housing ribs 263 formed on the side wall 256 of the second portion 244.

[0061] The housing ribs 263 can have any size, at least in terms of the width across each housing rib 263. Each housing rib 263 can extend integrally or partially along the height of the side wall 256 of each of the first portion 242 and the second portion 244. In an embodiment, as shown in the figure, the housing ribs 263 extend along the entire height of the side wall 256 of the first portion 242, while the housing ribs 263 extend partially along the height of the side wall 256 of the second portion 244. Additionally, the housing ribs 263 can be substantially the same in shape and size. Optionally, the housing ribs 263 can be different, where at least in terms of shape and size, one or more housing ribs 263 can be different from another housing rib 263.

[0062] Each of the first portion 242 and the second portion 244 of the housing 240 has a perimeter 264 defined by the outer surface 260 of the portions 242, 244. Additionally, each portion 242, 244 has a flange 265, and the flanges 265 are aligned to connect the first portion 242 to the second portion 244, for example, using a plurality of fasteners.

[0063] The first part 242 of the housing 240 also has a flange 266 that extends outwardly from the perimeter 264 of the first part 242. In an embodiment, the flange 266 has a larger surface area than the first part 242 and provides additional strength to the gearbox 210 such that the gearbox 210 can properly hold and / or support the electric motor 122 that is suspended from the gearbox 210. In an embodiment, the flange 266, in combination with the housing ribs 263 on the sidewall 256 of the first part 242 and the second part 244 of the housing 240, provides additional strength to the gearbox 210 such that the gearbox 210 can properly hold and / or support the electric motor 122 that is suspended from the gearbox 210.

[0064] As shown, the flange 266 has opposing first and second flange surfaces 268 and 270. The first flange surface 268 of the flange 266 is adjacent to the housing rib 263 of the sidewall 256 of the first part 242 of the housing 140. The second flange surface 270 of the flange 266 provides a connection surface for the electric motor 122 such that, when assembled, the second flange surface 270 of the flange 266 is adjacent to the electric motor 122. The flange 266 can be made of or include any suitable material, not limited to metals and metal alloys. In an embodiment, the flange 266 is made of or includes the same material as the housing 240 of the gearbox 210.

[0065] The gearbox 110 also has support ribs 272 that directly connect the flange 266 and the housing 240. In another embodiment, the gearbox 210 also has a plurality of support ribs 272, each of which directly connects the flange 266 to the housing 240. Each support rib 272 has any suitable shape and size and is generally larger than the housing rib 263. The support ribs 272 can extend along the entire height of the sidewall 256 of the first part 242 of the housing 240.

[0066] The support ribs 272 can have any suitable shape. In an embodiment, as shown, the support rib 272 has a wedge shape, where the larger end of the wedge is adjacent to the flange 266. The support ribs 272 can be substantially the same or different in terms of shape and size. If different, at least one of the support ribs 272 can be different from another support rib 272 in terms of shape and size. Additionally, the support ribs 272 can be distributed at selected locations along a portion of the perimeter 264 of the housing 260.

[0067] The various embodiments of the shaft assemblies 100 and 200 have been described in detail above. These embodiments overcome the challenge of effectively mounting an electric motor to the gearbox of the shaft assembly within the limited available space under the vehicle floor. For example, one challenge is that when the electric motor extends from the gearbox towards one side of the vehicle frame, since the electric motor is parallel to the drive shaft, the electric motor is subject to an undesired bending moment. This bending moment may be caused at least in part by several gravitational accelerations generated by the electric motor in the vertical direction when the vehicle is passing over an uneven road. This bending moment may also be caused at least in part by vibrations generated by the internal rotating components of the electric motor. The shaft assemblies 100 and 200 disclosed in the present invention overcome this challenge by providing gearboxes 110 and 210 with a more reasonable structure, which can transfer the loads experienced by the shaft assemblies 100 and 200 (e.g., the weight from the vehicle 10 and the passengers / cargo within the vehicle 10) to the first shaft housing 102 and the second shaft housing 104. The shaft assemblies 100 and 200 can support gravitational accelerations greater than 10 generated by the electric motor 122.

[0068] In addition, the arrangement of the electric motor 122 relative to the gearboxes 110 and 210 is such that the electric motor 122 is located near the first shaft housing 102 rather than above the first shaft housing 102. In this way, the electric motor 122 does not occupy the space between the vehicle frame 12, 32 and the shaft assemblies 100, 200. When used as a public transportation vehicle, such as a commercial bus, the spatial arrangement or position of the electric motor 122 provides the necessary clearance between the shaft assembly 100 and the vehicle floor 22. Therefore, the shaft assembly 100 does not limit the movement distance of the suspension components 136 and 138, which may otherwise have an adverse effect on the handling and overall ride quality of the vehicle 10. In addition, with a good clearance, the vehicle floor 22 of the vehicle 10 can be set closer to the ground, which increases the space within the passenger compartment of the vehicle 10.

[0069] Although the present invention has been described with reference to the above examples, those skilled in the art can understand that various changes can be made and equivalents can be used to replace its elements without departing from the scope of the present invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present invention without departing from the essential scope of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed as the best mode for carrying out the present invention, and the present invention will include all examples falling within the scope of the appended claims.

Claims

1. A vehicle, comprising: a frame having a front end and a rear end and opposite first and second sides; a floor connected to the frame and extending between the front end and the rear end to define a longitudinal axis adapted to extend along the length of the vehicle, and the floor further extending at least between the first side and the second side to define a transverse axis adapted to extend along the width of the vehicle; a first axle housing and a second axle housing having first and second housing ends respectively, the first housing end of the first axle housing extending towards the first side of the frame, and the first housing end of the second axle housing extending towards the second side of the frame, and the first axle housing and the second axle housing being aligned to define an axle axis parallel to the transverse axis; a first wheel end connected to the first housing end of the first axle housing adjacent to the first side of the frame; a second wheel end connected to the first housing end of the second axle housing adjacent to the second side of the frame; a first drive shaft disposed at least partially within the first axle housing and connected to the first wheel end; a second drive shaft disposed at least partially within the second axle housing and connected to the second wheel end; a gearbox having a housing with a first surface facing the first side of the frame and a second surface facing the second side of the frame, the first axle housing being connected to the first surface, the second axle housing being connected to the second surface, and the gearbox being externally suspended relative to the aligned first and second axle housings to define a gearbox axis parallel to the longitudinal axis and transverse to the axle axis; an electric motor connected to the first surface of the gearbox and extending towards the first side of the frame to define a motor axis parallel and offset from the axle axis, parallel to the transverse axis, transverse to the gearbox axis and transverse to the longitudinal axis, the electric motor being connected to the first and second drive shafts to rotate the first and second wheel ends; and a plurality of gears disposed within the gearbox; wherein the housing of the gearbox includes a base and a cover, the base includes a continuous side wall defining a cavity, the cover is connected to the continuous side wall of the base and covers the cavity, the plurality of gears are arranged within the cavity of the base, and the base includes the first surface of the housing of the gearbox connected to the first axle housing, the cover includes the second surface of the housing of the gearbox connected to the second axle housing, wherein the continuous side wall defines the outer surface of the housing of the gearbox; wherein the gearbox is vertically spaced downward from the floor along a vertical axis perpendicular and intersecting the axle axis and the gearbox axis, the gearbox axis extending longitudinally and parallel to the longitudinal axis; the electric motor is vertically spaced downward from the floor, and the motor axis is perpendicular to the gearbox axis and the vertical axis; Wherein, the housing of the gearbox has a periphery, and the gearbox further has a flange extending outward from the periphery of the housing adjacent to the motor, wherein the surface area of the flange is greater than the surface area of the second surface; Wherein, the housing has support ribs and a plurality of corrugations directly connecting the flange to the housing, the plurality of corrugations being formed in or on the outer surface of the housing, wherein each of the support ribs and the plurality of corrugations extends from the first surface of the housing to the second surface of the housing, and wherein the support rib has a tapered surface having a non-tapered end adjacent to the flange and a tapered end adjacent to the second surface of the housing, and the width of the support rib is greater than the width of each of the plurality of corrugations.

2. The vehicle according to claim 1, wherein, The support rib extends along the entire height of the continuous sidewall.

3. The vehicle according to claim 1, wherein, The support rib has a wedge shape defined by a smaller end and a larger end, wherein the larger end of the wedge is adjacent to the flange.

4. The vehicle according to claim 1, wherein, The housing has a plurality of support ribs, each support rib directly connecting the flange to the housing.

5. The vehicle according to claim 1, wherein, The housing of the gearbox has a plurality of housing ribs.

6. The vehicle according to claim 1, wherein, The motor is suspended from the gearbox.

7. The vehicle according to claim 1, wherein, The motor has an outer surface spaced apart from the first shaft housing.

8. The vehicle according to claim 1, wherein, The motor is directly connected to the flange of the gearbox.

9. The vehicle according to claim 1, further comprising a motor housing connected to the flange of the gearbox, the motor being disposed inside the motor housing.

10. The vehicle according to claim 1, further comprising a plurality of gears disposed inside the gearbox and a differential for connecting the motor to the first wheel end and the second wheel end.

11. The vehicle according to claim 1, wherein, Each of the first wheel end and the second wheel end has a planetary gear set.

12. A shaft assembly, comprising: A first shaft housing having a first housing end and a second housing end; A second shaft housing having a first housing end and a second housing end; A first wheel end connected to the first housing end of the first shaft housing; A second wheel end connected to the first housing end of the second shaft housing; A first drive shaft at least partially received inside the first shaft housing and connected to the first wheel end; A second drive shaft at least partially received inside the second shaft housing and connected to the second wheel end; A gearbox having a housing defining a periphery, the housing having a first portion and a second portion defining a cavity, the first shaft housing being connected to the first portion, the second shaft housing being connected to the second portion such that the first shaft housing and the second shaft housing extend in opposite directions and the first shaft housing and the second shaft housing are aligned to define an axle axis, the gearbox being suspended relative to the aligned first shaft housing and second shaft housing to define a gearbox axis, the gearbox axis being transverse to the axle axis; A motor connected to the first portion of the housing adjacent to the first shaft housing and extending away from the first portion to define a motor axis parallel and offset from the axle axis and transverse to the gearbox axis; And A plurality of gears disposed within the gearbox; Wherein, the gearbox further includes a flange extending outward from the periphery of the housing, and the surface area of the flange is greater than the surface area of the first portion; Wherein, the first portion of the housing of the gearbox includes a base that defines the cavity, the second portion of the housing of the gearbox includes a lid that is connected to the base and covers the cavity, the plurality of gears are disposed within the cavity of the base, and the base includes a first surface of the housing connected to the first axle housing, the lid includes a second surface of the housing connected to the second axle housing, the base includes a continuous sidewall that defines the outer surface of the housing of the gearbox; Wherein, the housing has support ribs and a plurality of corrugations that directly connect the flange to the housing, the plurality of corrugations are formed in or on the outer surface of the housing, wherein each of the support ribs and the plurality of corrugations extends from the first surface of the housing to the second surface of the housing, and the support rib has a tapered surface that has a non-tapered end adjacent to the flange and a tapered end adjacent to the second surface of the housing, and the width of the support rib is greater than the width of each of the plurality of corrugations.

13. The shaft assembly according to claim 12, wherein, The support rib extends along the entire height of the continuous sidewall.

14. The shaft assembly according to claim 12, wherein, The support rib has a wedge shape defined by a smaller end and a larger end, wherein the larger end of the wedge is adjacent to the flange.

15. The shaft assembly according to claim 12, wherein, The housing has a plurality of support ribs, each of which directly connects the flange to the housing.

16. The shaft assembly according to claim 12, wherein, The housing of the gearbox has a plurality of housing ribs.

17. The shaft assembly according to claim 12, wherein, The electric motor is suspended from the gearbox.

18. The shaft assembly according to claim 12, wherein, The electric motor has an outer surface that is spaced apart from the first axle housing.

19. The shaft assembly according to claim 12, wherein, The electric motor is directly connected to the flange of the gearbox.

20. The shaft assembly according to claim 12, further comprising: A plurality of gears disposed inside the gearbox and a differential including one of the plurality of gears, the differential being configured to connect the electric motor to the first drive shaft and the second drive shaft.

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