Electronic rear drive module with split half-shaft flange and cavity for a constant velocity joint

Abstract

Vehicle drive module (10), comprising: a case (32); an electric motor (40) which is coupled to the housing (32) and has a motor output shaft (42); a gear set (44) which is housed in the housing (32) and coupled to the motor output shaft (42) for the transmission of rotational force between the motor output shaft (42) and an output (152) of the gear set (44); a differential assembly (30), comprising: a differential housing (150) which is mounted inside the housing (32) for rotation about a first axis (56) and is drivenly coupled to the output (152) of the transmission gear set (44); a pair of gears (156) which are housed in the differential housing (150) and are rotatable relative to the differential housing (150) about a second axis which is perpendicular to the first axis (56); and a pair of side gears (158, 160) which are mounted in the differential housing (150) and are rotatable about the first axis (56), each of the side gears (158, 160) being in meshing engagement with the pair of gears (156); and a pair of output elements (16, 18), where each output element (16, 18) has: a driven body (410) with a first end (426) and a second end (438), wherein the first end (426) is drivenly coupled to a corresponding side gear (158, 160) to receive rotational force from it, and the second end (438) defines a circumferential lip (462); and an outer flange (414) with a radial inner surface (514) defining a first inner cavity (542), wherein the first inner cavity (542) is adapted to accommodate a first part of a constant velocity joint (210), and wherein the outer flange (414) is detachably mounted around the circumferential lip (462); wherein the driven body (410) has an outer surface (458) which is radially outside the circumferential lip (462) and is configured to bear against an axially inner surface (518) of the outer flange (414); wherein the driven body (410) defines a plurality of first bores (470) spaced apart from one another circumferentially around the outer surface (458) of the driven body (410), and the outer flange (414) defines a plurality of second bores (530), each of the second bores (530) being aligned with a corresponding first bore (470) and wherein the first and second bores (470, 530) are adapted to accommodate a suitable threaded fastening element (610) in order to detachably couple the driven body (410) and the outer flange (414) for common rotation.

Description

AREA

[0001] The present disclosure relates to an electronic rear drive module with a split half-shaft flange. BACKGROUND

[0002] This section provides background information to the present disclosure that is not necessarily prior art.

[0003] Example electronic drive modules ("eDMs", e.g., electronic rear-drive modules "eRDMs") are disclosed in US patent application publication US 2012 / 0 058 855 A1. The eDMs may be used as a means for propelling a vehicle and / or as a means for enhancing vehicle control through torque vectoring. The eDMs typically include an electric motor that transfers power to a transmission and differential assembly to drive a pair of vehicle wheels.

[0004] In some cases, it is desirable to remove the eDM from the vehicle. In conventional systems, various suspension components must be removed before the eDM can be removed from the vehicle. Removing and reinstalling such suspension components can be time-consuming. Accordingly, there is a need in the art for improved eDMs.

[0005] The object is achieved by a device according to claims 1, 6 and 13. Further developments of the device are the subject of the subclaims.

[0006] DE 39 12 304 A1 describes a drive arrangement for a motor vehicle; DE 94 03 308 U1 discloses a differential gear for a motor vehicle; DE 10 2006 057 218 A1 describes a drive arrangement with an intermediate shaft and a clutch unit; WO 2008 / 055 055 A2 relates to a spherical universal coupling; DE 42 28 488 A1 describes a flexible shaft coupling. SUMMARY

[0007] This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.

[0008] The present teachings provide a vehicle drive module including a housing, an electric motor, a transmission gear set, a differential assembly, and a pair of output members. The electric motor may be coupled to the housing and have an engine output shaft. The transmission gear set may be housed within the housing and may be coupled to the engine output shaft for transmitting rotational power between the engine output shaft and an output of the transmission gear set. The differential assembly may include a differential case, a pair of gears, and a pair of side gears. The differential case may be mounted for rotation about a first axis within the housing and may be drivingly coupled to the output of the transmission gear set. The pair of gears may be housed within the differential case and may be rotatable relative to the differential case about a second axis that is perpendicular to the first axis.The pair of side gears may be housed in the differential case and may be rotatable about the first axis. Each of the side gears may be in meshing engagement with the pair of gears. Each output member may include a driven body and an outer flange. The driven body may have a first end and a second end. The first end of the driven body may be drivingly coupled to a corresponding one of the side gears to receive rotational power therefrom. The outer flange may have a first side and a second side. The first side of the outer flange may be releasably coupled to the second end of the driven body. The second side of the outer flange may be adapted to be releasably coupled to a constant velocity joint.

[0009] The present teachings provide a vehicle drive module including a housing, an electric motor, a transmission gear set, a differential assembly, and a pair of output members. The electric motor may be coupled to the housing and have an engine output shaft. The transmission gear set may be housed within the housing and may be coupled to the engine output shaft for transmitting rotational power between the engine output shaft and an output of the transmission gear set. The differential assembly may include a differential case, a pair of gears, and a pair of side gears. The differential case may be mounted for rotation about a first axis within the housing and may be drivingly coupled to the output of the transmission gear set. The pair of gears may be housed within the differential case and may be rotatable relative to the differential case about a second axis that is perpendicular to the first axis.The pair of side gears may be received in the differential housing and may be rotatable about the first axis. Each of the side gears may be in meshing engagement with the pair of gears. Each output member may include a driven body and an outer flange. The driven body may have a first end and a second end. The first end of the driven body may be drivingly coupled to a corresponding one of the side gears to receive rotational power therefrom. The second end of the driven body may define a circumferential lip. The outer flange may have an inner surface defining a first interior cavity. The first interior cavity may be adapted to receive a portion of a constant velocity joint. The inner surface may be removably mounted around the circumferential lip.

[0010] The present teachings provide a vehicle drive module including a housing, an electric motor, a transmission gear set, a differential assembly, and a pair of output members. The electric motor may be coupled to the housing and have an engine output shaft. The transmission gear set may be housed within the housing and may be coupled to the engine output shaft for transmitting rotational power between the engine output shaft and an output of the transmission gear set. The differential assembly may include a differential case, a pair of gears, and a pair of side gears. The differential case may be mounted for rotation about a first axis within the housing and may be drivingly coupled to the output of the transmission gear set. The pair of gears may be housed within the differential case and may be rotatable relative to the differential case about a second axis that is perpendicular to the first axis.The pair of side gears may be housed in the differential case and may be rotatable about the first axis. Each of the side gears may be in meshing engagement with the pair of gears. Each output member may include a driven body and an outer flange. The driven body may have a first end and a second end. The first end of the driven body may be drivingly coupled to a corresponding one of the side gears to receive rotational power therefrom. The second end may include a first cylindrical portion and a second cylindrical portion. The first and second cylindrical portions may be coaxial with the first axis. The first cylindrical portion may have a diameter larger than the second cylindrical portion. The second cylindrical portion may extend axially in an outward direction from the first cylindrical portion.The outer flange may have an inner surface defining a first inner cavity. The first inner cavity may be adapted to receive a portion of a constant velocity joint. The inner surface may be removably mounted around the second cylindrical portion. DRAWINGS

[0011] The drawings described herein are for the purpose of illustrating selected embodiments and not all possible implementations and are not intended to limit the scope of the present disclosure. Fig. 1 is a cross-sectional view of an exemplary drive module having a pair of output members and half shafts constructed in accordance with the present disclosure; Fig. 2 is a perspective view of one of the output elements of Fig. 1; Fig. 3 is a sectional view of the output element of Fig. 2, shown with a corresponding half-wave of Fig. 1; and Fig. 4 is a sectional view of a portion of the output element of Fig. 2, showing an inner flange and an outer flange of the output element spaced apart from each other.

[0012] Corresponding reference numerals indicate corresponding parts in the several views of the drawings. DETAILED DESCRIPTION

[0013] Now, exemplary embodiments will be described in more detail with reference to the accompanying drawings.

[0014] In Fig. 1 of the drawings, a portion of an exemplary electronic drive module ("eDM") 10 constructed in accordance with the teachings of the present disclosure is illustrated. Except as noted herein, the eDM 10 may be generally similar to any of the drive modules disclosed in commonly assigned, co-pending U.S. patent application Ser. No. 13 / 835,043, filed March 15, 2013, the disclosure of which is incorporated herein by reference as if specifically set forth.

[0015] Briefly, the eDM 10 may include a torque distribution drive mechanism 14 operable to transmit torque to first and second output members 16, 18. Each output member 16, 18 may be coupled to a half-shaft 20, 22, as described below. The torque distribution drive mechanism 14 may include a drive mechanism 24, a power-transmitting component or clutch mechanism 26, a dual planetary gear set 28, a differential assembly 30, and a housing 32 into which the drive mechanism 24, the clutch mechanism 26, the dual planetary gear set 28, and the differential assembly 30 may be housed.

[0016] The drive mechanism 24 may include any type of motor, such as an electric motor 40, and may have a motor shaft 42 that may be selectively driven to provide rotational power to a reduction gear 44. The reduction gear 44 may include a first gear 46 that may be mounted on the motor shaft 42 for common rotation, and a second gear 48 that may be meshingly engaged with the first gear 46 and mounted on an intermediate shaft 50 for common rotation. The intermediate shaft 50 may be disposed along an intermediate axis 52 that is generally parallel to a motor axis 54 about which the motor shaft 42 of the motor 40 rotates. The intermediate axis 52 may be parallel to an output axis 56 about which the differential assembly 30 and the first and second output members 16 and 18 may rotate.

[0017] The intermediate shaft 50 may have a first stub shaft 60, a second stub shaft 62, and a drive portion 64 disposed between the first and second stub shafts 60 and 62. The drive portion 64 may have a plurality of external keys or teeth (not expressly shown). A first intermediate output gear 66 may be rotatably received on the first stub shaft 60, and a second intermediate output gear 68 may be rotatably received on the second stub shaft 62. Bearings (not expressly shown) may be received between the first and second stub shafts 60 and 62, respectively, and the first and second intermediate output gears 68 and 66, respectively. Thrust bearings (not expressly shown) may be disposed at various locations along the length of the intermediate shaft 50 to promote relative rotation between the drive portion 64 and the first and second intermediate output gears 66 and 68.

[0018] The clutch mechanism 26 may be used to selectively couple the first intermediate output gear 66 or the second intermediate output gear 68 to the intermediate shaft 50.

[0019] The double planetary gear set 28 may include a first planetary gear set 110 and a second planetary gear set 112. The first planetary gear set 110 may include a first sun gear 114, a first planet carrier 116, a plurality of first planet gears 118, and a first ring gear 120, while the second planetary gear set 112 may include a second sun gear 122, a second planet carrier 124, a plurality of second planet gears 126, and a second ring gear 128. The first sun gear 114 may be a hollow structure through which the second output member 18 may be received. The first planet carrier 116 may be rotatable relative to the housing 32 and may be coupled to the second output member 18 for common rotation. The first planet carrier 116 may have a plurality of first pins (not expressly shown) that may journal the first planet gears 118.The first planet gears 118 may mesh with the first sun gear 114 and the first ring gear 120. The first ring gear 120 may be non-rotatably coupled to the housing 32. The second sun gear 122 may be coupled with the first sun gear 114 for common rotation and may be a hollow structure through which the second output member 18 may be received. The second planet carrier 124 may be rotatable relative to the housing 32 and may have a plurality of second pins (not expressly shown) that may journal the second planet gears 126. The second planet gears 126 may mesh with the second sun gear 122 and the second ring gear 128. The second ring gear 128 may have a set of external teeth that may mesh with the second intermediate output gear 68.

[0020] The differential assembly 30 may include a differential case 150, an output 152, a cross pin 154, a plurality of differential pinions 156, and first and second side gears 158 and 160. The differential case 150 may be coupled to the second planetary carrier 124 for common rotation. The output 152 may be mounted to the differential case 150 for common rotation and may mesh with the first intermediate output gear 66. The cross pin 154 may be mounted to the differential case 150 perpendicular to the output axis 56. The differential pinions 156 may be journalled by the cross pin 154 and mesh with the first and second side gears 158 and 160. The first output member 16 may be coupled to the first side gear 100 for rotation therebetween, and the second output member 18 may be coupled to the second side gear 102 for rotation therebetween.

[0021] Operation of the clutch mechanism 26 in a first mode (i.e., a propulsion mode) can couple the first intermediate output gear 66 to the intermediate shaft 50 to thereby drive the output 152 of the differential assembly 30. Rotation of the output 152 drives the differential case 150 and cross pin 154 for rotation about the output axis 56, driving the differential pinion gears 156 to cause unified rotation of the first and second side gears 158 and 160. In this mode, the double planetary gear set 28 does not affect the operation of the differential assembly 30, and as such, the differential assembly 30 provides rotational power to the first and second output members 16 and 18 in the manner of a standard open differential assembly.

[0022] Operation of the clutch mechanism 26 in a second mode (i.e., a torque vectoring mode) may couple the second intermediate output gear 68 to the intermediate shaft 50 to thereby drive the second ring gear 128 of the dual planetary gear set 28. In this embodiment, rotational power is output from the second planetary gear set 112 to the differential case 150 (via the second planet carrier 124), and rotational power is output from the first planetary gear set 110 to the second output member 18 (via the first planet carrier 116). Since the second output member 18 is non-rotatably coupled to the second side gear 160, it should be understood that the first planet carrier 116 is also drivingly coupled to the second side gear 160.Those skilled in the art will appreciate from this disclosure that the double planetary gear set 28 may be employed to apply equal but opposite torques to the first and second output members 16 and 18, and that the direction of the rotational force / torque applied to a particular one of the output members 16, 18 depends on the direction in which the motor 40 is operated.

[0023] Each half shaft 20, 22 may include a constant velocity joint 210, 214, an axle shaft 218, 222, and a boot 226, 230. The constant velocity joint 210, 214 may be any suitable constant velocity joint, such as a Rzeppa, Weiss, or tripod constant velocity joint, configured to transmit rotational power from the output members 16, 18 to a corresponding one of the axle shafts 218, 222 such that the output member 16, 18 and the corresponding axle shaft 218, 222 rotate at the same angular velocity. The constant velocity joints 210, 214 may allow the axle shafts 218, 222 to articulate or pivot at angles relative to the output axis 56 while transmitting rotational power between the output member 16, 18 and the corresponding axle shaft 218, 222.In this manner, each axle shaft 218, 222 can rotate about a half-shaft axis 234, 238, which can be coaxial with the output axis 56 when the corresponding axle shaft 218, 222 is aligned with the corresponding output member 16, 18, or can be transverse to the output axis 56 when the corresponding axle shaft 218, 222 is not aligned with a corresponding one of the output members 16, 18. In the example provided, each constant velocity joint 210, 214 is a type known in the art as a Rzeppa style, although other types of constant velocity joints may be used. Accordingly, the constant velocity joints 210, 214 will be described only briefly below. The boot 226, 230 may be any type of boot configured to retain lubricant (not shown) within the constant velocity joint 210, 214 and to prevent water or dirt from entering the constant velocity joint 210, 214.In the example provided, the sleeve 226, 230 is a corrugated rubber sleeve that encloses a portion of the half-shaft 20, 22.

[0024] With additional reference to Fig. 2-4, the first output element 16 and the constant velocity joint 210 ( Fig. 3) in more detail. With special reference to Fig. 3, constant velocity joint 210 may include an outer member 310, an inner member 314, a cage 318, and a plurality of spherical bearings 322. Constant velocity joints 210, 214 may be similar. Accordingly, only one of constant velocity joints 210, 214 will be described in detail, and the description of constant velocity joint 210 is incorporated herein with reference to constant velocity joint 214.

[0025] The outer member 310 may be a generally cylindrical body having a first inner surface 326, a first outer periphery 330, a first inboard side 334, a first outboard side 338, and may define a plurality of first bores 342. The first inner surface 326 may be a generally cylindrical surface and may define a central cavity 346 and a plurality of outer races 350 (only one shown). The outer races 350 may be evenly spaced about the circumference of the first inner surface 326 and may extend axially along the central cavity 346. The first outer periphery 330 may have a first portion 354 and a second portion 358. The first portion 354 may have a first diameter. The second portion 358 may be concentric with the first portion 354 and may have a second diameter less than the first diameter.The intersection of the first and second portions 354, 358 may form a first step 362 where the first outer perimeter 330 may taper in diameter from the first portion 354 to the second portion 358. The first step 362 may be generally perpendicular to the output axis 56. Each of the first bores 342 may penetrate the outer member 310 from the first, inboard side 334 to the first, outboard side 338 of the outer member 310. The first bores 342 may be circumferentially spaced apart from one another throughout the outer member 310. In the example provided, the outer member 310 includes six of the first bores 342 that are evenly spaced apart from one another. The collar 226 may be fixedly coupled to the outer member 310 and the axle shaft 218 for common rotation, although other configurations may be used.

[0026] The inner member may be disposed within the central cavity 346. The inner member 314 may be coupled to the axle shaft 218 for common rotation about the half-shaft axis 234. The axle shaft 218 may be coupled to the inner member 314 in any suitable manner, such as by intermeshing bevel gears (not shown) formed, for example, on the axle shaft 218 and the inner member 314. The inner member 314 may define a plurality of inner races 366 (only one shown). The inner races 366 may be evenly spaced about the circumference of the inner member 314 and may extend axially along the inner member 314. Each inner race 366 may be aligned with one of the outer races 350.

[0027] The cage 318 may have an outer spherical surface 370 and may define a plurality of openings 374 (only one shown). The spherical surface 370 may be configured to slidably connect the first inner surface 326 between the outer races 350. The openings 374 may be circumferentially spaced apart from one another throughout the cage 318. Each opening 374 may penetrate the spherical surface 370 and may be configured to secure one of the spherical bearings 322. The openings 374 may be evenly spaced apart around the cage 318 to bring the spherical bearings 322 into rolling contact with the outer member 310 and the inner member 314 such that each spherical bearing 322 is received within one of the outer races 350 and one of the inner races 366.

[0028] Generally returning to the Fig. 2 through 4, the second output member 18 may be similar to the first output member 16. Accordingly, only the first output member 16 will be described in detail, and the description of the first output member 16 is incorporated herein with reference to the second output member 18. The first output member 16 may be a two-piece structure including a driven body 410 and an outer flange 414 separable from the driven body 410.

[0029] The driven body 410 may have a shaft portion 418 and an inner flange 422. The shaft portion 418 may be mounted in the housing 32 ( Fig. 1) of the eDM 10 and may extend outwardly from the housing 32. A first end 426 of the shaft portion 418 may be coupled to the first side gear 158 for common rotation about the output axis 56. In the example provided, the first end 426 of the shaft portion 418 defines a set of external bevel teeth 430 that mesh with an intermeshing set of bevel teeth (not shown) formed on the first side gear 158 to non-rotatably couple the first side gear 158 to the shaft portion 418, although other configurations may be used. In the example provided, the first end 426 of the shaft portion 418 defines a circumferential groove 434 that extends in a circumferential direction around the first end 426.A generally "C"-shaped retainer plate (not shown), commonly known as a C-lock, may be partially received within the circumferential groove 434 to axially retain the first side gear 158 on the shaft portion 418. A second end 438 of the shaft portion 418, opposite the first end 426, may have a diameter larger than the diameter of the first end 426, such that the shaft portion 418 may protrude in diameter at the second end 438.

[0030] The inner flange 422 may be fixedly coupled to the second end 438 of the shaft portion 418 for joint rotation therewith. The inner flange 422 may be disposed outside the housing 32 ( Fig. 1). The inner flange 422 may have a generally cylindrical disc or plate shape with a second outer periphery 450, a second inboard side 454, a second outboard side 458, and a lip or guide shoulder 462. The inner flange 422 may define a central second cavity 466 and a plurality of second bores 470. The second outer periphery 450 may have a diameter greater than the diameter of the second end 438 of the shaft portion 418. The second inboard side 454 may be fixedly coupled to the second end 438 of the shaft portion 418 for mutual rotation therewith. The second bores 470 may penetrate the inner flange 422 from the second outboard side 458 to the second inboard side 454. Each of the second bores 470 may have a plurality of internal threads 474.The second holes 470 may be circumferentially spaced apart from one another across the inner flange 422. In the example provided, the inner flange 422 includes six of the second holes 470 that are evenly spaced apart and configured to align with the first holes 342 of the constant velocity joint 210.

[0031] The guide shoulder 462 may have a generally cylindrical shape that may extend circumferentially about the output axis 56 and may extend axially in an outward direction 478 from the second, outboard side 458 to define a first guide surface 482. The first guide surface 482 may be generally perpendicular to the second, outboard side 458 and generally concentric with the output axis 56. In the example provided, the guide shoulder 462 may extend outward from the second outer side 458 a distance of approximately 2.5 mm, although other configurations may be used.

[0032] The second cavity 466 may be radially inward of the guide shoulder 462 and may extend axially inward from the second, outboard side 458, i.e., in an inward direction 486. In the example provided, the second cavity 466 is defined by a cavity wall 490 and a second inner surface 494. The cavity wall 490 may be generally parallel to the second, outboard side 458 and may face axially inward from the second, outboard side 458. The second inner surface 494 may extend between the cavity wall 490 and the guide shoulder 462. The second inner surface 494 may taper radially with increasing axial distance from the guide shoulder 462 in the inward direction 486 until the second inner surface 494 terminates at the cavity wall 490.

[0033] The outer flange 414 may be a generally cylindrical body having a third outer periphery 510, a third inner surface 514, a third inboard side 518, a third outboard side 522, and a guide ring 526. The outer flange 414 may define a plurality of third bores 530. Each of the third bores 530 may penetrate the outer flange 414 from the third inboard side 518 to the third outboard side 522 of the outer flange 414. The third bores 530 may be circumferentially spaced apart from one another throughout the outer flange 414. In the example provided, the outer flange 414 includes six of the third bores 530 that are evenly spaced apart from one another and configured to align with the first and second bores 342, 470.

[0034] The third outer circumference 510 may define the radial outer circumference of the outer flange 414. The guide ring 526 may extend axially from the third, outboard side 522 in the outward direction 478. The guide ring 526 may be concentric with the third outer circumference 510, and an outer circumference 534 of the guide ring 526 may be the same diameter as the third outer circumference 510. The guide ring 526 may define a second guide surface 538 that may be concentric with the output axis 56 and is radially inward of the outer circumference 534 of the guide ring 526. The second guide surface 538 may be located radially outward of the third bores 530.

[0035] The third inner surface 514 and the second guide surface 538 may define a central first cavity 542 located radially inward of the third outer periphery 510. The third inner surface 514 may have an innermost diameter slightly larger than the diameter of the first guide shoulder 462. The second guide surface 538 may have a fourth diameter larger than the innermost diameter of the third inner surface 514, such that the first cavity 542 may generally increase in diameter from the third inner surface 514 to the second guide surface 538.

[0036] The third inner surface 514 may include a series of annular segments 546 joined by a series of lobes 550. Each lobe 550 may extend radially inward from the annular segments 546 such that the lobes 550 define the innermost diameter, and the annular segments 546 have a diameter greater than the innermost diameter of the third inner surface 514. Each lobe 550 may align with and be concentric with one of the third bores 530, such that the annular segments 546 may be radially outward from a portion of the third bores 530.In an alternative construction, not specifically shown, the third inner surface 514 may be a continuous annular surface that is radially inward of the third bores 530 and defines the innermost diameter to be slightly larger than the diameter of the first guide shoulder 462.

[0037] After assembly, the driven body 410, the outer flange 414, and the outer member 310 of the constant velocity joint 210 are positioned coaxially about the output axis 56. With respect to the inner and outer flanges 422, 414, the third, inboard side 518 may abut the second, outboard side 458. The outer flange 414 may be disposed around the guide shoulder 462 such that the first guide surface 482 may make contact with the third inner surface 514 to position and radially secure the outer flange 414 to be coaxial with the inner flange 422. In the example provided, a portion of each of the lobes 550 forming part of the third inner surface 514 may make contact with the first guide surface 482, e.g., the lobes 550 may rest on the guide shoulder 462.

[0038] With respect to the outer flange 414 and the outer member 310 of the constant velocity joint 210, the first, inboard side 334 may abut the third, outboard side 522. The guide ring 526 may be disposed around the second portion 358 of the first outer perimeter 330 such that the second guide surface 538 may contact the second portion 358 of the first outer perimeter 330 to position and radially secure the outer member 310 to be coaxial with the outer flange 414.

[0039] The inner flange 422, the outer flange 414 and the outer member 310 are coupled together by a plurality of threaded fasteners 610 ( Fig.3) that may be received in the bores 342, 470, 530. In the example provided, the threaded fasteners may be inserted into the bores 342, 470, 530 from the first, outboard side 338 of the outer member 310 and may threadably engage the internal threads 474 of the second bores 470 to secure the half-shaft 20 to the output member 16.

[0040] To remove the eDM 10 from a vehicle (not shown), a typical flange (not shown) coupling a typical output member (not shown) to a typical half-shaft (such as half-shaft 20) requires the half-shaft 20 to have axial movement greater than the axial width of the entire flange to clear the entire flange. Typical half-shafts 20 do not have maximum axial movement distances large enough to clear the entire flange, and therefore, various suspension components (not shown) must be removed to move the half-shaft 20 out of the way and remove the eDM 10. In contrast, the output member 16 of the present disclosure allows the half-shaft 20 to be removed from the eDM 10 with minimal axial movement of the half-shaft 20 and without the need to remove and reinstall the suspension components (not shown).Specifically, after the threaded fasteners 610 are removed, the outer member 310 and outer flange 414 can be moved together in the outward direction 478 just enough that the outer flange 414 clears the guide shoulder 462. The half-shaft 20 can then be swung out of the way of the remaining portion of the output member 16, and the eDM 10 can be removed from the vehicle. In the example provided, the half-shaft 20 and outer flange 414 only need to be moved axially in the outward direction 478 by approximately 2.5 mm (i.e., a 2.5 mm axial movement) to clear the guide shoulder 462, although other configurations may be used.

[0041] Spatially relative terms such as "inside," "outside," "below," "lower," "above," "upper," and the like may be used herein for convenience of description to describe the relationship of one element or feature to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may also be intended to encompass different orientations of the device in use or operation in addition to the orientation illustrated in the figures. For example, when the device in the figures is inverted, elements described as being "below" other elements or features are then oriented "above" the other elements or features. Thus, the example term "below" can encompass both an above and below orientation.The device may be oriented differently (rotated 90 degrees or with other orientations), and the spatially relative descriptors used herein may be interpreted accordingly.

Claims

[1] Vehicle drive module (10), comprising: a housing (32); an electric motor (40) coupled to the housing (32) and having a motor output shaft (42); a transmission gear set (44) received in the housing (32) and coupled to the engine output shaft (42) for transmitting rotational power between the engine output shaft (42) and an output (152) of the transmission gear set (44); a differential assembly (30) comprising: a differential case (150) mounted for rotation about a first axis (56) within the housing (32) and drivingly coupled to the output (152) of the transmission gear set (44); a pair of gears (156) received in the differential housing (150) and rotatable relative to the differential housing (150) about a second axis perpendicular to the first axis (56); and a pair of side gears (158, 160) received in the differential case (150) and rotatable about the first axis (56), each of the side gears (158, 160) being in meshing engagement with the pair of gears (156); and a pair of output elements (16, 18), each output element (16, 18) comprising: a driven body (410) having a first end (426) and a second end (438), the first end (426) being drivingly coupled to a corresponding one of the side gears (158, 160) to receive rotational power therefrom, and the second end (438) defining a circumferential lip (462); and an outer flange (414) having a radially inner surface (514) defining a first inner cavity (542), the first inner cavity (542) being adapted to receive a first portion of a constant velocity joint (210), and the outer flange (414) being removably mounted around the circumferential lip (462); wherein the driven body (410) has an outer surface (458) radially outward of the circumferential lip (462) and configured to abut an axially inner surface (518) of the outer flange (414); wherein the driven body (410) defines a plurality of first bores (470) circumferentially spaced apart from one another around the outer surface (458) of the driven body (410), and the outer flange (414) defines a plurality of second bores (530), each of the second bores (530) being aligned with a corresponding one of the first bores (470), and wherein the first and second bores (470, 530) are adapted to receive a corresponding threaded fastener (610) therein to releasably couple the driven body (410) and the outer flange (414) for common rotation. [2] The vehicle drive module (10) of claim 1, wherein the circumferential lip (462) extends axially outwardly from the outer surface (458) of the driven body (410) by a distance less than 3 mm. [3] The vehicle drive module of claim 1, wherein the driven body (410) defines a second interior cavity (466) radially inward of the circumferential lip (462) and extending axially inward from the outer surface (458) of the driven body (410). [4] The vehicle drive module (10) of claim 1, wherein the outer flange (414) has an outboard surface (522) and a guide ring (526), ​​the outboard surface (522) of the outer flange (414) being opposite the axially inboard surface (518) of the outer flange (414), and the guide ring (526) being disposed radially outboard of the outboard surface (522) of the outer flange (414) and extending axially outboard from the outboard surface (522) of the outer flange (414) a first distance to define a further interior cavity adapted to receive a second portion of a constant velocity joint (210). [5] The vehicle drive module of claim 4, wherein the circumferential lip (462) extends axially outwardly from the outer surface (458) of the driven body (410) a second distance that is less than the first distance. [6] Vehicle drive module (10), comprising: a housing (32); an electric motor (40) coupled to the housing (32) and having a motor output shaft (42); a transmission gear set (44) received in the housing (32) and coupled to the engine output shaft (42) for transmitting rotational power between the engine output shaft (42) and an output (152) of the transmission gear set (44); a differential assembly (30) comprising: a differential case (150) mounted for rotation about a first axis (56) within the housing (32) and drivingly coupled to the output (152) of the transmission gear set (44); a pair of gears (156) received in the differential housing (150) and rotatable relative to the differential housing (150) about a second axis perpendicular to the first axis (56); and a pair of side gears (158, 160) received in the differential case (150) and rotatable about the first axis (56), each of the side gears (158, 160) meshing with the pair of gears (156); and a pair of output members (16, 18), each output member (16, 18) comprising: a driven body (410) having a first end (426) and a second end (438), the first end (426) of the driven body (410) being drivingly coupled to a corresponding one of the side gears (158, 160) to receive rotational power therefrom, and the second end (438) of the driven body (410) having a first cylindrical portion (422) and a second cylindrical portion (462), wherein the first and second cylindrical portions (462) are coaxial with the first axis (56), and the first cylindrical portion (422) has a diameter greater than the second cylindrical portion (462), and wherein the second cylindrical portion (462) extends axially in an outward direction from the first cylindrical portion (422); and an outer flange (414) having a radially inner surface (514) defining a first inner cavity (542), the first inner cavity (542) being adapted to receive a first portion of a constant velocity joint (210), and the outer flange (414) being removably mounted around the second cylindrical portion (462); wherein the outer flange (414) has an outboard surface (522) and a guide ring (526), ​​wherein the guide ring (526) is disposed radially outwardly from the outboard surface (522) of the outer flange (414) and extends axially outwardly from the outboard surface (522) of the outer flange (414) a first distance to define a further internal cavity adapted to receive a portion of a constant velocity joint (210). [7] The vehicle drive module (10) of claim 6, wherein the first cylindrical portion (422) has an outboard surface (458) configured to abut an axially inboard surface (518) of the outer flange (414). [8] The vehicle drive module (10) of claim 7, wherein the driven body (410) defines a second interior cavity (466) radially inward from an outermost radial surface (482) of the second cylindrical portion (462) and extending axially inward from the outermost surface (450) of the first cylindrical portion (422). [9] The vehicle drive module (10) of claim 6, wherein the second cylindrical portion (462) extends axially outwardly from the first cylindrical portion (422) by a distance less than 3 mm. [10] The vehicle drive module (10) of claim 6, wherein the first cylindrical portion (422) defines a plurality of first bores (470) circumferentially spaced apart from one another around the first cylindrical portion (422), and the outer flange (414) defines a plurality of second bores (530), each of the second bores (530) being aligned with a corresponding one of the first bores (470), and wherein the first and second bores (470, 530) are adapted to receive a plurality of threaded fasteners (610) therein for removably coupling the driven body (410) and the outer flange (414) for rotation together. [11] The vehicle drive module (10) of claim 1, wherein the first bores (470) have a plurality of threads (474) configured to engage the threads of the corresponding threaded fasteners (610). [12] The vehicle drive module (10) of claim 9, wherein the first bores (470) have a plurality of threads (474) configured to engage the threaded fasteners. [13] Half-shaft assembly (20) comprising: a shaft (418) having an inboard end (426) and an outboard end (438), the inboard end (426) having a set of external bevel teeth (430) configured to receive torque to rotate the shaft (418) about an axis (56); an inner flange (422) fixedly connected to the outer end (438) of the shaft (418) for common rotation about the axis (56), the inner flange (422) comprising a cylindrical first disk (422) and a guide shoulder (462), the first disk (422) having an outer surface perpendicular to the axis (56) and defining a plurality of first bores (470) circumferentially spaced from one another about the axis (56), each first bore (470) being adapted to receive a fastener, the guide shoulder (462) extending axially outwardly from the outer surface (458) of the first disk (422), the guide shoulder (462) having an outermost cylindrical surface (482) extending radially inwardly of the first bores (470) and parallel to the axis (56); an outer flange (414) having an axially inner surface (518), an outer surface (522), a radially inner surface (514), and a plurality of second bores (530), the axially inner surface (518) of the outer flange (414) abutting the outer surface (458) of the first disc (422), the outer surface (522) of the outer flange (414) being opposite and adapted to contact an inner surface of a constant velocity joint (210), the second bores (530) extending through the axially inner and outer surfaces (518, 522) of the outer flange (414) and being aligned with the first bores (470), the radially inner surface (514) being radially outward of the outermost cylindrical surface (482) of the guide shoulder (462) and radially inward of the first and second bores (470, 530). [14] The half-shaft assembly (20) of claim 13, wherein the guide shoulder (462) extends axially outwardly from the outer surface (458) of the first disc (422) by a distance less than 3 mm. [15] The half-shaft assembly (20) of claim 13, wherein the inner flange (422) defines a second cavity (466) radially inward of the guide shoulder (462) and extending axially inward from the outer surface (458) of the first disk (422). [16] The half-shaft assembly (20) of claim 13, wherein the outer flange (414) includes a guide ring (526), ​​the guide ring (526) being radially outward of the second bores (530) and extending axially from the outer surface (522) of the outer flange (414) such that a portion of the constant velocity joint (210) abutting the outer surface (522) of the outer flange (414) is radially inward of the guide ring (526). [17] The half-shaft assembly (20) of claim 16, wherein the guide shoulder (462) extends axially outwardly from the outer surface (458) of the first disk (422) a first distance and the guide ring (526) extends axially outwardly a second distance greater than the first distance. [18] The half-shaft assembly (20) of claim 16, further comprising a constant velocity joint (210), the constant velocity joint (210) comprising a cylindrical outer body (310) having an inboard surface (334), an outboard surface (338), a cylindrical outer surface (358), and a plurality of third bores (342), the third bores (342) extending through the inboard and outboard surfaces (334, 338) of the cylindrical outer body (310) and aligned with the first and second bores (470, 530), the inboard surfaces (334) of the cylindrical outer body (310) abutting the outboard surface (522) of the outer flange (414), and the cylindrical outer surface (358) of the cylindrical outer body (310) being radially inboard of the guide ring (526). [19] The half-shaft assembly (20) of claim 13, wherein the first bores (470) extend through an inner surface (454) of the first disc (422) and the inner surface (454) of the first disc (422) is opposite the outer surface (458) of the first disc (422).

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