Drive unit for a drive axle, drive axle and motor vehicle

The drive unit with an electric dual machine and spur gear transmissions addresses the challenge of compact high-torque transmission by enhancing axial torque density and reducing radial dimensions, achieving efficient and lightweight drive units for electric and hybrid vehicles.

DE102024102746A1Pending Publication Date: 2025-07-31BAYERISCHE MOTOREN WERKE AG
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Patent Information

Application Number
DE102024102746
Authority / Receiving Office
DE · DE
Patent Type
Applications
Current Assignee / Owner
Filing Date
2024-01-31
Publication Date
2025-07-31

AI Technical Summary

Technical Problem

Existing drive units for electric and hybrid-electric vehicles face challenges in achieving high torque transmission while maintaining compactness and efficient packaging due to limitations in radial and axial space utilization.

Method used

A drive unit with an electric dual machine and two spur gear transmissions, featuring double-helical pinions and spur gears, which allows for increased axial torque density and reduced radial dimensions, utilizing axial flux active subassemblies and spur gear stages to enhance torque transmission efficiency and reduce mass.

Benefits of technology

The solution enables high torque transmission with reduced component size and mass, optimizing space utilization and efficiency, while minimizing axial forces and enabling lighter, more compact drive units.

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Abstract

The invention relates to a drive unit (1), a drive axle comprising the drive unit (1), and a motor vehicle having the drive axle. The drive unit (1) has an electric double machine (2) with two active subassemblies (3), each having a stator (5) fixed in a rotationally fixed manner to a housing (4) of the drive unit (1), and a rotor (6). The drive unit (1) also comprises two spur gears (10), each having a double-helical drive pinion (11) connected in a rotationally fixed manner to a respective rotor shaft (7) of the active subassemblies (3), and a double-helical output spur gear (12) meshing with the drive pinion (11).An axial tooth engagement zone (14) of the respective spur gear (10), in which the drive pinion (10) and the output spur gear (12) are in tooth engagement (15) with each other, is increased in order to transmit a predetermined maximum torque in favor of the smallest possible drive pinion radius and the smallest possible output spur gear radius.
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Claims

[1] Drive unit (1) for a drive axle for a motor vehicle, with - an electric double machine (2) with two active component assemblies (3), each having a stator (5) and a rotor (6) fixed in a rotationally fixed manner to a housing (4) of the drive unit (1), - two spur gears (10), each having: - a double helical drive pinion (11) which is connected in a rotationally fixed manner to a respective rotor shaft (7) of the active part assemblies (3), - a double-helical driven spur gear (12) meshing with the drive pinion (11), wherein an axial tooth engagement zone (14) of the respective spur gear (10), in which the drive pinion (10) and the driven spur gear (12) are in tooth engagement (15) with each other, is increased to transmit a predetermined maximum torque in favor of the smallest possible drive pinion radius and the smallest possible output spur gear radius. [2] Drive unit (1) according to claim 1, characterized by that the respective spur gear (10) has two or more drive pinions (11) and the same number of output spur gears (12), wherein the respective drive pinion (11) and the associated one of the rotor shafts (7) are connected to one another in a rotationally fixed manner, and one drive pinion (11) meshes with one of the output spur gears (12). [3] Drive unit (1) according to claim 1, characterized by that the respective spur gear (10) has exactly one drive pinion (11) and exactly one output spur gear (12). [4] Drive unit (1) according to one of the preceding claims, characterized by that the active part assemblies (3) are each designed as axial flow active part assemblies. [5] Drive unit (1) according to claim 4, characterized bythat the respective stator (5) of the active part assemblies (3) has a stator disc (9) which is arranged axially between two rotor discs (6a, 6b) of the rotor (6) of the same active part assembly (3). [6] Drive unit (1) according to claim 4, characterized by that the respective rotor (6) of the active part assemblies (3) has a rotor disc which is arranged axially between two stator discs of the stator (5) of the same active part assembly (3). [7] Drive axle for a motor vehicle with a drive unit (1) designed according to one of the preceding claims. [8] Motor vehicle with a drive axle designed according to claim 7.

Citation Information

Patent Citations

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