DRIVE ARRANGEMENT FOR A VEHICLE

Abstract

Drive arrangement (101, 101A) for a vehicle (103, 1603), wherein the drive arrangement (101, 101A) comprises: a drive mechanism (104, 104A) with two output shafts (113) for connection with the wheels (105A, 105B) of the vehicle (103, 1603); a subframe (106, 106A, 106B, 106C) with at least one first mounting device (107) for mounting the drive assembly (101, 101A) on a first side of the body (102, 1602) of the vehicle (103, 1603) and at least one second mounting device (108) for mounting the drive assembly (101, 101A) on a second side of the body (102, 1602) of the vehicle (103, 1603); a removable cover (208, 208A) that is attached to the subframe (106, 106A, 106B, 106C) and covers at least part of the drive mechanism (104, 104A); wherein the subframe (106, 106A, 106B, 106C) comprises a continuous component (110, 110A) extending from the first mounting device (107) to the second mounting device (108), and the continuous component (110, 110A) has a hole (401, 1801) or recess (901, 1201) in which at least a part of the drive mechanism (104, 104A) is located, wherein each of the two output shafts (113) is connected to the respective wheel (105A, 105B) via a universal joint (115, 1615, 1653, 1654) and a wheel axle (117), and wherein the wheel axles (117) are functionally connected to the subframe by a suspension mechanism to support the body (102, 1602) of the vehicle (103, 1603).

Description

TECHNICAL AREA

[0001] The present disclosure relates to a drive arrangement for a vehicle. In particular, but not exclusively, it relates to a drive arrangement for a road vehicle, such as a car.

[0002] Aspects of the invention relate to a drive arrangement, a vehicle and a method. BACKGROUND

[0003] It is known that a subframe for a vehicle comprises two longitudinal members configured to be attached to a vehicle body, and a cross member connecting the two longitudinal members and housing a drive component such as an electric motor. One problem with the arrangement is that the construction of the subframe is quite complex, as it consists of several different components, including the two longitudinal members and the cross member, which are bolted together. A second problem is that the subframe must be disassembled to access the electric motor.

[0004] DE 10 2008 034 514 A1 discloses a carrier assembly having a unique architecture that allows the carrier assembly to be defined by a very small package envelope. The carrier includes a main carrier housing with an internal cavity for receiving a differential and a carrier cover that closes the internal cavity after installation of the differential. Examples of architectural features include a differential lock actuator mounted to the carrier cover, locating pins that accommodate differential leg thrust loads and align the carrier cover with respect to the main carrier housing, and screw-in differential leg structures to facilitate pinion gear installation. Furthermore, the carrier assembly can be used with an independent suspension to provide an increased range of suspension travel.

[0005] US 2005 / 0091823 A1 discloses a drive axle assembly for motor vehicles, which comprises a support beam element with a substantially flat, enlarged center plate section and two opposing wishbone sections, and which comprises a differential assembly module attached to the center plate profile and enclosed in a housing consisting of a rear cover and a front cover attached to opposite surfaces of the center plate profile. A method for assembling the drive axle assembly comprises the steps of attaching the front cover to a front mounting surface of the support beam element, attaching the differential assembly module to the center plate section of the support beam element, and attaching the rear cover to the rear mounting surface of the support beam element.

[0006] US 2014 / 0243140 A1 discloses an axle assembly with a hollow beam and a cover plate. The hollow beam has upper and lower beams welded together to define a central support portion and a pair of tubes. The upper support member has a pair of upper spring seats disposed on opposite sides of the central support portion. The lower support member has a pair of lower spring seats disposed on opposite sides of the central support portion. The cover shell consists of a welding flange and a cover portion. The welding flange is fillet welded to the central support portion to occupy a first opening formed in the central support portion. The cover portion includes a wall bar having a pair of reinforcing projections formed therein. The reinforcing projections are disposed on opposite lateral sides of a centerline of the central support portion.

[0007] The aim of the present invention is to eliminate disadvantages of the prior art. SUMMARY OF THE INVENTION

[0008] Aspects and embodiments of the invention provide a drive assembly, a vehicle and a method as required in the appended claims.

[0009] According to one aspect of the invention, a drive assembly for a vehicle is provided, the drive assembly comprising: a drive mechanism having two output shafts for connection to wheels of the vehicle; a subframe having at least a first mounting feature for securing the drive assembly to a first side of the body of the vehicle and at least a second mounting feature for securing the drive assembly to a second side of the body of the vehicle; and a removable cover attached to the subframe and covering at least a portion of the drive mechanism; wherein the subframe includes a continuous component extending from the first mounting feature to the second mounting feature, the continuous component having a bore or recess in which at least a portion of the drive mechanism is located.

[0010] This offers the advantage that the drive mechanism can be supported within the bore or recess of the single continuous component of the subframe, which transfers the loads from the drive mechanism to the body of the vehicle in which it is installed. This reduces the number of components and component interfaces, making it possible to reduce weight and space requirements within a vehicle. Furthermore, the installation and / or replacement of the drive mechanism is facilitated by a removable cover.

[0011] In some embodiments, the extruded component comprises a continuous casting or extruded sheet of pressed metal.

[0012] The term “metal” as used herein means either a pure metal or a metal alloy.

[0013] In some embodiments, the drive assembly may include a reservoir located within the hole or recess, and a seal may be provided between the removable cover and the reservoir to allow the lubricant to be contained by the combined removable cover and reservoir. This has the advantage that the continuous component does not need to be configured to retain the lubricant and can therefore be provided with a lighter, perforated structure.

[0014] In some embodiments, the continuous component of the subframe includes a recess in which at least a portion of the drive mechanism is located, and the drive assembly includes a seal between the removable cover and the subframe so that the lubricant can be contained by the removable cover and the subframe in combination.

[0015] The drive mechanism may comprise an electric motor. Alternatively, the drive mechanism may also comprise a differential having an input shaft for connection via a drive shaft to a motor mounted remotely from the drive mechanism.

[0016] In some embodiments, the removable cover comprises a plastic material and / or the drive assembly comprises a container located within the hole or recess, and the container is formed from a plastic material. This has the advantage of allowing the drive assembly to be made lighter while maintaining the required strength provided by the continuous component of the subframe.

[0017] The drive assembly includes a bracket located above the removable cover, with the bracket being attached to the continuous component of the subframe. Using a removable cover and a separate bracket offers the advantage that the cover can be formed from a lightweight material such as a polymer, which is only required to maintain the presence of a lubricant around the drive mechanism, while the bracket can be designed solely to provide mechanical strength to support the removable cover or to provide additional strength to the subframe.

[0018] In some embodiments, the drive assembly includes bearings that support the output shafts, and the bearings are located between the removable cover and the subframe. Locating the bearings between the removable cover and the subframe simplifies assembly of the drive assembly.

[0019] In some embodiments, the removable cover comprises a plastic material and a metal structure embedded in the plastic material adjacent to the bearings; and / or the drive assembly comprises a container located within the hole or recess, and the container comprises a plastic material with a metal structure embedded in the plastic material adjacent to the bearings. This composite structure enables load transfer between the bearings of the drive mechanism and the fasteners while also allowing the removable cover and / or container to be formed from a relatively lightweight (plastic) material.

[0020] In some embodiments, the continuous component defines bearing surfaces for receiving the bearings.

[0021] In some embodiments, the subframe includes at least two first attachment features for attaching the drive assembly to a first side of the body of the vehicle and at least two second attachment features for attaching the drive assembly to a second side of the body of the vehicle.

[0022] In some embodiments, the subframe includes a third mounting function for securing the drive assembly to the body in front of or behind the drive mechanism. This has the advantage of minimizing the number of fasteners required to mount the subframe to the body. According to a further embodiment of the invention, a vehicle is provided which comprises a body and a drive arrangement, at least the first mounting element and the second mounting element being mounted on the body.

[0023] According to a further embodiment of the invention, a method of assembling a drive mechanism is provided, the drive mechanism having two output shafts for connection to wheels of a vehicle, the method comprising: positioning at least a portion of a drive mechanism within a hole or recess formed in a continuous component of a subframe, the continuous component having at least a first mounting fixture for mounting the drive assembly on a first side of a body of a vehicle and at least a second mounting fixture for mounting the drive assembly on a second side of the body of the vehicle; and attaching a removable cover to the subframe, the removable cover covering at least a portion of the drive assembly.

[0024] In some embodiments, the extruded component comprises a continuous casting or extruded sheet of pressed metal.

[0025] In some embodiments, the method includes positioning a container within the hole or recess and providing a seal between the removable lid and the container such that lubricant can be received by the removable lid and the container in combination.

[0026] In some embodiments, the continuous component of the subframe includes a recess in which at least a portion of the drive mechanism is located; and the drive assembly includes a seal between the removable cover and the continuous component such that the lubricant can be contained by the removable cover and the continuous component in combination.

[0027] The drive mechanism may comprise an electric motor. Alternatively, the drive mechanism may also comprise a differential.

[0028] In some embodiments, the removable cover is made of a plastic.

[0029] In some embodiments, the method includes positioning a bracket over the removable cover and attaching the bracket to the continuous component of the subframe.

[0030] In some embodiments, the drive assembly includes bearings that support the output shafts, and the method includes positioning the bearings between the removable cover and the subframe.

[0031] In some embodiments, the removable cover comprises a plastic material and a metallic structure embedded in the plastic material to provide reinforcement of the plastic material, and the method includes positioning a portion of the removable cover comprising the metallic structure over the bearings.

[0032] In some embodiments, the method includes positioning the bearings within bearing surfaces defined by the continuous component of the subframe.

[0033] For the purposes of this application, it is expressly intended that the various aspects, embodiments, examples, and alternatives set forth in the preceding paragraphs, in the claims, and / or in the following descriptions and drawings, and in particular the individual features thereof, may be adopted independently or in any combination. That is, all embodiments and / or features of an embodiment may be combined in any manner and / or combination, unless these features are incompatible. The applicant reserves the right to amend an originally filed claim or to file a new claim accordingly, including the right to amend an originally filed claim to depend on another claim and / or to incorporate a feature of another claim even though it was not originally asserted in that manner. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] One or more embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: Fig. shows a vehicle 103 comprising a car having a drive assembly 101; Fig. shows a plan view of an example of the drive assembly 101 from Fig. ; Fig. shows a cross-sectional side view of the drive assembly 101 of Fig. ; Fig. shows a bottom view of the drive assembly 101 of Fig. ; Fig. shows a cross-sectional view of the drive assembly 101 in the Fig. shown level “A”; Fig. shows a cross-sectional view of the drive assembly 101 in the Fig. shown level “B”; Fig. shows an end view of the drive assembly 101 in the direction of arrow C in Fig. ; Fig. shows a plan view of an alternative example of the drive assembly 101 from Fig. ; Fig. shows a cross-sectional side view of the drive assembly 101 of Fig. ; Fig. shows a cross-sectional view of the drive assembly 101 in the Fig. shown level “D”; Fig. shows a plan view of a second alternative example of the drive arrangement 101 from Fig. ; Fig. shows a cross-sectional side view of the drive assembly 101 of Fig. ; Fig. shows a second cross-sectional view of the drive assembly 101 in the Fig. shown level “E”; Fig. shows a third cross-sectional view of the drive assembly 101 in the Fig. shown level “F”; Fig. shows a flowchart describing a method 1500 for assembling a drive mechanism 104; Fig. schematically shows a second vehicle 1603 comprising a rear-wheel drive vehicle having a drive assembly 101A; Fig. shows a plan view of an example of the drive assembly 101A from Fig. ; Fig. shows a cross-sectional side view of the drive assembly 101A of Fig. ; Fig. shows a second cross-sectional view of the drive assembly 101A in the Fig. shown level “G”; Fig. shows a bottom view of a drive arrangement; and Fig. shows a cross section taken in the Fig. 20 shown level “H”. DETAILED DESCRIPTION

[0035] The figures illustrate a drive assembly 101, 101A for a vehicle 103, 1603, the drive assembly 101, 101A comprising: a drive mechanism 104 having two output shafts 113 for connection to wheels 105A of the vehicle 103; a subframe 106, 106A, 106B, 106C having at least a first fastening function 107 for fastening the drive assembly 101, 101A to a first side of the body 102, 1602, at least a second fastening function 108 for fastening the drive assembly 101, 101A to a second side of the body 102, 1602; a removable cover 208, 208A attached to the subframe 106, 106A, 106B, 106C and covering at least a portion of the drive mechanism 104, 104A; wherein the subframe 106, 106A, 106B, 106C includes a continuous component 110, 110A extending from the first attachment member 107 to the second attachment member 108.

[0036] In the various embodiments described below, the strand component 110, 110A comprises a continuous casting or a continuous sheet of pressed metal. The continuous component 110, 110A may be formed from a metal such as steel or an aluminum alloy.

[0037] A vehicle 103 comprising a vehicle having a drive arrangement 101 is shown in Fig. shown schematically. In the present example, the car 103 has an engine 111 that drives the front wheels 105B via a transmission 112. The car 103 also has rear wheels 105A, which are separately driven by a drive mechanism 104 comprising an electric motor 114 forming part of the drive assembly 101.

[0038] The drive mechanism 104 is mounted on a subframe 106 having two first mounting features 107 for securing the drive assembly 101 to a first side of the body 102 of the vehicle 103 and two second mounting features 108 for securing the drive assembly 101 to a second side of the body 102. The mounting features 107 and 108 may include holes for receiving bushings 118 of known types. The bushings 118 may be secured to the side members 120 defined by the body 102 and extending rearward toward the vehicle 103. It should be noted that the body 102 may be referred to as a "body in white" or "body shell" and is comprised of a plurality of pressed metal plates welded together.

[0039] Although the subframe 106 includes first two mounting features 107 for mounting the drive assembly 101 to a first side of the body 102 of the vehicle 103 and second two mounting features 108 for mounting the drive assembly 101 to a second side of the body 102 in alternative embodiments, the drive assembly 101 may include a first single mounting feature 107 for mounting the drive assembly 101 to a first side of the body 102 of the vehicle 103 and a second single mounting feature 108 for mounting the drive assembly 101 to a second side of the body 102.In such embodiments, the subframe 106 may be provided with a third mounting device arranged to attach to the body 102 of the vehicle 103 either in front of or behind the drive mechanism, such that the first mounting device 107, the second mounting device 108, and the third mounting device are positioned at the corners of a triangle. The subframe may comprise a continuous component extending between each of the first, second, and third mounting features. The third mounting member may be positioned near a centerline of the body 102 and closer to the centerline than to either the first or second mounting members. Typically, the third mounting member is positioned on the centerline of the housing 102.

[0040] The subframe 106 of Fig. comprises a continuous component 110 extending from the first two fastening elements 107 to the second two fastening elements 108 and formed as a single cast component. In an alternative embodiment, however, the subframe is formed from a single sheet of metal, which is, for example, laser-cut and pressed into the desired shape.

[0041] The drive mechanism 104 includes two output shafts 113, each connected to the respective wheel 105A via a universal joint (115, 1615, 1653, 1654) and a wheel axle (117) (see dashed sketch 115), a drive shaft (or half shaft) 116, and wheel axles 117. The wheel axles 117 can be operatively connected to the subframe 106 by a suspension mechanism (not shown) to support the body 102 of the vehicle 103.

[0042] In the present example, the front wheels 105B are driven independently of the rear wheels 105A. However, in alternative embodiments, the vehicle 103 is driven exclusively by a drive mechanism 104 comprising an electric motor that drives the rear wheels 105A. In further alternative embodiments, the subframe 106 is mounted on longitudinal members located towards the front of the vehicle 103, and a drive mechanism 104 with an electric motor that drives the front wheels 105B is mounted on the subframe 106. In a further alternative embodiment, which will be described below with reference to the Fig. As will be described in more detail, a subframe 106C is arranged to be mounted towards the rear of a vehicle 1603, and the drive mechanism 104 includes a differential driven by an engine mounted at the front of the vehicle 1603.

[0043] An example of the drive arrangement 101 from Fig. is in the Fig. shown. Fig. shows a plan view of the drive assembly 101; Fig. shows a cross-sectional side view; Fig. shows a top view; Fig. show cross-sectional views in the Fig. shown levels A and B; and Fig. shows an end view in the direction of arrow C in Fig. .

[0044] As in the Fig. As can be seen, the drive mechanism 104 comprises an electric motor 114 having a stator 201, which may include coils, and a rotor 202, which may include permanent magnets, mounted on a hollow shaft 203. The hollow shaft 203 is operatively connected to a gearbox and differential mechanism 204 arranged to provide equal torque to each of the two output shafts 113. The gearbox and differential mechanism 204 may comprise a planetary gear set providing a required gear ratio of, for example, 9:1.

[0045] A first of the two output shafts 113 is supported by a bearing 205. The other of the two output shafts 113 extends through the hollow shaft 203 and is supported by a bearing 206. The output shafts 113 can be provided with internal gears for receiving external gears of axles 207, which connect to a corresponding universal joint 115.

[0046] The subframe 106 of the Fig. defines a hole 401 (which is best seen in the Fig. can be seen), in which part of the drive mechanism 104 is located. The drive assembly 101 of the Fig. includes a reservoir 301 located within the bore 401. The reservoir 301 contains at least a portion of the drive mechanism 104. The drive assembly 101 also includes a removable cover 208 attached to the subframe 106 and covering a portion of the drive mechanism 104. The removable cover 208 has edges configured to extend along the edges of the reservoir 301. A seal 501 is provided between the edges of the removable cover 208 and the reservoir 301 to enable the combined retention of lubricant by the removable cover 208 and the reservoir 301.

[0047] It should be noted that in the present example, the bore 401 extends through the continuous component 110 of the subframe 106 from a top surface 304 to a bottom surface 305 (see Fig. ). Thus, in the present example, the container 301 may extend through the continuous component 110 of the subframe 106 and beyond the bottom surface 305.

[0048] In the example of Fig. the container 301 and the removable lid 208 are similarly shaped shells, each extending approximately halfway around the drive mechanism 104 and having flanges 210 and 211 (see Fig. ) to enable the connection of the removable cover 208 to the container 301 and also to enable the attachment of the removable cover 208 and the container 301 to the subframe 106. The removable cover 208 and the container 301 are attached to the subframe 106 by the fasteners 212. The fasteners 212 may comprise screws that extend through holes in the flanges 210 and 211 of the removable cover 208 and the container 301 and into the threaded holes provided in the subframe 106.

[0049] The seal 501 may comprise a bead seal located in a groove formed in the flanges 210 on the removable lid 208 and / or in the flanges 211 on the container 301. As in Fig. As shown, a second bead seal 501A may be provided parallel to the bead seal 501 with the fastening elements 212 between the two bead seals 501, 501A.

[0050] The container 301 and the removable lid 208 each define a portion of a first opening 302 and a portion of a second opening 303 (shown in Fig. ) provided to allow access to the respective output shafts 113. Radial shaft seals 209 are also provided between the removable cover 208 and the reservoir 301 within the openings 302 and 303 to retain the lubricant in the reservoir 301 and the removable cover 208. The radial shaft seals 209 have a cylindrical outer surface arranged to form a seal with the removable cover 208 and the reservoir 301, and a bore arranged to form a seal with a respective axis 207 connected to the output shafts 113.

[0051] The removable cover 208 and the container 301 may be formed from a plastic or, alternatively, from a metal. If the removable cover 208 and / or the container 301 are formed from plastic, parts of the removable cover 208 and / or the container 301 may be reinforced with a metallic structure around which the plastic is molded. In particular, if the removable cover 208 is formed from a plastic material, portions of the removable cover 208 around the position of the bearings 205 and 206, extending along the flanges 210 to the positions of the fastening elements 212, may be reinforced with a metallic structure 601, as shown in the cross-section of the Fig. shown. Likewise, if the container 301 is formed of a plastic, parts of the container 301 around the position of the bearings 205 and 206 extending along the flanges 211 may be reinforced with a metallic structure 602.

[0052] Fig. also shows one of two C-shaped bearing surfaces 603 defined by the continuous component 110 of the subframe 106, which are provided for supporting the container 301 at the positions of the bearings 205, 206. Thus, it is understood that the continuous component 110 transfers loads between the bearings 205, 206 and the fastening elements 107 and 108.

[0053] To attach the removable cover 208 to the container 301, separate fasteners 213, such as screws, rivets, or clamps, may be provided before the removable cover 208 and the container 301 are positioned on the subframe 106. Consequently, the drive mechanism 104 located within the container 310 and the removable cover 208, the bearings 205, 206 supporting the output shafts 113, and the radial shaft seals 209 may be configured as a module. Consequently, the module may be installed as a unit on the subframe 106 by positioning the container 301 in the bore 401 formed in the subframe 106 and securing the removable cover 208 and the container 301 to the subframe 106 with fasteners 212. Axles 207 with external gearing can then be guided through the radial shaft seals 209 and inserted into the internal gearing provided in the output shafts 113.

[0054] Cables (not shown) may be routed through an opening in the removable cover 208 or container 301, establishing an electrical connection to the coils of the stator 201. Alternatively, the removable cover 208 or container 301 may be provided with an impermeable electrical connector connected to the stator 201 and allowing electrical connection to external electrical wiring.

[0055] An alternative example of the drive arrangement 101 from Fig. is in plan view from Fig. , the cross-sectional side view from Fig. and a second cross-sectional view from Fig. shown in Fig. referred to as D. The features of the drive assembly 101 of the Fig. are generally the same as those of the Fig. and were marked with the same reference numerals.

[0056] The drive arrangement 101 of the Fig. differs from the drive arrangement 101 of the Fig. First, the subframe 106A is the Fig. instead of a hole 401 with a recess 901 (shown in Fig. ) in which the container 301 is located. Thus, a portion of the drive mechanism 104, including the electric motor 114, is located within the container 301 in the recess 901. A portion 902 of the subframe, which provides the recess 901, increases the strength and rigidity of the subframe 106A compared to the subframe 106. Furthermore, it serves to mechanically support the container 301, which can therefore be formed from a thinner and lighter material. As already mentioned, the container 301 can be molded from a plastic.

[0057] The section 902 of the subframe 106A in which the container 301 is located may be provided with one or more openings 903 to reduce the weight of the subframe 106A. As in the example of Fig. However, the container 301 in combination with the removable cover 208 is arranged to contain oil (not shown) which may be provided for lubricating the drive mechanism 104.

[0058] The drive arrangement 101 of the Fig. also includes a support 801 that extends over the removable cover 208. The support 801 may be formed from a stronger material than the removable cover 208, which may be formed from a plastic. For example, the support 801 may be formed from a metal, such as steel or an aluminum alloy.

[0059] The support 801 may have flanges 802 (shown in the Fig. ) configured to extend the length of the flanges 210 provided on the removable cover 208. The fasteners 212 can clamp the flanges 802 of the carrier 801 to the subframe 106A and the flanges 210, 211 of the removable cover 208 and the container 301 between the subframe 106A and the flanges of the carrier 801.

[0060] The carrier 801 may also have one or more other sections 803 having a recess 904 (shown in Fig. ) in which a central portion of the removable cover 208 is located. The bracket 801 can therefore support the wall of the removable cover 208. In addition, the bracket 801 can also provide additional strength to the subframe 106A.

[0061] The end portions 804 of the beam 801 may extend around the bearings 205 and 206 so that the bearings 205 and 206 may be held more rigidly with respect to the subframe 106A.

[0062] The bracket 801 may define one or more openings 805 to reduce the weight of the bracket 801.

[0063] A second alternative example of the drive arrangement 101 of Fig. is in the top view of Fig. shown; a cross-sectional side view of Fig. ; a second cross-sectional view in Fig. , which in Fig. referred to as plane E; and a third cross-sectional view in Fig. , which in Fig. referred to as plane F. The features of the drive assembly 101 of the Fig. are generally the same as those of the Fig. and were marked with the same reference numerals.

[0064] The drive arrangement 101 of the Fig. differs from the drive arrangement 101 of the Fig. by not including the container 301. Instead, the subframe 106B defines the Fig. a recess 1201 (shown in the Fig. ), into which the drive mechanism 104 is directly inserted. Thus, the stator 201 can be attached to the subframe 106B in direct contact with the inner surface of the recess 1201. The inner surface of the recess 1201 is continuous, and therefore the subframe 106 in combination with the removable cover 208 is arranged to form a container for retaining a lubricant into which the drive mechanism 104 can be immersed. Bead seals 1301 (see Fig. ) may be provided between the flanges 210 of the removable cover 208 and the adjacent surfaces of the subframe 106B.

[0065] The subframe 106B and the removable cover 208 each define portions of 1101 openings located at each of the two ends of the drive assembly 101 of the Fig. are provided to allow access to the output shafts 113. The bearings 205, 206 are arranged between the subframe 106B and the removable cover 208 near the openings 1101. The continuous component 110 of the subframe 106B defines C-shaped bearing surfaces 1203 (shown in the Fig. ), against which the bearings 205, 206 can be directly positioned.

[0066] Radial shaft seals 209 are also provided at the openings 1101. The radial shaft seals 209 have an inner surface for sealing with an axle 207 and an outer surface that seals against the removable cover 208 and the subframe 106B.

[0067] In further alternative embodiments, a drive arrangement 101 as described with respect to the Fig. described, with a holder 801 above the removable cover 208 like the holder 801 of the Fig. be provided.

[0068] A flowchart describing a method 1500 for assembling a drive mechanism 104 is shown in Fig. shown. At block 1501, a drive mechanism 104 is positioned in a bore 401 or recess 901, 1201 of a subframe 106, 106A, 106B, the subframe 106, 106A, 106B having at least a first mounting fixture 107 for attaching the drive device 101 to a first side of a body 102 of a vehicle 103 and at least a second mounting fixture 108 for attaching the drive device 101 to a second side of the body 102 of the vehicle 103. Furthermore, the subframe 106, 106A, 106B includes a continuous component 110, 110A extending from the first mounting fixture 107 to the second mounting fixture 108. For example, the subframe 106, 106A, 106B, 106B in the Fig. illustrated embodiments, first two attachment features 107 for attaching the drive assembly 101 to a first side of a body 102 of a vehicle 103 and second two attachment features 108 for attaching the drive assembly 101 to a second side of the body 102 of the vehicle 103; and the subframe 106, 106A, 106B includes a continuous component 110, 110A extending from the first two attachment features 107 to the second two attachment features 108.

[0069] In the example of Fig. The drive mechanism 104 can be pre-assembled inside the container 301 with the removable cover 208 and the bearings 205, 206 on the output shafts 113. The radial shaft seals 209 can also be pre-installed in the openings (such as the openings 302 and 303 of Fig. ) formed at each end of the container 301 and the removable cover 208, which allow access to the two output shafts 113. However, if the seals 209 are not already mounted, they can be inserted axially before or after the process at block 1502.

[0070] In the example of Fig. The rotor 202 and stator 201 of the electric motor 114 are preassembled and connected to the transmission and differential mechanism 204, and the bearings 205 and 206 are mounted on the output shafts 113. This assembly is then positioned on the subframe 106B at block 1501 of method 1500 so that the stator 201 bears against the inner surface of the recess 1201 in the subframe 106B and the bearings 205, 206 lie within the C-shaped bearing surfaces 1203 of the subframe 106B. The removable cover 208 can then be mounted over the motor 114 and the transmission and differential mechanism 204. Upon installation of the cover 208, cables from the stator 201 can be routed through an opening in the removable cover 208.

[0071] At block 1502, the removable cover 208 is attached to the subframe 106, 106A, or 106B such that the removable cover 208 covers at least a portion of the drive assembly 104. In one example, the removable cover 208 may be formed from a plastic material and the flange 210 of the removable cover 208 may be reinforced with steel, and the method at block 1502 may include bolting the steel-reinforced flange of the removable cover 208 to the subframe 106, 106A, or 106B. Alternatively, a support 801 may be disposed over the removable cover 208, and the flange 210 of the removable cover 208 may be clamped between the support 801 and the subframe 106, 106A, or 106B, for example, by bolting the support 801 to the subframe 106, 106A, or 106B.

[0072] If the radial shaft seals 209 are not already installed, they can be installed after the process on the block 1502 by axially inserting the seals 209 into the openings 302, 303, or 1101. The externally splined axles 207 can then be axially inserted through the radial shaft seals 209 into the internal splines provided in the output shafts 113 of the drive mechanism 104.

[0073] A second vehicle 1603, which comprises a rear-wheel drive vehicle, is in Fig. shown schematically. The vehicle 1603 includes a drive assembly 101A mounted on the body 1602 of the vehicle 1603. The drive assembly 101A includes a drive mechanism 104A having two output shafts 1613 for connection to the wheels 1605A of the vehicle 1603. The drive mechanism 104A includes a differential 1614 having an input shaft 1651 driven by an engine 1611 via a transmission 1612, a drive shaft 1652, and universal joints 1653 and 1654. The differential 1614 may be of a known type for driving the rear wheels of a vehicle.

[0074] In the present example, the motor 1611 is mounted remotely from the drive mechanism 104A, with the motor 1611 being mounted in an engine compartment 1655 toward the front of the vehicle 1603, while the drive assembly 101A is mounted toward the rear of the vehicle 1603.

[0075] The two rear wheels 1605A of the carriage 1603 are driven via half shafts 1616, which are connected via axles 1607 and universal joints 1615 to the output shafts 1613 of the drive mechanism 104A.

[0076] The drive assembly 101A also includes a subframe 106C having first two mounting features 107 for mounting the drive assembly to a first side of the body 1602 of the vehicle 1603 and second two mounting features 108 for mounting the drive assembly to a second side of the body 1602 of the vehicle 1603. The mounting features 107 and 108 may have holes for receiving bushings, as described above with respect to the drive assembly 101 of Fig. described.

[0077] A removable cover 208A is attached to the subframe 106C and covers at least a portion of the drive mechanism 104A.

[0078] Like the previously described embodiments, the subframe 106C of the drive assembly 101A includes a continuous component 110A extending from the first two fastening elements 107 to the second two fastening elements 108.

[0079] An example of the drive assembly 101A is shown in plan view in Fig. , the cross-sectional side view in Fig. and a second cross-sectional view in Fig. represented by a plane “G” which is Fig. is identified.

[0080] In the example of Fig. The drive mechanism 104A is located in a container 301A (shown in the Fig. ), the edges of which are sealed against the edges of the removable cover 208A. For example, the edges of the removable cover 208A and the container 301A may be provided with flanges 210A and 211A, similar to the container 301 and the removable cover 208 described above. A bead seal may be provided between the flanges 210A and 211A to allow the container 301A, in combination with the removable cover 208A, to contain oil for lubricating the differential 1614. The container 301A and the removable cover 208A may be attached to the subframe 106C with fasteners 212, such as bolts, extending through holes in the flanges 210A and 211A and engaging threaded holes in the subframe 106C.

[0081] The removable lid 208A and the container 301A are different from the removable lid 208 and the container 301 of the Fig. by defining a third opening for access to the input shaft 1651 and two openings for the output shafts 1613. Each of the three openings is provided with a radial shaft seal 209 having an outer surface sealing against inner surfaces of the reservoir 301A and a removable cover 208A. Two of the radial shaft seals 209 have an inner surface sealing against an axle 1607 mounted on the output shafts 1613 of the differential, and the third radial shaft seal 209 against an axle 1607A mounted on the input shaft 1651.

[0082] Each of the output shafts 1613 and the input shaft 1651 is supported by a corresponding bearing 205, 206 and 1701. The continuous component 110A of the subframe 106C defines C-shaped bearing surfaces 1901 (shown in Fig. ) at the positions of bearings 205, 206, and 1701 to support the bearings and to enable the transfer of loads from bearings 205, 206, and 1701 through the continuous component of subframe 106C to mounting features 107 and 108. Receptacle 301A and removable cover 208A may be formed from a plastic material having steel reinforcement, such as bolts, at the position of bearings 205, 206, and 1701 and along flanges 210A and 211B at positions where receptacle 301A and removable cover 208A are attached to subframe 106C.

[0083] In the present example, the reservoir 301A and a lower portion of the differential 1614 are located in a hole 1801 in the continuous component 110A of the subframe 106C. However, it should be noted that the reservoir 301A and a lower portion of the differential 1614, like the embodiment of the Fig. may be located within a recess formed in the continuous component 110A of the subframe 106C. Just as the embodiment of the Fig. The lower portion of the differential 1614 may be located in a recessed portion of the continuous component 110A of the subframe 106C, allowing the reservoir 301A to be omitted. In this case, the removable cover 208A may be attached directly to the subframe 106 and seals against the subframe 106C.

[0084] It should also be noted that a metal carrier, similar to carrier 801 of the Fig. , can be mounted over the removable cover 208A to support the removable cover (which may be formed from a plastic) and / or to provide additional strength to the subframe 106C.

[0085] Although the embodiments of the present invention have been described in the preceding paragraphs using various examples, it should be noted that changes may be made to the cited examples without departing from the scope of the claimed invention. For example, in an alternative embodiment, the drive mechanism is located in a recess in the endless component forming the subframe. The recess has a main opening so that the drive mechanism can be installed in the recess. In this alternative embodiment, the subframe defines two additional openings that provide access to the output shaft and that contain the radial shaft seals; that is, the radial shaft seals are completely enclosed by the subframe.Access to the support surfaces for the output shaft bearings is via the main opening, and additional fasteners are provided to hold the bearings in position on the bearing surfaces. In this embodiment, the removable cover is sealed against the subframe and does not seal against the radial shaft seals. Therefore, when assembling this alternative drive arrangement, the drive mechanism with the bearings mounted on the output shafts is guided through the main opening into the recess, and the bearings are fixed to the bearing surfaces of the subframe. The cover is positioned over the main opening and fixed in place to seal. The radial shaft seals are inserted into the additional openings in the subframe, and then external splines of axle stub axles can be inserted through the radial shaft seals and into internal splines in the output shaft.

[0086] The subframes 106, 106A, 106B, 106C described above include two first attachment features 107 for attaching the drive assembly 101 to a first side of the body 102 of the vehicle 103 and two second attachment features 108 for attaching the drive assembly 101 to a second side of the body 102. However, in alternative embodiments, the drive assembly 101 includes a subframe having a first single attachment feature 107 for attaching the drive assembly 101 to a first side of the body 102 of the vehicle 103 and a second single attachment feature 108 for attaching the drive assembly 101 to a second side of the body 102.In such embodiments, the subframe may be provided with a third mounting device arranged to be attached to the body 102 of the vehicle 103 either in front of or behind the drive mechanism, such that the first mounting device 107, the second mounting device 108, and the third mounting device define a triangle. In such embodiments, the third mounting element may be positioned near a centerline of the body 102 and closer to the centerline than either of the first or second mounting elements. Typically, the third mounting element is positioned on the centerline of the housing 102.

[0087] A further embodiment is now shown in Fig. 20, which shows a bottom view of a drive assembly 1002. The Fig. The drive assembly 1002 shown in Figure 20 has three fastening features 107, 108, 109. The drive assembly 1002 includes a subframe 106D having a first single mounting feature 107 for attaching the drive assembly 1002 to a first side of the body 102 of the vehicle 103, a second single mounting feature 108 for attaching the drive assembly 1002 to a second side of the body 102, and a third single mounting feature 109 mounted to a suitable body panel either at the front or rear of the vehicle 103. The third single fastener 109 may be positioned on the centerline of the vehicle 103 such that the geometry of the three mounts forms a symmetrical triangular shape. Alternatively, the third single mount 109 may be placed slightly off-center of the vehicle. In an alternative embodiment, in which a mechanical drive shaft (not shown) is used as input to the embodiment of Fig. 20, it may be necessary to position the third individual mounting element 109 in a position that does not interfere with the mechanical drive shaft. The third individual mounting function 109 may be higher or lower in the vehicle to avoid a mechanical drive shaft (not shown) to meet the requirements of the housing.

[0088] Fig. 21 shows a cross section from the Fig.20. The subframe 106D provides a continuous component extending from the first mounting fixture (107) through the second mounting fixture (108) to the third mounting fixture (109). The subframe 106D includes a recess into which the container 301 can be inserted. For example, the container 301 sits within the recess of the subframe 106D, and the removable lid 208B is secured over the drive mechanism 104 with fasteners 212A. As an example, the fasteners 212A could thread directly through the removable lid 208B and the container 301 to engage an internal thread provided in the subframe 106D. In another example, the removable lid 208B and the container 301 could be directly connected to each other with local fasteners.The subsequent attachment of the connected container 301 and the removable lid 208B to the subframe 106D can be made with other conventional attachments (not shown) from above or below the subframe 106D. The drive assemblies 101 described above are generally arranged such that the drive mechanism 104, 104A is mounted above an upwardly facing surface of the respective subframe 106, 106A, 106B, 106C. However, in alternative embodiments, the drive mechanism (104, 104A) may be mounted below a downwardly facing surface of the respective subframe 106, 106A, 106B, 106C. For example, the drive mechanism 104, 104A may be detached from the subframe 106, 106A, 106B, 106C and lowered while the subframe remains attached to the vehicle 103, 106C.

[0089] The features described in the above description may be used in combinations other than those expressly described.

[0090] Although functions have been described with reference to certain features, these functions can be performed by other features, whether described or not.

[0091] Although features have been described with reference to particular embodiments, these features may also be present in other embodiments, whether described or not.

[0092] Although the foregoing specification attempts to draw attention to those features of the invention which are believed to be of particular importance, it is to be understood that the applicant claims protection for any patentable feature or combination of features referred to and / or shown in the drawings, whether or not particular emphasis has been placed thereon.

Claims

[1] Drive arrangement (101, 101A) for a vehicle (103, 1603), the drive arrangement (101, 101A) comprising: a drive mechanism (104, 104A) having two output shafts (113) for connection to the wheels (105A, 105B) of the vehicle (103, 1603); a subframe (106, 106A, 106B, 106C) having at least one first mounting device (107) for mounting the drive assembly (101, 101A) on a first side of the body (102, 1602) of the vehicle (103, 1603) and at least one second mounting device (108) for mounting the drive assembly (101, 101A) on a second side of the body (102, 1602) of the vehicle (103, 1603); a removable cover (208, 208A) attached to the subframe (106, 106A, 106B, 106C) and covering at least a portion of the drive mechanism (104, 104A); wherein the subframe (106, 106A, 106B, 106C) comprises a continuous component (110, 110A) extending from the first mounting device (107) to the second mounting device (108), and the continuous component (110, 110A) has a hole (401, 1801) or recess (901, 1201) in which at least a part of the drive mechanism (104, 104A) is located, wherein each of the two output shafts (113) is connected to the respective wheel (105A, 105B) via a universal joint (115, 1615, 1653, 1654) and a wheel axle (117), and wherein the wheel axles (117) are operatively connected to the subframe by a suspension mechanism to support the body (102, 1602) of the vehicle (103, 1603). [2] The drive assembly (101, 101A) of claim 1, wherein the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C) comprises a continuous piece of cast metal or a continuous sheet of pressed metal. [3] The drive assembly (101, 101A) of claim 1 or claim 2, wherein the drive assembly (101, 101A) includes a reservoir (301, 301A) located within the hole (401, 1801) or recess (901, 1201), and a seal (501, 501A) is provided between the removable cover (208, 208A) and the reservoir (301, 301A) to allow lubricant to be received by the removable cover (208, 208A) and the reservoir (301, 301A) in combination. [4] The drive assembly (101, 101A) of claim 1 or claim 2, wherein the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C) includes a recess (901, 1201) in which at least a portion of the drive mechanism (104, 104A) is located, and the drive assembly (101, 101A) includes a seal (501, 501A) between the removable cover (208, 208A) and the subframe (106, 106A, 106B, 106C) such that lubricant can be received by the removable cover (208, 208A) and the subframe (106, 106A, 106B, 106C) in combination. [5] Drive arrangement (101, 101A) according to one of claims 1 to 4, wherein the drive mechanism (104, 104A) comprises an electric motor (114). [6] A drive arrangement (101, 101A) according to any one of claims 1 to 4, wherein the drive mechanism (104, 104A) comprises a differential (204, 1614) having an input shaft (1651) for connection via a drive shaft (1652) to a motor (1611) mounted remotely from the drive mechanism (104, 104A). [7] The drive assembly (101, 101A) of any one of claims 1 to 6, wherein the removable cover (208, 208A) comprises a plastic material and / or the drive assembly (101, 101A) comprises a container (301, 301A) located within the hole (401, 1801) or the recess (901, 1201), the container (301, 301A) being formed from a plastic material. [8] The drive assembly (101, 101A) of claim 7, wherein the drive assembly (101, 101A) includes a bracket disposed over the removable cover (208, 208A), the bracket being secured to the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C). [9] A drive assembly (101, 101A) according to any one of claims 1 to 8, wherein the drive assembly (101, 101A) comprises bearings (205, 206) supporting the output shafts (113); and the bearings (205, 206) are disposed between the removable cover (208, 208A) and the subframe (106, 106A, 106B, 106C). [10] The drive assembly (101, 101A) of claim 9, wherein: the removable cover (208, 208A) comprises a plastic material and a metal structure (601) embedded in the plastic material adjacent to the bearings (205, 206); and / or the drive assembly (101, 101A) comprises a container (301, 301A) located within the hole (401, 1801) or the recess (901, 1201), and the container (301, 301A) comprises a plastic material with a metal structure (602) embedded in the plastic material adjacent to the bearings (205, 206). [11] A drive assembly (101, 101A) according to claim 9 or claim 10, wherein the continuous component (110, 110A) defines bearing surfaces (603) for receiving the bearings (205, 206). [12] Drive assembly (101, 101A) according to one of claims 1 to 11, wherein the subframe (106, 106A, 106B, 106C) has at least two first attachment features for attaching the drive assembly (101, 101A) to a first side of the body (102, 1602) of the vehicle (103, 1603) and at least two second attachment features for attaching the drive assembly (101, 101A) to a second side of the body (102, 1602) of the vehicle (103, 1603). [13] Drive assembly (101, 101A) according to one of claims 1 to 11, wherein the subframe (106, 106A, 106B, 106C) has a third fastening function for fastening the drive assembly (101, 101A) to the body (102, 1602) in front of or behind the drive mechanism (104, 104A). [14] A vehicle (103, 1603) comprising a body (102, 1602) and a drive assembly (101, 101A) according to any one of claims 1 to 13 mounted on the body (102, 1602) via at least the first mounting device (107) and the second mounting device (108). [15] A method for assembling a drive mechanism (104, 104A) to a subframe (106, 106A, 106B, 106C), the drive mechanism (104, 104A) comprising two output shafts (113), the output shafts (113) each being connectable to the respective wheel (105A, 105B) via universal joints (115, 1615, 1653, 1654) and wheel axles (117) so that the wheel axles (117) can be operatively connected to the body (102, 1602) of the vehicle (103) by a suspension mechanism, the method comprising: Positioning at least a portion of a drive mechanism (104, 104A) within a hole (401, 1801) or a recess (901, 1201) formed in a continuous component (110, 110A) of a subframe (106, 106A, 106B, 106C), wherein the continuous component (110, 110A) has at least one first mounting device (107) for mounting the drive assembly (101, 101A) on a first side of a body (102, 1602) of a vehicle (103, 1603) and at least one second mounting device (108) for mounting the drive assembly (101, 101A) on a second side of the body (102, 1602) of the vehicle (103, 1603); and Attaching a removable cover (208, 208A) to the subframe (106, 106A, 106B, 106C), the removable cover (208, 208A) covering at least a portion of the drive assembly (101, 101A). [16] The method of claim 15, wherein the continuous component (110, 110A) comprises a continuous piece of cast metal or a continuous sheet of pressed metal. [17] The method of claim 15 or 16, wherein the method comprises positioning a container (301, 301A) within the hole (401, 1801) or recess (901, 1201) and providing a seal (501, 501A) between the removable cover (208, 208A) and the container (301, 301A) to allow the lubricant to be contained by the removable cover (208, 208A) and the container (301, 301A) in combination. [18] The method of any one of claims 15 to 17, wherein the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C) has a recess (901, 1201) in which at least a portion of the drive mechanism (104, 104A) is located; and the drive assembly (101, 101A) includes a seal (501, 501A) between the removable cover (208, 208A) and the continuous component (110, 110A) to allow the lubricant to be contained by the removable cover (208, 208A) and the continuous component (110, 110A) in combination. [19] A method according to any one of claims 15 to 18, wherein the drive mechanism (104, 104A) comprises an electric motor (114). [20] A method according to any one of claims 15 to 19, wherein the removable cover (208, 208A) comprises a plastic material. [21] The method of any one of claims 15 to 20, wherein the method comprises positioning a carrier over the removable cover (208, 208A) and attaching the carrier to the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C). [22] A method according to any one of claims 15 to 21, wherein the drive assembly (101, 101A) comprises bearings (205, 206) supporting the output shafts (113), and the method comprises positioning the bearings (205, 206) between the removable cover (208, 208A) and the subframe (106, 106A, 106B, 106C). [23] The method of claim 22, wherein the removable cover (208, 208A) comprises a plastic material and a metal structure (601) embedded in the plastic material to provide reinforcement of the plastic material, and the method comprises positioning a portion of the removable cover (208, 208A) comprising the metal structure (602) over the bearings (205, 206). [24] A method according to claim 22 or claim 23, wherein the method comprises positioning the bearings (205, 206) within bearing surfaces (603) defined by the continuous component (110, 110A) of the subframe (106, 106A, 106B, 106C).

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