Axis system with insulated trumpet arms and fastening elements for the implementation

Abstract

Axis, comprising: a gear housing (109) having lateral ribs / webs (224, 226), compression tubes (704, 706) extending from one side to an opposite side of the gear housing, and coupling holes (216a, 216b) arranged around a circumference of the gear housing; a first side cover (210) coupled to the transmission housing via bolts and fasteners (314) extending through coupling holes disposed on one side of the first side cover; a first trumpet arm (302) connected to the first side cover and the gear housing via fasteners extending through coupling holes arranged around the circumference of a flange (312, 408) of the first trumpet arm and the gear housing, wherein a mounting location of the first trumpet arm is isolated from side walls of the gear housing and side walls of the first side cover; and a second trumpet arm (304) connected to the gear housing via fasteners extending through coupling holes arranged around the circumference of the flange of the second trumpet arm and the gear housing, wherein a mounting location of the second trumpet arm is isolated from the side walls of the gear housing.

Description

TECHNICAL FIELD

[0001] This description generally relates to a trumpet arm configuration for an axle of a vehicle. BACKGROUND AND OVERVIEW

[0002] Axle assemblies are designed to transfer rotational power from a vehicle's power source to its wheels. An axle assembly typically includes a differential assembly rotatably mounted within a non-rotating central housing. The differential is connected between an input shaft from the power source / transmission and a pair of output axleshafts leading to the vehicle's wheels. The axleshafts are housed in respective non-rotatable carrier housing portions attached to the central housing. Rotation of the differential by the input shaft thus causes a corresponding rotation of the axleshafts. The central axle housing and the carrier housing portions form an axle housing for these driveline components of the axle assembly, in which the differential and axleshafts are rotatably mounted.

[0003] One type of axle housing includes a unitary central housing construction, commonly referred to as a Salisbury axle arrangement. Another type of axle housing, called the banjo axle housing, includes a central housing construction that is continuous with two arm sections, with each of the arm sections forming a smooth, gradual, flared connection with the central housing. As electric vehicles increasingly utilize electric axles, conventional banjo and Salisbury axles, with their streamlined housings, may not provide enough space to accommodate all the components required for an electric axle, such as one or more electric machines, gears, shafts, bearings, shift actuators, differentials, pumps, heat exchangers, filters, sensors, etc. Electric machines can refer to electric motors and electric motor-generators.

[0004] There is therefore a need for an axle that offers the desired installation space for the electric axle components in a suitable form. One possible solution is an axle with a gearbox housing with relatively flat sides and two trumpet arms extending along an output axle axis. This can help achieve the installation space required for the electric axle components. However, it becomes problematic when the flange of a trumpet arm meets the side walls of the gearbox housing and / or a surface of a side cover bolted to the gearbox housing, where the trumpet arm flange is used to bolt the trumpet arm to the gearbox housing or side cover. The trumpet flange / trumpet arm interface is a highly stressed area that can be deformed by road loads, leading to fatigue of the gearbox housing and / or side cover.

[0005] Another problem that can arise from side cover deflection along its stud flange is the failure of the side cover flange seals, causing leaks. The trumpet flange-arm transition area houses bearings along the output axis that support the differential, as well as bearings that support other rotating components. Additionally, the gearbox sidewalls and side covers contain pockets for upstream support bearings that support the rotation of the reduction gear parallel to the output axis. If the trumpet arms are rigidly connected to the side covers or main case, deflections from road loads are transmitted through the trumpet arm to the gearbox or sidecover sidewalls.Deflections of the gearbox sidewalls or sidecovers can lead to misalignment between the bearings supported by the respective gearbox sidewalls or sidecovers, which can reduce bearing and gear life and increase noise, vibration, and harshness. As a result of sidewall deflections and sidecover leaks, there is a need to isolate the trumpet arms from the sidewalls and sidecovers. This is achieved by separate trumpet arms bolted to the perimeter of the gearbox, allowing the sidewalls and sidecovers to respond to internal loads and are isolated from the external trumpet arms that interact with road loads. When isolated, the sidewalls and sidecovers are no longer part of the external path from the road load to the gearbox case.

[0006] Described is an axle system comprising a transmission housing with lateral ribs / webs, compression tubes extending from one side to an opposite side of the transmission housing, and coupling holes arranged around a periphery of the transmission housing, a first side cover coupled to the transmission housing via bolts and fasteners extending through coupling holes arranged on one side of the first side cover, a first trumpet arm coupled to the first side cover and the transmission housing via fasteners extending through coupling holes arranged around the periphery of the flange of the first trumpet arm and the transmission housing, the attachment point of the first trumpet arm thus being isolated from the side walls of the transmission housing and the side walls of the first side cover, a second side cover,which is connected to the gearbox housing via bolts, and a second trumpet arm connected to the gearbox housing via fasteners extending through coupling holes arranged around the circumference of the flange of the second trumpet arm and the gearbox housing, the attachment point of the second trumpet arm thus being isolated from the side walls of the gearbox housing and the side walls of the second side cover.

[0007] The first side cover may be disposed between the transmission housing and the first trumpet arm. The second side cover may be disposed between the transmission housing and the second trumpet arm, and the side walls of the second side cover may be insulated from the second trumpet arm. By isolating the first trumpet arm and the second trumpet arm from the side walls of the side covers and the side walls of the transmission housing, the effects of deflections from road loads transmitted to the transmission housing via the trumpet arms are reduced on the side walls and side covers, since the deflections are first transmitted between the first trumpet arm and the second trumpet arm via the fasteners to the transmission housing.

[0008] It should be understood that the above summary is intended to introduce, in simplified form, a selection of concepts that are further explained in the detailed description. It is not intended to identify the most important or essential features of the claimed subject matter, the scope of which is clearly defined by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that address the disadvantages noted above or elsewhere in this disclosure. SHORT DESCRIPTION OF THE CHARACTERS Fig. 1 shows a schematic representation of an electric drive system with trumpet arms. Fig. 2A shows a side view of an electric drive system according to an example in which two trumpet arms are not mounted. Fig. Figure 2B shows a cross-sectional view of the electric drive system of Fig. 2A. Fig. 3 shows a side view of an electric drive system according to an example, which includes two trumpet arms. Fig. 4 shows a side view of a trumpet arm. Fig. 5 shows a first cross-sectional view of an electric drive system according to the embodiments described here. Fig. 6 shows a second cross-sectional view of the electric drive system of Fig. 5, according to the embodiments described here. Fig. Figure 7 shows a profile view of the electric drive system of Fig. 5. Fig. Figure 8 shows a third cross-sectional view of the electric drive system including a fastener with a damping component. Fig. 9A and Fig. 9B show a first side view and a second side view of a first side cover according to the embodiments described herein. DETAILED DESCRIPTION

[0009] The following description refers to systems for an axle that includes a trumpet arm with a mounting location isolated from the side walls of the transmission housing and the side walls of the side covers of a transmission housing. The mounting location is isolated by the integration of fasteners such as tie rods, through-bolts, or studs (e.g., long, variable-length studs) that extend through coupling holes on the perimeter of the flange of a first trumpet arm on one side of the axle, through coupling holes on the side of the first side cover, through coupling holes on the perimeter of the transmission housing, and through coupling holes on the perimeter of the flange of a second trumpet arm. The fasteners can extend through inner side webs / ribs, outer side webs / ribs, inner compression tubes, and outer compression tubes of the transmission housing.Fastener vibrations can be dampened by flexible members surrounding a portion of the fasteners. Isolating the fastener location allows reaction forces due to road-load deflections to be transferred from the first trumpet arm through the gearbox housing to the second trumpet arm. The fasteners can be placed in a tensile state via nuts to compress the gearbox housing and increase axle strength. Thus, the trumpet arm arrangement described here provides a geometry that enables the mounting of electrical machine components and suspension packages on an axle while providing strength and rigidity that can protect against damage to the gearbox housing sidewalls, the sidewalls of the side covers, and the gears and bearings in a gear assembly within the gearbox housing.

[0010] Fig. 1 schematically shows an electric drive system in a vehicle with at least one trumpet arm used for an axle of the electric drive system, the electric drive system being configured as described herein. Fig. Figure 2A shows a view of an electric drive system (e.g. of Fig. 1), in which a first trumpet arm and a second trumpet arm are not assembled and are thus coupled to a gear housing. Fig. 2B shows a partial cross-section of an electric drive system (e.g. from Fig. 2A) with a section of a first trumpet arm. Fig. 3 shows a view of an electric drive system in which a first trumpet arm and a second trumpet arm are arranged to form a space in which a gear housing can be arranged and connected to the first trumpet arm and the second trumpet arm. Fig. 4 shows a side view of a trumpet arm that fits into the systems of the Fig. 1-3 can be integrated. Fig. 5-8 show various side and cross-sectional views of an electric drive system, which are different embodiments of the systems of Fig. 1-3 can involve additional components such as inner compression tubes, outer compression tubes, and damping components that may surround a fastener. Fig. 9A and Fig. 9B show side views of a first side cover which is integrated into the electric drive system of the Fig. 1-3 can be integrated.

[0011] Fig. 1 schematically illustrates a vehicle 100 having an electric drive system 102 that powers and / or is integrated with an axle assembly 104 of the vehicle 100. The vehicle 100 may, in various examples, take a variety of forms, such as a light-duty, medium-duty, or heavy-duty vehicle. Furthermore, the electric drive system 102 may be configured for use in front and / or rear axles and in steerable and non-steerable axles. To generate power, the electric drive system 102 may include an electric machine 106. In some examples, the electric machine 106 may be an electric motor-generator and thus may include conventional components such as a rotor, a stator, and the like housed within a housing 107 of the electric machine to generate mechanical power as well as, in some cases, electrical power during a regenerative mode.In further examples, the electric machine 106 may be replaced with a prime mover, e.g., an internal combustion engine (ICE). Further, in other examples, the vehicle 100 may include an additional motive power source, such as an internal combustion engine (ICE) (e.g., a spark-ignition engine and / or a compression-ignition engine), to provide power to another axle. As such, the electric drive system 102 may be used in an internal combustion engine (ICE) vehicle or an electric vehicle (EV), such as a hybrid electric vehicle (HEV) or a battery electric vehicle (BEV), including cars, trucks, boats, ATVs, commercial vehicles, light vehicles, off-highway vehicles, mining vehicles, rail vehicles, manufacturing equipment, industrial equipment, and the like.

[0012] In some examples, the housing of the electric machine 107 may be connected to a transmission housing 109 of a transmission 108 (e.g., via bolts). In addition, the electric machine 106 may provide mechanical power to a differential 110 via the transmission 108. From the differential 110, the mechanical power may be transmitted to a first drive wheel 112 and a second drive wheel 114, respectively, via the axle shaft 117 and the axle shaft 115 of the axle assembly 104. Thus, the differential 110 may distribute the torque received from the electric machine 106 via the transmission 108 to the first drive wheel 112 of the axle shaft 117 and to the second drive wheel 114 of the axle shaft 115 under certain operating conditions. In some examples, the differential 110 may be an open differential, a limited-slip differential, an active or passive limited-slip differential, or a torque vectoring differential.

[0013] One or both of the axle shaft 117 and the axle shaft 115 may be housed in a trumpet arm, as further described herein. For example, the axle shaft 117 is housed in a first trumpet arm 118 and the axle shaft 115 is housed in a second trumpet arm 116. The first trumpet arm 118 and the second trumpet arm 116 may each be connected to the differential 110 at a flat surface of the flange.

[0014] In some embodiments, the axle assembly 104 includes additional elements coupled, attached, or otherwise connected to the first trumpet arm 118 and / or the second trumpet arm 116. For example, a suspension 152 may be attached to each of the first trumpet arm 118 and the second trumpet arm 116 along the respective arm portion 162. In some embodiments, a spindle 154 may be connected to the outlet of the first trumpet arm 118 and the second trumpet arm 116. For example, a first spindle end of the spindle 154 may be coupled to the respective trumpet arm, and drive gears (e.g., the first drive gear 112 or the second drive gear 114) may be coupled to both the first spindle and the second spindle at a second spindle end of the respective spindle that is opposite the first spindle end of the spindle.

[0015] As further described herein, one or more of the first trumpet arms 118 and the second trumpet arm 116 may also include a differential lock / axle disconnect assembly disposed within a body of the flange 164. The differential lock / axle disconnect assembly may be configured to selectively mesh with a mating clutch of the differential 110 and / or the transmission 108.

[0016] The transmission 108 may be a single-speed transmission, in which the transmission 108 operates with a single gear ratio. However, other transmission arrangements are also conceivable, such as a multi-speed transmission designed to operate at several different gear ratios. In one example, the transmission 108 and the differential 110 may be incorporated into the axle assembly 104 and form an axle in the vehicle 100. In another example, the electric machine 106, the transmission 108, and the differential 110 may be integrated into the axle assembly 104 and form an electric axle (E-axle) in the vehicle 100. The E-axle serves, among other things, to supply motive power to the first drive wheel 112 and the second drive wheel 114 during operation.In particular, in the E-axle embodiment, the electric machine 106 and the transmission 108 may be coupled to and / or otherwise support the first trumpet arm 118 and the second trumpet arm 116. Both the E-axle and axle embodiments may provide a compact arrangement for directly supplying power to the axle assembly 104. For example, the first trumpet arm 118 may be coupled to a first side of the transmission housing 109, and the second trumpet arm 116 may be coupled to a second side of the transmission housing 109 opposite the first side, as shown in FIGS. Fig. 2A-3 described in more detail.

[0017] The electric drive system 102 may further include a lubricant circuit 120 for circulating lubricant through the transmission housing 109 to lubricate and / or cool various system components. The lubricant circuit 120 may be an oil circuit for circulating oil (e.g., natural and / or synthetic oil) through the transmission housing 109 to lubricate and / or cool various system components, wherein the lubricant is oil. The lubricant circuit 120 may include a filter 123 and an oil pump 124 that draws oil from an oil reservoir 111 (e.g., a sump) in the transmission housing 109 via an outlet 122 and directs a pressurized oil flow through a delivery line 126 to an inlet 128 of the transmission housing 109. In some examples, the pump 124 may be provided on an exterior portion of the transmission housing 109. However, in other examples, the pump may be contained within the transmission housing 109.Various distribution components and assemblies (e.g., nozzles, valves, jets, oil passages, and the like) of the lubricant circuit 120 may be included in the electric drive system 102 to facilitate the routing of the lubricant (e.g., oil) within the transmission housing 109 and, in a particular example, to a portion of the housing of the electric machine 107. In some cases, the lubricant circuit 120 may be used to route lubricant to various transmission bearings and gears, as well as to the motor stator, motor rotor, and rotor shaft bearings of the electric machine 106, thereby providing an efficient system for effectively utilizing the transmission lubricant to cool these systems. In some embodiments, the lubricant circuit 120 may also include a heat exchanger or cooler that adds heat (e.g.,thermal energy).

[0018] The electric drive system 102 may further include a coolant circuit 130 that circulates coolant (e.g., water, glycol, and / or oil) through coolant channels 131 formed in the electric machine 106, the electric machine housing 107, or an inverter. The coolant circuit 130 may include a coolant inlet 138 and a coolant outlet 132 positioned on (or in) the housing 107 of the electric machine. The coolant circuit 130 may further include a filter 133 and a pump 134 that circulates coolant via a coolant supply line 136 from the coolant outlet 132 to the coolant inlet 138. From the coolant inlet 138, the coolant enters the coolant channels 131 formed in the electric machine 106, the electric machine housing 107, or an inverter, which dissipate heat from the components.In some examples, the coolant circuit 130 may also include a heat exchanger (e.g., a radiator) that removes heat from the coolant exiting the coolant circuit via the coolant outlet 132.

[0019] The vehicle 100 may also include a control system 140 with a control unit 141. The control unit 141 may include a processor 142 and a memory 144. Instructions may be stored in the memory that, when executed by the processor, cause the controller 141 to perform various methods, control techniques, and the like. The processor 142 may include a microprocessor unit and / or other types of circuitry. The memory 144 may include known data storage media, such as random access memory, read-only memory, persistent memory, combinations thereof, and the like. The control unit 141 may receive various signals from sensors 146 positioned at various locations in the vehicle 100 and the electric drive system 102.The control unit 141 may also send control signals to various actuators 148 connected at various locations in the vehicle 100 and the electric drive system 102. For example, the control unit 141 may send command signals to the oil pump 124 and / or the pump 134, and in response, the actuator(s) in the pump(s) may be adjusted to change the flow rate of oil and / or coolant supplied therefrom. In other examples, the controller may receive a command to change the throttle position requested by the driver via a change in foot position on the accelerator pedal. The controller may send control signals to the electric machine 106, and in response to receiving the command signals, the electric machine may be adjusted to change a rotor speed or torque.The other controllable components in the system can be operated in a similar manner with regard to sensor signals and actuator adjustment.

[0020] An axis system 150 is in Fig. 1. The z-axis can be a vertical axis (e.g., parallel to a gravitational axis), the x-axis can be a longitudinal axis (e.g., a horizontal axis), and / or the y-axis can be a lateral axis, in one example. However, in other examples, the axes can have other orientations. When specifying direction, positive can refer to the arrow direction of the y-axis, x-axis, and z-axis, and negative can refer to the opposite arrow direction of the y-axis, x-axis, and z-axis. A filled circle can represent an arrow and axis pointing toward, or positively relative to, a view. An open circle can represent an arrow and axis pointing away from, or negative relative to, a view.

[0021] Fig. 2A shows an example of an electric drive system 200 with electric axle components for supplying power to an axle assembly 202. The electric axle components of the electric drive system 200 may include an electric machine 206 electrically coupled to an inverter 204 and connected to a transmission housing 208, and may be used in a vehicle such as the one shown in Fig. 1. The electric drive system 200 may therefore have similarities to the electric drive system 102. For example, at least some of the components related to the Fig. 1 illustrated electric drive system 102 were discussed, in which Fig. 2A, or vice versa. A cross section 201 may be shown on a dashed line in Fig. 2A. The cross-section 201 can be taken in a plane between the dashed line and an axis parallel to the y-axis of the reference axes.

[0022] The electric drive system 200 may further include a first side cover 210 connected to the transmission housing 208 via fasteners 214. The fasteners 214 may be bolts. The first side cover 210 has a plurality of coupling holes, including a first coupling hole 216a and a second coupling hole 216b, disposed on one side of the first side cover and configured to allow fasteners, such as threaded tie rods, through bolts, or bolts (e.g., long bolts), to pass through the first side cover 210 to couple the first trumpet arm (not shown) to electric axle components, such as the transmission housing 208.The first coupling hole 216a and the second coupling hole 216b, located on the first side cover side, may be positioned at locations where the first side cover 210 can be supported by a protrusion or connection on the inside of the first side cover 210. The protrusion or connection on the inside of the first side cover may be an integral part of the first side cover 210, an extension of an inner lateral rib(s) or an outer lateral rib(s) of the transmission housing 208. The protrusion or connection between the first side cover 210 and the transmission housing 208 may be sealed with an O-ring, a gasket, a sealant, a thrust washer, a combination, or the like.

[0023] Fig. 2B shows the cross-section 201 of the electric drive system 200. A plurality of coupling holes are provided at various locations on the side of the first side cover 210. In one example, the first side cover 210 may include a first coupling hole 216a and a second coupling hole 216b. Likewise, the transmission housing 208 includes corresponding coupling holes. Furthermore, the transmission housing 208 may include a plurality of coupling holes arranged around the perimeter of the transmission housing 208. For example, the transmission housing 208 may include a third coupling hole 216c, a fourth coupling hole 216d, a fifth coupling hole 216e, a sixth coupling hole 216f, a seventh coupling hole 216g, and an eighth coupling hole 216h.

[0024] In some embodiments, each of the numerous coupling holes on the side of the first side cover 210 may include a raised bolt pad, which may assist in positioning a fastener, such as a threaded tie rod or a bolt (e.g., a long bolt), and in distributing the bolt load. The raised bolt pad may further facilitate the manufacturing of the first side cover 210. In some embodiments, the raised pads may or may not be used. For example, a flat may be used instead. Each of the numerous coupling holes may be strategically positioned on the first side cover 210 and around the perimeter of the gear housing 208 to facilitate the alignment of each through coupling hole of the first and second trumpet arms (not shown) with a coupling hole of the first side cover 210 and the gear housing 208.The first side cover 210 may also include a bearing 212 connecting a fifth shaft to the first side cover 210. The first side cover 210 may have an output seal engaging a first axle shaft, and a second side cover (not shown) may also have an output seal engaging a second axle shaft, both of which retain oil in the transmission housing, allowing the trumpet arms (not shown) to run dry. Because no oil is supplied to the bearings at the wheel ends for lubrication (e.g., due to efficient sealed wheel end bearings) and the oil is retained in the transmission housing 208, the resulting reduction in the amount of oil used in the electric drive system 200 may reduce the weight and cost of the electric drive system 200.

[0025] The electric machine 206 may supply power to a differential (not shown) via the transmission housing 208 to provide rotational power to the first axle shaft and the second axle shaft (to which drive wheels may be coupled) of the axle assembly 202. The first axle shaft and the second axle shaft are in Fig. 2A and are to be understood as being at least partially enclosed in the housing of the two trumpet arms (not shown).

[0026] In Fig. 2B shows the cross-section 201 of the electric drive system 200, including the transmission housing 208 and the first side cover 210. The elements of the transmission housing 208 and the first side cover 210 are omitted for brevity. The cross-section 201 shows an interior of the electric drive system 200 when the electric drive system is bisected by a line running from the first coupling hole 216a to the second coupling hole 216b. As shown, the first side cover 210 is connected to the transmission housing 208 via bolts 214. In particular, the first side cover 210 may be connected to the transmission housing 208 via, among other things, a first bolt 214a and a second bolt 214b.

[0027] The cross-section 201 of the electric drive system 200 includes a first trumpet arm flange 218 connected to the first trumpet arm 230 and coupled to the gear housing 208 via a first fastener 220a and a first nut 222a. The fasteners extend from the first trumpet arm flange 218 of the first trumpet arm on one side of the electric drive system 200 to the flange of a second trumpet arm (not shown) on an opposite side of the electric drive system. More specifically, the fasteners extend through coupling holes, the coupling holes being located on the circumference of the flange (e.g., the first trumpet arm flange 218) of the first trumpet arm 230, to coupling holes of the gear housing 208 in lateral ribs / webs of the gear housing 208, to coupling holes in the flange of the second trumpet arm (not shown).The lateral ribs / webs of the transmission housing 208 can be inner lateral ribs / webs 224 or outer lateral ribs / webs 226 and outer lateral ribs / webs 228. The lateral ribs / webs can be arranged on the periphery of the transmission housing 208. The inner lateral ribs / webs, the outer lateral ribs / webs, and the trumpet arms (e.g., a first trumpet arm 230 and a second trumpet arm) are parallel to the axle axis. The cross-section 201 further includes the first trumpet arm 230, which is connected to the first side cover 210 and the transmission housing 208 via fasteners and nuts. The fasteners extend through coupling holes of the first trumpet arm 230, to coupling holes of the first side cover 210 and the gear housing 208 into lateral ribs / webs of the gear housing 208, to coupling holes in the flange of the second trumpet arm (not shown).

[0028] The fastening elements may, for example, include a first fastening element 220a, a second fastening element 220b, and a third fastening element 220c. The first fastening element 220a extends from the first trumpet arm flange 218 of the first trumpet arm 230, located on one side of the electric drive system, into the gear housing 208 to the flange of the second trumpet arm (not shown), located on the other side of the electric drive system, via the respective coupling holes. The second fastening element 220b and the third fastening element 220c extend from the first trumpet arm 230, located on one side of the electric drive system, via the respective coupling holes in the first side cover 210 and the gear housing 208 to the flange of the second trumpet arm (not shown), located on the other side of the electric drive system.

[0029] Two nuts are connected to each of the fasteners on each side of the respective fastener, such that one nut is connected to a fastener on one side of the electric drive system 200 and another nut (not shown) is connected to the fastener on the other side of the electric drive system 200. For example, a first nut 222a is connected to the first fastener 220a, a second nut 222b is connected to the second fastener 220b, and a third nut 222c is connected to the third fastener 220c. Although not shown, each of the first fastener 220a, the second fastener 220b, and the third fastener 220c is connected to a different nut.In this way, the fasteners are in a tensile state via the nuts, allowing the central region of the gear housing 208 to be compressed, which in turn strengthens the gear housing 208. By using fasteners extending from one side to the other of the electric drive system 200 to connect the first trumpet arm 230, the first side cover 210, the gear housing 208, a second side cover (not shown), and the second trumpet arm, forces can be transferred from the first trumpet arm to the second trumpet arm while isolating the side covers and side walls of the gear housing 208.

[0030] In embodiments where the fasteners are bolts (e.g., long bolts), a periphery of the gear housing 208 and / or the inner lateral ribs / webs and / or the outer lateral ribs / webs of the gear housing 208 may be deeply drilled and threaded near the mid-region of the inner lateral ribs / webs and / or the outer lateral ribs / webs such that the unthreaded length of the bolt is at least five times the bolt diameter. In other words, the inner lateral rib(s) and outer lateral rib(s) may be drilled and threaded such that the full drill shoulder depth of the drilled lateral rib or lateral rib is equal to or greater than five times the diameter of the lateral rib or lateral rib drill hole.For compression tubes (not shown) with collinear coupling holes, the compression tubes may also be drilled and tapped such that the total compression tube shoulder depth equals or exceeds five times the compression tube bore diameter, and the compression tubes are threaded near a mid-section of the compression tubes. The bolts may be either partially or fully threaded, and the opposing trumpet arm coupling holes may be aligned or staggered in the inner lateral ribs / webs 224 and / or outer lateral ribs / webs of the gear housing 208.

[0031] In embodiments where the fasteners are tie rods or through-bolts with a nut, the perimeter of the gearbox housing 208 and / or the outer lateral ribs / webs, the inner lateral ribs / webs, and / or the compression tubes are unthreaded in the central region of the outer lateral ribs / webs, the inner lateral ribs / webs, and the compression tubes. Additionally, the opposing trumpet arm flange holes extending from one side of the gearbox to another side of the gearbox may be coaxial (e.g., colinear) to align with a through hole in the gearbox housing 208. Tie rods and / or long through-bolts may be either partially threaded or fully threaded. Partially threaded tie rods, in which the threads are rolled on both ends, may have manufacturing and economic advantages over fully threaded rods or through-bolts.The machining of through holes in the gearbox housing 208 can also have economic advantages over drilling and tapping holes for bolts (e.g., long bolts). For example, drilling a through hole in the gearbox from one side can be accomplished in a single operation (drilling the through hole), whereas drilling and tapping the holes for the bolts requires machining two sides of the gearbox and a tool change for each hole (e.g., for the drill and the tap). Therefore, compared to drilling and tapping holes for bolts, drilling a single through hole can reduce cycle time by shortening the tool path and eliminating a tool change, and can reduce costs by eliminating the need for a thread cutter.As an alternative to a nut for the through bolts, a trumpet arm can be provided with flange threaded holes into which the threaded end of the through bolts can be screwed, thus eliminating the need for a nut.

[0032] Both bolts (e.g., long bolts), tie rods, and through bolts allow for a longer tension member (e.g., a long bolt or threaded rod) with a high preload, which increases the fatigue strength of the threaded connection and affects thread locking. Furthermore, the bolts, tie rods, and through bolts shift the thread stress away from the sides of the gearbox housing 208, reducing thread fatigue and gearbox sidewall fracture. Furthermore, the gearbox housing 208 is reinforced and ribbed because the gearbox housing 208 is under compression when either bolts, tie rods, or through bolts are incorporated into the electric drive system 200.When the central portion of the gear housing 208 is threaded for the bolts, especially for long bolts, each half of the gear housing 208 is subjected to compression, whereas for the tie rods and through bolts the entire width of the gear housing 208 is subjected to compression.

[0033] Because the gear housing 208 is under compression and thread stress at the gear housing flange is reduced or nearly eliminated, the gear housing 208 can be constructed of aluminum or another lightweight alloy instead of an iron alloy. When using tension rods instead of bolts (e.g., long bolts), the exclusion of the center threaded region of the gear housing 208 allows for a more even distribution of stresses from the trumpet arms throughout the gear housing 208, as there is no local reaction from threads located in the center region of the inner lateral ribs / webs 224 and the outer lateral ribs / webs. Additionally, the tension rods transfer reaction forces directly from the first trumpet arm to the second trumpet arm, with the gear acting as a spacer.By compressing the transmission housing 208, the bolts and tie rods can also dampen the vibrations of the electric drive system 200.

[0034] Fig. 3 shows an example of an electric drive system 300 with isolated trumpet arms, which is an embodiment of the Fig. 2A. Elements of the axle assembly 202, such as the inverter 204, the electric machine 206, the transmission housing 208, and the first side cover 210, are not shown for brevity. The electric drive system 300 may have an axle 301. The axis may be a longitudinal axis for the axle assembly 202 (e.g., the axis may be an axle axis). The axis 301 may be a rotational axis for components of the electric drive system 300 and the axle assembly 202. The axle assembly 202 includes a first trumpet arm 302 and a second trumpet arm 304, both of which are examples of a trumpet arm including a housing 306 having an arm portion 308 extending an arm length, the arm portion 308 having an outlet at a first end 310 and a flange 312 having a flat surface at a second end opposite the first end.The first trumpet arm 302 and the second trumpet arm 304 may be centered around the axis 301 such that the centerlines of the first trumpet arm 302 and the second trumpet arm 304 are coaxial with the axis 301. A mounting location of the first trumpet arm 302 may be isolated from the sides of the transmission housing and the first side cover 210. The mounting location of the second trumpet arm 304 may be isolated from the sides of the transmission housing and the second side cover (not shown).The attachment points of the first trumpet arm 302 and the second trumpet arm 304 may be isolated from the sides of the transmission housing 208, the first side cover 210 and the second side cover (not shown) via fasteners that extend around the circumference of the flange 312 of the trumpet arms and the gear housing, such that the attachment points of the trumpet arms are isolated from the side walls of the gear housing, the side walls of the first side cover and the side walls of the second side cover.

[0035] The curved extension 316 of the flange of both the first trumpet arm 302 and the second trumpet arm 304 can help create a substantially dimensionally stable enclosure in which electric axle components can be housed. For example, the flat surface of the flange 312 allows for the positioning of electric axle components, such as the electric machine 206, the transmission housing 208, the gear, and / or a differential (in Fig. 2A not shown) in the axle assembly 202 while achieving a desired strength and stiffness of the axle assembly 202 that distributes road load and reduces stress on the trumpet arms.

[0036] As further described herein, the flange 312 of the first trumpet arm 302 and the second trumpet arm 304 includes a plurality of through-holes along a perimeter of the flange 312 at the flat surface. Fasteners 314 can extend through each of the numerous through-holes and connect the first trumpet arm 302 and the second trumpet arm 304 to the gear housing 208. For example, a first fastener 314a, a second fastener 314b, a third fastener 314c, a fourth fastener 314d, a fifth fastener 314e, a sixth fastener 314f, a seventh fastener 314g, and an eighth fastener 314h may extend through a corresponding through-hole of the flange 312 to connect the first trumpet arm 302 and the second trumpet arm 304 to the gear housing 208.The first trumpet arm 302, the second trumpet arm 304, and the gear housing 208 may each be formed of metal (e.g., aluminum, steel, iron, combinations thereof, and the like), with the first trumpet arm 302 and the second trumpet arm 304 being formed of the same or a different metal than the gear housing 208.

[0037] In some embodiments, both the first trumpet arm 302 and the second trumpet arm 304 have a journal connected to the housing 306 at the output of the arm portion 308. For example, a first spindle 318 is connected to the first trumpet arm 302 and a second spindle 320 is connected to the second trumpet arm 304 at the first end 310 of each trumpet arm. A drive gear may be attached to the first journal 318 and the second journal 320, respectively, and the first axle shaft and the second axle shaft may extend through the first journal 318 and the second journal 320, respectively, to drive the rotation of the respective drive gear. The first axle shaft and the second axle shaft are the first axle shaft and the second axle shaft, which are provided up there for Fig. 2 are described.

[0038] The gear housing 208 may further include outer lateral ribs / webs 322. As shown in Fig. 3, the outer side ribs / webs 322 structurally support the clamping of the first trumpet arm 302, the second trumpet arm 304, the gear housing 208, the first side cover 210, and optionally a second side cover (not shown) to allow the aforementioned gear housing 208 to be compressed. The gear housing 208 may further include compression tubes, including a first compression tube 324a and a second compression tube 324b. The compression tubes also structurally support the clamping of the gear housing 208 and enable the gear housing 208 to be compressed. The gear housing 208 may be equipped with compression tubes in place of side ribs / webs at certain locations to facilitate assembly, reduce weight, or to also use the compression tubes as brackets and / or supports.O-rings, gaskets, or sealing material may surround the ends of the compression tubes to provide a seal and prevent modal vibrations.

[0039] Fig. Figure 4 shows a side view 400 of a trumpet arm 402, allowing a partial visualization of fasteners protruding from through holes in a flange of the trumpet arm. The trumpet arm 402 may be centered on an axis 401, so that the trumpet arm 402 may have a centerline coaxial with the axis 401. The axis 401 may be coaxial with the axis 301 of Fig. 3. The trumpet arm is an example of the first trumpet arm 302 and the second trumpet arm 304 of Fig. 3, and some elements of Fig. 3 may be omitted for brevity. The trumpet arm 402 may include through-holes arranged along the perimeter of a flat surface of the flange 408. Fasteners may extend from the through-holes to enable the fasteners to couple the electric axle component described herein. For example, the trumpet arm 402 may include a first tension rod 404a, a second tension rod 404b, a third tension rod 404c, a fourth tension rod 404d, a fifth tension rod 404e, a sixth tension rod 404f, a seventh tension rod 404g, and an eighth tension rod 404h extending from a respective through-hole along the perimeter of the flange 408. Each fastener is in a tension state via a nut to connect an electric drive system, which is an embodiment of the electric drive system described above in the Fig. 2A-3 may be the electric drive systems shown.

[0040] Accordingly, the first tension rod 404a, the second tension rod 404b, the third tension rod 404c, the fourth tension rod 404d, the fifth tension rod 404e, the sixth tension rod 404f, the seventh tension rod 404g, and the eighth tension rod 404h may be in a tension state via a first nut 406a, a second nut 406b, a third nut 406c, a fourth nut 406d, a fifth nut 406e, a sixth nut 406f, a seventh nut 406g, and an eighth nut (not shown), respectively. This ensures that the tie rods are sufficiently stretched so that they are in a state of tensile stress, preventing the stress from falling to zero or causing tension reversals during the deflection cycles of the road load, thus ensuring that the nuts do not loosen during the deflection cycles of the road load. The tie rods can be fully or partially threaded at the ends.

[0041] Various embodiments of the trumpet arm 402 may include fewer or additional through-holes, and thus fewer or additional fasteners and nuts, without departing from the scope of the present disclosure. Various embodiments of the trumpet arm may include a suitable number of through-holes, fasteners, and nuts to ensure sufficient compression of the electrical axis components.

[0042] Fig. 5 is a first cross-section 500 of an electric drive system 501 that includes an embodiment of the system described above in Fig. 2A-3. As such, the electric drive system 501 may share at least some of the structural and functional features with the electric drive systems of Fig. 2A-3, and redundant description of these overlapping features is omitted for clarity, including the electric machine 206, the transmission housing 208 and the first side cover 210, the first trumpet arm 302, and the second trumpet arm 304. The first cross section 500 allows partial visualization of a gear assembly 506 disposed within the transmission housing 208 of a transmission.

[0043] A first axle shaft 502 extends from the first trumpet arm 302 on one side of the electric drive system 501, through the first side cover 210 and partially through the transmission housing 208. A second axle shaft 504 extends from the second trumpet arm 304 on another side of the electric drive system 501 to the transmission housing 208. The first axle shaft 502 and the second axle shaft 504 are spaced apart from each other by various components of the transmission assembly 506. The first axle shaft 502 and the second axle shaft 504 may include gearing for engagement and connection with various components of the transmission assembly 506. The first and second axle shafts 502, 504 may be centered about the axis 301 such that the first and second axle shafts 502, 504 may have their respective centerlines coaxial with the axis 301.The axis 301 can be a rotation axis for the first and second axle shafts 502, 504, so that the first and second axle shafts 504 can rotate about the axis 301.

[0044] In the Fig. 9A and Fig. 9B shows a first side view 900 and a second side view 901 of the first side cover 210. The first side view 900 and the second side view 901 partially show pockets on each side of the first side cover 210. The first side cover 210 includes a first pocket 902, a second pocket 904, and a third pocket 906. Each of the pockets has a circular cross-section, and the diameters of the pockets can vary. The diameter of the third pocket 906 is the largest to accommodate a large gear, and the diameter of the first pocket 902 is the smallest of the three circular cross-sections to accommodate a small motor pinion. The third pocket 906 is located at the wider end, and the first pocket 902 is located at the narrower end of the first side cover 210.In other embodiments, the size of the pockets and the number of pockets may vary depending on the diameters of the bearings, the gears, and the number of gears and shafts to be accommodated in the pockets of the first side cover 210.

[0045] The second pocket 904 is located between the first pocket 902 and the third pocket 906. Bearings are located within the pockets to facilitate rotation of the various components of the gear assembly 506 and the various components of the gear assembly. At least one bearing may be disposed in each of the first pocket 902, the second pocket 904, and the third pocket 906. For example, the first pocket 902 may position a bearing to facilitate rotation of a third shaft (not shown) connected to the electric machine 206, the second pocket 904 may position a bearing to facilitate rotation of a fourth shaft, and the third pocket 906 may position a bearing to facilitate rotation of a fifth shaft (not shown).

[0046] Fig. 6 is a second cross-section 600 of an electric drive system 501 that includes an embodiment of the system described above in Fig. 2A-3. As such, the electric drive system 501 may share at least some of the structural and functional features with the electric drive systems of Fig. 2A-3 and 5, and redundant descriptions of these overlapping features are omitted for clarity, including the electric machine 206, the transmission housing 208 and the first side cover 210, the first trumpet arm 302 and the second trumpet arm 304. The second cross section 600 allows partial visualization of a gear assembly 506 disposed within the transmission housing 208.

[0047] The gear assembly 506 includes the third shaft (not shown) connected to the electric machine 206. The third shaft is located in the first pocket 902 of the first side cover 210 and is connected to a first bearing 602, a first gear 604, and a second bearing 606. The first bearing 602 is located at one end of the third shaft closest to the first trumpet arm 302, and the second bearing 606 is located at the opposite end of the third shaft closest to the electric machine 206. The first gear 604 is located in the space between the first bearing 602 and the second bearing 606 on the third shaft.

[0048] The gear assembly 506 also includes the fourth shaft 640. The fourth shaft 640 is disposed in the second pocket 904 of the first side cover 210 and is connected to a third bearing 608, a second gear 610, a third gear 612, and a fourth bearing 642. The third bearing 608 is located at one end of the fourth shaft 640 closest to the first trumpet arm 302, and the fourth bearing 642 is located at the opposite end of the fourth shaft 640 closest to the electric machine 206. The second gear 610 is disposed between the third bearing 608 and the third gear 612, while the third gear 612 is disposed between the second gear 610 and the fourth bearing 642. The third gear 612 meshes with the first gear 604 to transmit torque from the electric machine to the first gear 604, from the first gear 604 to the third gear 612, and from the third gear 612 to the fourth shaft 640.

[0049] The gear assembly 506 also includes a fifth shaft 514 which is Fig. 5. The fifth shaft 514 is located in the third pocket 906 of the first side cover 210 and is coupled to a fifth bearing 614, a fourth gear 616, a sixth bearing 618, a bearing plate 620, a seventh bearing 622, a first shift fork 624, a first planetary gear 626, an eighth bearing 628, a second shift fork 630, a second planetary gear 632, a ninth bearing 634, and a second side cover 516, and is connected to the first axle shaft 502 and the second axle shaft 504 within the second planetary gear 632. The fourth gear 616 is located in the space between the fifth bearing 614 and the sixth bearing 618. The fourth gear 616 meshes with the second gear 610 to transmit torque from the fourth shaft 640 to the second gear 610, from the second gear 610 to the fourth gear 616, and from the fourth gear 616 to the fifth shaft 514.

[0050] The sixth bearing 618 is located in the space between the fourth gear 616 and the bearing plate 620. The bearing plate 620 is located in the space between the sixth bearing 618 and the seventh bearing 622. The seventh bearing 622 is located between the bearing plate 620 and the first shift fork 624. The first shift fork 624 is located in the space between the seventh bearing 622 and the first gear 626 of the planetary gear. The first gear 626 is located in the space between the first shift fork 624 and the eighth bearing 628. The eighth bearing 628 is located in the space between the first gear 626 and the second shift fork 630. The second shift fork 630 is located in the space between the eighth bearing 628 and the second gear 632. The second gear 632 is located in the space between the second shift fork 630 and the ninth bearing 634. The ninth bearing 634 is located in the second side cover 516.

[0051] More specifically, the ninth bearing 634 may be disposed in a pocket (not shown) on an inner side of the second side cover. In other embodiments, the second side cover may include one or more pockets on the inner side of the second side cover and a seal for the second axle shaft. In further embodiments, the second side cover may also include coupling holes disposed on a side of the second side cover for connecting the second trumpet arm to the second side cover via fasteners. In this way, the second side cover may be connected to the transmission housing via fasteners extending through coupling holes on the side of the second side cover.

[0052] Movement of the first shift fork 624 via actuators may enable engagement of the first planetary gear 626, and movement of the second shift fork 630 via actuators may enable engagement of the second planetary gear 632. The first shift fork 624 and the second shift fork 630 may be rotating shift forks. It should be understood that the transmission assembly 506 described herein is exemplary and may vary from the example presented above without departing from the scope of the present disclosure. For example, the number of gears, the type of gears, the number of bearings, and the type of bearings may vary from the above example.

[0053] Fig. Figure 7 shows a profile view 700 of the electric drive system 501, which is an embodiment of the system described above in Fig. 2A-6. As such, the electric drive system 501 may share at least some of the structural and functional features with the electric drive systems of Fig. 2A-3, and redundant description of these overlapping features is omitted for clarity, including the electric machine 206, the gear housing 208, the first trumpet arm 302, and the second trumpet arm 304.

[0054] The electric drive system 501 includes, for example, the transmission housing 208 with inner lateral ribs / webs and outer lateral ribs / webs, compression tubes extending from one side to an opposite side of the transmission housing, and coupling holes arranged around a perimeter of the transmission housing 208 on both sides of the transmission housing. The electric drive system 501 also includes the first side cover 210, which is connected to the transmission housing 208 via fasteners extending through coupling holes arranged on the side of the first side cover 210 in areas where a protrusion or connection is arranged on an inner side of the first side cover 210.The electric drive system 501 further includes the first trumpet arm 302 coupled to the first side cover 210 via fasteners that extend through coupling holes disposed around a periphery of a flange of the first trumpet arm 302, extend through coupling holes of the first side cover 210, extend from the coupling holes of the first side cover 210 through the coupling holes of the gear housing 208 on one side, and extend through coupling holes of the gear housing 208 on the other side of the gear housing 208 to coupling holes disposed around a periphery of a flange of a second trumpet arm 304.

[0055] The profile view 700 allows partial visualization of a window 702, which provides access to the interior of the transmission housing 208 and to various types of compression tubes, which are examples of the Fig. 3. Access to the interior of the transmission housing 208 via the window 702 allows the assembly of the first shift fork 624, the second shift fork 630 and the actuators that move the shift fork to engage the gears (e.g., the planetary gears of Fig. 6) of the gear assembly 506.

[0056] The electric drive system 501 may include a first compression tube 704 and a second compression tube 706. As described above, compression tubes are used instead of inner and outer lateral ribs / webs. By using compression tubes instead of outer lateral ribs / webs, physical access to the window 702, and thus to the actuators, is possible as desired, since the compression tubes can be installed after the actuation mechanism is assembled. The compression tubes may be located inside or outside the transmission housing 208. For example, the first compression tube 704 is located inside the transmission housing 208. The second compression tube 706, however, is located outside the transmission housing 208. In other examples, both the first compression tube 704 and the second compression tube 706 may be inside.In further examples, both the first compression tube 704 and the second compression tube 706 may be external.

[0057] The use of compression tubes can provide a variety of advantages over electric drive systems that do not include compression tubes as components. For example, the integration of compression tubes into the electric drive system 501 can allow compression tubes to be made of a lighter material than the inner and outer lateral webs / ribs, and thus have a smaller cross-sectional area than the inner and outer lateral webs / ribs. Another example is that the compression tubes can be made of a different alloy than the transmission housing 208. If the electric drive system 501 includes one or more compression tubes, the length of each compression tube can vary for assembly purposes and / or to reduce modal vibrations.Additionally, a compression tube may be used as a connector, support, and / or bracket, or may be integrated with other compression tubes and / or be part of a bracket structure. In one example, an inner compression tube may be used to secure and support the shift fork mechanism within the transmission housing 208. Another example: When the two outer lateral ribs / webs 322 shown in FIG. Fig. 3 on the top of the transmission housing 208 are replaced by two compression tubes, the two compression tubes could be integrated into a plate to form a bracket acting as a "V" bracket or IROS bracket.

[0058] Fig. 8 is a third cross-section 800 of an electric drive system 501 that includes an embodiment of the system described above in Fig. 2A-7. As such, the electric drive system 501 may share at least some of the structural and functional features with the electric drive systems of Fig. 2A-7, and redundant description of these overlapping features is omitted for clarity, including the electric machine 206, the transmission housing 208, the first side cover 210, the first trumpet arm 302, and the second trumpet arm 304. A fastener 802 extends through the transmission housing 208.

[0059] The fastener 802 can be thought of as a long, thin member that is under tension when tightened by nuts as described herein. Because the fastener 802 is under tension, it can have a strong natural frequency, so that deflections due to road loading can cause the fastener 802 to vibrate uncontrollably at a frequency crossover. The fastener 802 can be configured to position a flexible member 804 along a length of the fastener 802 to prevent unwanted vibrations. In some examples, multiple flexible members 804 can be arranged along the length of the fastener 802. The fastener 802 and the cylindrical tube through which the fastener extends are both in contact with the flexible member to allow the flexible member to dampen the unwanted vibrations.For example, the flexible member 804 may be a bushing, grommet, or O-ring surrounding a machined groove along the length of the flexible member or disposed along the length of the through-bore in the transmission housing 208. Thus, the fastener 802 may be configured to position the bushing, grommet, or O-ring along the length of the fastener 802.

[0060] The technical effect of the electric axle with trumpet arms, in which the attachment point of the trumpet arms is isolated from the side walls of the side covers and the side walls of the gearbox housing, is that the deflection of the side walls of the side covers and the side walls of the gearbox housing due to road loading can be reduced, as the deflections from the trumpet arm on the gearbox housing are transmitted to the other trumpet arm via the fastening elements that extend through the side cover and gearbox housing. In this way, the skew between the bearings supported by the respective side walls can be reduced, which increases the service life of the bearings and the gear and reduces noise, vibration, and sound.

[0061] The disclosure further provides an axle comprising: a transmission housing having lateral ribs / webs, compression tubes extending from one side to an opposite side of the transmission housing, and coupling holes disposed around a periphery of the transmission housing, a first side cover coupled to the transmission housing via bolts and fasteners extending through coupling holes disposed on one side of the first side cover, a first trumpet arm coupled to the first side cover and the transmission housing via fasteners extending through coupling holes disposed around the periphery of a flange of the first trumpet arm and the transmission housing, an attachment point of the first trumpet arm being isolated from the side walls of the transmission housing and the side walls of the first side cover, and a second trumpet arm,which is connected to the gear housing via fastening elements extending through coupling holes arranged around the circumference of the flange of the second trumpet arm and the gear housing, wherein a fastening point of the second trumpet arm is isolated from the side walls of the gear housing.

[0062] In a first example of the system, a second side cover is bolted to the transmission housing, the second side cover being disposed between the transmission housing and the second trumpet arm, and the side walls of the second side cover being isolated from the second trumpet arm. In a second example of the system, optionally including the first example, lateral ribs / webs are located on a perimeter of the transmission housing, the lateral ribs / webs comprising either inner lateral ribs / webs, outer lateral ribs / webs, or both. In a third example of the system, optionally including one or both of the first and second examples, compression tubes are located on the perimeter of the transmission housing, the compression tubes being inner compression tubes, outer compression tubes, or both inner compression tubes and outer compression tubes.

[0063] In a fourth example of the system, optionally comprising one or more or each of the first to third examples, the fasteners are in a tensile state to couple the first trumpet arm to the first side cover and the transmission housing, and to couple the second trumpet arm to the transmission housing, thereby pressurizing a mid-region of the transmission housing. In a fifth example of the system, optionally comprising one or more or each of the first to fourth examples, the fasteners are wholly or partially threaded. In a sixth example of the system, optionally comprising one or more or each of the first to fifth examples, the fasteners are tie rods with nuts on each side, through bolts with a nut opposite the bolt head, or through bolts threaded into an opposite trumpet arm.

[0064] In a seventh example of the system, optionally including one or more or each of the first to sixth examples, the fasteners are bolts. In an eighth example of the system, optionally including one or more or each of the first to seventh examples, opposing coupling holes of the gear housing in the side ribs / webs can be collinear or offset. In a ninth example of the system, optionally including one or more or each of the first to eighth examples, a fastener is configured to position one or more bushings, grommets, or O-rings along a length of the fastener to dampen vibrations of the fastener.

[0065] The disclosure further provides a transmission comprising: a gear assembly having bearings for facilitating rotation of a first axle shaft, a second axle shaft, a third shaft, a fourth shaft, and a fifth shaft, shift forks and actuators that move a shift fork to engage the gears of the gear assembly, a transmission housing enclosing the transmission assembly and having inner lateral ribs / webs, outer lateral ribs / webs, inner compression tubes, outer compression tubes, a window for accessing the shift forks and actuators of the transmission assembly, and coupling holes disposed around the periphery of the transmission housing for coupling a first trumpet arm to the transmission housing via fasteners, the coupling holes disposed on the periphery of each side of the transmission housing, a first side cover having pockets on an inner side of the first side cover,a seal for the first axle shaft and coupling holes arranged on one side of the first side cover for coupling the first trumpet arm to the first side cover via fasteners, and a second side cover comprising one or more pockets on an inner side of the second side cover, a seal for the second axle shaft, and bolts for coupling the second side cover to the transmission.

[0066] In a first example of the system, the inner lateral ribs / webs, the outer lateral ribs / webs, the inner compression tubes, the outer compression tubes, the first trumpet arm, and the second trumpet arm are parallel to an axle axis. In a second example of the system, optionally including the first example, for opposed coupling holes that position bolts, the inner lateral ribs / webs, the outer lateral ribs / webs, and compression tubes are drilled and tapped such that a full drill shoulder depth of a drilled lateral rib / web is equal to or greater than five times the diameter of a drilled lateral rib / web hole, and wherein the inner lateral ribs / webs and the outer lateral ribs / webs are threaded near a mid-region of the inner lateral ribs / webs and the outer lateral ribs / webs.In a third example of the system, optionally comprising one or both of the first and second examples, the inner lateral ribs / webs, the outer lateral ribs / webs, and the compression tubes for opposing coupling holes that position tie rods and through-bolts have through-holes that extend from one side of the transmission to another side of the transmission and have no threads in the central region of the inner lateral ribs / webs, the outer lateral ribs / webs, and the compression tubes.

[0067] In a fourth example of the system, optionally comprising one or more or each of the first to third examples, the first side cover includes a first pocket that positions the third shaft, a second pocket that positions the fourth shaft, and a third pocket that positions the fifth shaft, and the second pocket is spaced between the first pocket and the third pocket. In a fifth example of the system, optionally comprising one or more or each of the first to fourth examples, the coupling holes arranged on a side of the first side cover are positioned at locations where the first side cover can be supported by a projection or connection on an inner side of the first side cover.In a sixth example of the system, optionally including one or more or each of the first to fifth examples, the projection or connection point on the inside of the first side cover is integral with the first side cover, an inner side rib(s) of the transmission housing, or an outer side rib(s) of the transmission housing. In a seventh example of the system, optionally including one or more or each of the first to sixth examples, the inner compression tubes and the outer compression tubes are used as a connection, support, bracket, or mounting bracket for additional components mounted both outside and inside the transmission housing.

[0068] The disclosure also provides a mount for an electric axle, comprising: an inverter, an electric machine, a transmission housing having inner lateral ribs / webs and outer lateral ribs / webs, compression tubes extending from one side to an opposite side of the transmission housing, and coupling holes positioned around a perimeter of the transmission housing on both sides of the transmission housing, a first side cover coupled to the transmission housing via fasteners extending through coupling holes positioned on one side of the first side cover in areas where a projection or joint is positioned on an inner side of a side cover, and a first trumpet arm connected to the first side cover via fasteners extending through coupling holes,positioned around the periphery of a flange of the first trumpet arm, extending through coupling holes of the first side cover, extending through coupling holes of the gear housing on one side to coupling holes of the gear housing on another side, extending through coupling holes positioned around the periphery of the flange of a second trumpet arm, and a second side cover connected to the gear housing via fasteners. In a first example of the system, the projection or connection between the first side cover and the gear housing is sealed with an O-ring, gasket, sealant, thrust washer, combination, and the like.

[0069] The Fig.1-9B show example configurations with relative positioning of the various components. When these elements are in direct contact with each other or are directly coupled, they may be referred to as being in direct contact or directly coupled, respectively, at least in one example. Similarly, elements shown side by side or adjacent to each other may be adjacent to each other or adjacent to each other, at least in one example. For example, components that are in surface-to-surface contact with each other may be referred to as being in surface-to-surface contact. As another example, in at least one instance, elements that are separated from each other with only a space between them and that do not have any other components may be referred to as such.In yet another example, elements depicted above / below, on opposite sides, or to the left / right of each other may be referred to as such, relative to each other. Further, in at least one example, as depicted in the figures, a topmost element or point of an element may be referred to as a "top" of the component, and a bottommost element or point of the element may be referred to as a "bottom" of the component. As used herein, the terms top / bottom, upper / lower, above / below may refer to a vertical axis of the figures and may be used to describe the positioning of elements of the figures relative to each other. Thus, in one example, elements displayed above other elements are arranged vertically above the other elements.As a further example, the shapes of the elements depicted in the figures may be referred to as such (e.g., circular, straight, flat, curved, rounded, beveled, angled, or the like). Furthermore, in at least one example, depicted elements that intersect each other may be referred to as intersecting elements or as intersecting elements. Furthermore, an element depicted inside another element or outside another element may be referred to as such.

[0070] Features described as axial may be approximately parallel to a datum axis unless otherwise specified. Features described as reverse may be approximately perpendicular to the datum axis unless otherwise specified. Features described as radial may extend around an axis, such as the datum axis, or a component or feature previously described as radial to a datum axis, or may extend radially outward unless otherwise specified.

[0071] It should be understood that the configurations and routines disclosed herein are exemplary in nature, and that these specific embodiments are not intended to be limiting, as numerous variations are possible. Unless expressly stated otherwise, the terms "first," "second," "third," etc., are not intended to denote an order, position, quantity, or importance, but are used merely to distinguish the individual elements. The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, as well as other features, functions, and / or characteristics disclosed herein.

[0072] The term “approximately” means plus or minus five percent of the range, unless otherwise stated.

[0073] The following claims particularly point out certain combinations and subcombinations that are considered novel and non-obvious. These claims may refer to "a" element or "a first" element, or the equivalent thereof. Such claims are to be construed as including the inclusion of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and subcombinations of the disclosed features, functions, elements, and / or properties may be claimed by amending the present claims or by filing new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope than the original claims, are also to be considered included within the subject matter of the present disclosure.

Claims

[1] Axis, comprising: a gear housing (109) having lateral ribs / webs (224, 226), compression tubes (704, 706) extending from one side to an opposite side of the gear housing, and coupling holes (216a, 216b) arranged around a circumference of the gear housing; a first side cover (210) coupled to the transmission housing via bolts and fasteners (314) extending through coupling holes disposed on one side of the first side cover; a first trumpet arm (302) connected to the first side cover and the gear housing via fasteners extending through coupling holes arranged around the circumference of a flange (312, 408) of the first trumpet arm and the gear housing, wherein a mounting location of the first trumpet arm is isolated from side walls of the gear housing and side walls of the first side cover; and a second trumpet arm (304) connected to the gear housing via fasteners extending through coupling holes arranged around the circumference of the flange of the second trumpet arm and the gear housing, wherein a mounting location of the second trumpet arm is isolated from the side walls of the gear housing. [2] The axle of claim 1, wherein a second side cover (516) is connected to the transmission housing (109) via bolts, the second side cover being disposed between the transmission housing and the second trumpet arm (304), and the side walls of the second side cover being insulated from the second trumpet arm. [3] The axle of any preceding claim, wherein lateral ribs / webs (224, 226) are disposed on a periphery of the gear housing (109), the lateral ribs / webs comprising either inner lateral ribs / webs (224), outer lateral ribs / webs (226), or both. [4] Axle according to one of the preceding claims, wherein compression tubes (704, 706) are arranged on a circumference of the transmission housing (109), the compression tubes being inner compression tubes, outer compression tubes or both inner compression tubes and outer compression tubes. [5] An axle according to any preceding claim, wherein the fastening elements (314) are in a tensile state to couple the first trumpet arm (302) to the first side cover (210) and the transmission housing (109), and to couple the second trumpet arm to the transmission housing, thereby compressing a central region of the transmission housing. [6] Axle according to claim 5, wherein the fastening elements (314) are wholly or partially threaded. [7] Axle according to claim 6, wherein the fastening elements (314) are tie rods with nuts on each side, through bolts with a nut opposite the bolt head, or through bolts screwed into an opposite trumpet arm. [8] Axle according to claim 6, wherein the fastening elements (314) are bolts. [9] Axle according to one of claims 5 to 8, wherein opposite coupling holes (216a) of the gear housing in the lateral ribs / webs can be arranged collinearly or offset. [10] An axle according to any preceding claim, wherein a fastener (314) is adapted to position one or more bushings, grommets or O-rings along a length of the fastener to dampen vibrations of the fastener. [11] Transmission, comprising: a transmission assembly (506) having bearings (608, 614) for facilitating rotation of a first axle shaft (502), a second axle shaft (504), a third shaft, a fourth shaft (640), and a fifth shaft (514), shift forks (624, 630), and actuators that move a shift fork to engage the gears of the transmission assembly; a transmission housing (109) enclosing the transmission assembly and including inner lateral ribs / webs (224), outer lateral ribs / webs (226), inner compression tubes, outer compression tubes, a window (702) for accessing the shift forks and actuators of the transmission assembly, and coupling holes (216a, 216b) arranged around a periphery of the transmission housing for coupling a first trumpet arm (118) to the transmission housing via fasteners (314), the coupling holes being arranged on the periphery of each side of the transmission housing; a first side cover (210) comprising pockets (902, 904, 906) on an inner side of the first side cover, a seal for the first axle shaft, and coupling holes arranged on one side of the first side cover for connecting the first trumpet arm (118) to the first side cover via fasteners; and a second side cover including one or more pockets on an inner side of the second side cover (516), a seal for the second axle shaft, and bolts for connecting the second side cover to the transmission (108). [12] The transmission of claim 11, wherein the inner lateral ribs / webs (224), the outer lateral ribs / webs (226), the inner compression tubes, the outer compression tubes, the first trumpet arm (118) and the second trumpet arm (116) are parallel to an axle axis. [13] The transmission of claim 11 or 12, wherein for opposed coupling holes (216a) positioning bolts, the inner lateral ribs / webs (224), the outer lateral ribs / webs (224) and compression tubes are drilled and tapped such that a full drill shoulder depth of a drilled lateral rib / web is equal to or greater than five times the diameter of a drilled lateral rib / web hole, and wherein the inner lateral ribs / webs and the outer lateral ribs / webs are threaded near a central region of the inner lateral ribs / webs and the outer lateral ribs / webs. [14] The transmission of claim 13, wherein the inner lateral ribs / webs (224), the outer lateral ribs / webs (226) for opposing coupling holes (216a) positioning tie rods (404a, 404b) and through bolts have through holes extending from one side of the transmission (108) to another side of the transmission and are unthreaded in the central region of the inner lateral ribs / webs, the outer lateral ribs / webs and the compression tubes. [15] The transmission of any one of claims 11 to 14, wherein the first side cover (210) includes a first pocket (902) positioning the third shaft, a second pocket (904) positioning the fourth shaft (640), and a third pocket (906) positioning the fifth shaft (514), and the second pocket is spaced between the first pocket and the third pocket.

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