Modular and adaptable multi-speed and multiple reduction axle

Abstract

Electric multi-speed and multi-reduction axle system, including: a housing with at least one cover that completely encloses the electrical multi-gear and multiple reduction axle system; an electric motor rotatably coupled to a motor shaft, wherein the motor shaft is connected to an input shaft via splined connections and a support; no more than two planetary gear sets, each planetary gear set comprising a ring gear, a sun gear, planet gears and a planet carrier; no more than two synchronizers, each synchronizer being coupled to a corresponding sun gear and being axially movable to engage the sun gear with one of the at least one cover of the housing or a planet carrier of a corresponding planetary gear set system; at least two helical gears, wherein at least one helical gear is arranged over another helical gear, enabling the at least two helical gears to mesh with each other; and a pinion which is coupled to a helical gear via a splined connection and engages with a ring gear, the ring gear being coupled to a differential.

Description

AREA OF TECHNOLOGY

[0001] The present disclosure relates to a multi-speed and multiple reduction axle with a modular and adaptable arrangement. BACKGROUND AND DETOUR

[0002] Electric and hybrid-electric vehicles utilize electric motors / generators that harness energy from electrical power sources to provide propulsion or enhanced propulsion to the vehicle. Some types of electric and hybrid vehicles have attempted to adopt electric drive axles due to their increased adaptability and modularity compared to vehicles where electric motors are spaced apart from the axles.

[0003] The inventors recognized, however, that previous electric drive axles exhibited practical disadvantages related to axle configuration and gear selection. In certain electric drivetrain designs, compromises were made regarding axle compactness, gear selectability, and structural integrity. For example, in some electric drivetrains, the available gear range was expanded at the expense of gearbox compactness. Recognizing these problems with previous electric axles, the inventor developed an electric multi-gear and multi-reduction axle system with a modular and adaptable configuration.

[0004] In one example, the electric multi-gear and multiple reduction shaft system can comprise a housing with at least one cover surrounding the electric multi-gear and multiple reduction shaft system, an electric motor rotatably coupled to a motor shaft, the motor shaft being connected to an input shaft via splined connections and a carrier, no more than two planetary gear sets, each planetary gear set comprising a ring gear, a sun gear, planet gears, and a planet carrier, no more than two synchronizers, each synchronizer being coupled to a corresponding sun gear and axially movable to engage the sun gear with one of the at least one cover of the housing or the planet carrier of a corresponding planetary gear set, and at least two helical gears, with at least one helical gear arranged over another helical gear.This allows at least two helical gears to mesh with each other, and a pinion gear coupled to a helical gear via splined connections and meshing with a ring gear, the ring gear being coupled to a differential. In this way, an electric multi-speed and multi-reduction axle system with the desired compactness can be realized.

[0005] Furthermore, various configurations of the electric multi-speed and multi-reduction axle system can be included as part of a series of electric axles. The series of electric axles can comprise a first gearbox with a first configuration, a second gearbox with a second configuration, and a third gearbox with a third configuration of the electric multi-reduction axle system. A modular and adaptable electric multi-speed and multi-reduction axle system, in which different configurations of the electric axle are part of the series, can increase the ease of assembly of the electric axle and thus of the series of electric axles, resulting in fewer assembly errors while offering a wide range of speed and reduction ratio options.

[0006] It should be noted that the foregoing summary serves to present, in simplified form, a selection of concepts that are further explained in the detailed description. It does not serve to identify essential features of the claimed subject matter, the scope of which is clearly defined by the claims following the detailed description. Furthermore, the claimed subject matter is not limited to implementations that overcome all the disadvantages mentioned above or in any part of this disclosure. BRIEF DESCRIPTION OF THE FIGURES Fig. Figure 1 shows a first example of an electric multi-gear and multiple reduction axle system of a vehicle. Fig. 2 is a representation of a force path for the various operating modes of the in Fig. 1 depicted electric multi-speed and multiple reduction axle system. Fig. Figure 3 shows a second example of an electric multi-gear and multiple reduction axle system of a vehicle. Fig. 4A and Fig. 4B are representations of the force path for the various operating modes of the in Fig. 3 illustrated electric multi-speed and multiple reduction axle systems. Fig. Figure 5 shows a third example of an electric multi-gear and multiple reduction axle system of a vehicle. Fig. Figures 6A to 6D are representations of the force path for the various operating modes of the [unclear text]. Fig. 5 illustrated electric multi-speed and multiple reduction axle systems. Fig. Figure 7 shows a flowchart of a method for operating a modular electric multi-speed and multiple reduction axle system according to the embodiments described herein. Fig. Figure 8 shows a series of electric axes with different arrangements of the electric multiple reduction axis system according to the embodiments described here. DETAILED DESCRIPTION

[0007] This document describes an electric multi-speed and multiple reduction axle system, wherein different embodiments of the electric multi-speed and multiple reduction axle system have different selectable gear ratios. The various embodiments of the electric multi-speed and multiple reduction axle system can comprise a series of electric axles with three gearboxes. The various embodiments of the electric multi-speed and multiple reduction axle system can differ in their configuration, depending on how many synchronizers and planetary gear sets are included in the electric axle system.For example, the electric multi-speed and multiple reduction axle system can be arranged with a housing configured with at least one cover and enclosing the electric multi-speed and multiple reduction axle system, an electric motor rotatably coupled to a motor shaft, an input shaft coupled to the motor shaft via splined connections, a carrier coupled to the motor shaft, at least two meshing helical gears, and a pinion coupled via splined connections to one of the helical gears and meshing with a ring gear coupled to a differential. The at least one cover is arranged on one side of the electric multi-speed and multiple reduction axle system on the housing.

[0008] The electric multi-speed and multi-reduction axle system can comprise at most two planetary gear sets and at most two synchronizers. Each planetary gear set can comprise a ring gear, a sun gear, planet gears, and a planet carrier. Each synchronizer is coupled to a corresponding sun gear and is axially movable to engage the sun gear with at least one cover of the housing or the planet carrier of a corresponding planetary gear set. In fact, one synchronizing cone of each synchronizer is coupled to the planet carrier, and another synchronizing cone of each synchronizer is coupled to the cover.For example, one embodiment of the electric multi-speed and multi-reduction axle system may include no synchronizers or planetary gear sets and achieve two reduction ratios, another embodiment may include one synchronizer and one planetary gear set and achieve three reduction ratios, and yet another embodiment may include two synchronizers and two planetary gear sets and achieve five reduction ratios.

[0009] Fig. Figure 1 shows an electric vehicle (EV) with a first example of an electric multi-gear and multiple reduction axle system. Fig. 2 is a representation of a force path for the various operating modes of the in Fig. 1 depicted electric multi-speed and multiple reduction axle system. Fig. Figure 3 shows an electric vehicle (EV) with a second example of an electric multi-gear and multiple reduction axle system. Fig. 4A and Fig. 4B are representations of the force path for the various operating modes of the in Fig. 3 exemplary illustrated electric multi-speed and multiple reduction axle systems. Fig. Figure 5 shows an electric vehicle (EV) with a third example of an electric multi-gear and multiple reduction axle system. Fig. Figures 6A to 6D are representations of the force path for the various operating modes of the [system / machine]. Fig. 5 exemplary illustrated electric multi-speed and multiple reduction axles. Fig. 7 describes a method for operating two different configurations of the modular electric multi-speed and multiple reduction axle. Fig. Figure 8 shows a series of electric axes based on different arrangements of the electric multi-speed and multiple reduction axes.

[0010] Fig. Figure 1 shows an electric multi-speed and multiple reduction axle 100 of a vehicle. The electric multi-speed and multiple reduction axle 100 generates drive power for the vehicle's propulsion. The electric multi-speed and multiple reduction axle is henceforth referred to as the electric axle 100. The electric axle 100 is an embodiment of the electric multi-speed and multiple reduction axle described herein. The electric axle 100 achieves two reduction ratios. The vehicle can be a light, medium, or heavy-duty vehicle. A fully electric vehicle can be used, in particular, due to its lower complexity and the associated lower number of potential component defects. However, embodiments of hybrid electric vehicles (HEVs), where the vehicle contains an internal combustion engine (ICE), can also be used.

[0011] The electric axle 100 does not contain a synchronizer or a planetary gear set system, so the reduction ratios for the electric axle are fixed. Various components of the electric axle 100 are enclosed circumferentially in a housing 106 of the electric axle. The housing 106 can include at least one cover, with the at least one cover being located on one side of the housing of the electric axle 100. The arrangement of the electric motor at this location allows the electric axle 100 to meet the packaging requirements for a larger number of vehicles, thereby expanding the application range of the axle. The gears described here are toothed, and the mechanical connection between the gears is achieved by the meshing of the teeth of one gear with another associated gear.

[0012] The electric axle 100 comprises an electric motor 102 on one side of the axle, which is connected to a first support 124 and a motor shaft 104. The first support 124 and a second support 118 are coupled to the housing 106 via fasteners. The electric motor 102 can include components such as a rotor and a stator, which interact electromagnetically during operation to generate driving force. In another example, the electric motor 102 can be a motor-generator configured to generate electrical energy during regeneration operation. In this way, the electric motor 102 can transmit torque via the motor shaft 104 to the motor shaft 104 and various components of the electric axle 100.

[0013] In some embodiments, the motor can be electrically coupled to one or more energy storage devices (e.g., one or more traction batteries, fuel cells, capacitors, combinations thereof, and the like) via an inverter (not shown) when the motor is designed as an alternating current (AC) motor. This inverter serves to convert direct current (DC) to alternating current (AC) and vice versa. In one application example, the electric motor 102 and the inverter can be three-phase devices, which can achieve higher efficiency compared to other device types. However, a motor and an inverter have been configured to operate with more than three phases. In other examples, the inverter can be omitted from the axis, and a DC motor can be used in the electric axis 100.

[0014] The motor shaft 104 is coupled to an input shaft 108 via splined connections at one end of the input shaft. The input shaft 108 extends from one side of the electric axis 100 to the opposite side of the electric axis. The input shaft 108 is connected to an output shaft 110 via splined connections at the other end of the input shaft on the opposite side of the electric axis 100. A first helical gear 112 is connected to the output shaft 110 via splined connections or an alternative method, such as a keyed connection, an interference fit, a one-piece component, or a welded connection. The electric motor 102, the motor shaft 104, the input shaft 108, the output shaft 110, and the first helical gear 112 are located in the upper half of the electric axis 100.The electric motor 102 and the motor shaft 104 are arranged on an opposite side of the electric axis 100 relative to the at least one cover.

[0015] The first helical gear 112, located in the upper half of the electric axle 100, meshes with a second helical gear 114, located in the lower half of the electric axle. The second helical gear 114 is connected to the pinion 116 via splines or an alternative method, such as a keyway connection. The pinion 116 is located in the lower half of the electric axle 100. The pinion 116 extends from the opposite side of the electric axle toward a central section of the electric axle, where it engages with a ring gear 120. A differential 122 is located in the central section of the electric axle 100, allowing the ring gear to be coupled to the differential 122 and thus to the vehicle's wheels.In the example shown, the differential 122 can be a compensating bevel gear differential, a spur gear differential, a planetary differential, and the like.

[0016] Additionally or alternatively, the differential may have a locking function, a slip-limiting function, and the like. Although not shown, the electric axle 100 may include bearings that facilitate the rotation of the motor shaft 104, the input shaft 108, the output shaft 110, the gears, and the like. The first helical gear 112, the second helical gear 114, and the pinion 116 are arranged on the same side of the electric axle 100 as the at least one cover, such that the first helical gear 112, the second helical gear 114, and the pinion 116 are located on one side of the electric axle 100, and the electric motor 102 and the motor shaft 104 are located on an opposite side of the electric axle 100.

[0017] The vehicle also includes a control system 170 with a control unit 172, as shown in Fig. Figure 1 shows the control unit 172. The control unit 172 can include a microcomputer with components such as a processor 174 (e.g., a microprocessor unit), input / output ports, and an electronic storage medium 176 for executable programs and calibration values ​​(e.g., a read-only memory chip, a read-only memory, a diagnostic memory, a data bus, and the like). The storage medium can be programmed with computer-readable data representing instructions that can be executed by the processor to perform the procedures and control techniques described herein, as well as other variations that are expected but not explicitly listed.

[0018] The control unit 172 can receive various signals from sensors 178, which are coupled to different areas of the vehicle and the electric axle 100. These sensors 178 can include, for example, a pedal position sensor that detects the depressing of a pedal operated by the driver, such as an accelerator and / or brake pedal; a speed sensor on the transmission output shaft; a state-of-charge (SOC) sensor for the energy storage devices; clutch position sensors; and the like. The motor speed can be determined from the power supplied to the electric machine by the inverter. An input device 180 (e.g., accelerator pedal, brake pedal, drive mode selector, combinations thereof, and the like) can also provide input signals indicating the driver's intention to control the vehicle.

[0019] After receiving the signals from the various sensors 178 from Fig. 1. The control unit 172 processes the received signals and uses various actuators 182 of vehicle components to adjust the components based on the received signals and the instructions stored in the memory of the control unit 172. For example, the control unit 172 can receive an accelerator pedal signal indicating the driver's request for stronger vehicle acceleration. In response, the control unit 172 can adjust the power output of the electric motor and increase the power delivered by the electric motor 102 to other components of the electric axle 100. The other controllable components in the vehicle can function similarly, for example, with respect to sensor signals, control commands, and actuator settings.

[0020] For reference, an axis system of 199 is used. Fig. 1 as well as in Fig. 2-6D provided. In one example, the z-axis can be a vertical axis (e.g., parallel to a gravitational axis), the x-axis can be a lateral axis (e.g., a horizontal axis), and / or the y-axis can be a longitudinal axis. In other examples, however, the axes can have other orientations.

[0021] Fig. Figure 2 shows a mechanical force path of 200, while the one in Fig. The electric multi-speed and multi-reduction axle shown in Figure 1 is in operation. The mechanical force path 200 proceeds as follows: The mechanical force is transmitted from the electric motor 102 to the motor shaft 104; from the motor shaft 104 to the input shaft 108; from the input shaft 108 to the output shaft 110; from the output shaft 110 to the first helical gear 112; from the first helical gear 112 to the second helical gear 114; from the second helical gear 114 to the pinion 116; from the pinion 116 to the ring gear 120; from the ring gear 120 to the differential 122; and from the differential 122 to the downstream components.

[0022] In this way, the electric axle 100 achieves two reduction ratios, including a first reduction ratio R1 and a second reduction ratio R2. The first reduction ratio R1 is achieved by the meshing of the first helical gear 112 and the second helical gear 114, and a second reduction ratio R2 is achieved by the meshing of the ring gear 120 and a pinion 116. The first reduction ratio R1 is the quotient of the number of teeth Z2 of the second helical gear 114 and the number of teeth Z1 of the first helical gear 112. The second reduction ratio R2 is the quotient of the number of teeth Z4 of the ring gear 120 and the number of teeth Z3 of the pinion 116. The overall reduction ratio of the electric multi-speed and multiple reduction shaft is the product of the first reduction ratio and the second reduction ratio.

[0023] Fig. Figure 3 shows an electric multi-speed and multiple reduction axle 300 of a vehicle. The electric multi-speed and multiple reduction axle 300 generates drive power for the vehicle's propulsion. The electric multi-speed and multiple reduction axle will henceforth be referred to as the electric axle 300. The electric axle 300 is an embodiment of the electric multi-speed and multiple reduction axle described here. The electric axle 300 achieves three reduction ratios. The electric axle 100 of Fig. The elements contained in section 1 may not be listed again for the sake of brevity. Similar to in Fig. 1. The vehicle can be a light, medium, or heavy-duty vehicle. A fully electric vehicle can be used, in particular, due to its lower complexity and the associated smaller number of potential components. However, hybrid electric vehicle (HEV) designs, where the vehicle includes an internal combustion engine (ICE), can also be used.

[0024] The electric axle 300 includes a synchronizer and a planetary gear set system, allowing for variable gear ratios. Similar to in Fig. 1. Various components of the electric axle 300 are enclosed circumferentially in a housing 106 of the electric axle. The housing 106 can include at least one cover, wherein the at least one cover comprises a first cover 310 located on one side of the housing of the electric axle 300. The electric axle 300 includes an electric motor 102 on one side of the electric axle, which is connected to a first support 124 and a motor shaft 104. The first support 124 and the second support 118 are coupled to the housing 106 via fasteners. The electric motor 102 is located on the same side as the second cover. The motor shaft 104 is coupled to an input shaft 108 at one end via splined connections.

[0025] The input shaft 108 extends from one side of the electrical shaft 300 to the opposite side of the electrical shaft 300, where the input shaft is coupled via splined connections at the other end of the input shaft to a first ring gear 302 of a first planetary gear set 304. The first planetary gear set 304 is located in the upper half of the electrical shaft 300 and is arranged on the same side as the first cover 310. The first planetary gear set 304 comprises the first ring gear 302, a first set of planet gears 306, a first sun gear 312, and a first planet carrier 314. The first ring gear 302 engages with the first planetary gear set 306, with the first planetary gear set being enclosed within the first planet carrier 314 of the first planetary gear set 304. The first set of planet gears 306 engages with the first sun gear 312 and the first ring gear 302 of the first planet gear set system 304.

[0026] A first synchronizer 308 is coupled to the first sun gear 312. The first synchronizer 308 is located in the upper half of the electrical shaft 300 and is arranged on the same side as the first cover 310. One synchronization cone of the first synchronizer 308 is coupled to the first planetary gear set 306, and another synchronization cone is coupled to the first cover 310 of the housing. The first synchronizer 308 can be moved axially to the right so that it can engage with the first planet carrier 314, thereby deactivating the first planetary gear set 304. The first synchronizer 308 can be moved axially to the left so that it can engage with the first cover 310, thereby activating the first planetary gear set 310.The first helical gear 112 is coupled to the first planet carrier 314 via splined connections or an alternative method, such as a keyed splined connection or a key and keyways. The electric motor 102, the motor shaft 104, the input shaft 108, the first helical gear 112, the first planetary gear set 304, including the first ring gear 302, the first set of planet gears 306, the first sun gear 312 and the first planet carrier 314, the first cover 310 and the first synchronizer 308 are located in an upper half of the electric shaft 300. The electric motor 102 and the motor shaft 104 are arranged on opposite sides of the electric shaft 300 relative to the first cover 310. The first helical gear 112, the first planetary gear set system 304, and the first synchronizer are located on the same side as the first cover 310.

[0027] The first helical gear 112 engages with the second helical gear 114, the second helical gear 114 being located in a lower half of the electric shaft 300 and the first helical gear 112 in an upper half of the electric shaft 300. The first helical gear 112 and the second helical gear 114 are located on the same side of the electric shaft 300 as the first cover 310. The second helical gear 114 is connected to the pinion 116 by splined connections or an alternative method. The pinion 116 is located in the lower half of the electric shaft 300. The pinion 116 extends from the opposite side of the electric shaft 300 toward a central region of the electric shaft, where the pinion engages with a ring gear 120.A differential 122 is arranged in the central area of ​​the electric axle 300, allowing the ring gear to be coupled to the differential 122 and thus to the vehicle's wheels. Although not shown, the electric axle 300 may include bearings that facilitate the rotation of the motor shaft 104, the input shaft 108, the gears, and the like.

[0028] The vehicle also includes a control system 170 with a control unit 172, as shown in Fig. Figure 1 shows the control unit 172. The control unit 172 can include a microcomputer with components such as a processor 174 (e.g., a microprocessor unit), input / output connectors, and an electronic storage medium 176 for executable programs and calibration values ​​(e.g., a read-only memory chip, a read-only memory, a diagnostic memory, a data bus, and the like). The storage medium can be programmed with computer-readable data representing instructions that can be executed by the processor to perform the procedures and control techniques described herein, as well as other variations that are expected but not explicitly listed. For example, the storage medium 176 can store instructions for axially adjusting the position of the first synchronizer based on signals received from sensors. Fig. Section 7 describes an operating method for the electric axis 300.

[0029] The control unit 172 can receive various signals from sensors 178, which are coupled to different areas of the vehicle and the electric axle 300. An input device 180 (e.g., accelerator pedal, brake pedal, driving mode selector, combinations thereof, and the like) can also provide input signals indicating the driver's intention to control the vehicle. After receiving the signals from the various sensors 178, Fig. 1. The control unit 172 processes the received signals and uses various actuators 182 of vehicle components to adjust the components based on the received signals and the instructions stored in the memory of the control unit 172.

[0030] Fig. Figure 4A shows the mechanical force path of 400, while the one in Fig. The electric axis 300 shown in Figure 3 is in operation. The mechanical force path 400 unfolds as follows when the first synchronizer 308 is moved axially to the right: The mechanical force is transmitted from the electric motor 102 to the motor shaft 104; from the motor shaft 104 to the input shaft 108; from the input shaft 108 to the first ring gear 302; from the first ring gear 302 to the first planet gear set 306; from the first planet gear set 306 to the first sun gear 312 or from the first planet gear set 306 to the first planet carrier 314 and from the first planet carrier to the first sun gear 312; from the first sun gear 312 to the first helical gear 112; from the first helical gear 112 to the second helical gear 114; from the second helical gear to the pinion 116; from pinion 116 to ring gear 120; from ring gear 120 to differential 122; and from differential 122 to the downstream components.

[0031] The first synchronizer moved axially to the right to engage the first sun gear 312 and the first planet carrier 314, thereby deactivating the first planetary gear set. The electric shaft achieves the first reduction ratio R1, the second reduction ratio R3, and a third reduction ratio R3. The electric shaft 300 achieves the first reduction ratio R1 through the engagement of the first sun gear 312 and the planet gears 306, the second reduction ratio R2 through the engagement of the first helical gear 112 and the second helical gear 114, and the third reduction ratio R3 through the engagement of the ring gear 120 and the pinion gear 116. The first reduction ratio R1 corresponds to the first planetary gear set ratio. Since the first planetary gear set is inactive, the first planetary gear set ratio is 1:1.The second reduction ratio R2 is a quotient of the number of teeth Z2 of the second helical gear 114 and the number of teeth Z1 of the first helical gear 112. The third reduction ratio R3 is a quotient of the number of teeth Z4 of the ring gear 120 and the number of teeth Z3 of the pinion 116. The total reduction ratio of the electric axle 300 is the product of the first reduction ratio R1, the second reduction ratio R2, and the third reduction ratio R3.

[0032] Fig. Figure 4B shows the mechanical force path 401, while the one in Fig. The electric axle 300 shown in Figure 3 is in operation. The mechanical force path 401 unfolds as follows when the first synchronizer 308 is moved axially to the left: The mechanical force is transmitted from the electric motor 102 to the motor shaft 104; from the motor shaft 104 to the input shaft 108; from the input shaft 108 to the first ring gear 302; from the first ring gear 302 to the first planet gear set 306; from the first planet gear set 306 to the first planet carrier 314; from the first planet carrier 314 to the first helical gear 112; from the first helical gear 112 to the second helical gear 114; from the second helical gear to the pinion 116; from the pinion 116 to the ring gear 120; from the ring gear 120 to the differential 122; and from differential 122 to the downstream components.

[0033] The first synchronizer moved axially to the left to engage the sun gear and the cover, thereby activating the first planetary gear set. The electric shaft 300 achieves the first reduction ratio R1, the second reduction ratio R2, and the third reduction ratio R3. The electric shaft 300 achieves the first reduction ratio R1 through the engagement of the first sun gear 312 and the first cover 310, the second reduction ratio R2 through the engagement of the first helical gear 112 and the second helical gear 114, and the third reduction ratio R3 through the engagement of the ring gear 120 and the pinion 116. The first reduction ratio R1 corresponds to the first planetary gear set ratio. Since the first planetary gear set is active, the first planetary gear set ratio is the quotient of the number of teeth of the ring gear ZR1 and the number of teeth ZS1 of the first sun gear 312 plus one.The second reduction ratio R2 is a quotient of the number of teeth Z2 of the second helical gear 114 and the number of teeth Z1 of the first helical gear 112. The third reduction ratio R3 is a quotient of the number of teeth Z4 of the ring gear 120 and the number of teeth Z3 of the pinion 116. The total reduction ratio of the electric axle 300 is the product of the first reduction ratio R1, the second reduction ratio R2, and the third reduction ratio R3.

[0034] Fig. Figure 5 shows an electric multi-speed and multiple reduction axle 500, which generates motive power for the vehicle's propulsion. The electric multi-speed and multiple reduction axle will henceforth be referred to as the electric axle 500. The electric axle 500 is an embodiment of the electric multi-speed and multiple reduction axle described herein. The electric axle 500 achieves five reduction ratios. Elements that are also found in the electric axle 300 are Fig. 3 as well as in the electric axle 100 from Fig. Items already included in item 1 are not listed again for the sake of brevity. Similar to... Fig. 1 and Fig. 3. The vehicle can be a light, medium, or heavy-duty vehicle. A fully electric vehicle can be used, in particular, due to its lower complexity and the associated smaller number of potential components. However, hybrid electric vehicle (HEV) designs, where the vehicle includes an internal combustion engine (ICE), can also be used.

[0035] The electric axle 500 comprises two synchronizers and two planetary gear sets, allowing for variable gear ratios. Similar to... Fig. 1 and Fig. Three components of the electric axis 500 are enclosed circumferentially within a housing 524 of the electric axis. The housing 524 includes at least one cover. Therefore, the housing 524 comprises a first cover 533, located on one side of the electric axis 500, and a second cover 513, located on the opposite side of the electric axis. The electric axis 500 includes an electric motor 502 on one side of the electric axis, which is connected to a first support 550 and a motor shaft 504. The first support 550 and a second support 544 are coupled to the housing 524. The motor shaft 504 is coupled to an input shaft 506 via splined connections at one end of the input shaft. The input shaft 506 extends from one side of the electric axis 500 to the central region of the electric axis.The third helical gear 508 is coupled to the input shaft 506 via splined connections or an alternative method, such as a keyed spline connection. The electric motor 502, the motor shaft 504, the input shaft 506, and the third helical gear 508 are located in a lower half of the electric shaft 500 and on the same side of the electric shaft 500 as the second cover 513.

[0036] Furthermore, the first helical gear 508 engages with the external splined teeth of a second ring gear 516 of a second planetary gear set 518. The second planetary gear set 518 comprises the second ring gear 516, a second planetary gear set 520, a second sun gear 512, and a second planet carrier 510. The second ring gear 518 of the second planetary gear set 516 is equipped with both external and internal splined teeth. The internal splined teeth of the second ring gear 516 engage with a second planetary gear set 520. The second planetary gear set 520 is enclosed in the second planet carrier 510 and engages with the second sun gear 512 and the second ring gear 516 of the second planetary gear set 518. A second synchronizer 514 is coupled to the second sun gear 512.The second planetary gear set system 518 and the second synchronizer 514 are located in the upper half of the electric shaft 500 and are arranged on the same side of the electric shaft 500 as the second cover 513.

[0037] A synchronizing cone of the second synchronizer 514 is coupled to the second planet carrier 510, and another synchronizing cone of the second synchronizer is coupled to the second cover 513, thereby enabling the second planetary gear set 518 to be either inactive or active. More precisely, the second synchronizer 514 can be moved axially to the left to engage the second synchronizer with the second planet carrier 510 and deactivate the second planetary gear set 518, or to the right to engage the second synchronizer with the second cover 513 and activate the second planetary gear set.

[0038] The second planet carrier 510 engages with the intermediate shaft 522 via splined teeth at one end. The intermediate shaft 522 extends from one side to the opposite side of the electrical axis, where it is coupled to a first ring gear 530 via splined teeth at its other end. The first ring gear 530 engages with the first planet gear set 526 of a first planet gear set system 528. The first planet gear set system 528 comprises the first ring gear 530, a first planet gear set 526, a first sun gear 532, and a first planet carrier 536. The first ring gear 530 has only internal splined teeth. The first planet gear set 526 of the first planet gear set system 528 is enclosed within the first planet carrier 536. The first planetary gear set 526 engages with the first sun gear 532 and the first ring gear 530.

[0039] A first synchronizer 534 is coupled to the first sun gear 532. The first synchronizer 534 and the first planetary gear set 528 are located in the upper half of the electrical shaft 500 and are arranged on the same side as the first cover 533. One synchronization cone of the first synchronizer 534 is coupled to the first planet carrier 536, and another synchronization cone is coupled to the first cover 533 of the housing. The first synchronizer 534 can be moved axially to the left so that it engages with the first cover 533 to activate the first planetary gear set 528, or to the right so that it engages with the first planet carrier 536 to deactivate the first planetary gear set.

[0040] A first helical gear 538 is coupled to the first planet carrier 536 via splined connections or an alternative method. The first gear 538 is rotaryally coupled to a second helical gear 542. The first helical gear 538 is located in the upper half of the electrical shaft 500, and the second helical gear 542 is located in the lower half of the electrical shaft. The first helical gear 538 and the second helical gear 542 are located on the same side of the electrical shaft 500 as the first cover 533. The second helical gear 542 is connected to the pinion 540 via splined connections or an alternative method. The pinion 540 extends from the opposite side of the electric axis towards a central area of ​​the electric axis, where the pinion engages with a ring gear 546.The pinion 540 is located in the lower half of the electric axle. A differential 548 is located in the middle section of the electric axle 500, allowing the ring gear 546 to be coupled to the differential and thus to the vehicle's wheels. Although not shown, the electric axle 500 may include bearings that facilitate the rotation of the motor shaft 504, the input shaft 506, the intermediate shaft 522, the gears, and the like.

[0041] The vehicle also includes a control system 170 with a control unit 172, as shown in Fig. Figure 1 shows the control unit 172. The control unit 172 can include a microcomputer with components such as a processor 174 (e.g., a microprocessor unit), input / output connectors, and an electronic storage medium 176 for executable programs and calibration values ​​(e.g., a read-only memory chip, a read-only memory, a diagnostic memory, a data bus, and the like). The storage medium can be programmed with computer-readable data representing instructions that can be executed by the processor to perform the procedures and control techniques described herein, as well as other variations that are expected but not explicitly listed. For example, the storage medium 176 can store instructions for axially adjusting the position of the first and second synchronizers based on signals received from sensors. Fig. Section 7 describes an operating method for the electric axis 500.

[0042] The control unit 172 can receive various signals from sensors 178, which are coupled to different areas of the vehicle and the electric axle 500. An input device 180 (e.g., accelerator pedal, brake pedal, driving mode selector, combinations thereof, and the like) can also provide input signals indicating the driver's intention to control the vehicle. After receiving the signals from the various sensors 178, Fig. 1. The control unit 172 processes the received signals and uses various actuators 182 of vehicle components to adjust the components based on the received signals and the instructions stored in the memory of the control unit 172.

[0043] Fig. Figure 6A shows a mechanical force path of 600, while the one in Fig. Figure 5 shows the electric multi-speed and multi-reduction axle in operation. The mechanical force path 400 unfolds as follows when the second synchronizer 514 is moved axially to the right and the first synchronizer 534 is moved axially to the left: The mechanical force is transmitted from the electric motor 502 to the motor shaft 504; from the motor shaft 504 to the input shaft 506; from the input shaft 506 to the third helical gear 508; from the third helical gear 508 to the second ring gear 516; from the second ring gear 516 to the second planetary gear set 520; from the second planetary gear set 520 to the second sun gear 512; from the second sun gear 512 to the intermediate shaft 522; from the intermediate shaft 522 to the first ring gear 530; from the first ring gear 530 to the first planetary gear set 526; from the first planet gear set 526 to the first planet carrier 536 and to the first sun gear 532; from the first planet carrier 536 to the first sun gear 532;from the first sun gear 532 to the first helical gear 538; from the first helical gear 538 to the second helical gear 542; from the second helical gear 542 to the pinion 540; from the pinion 540 to the ring gear 546; from the ring gear 546 to the differential 548; and from the differential 548 to the downstream components.

[0044] The second synchronizer 514 is moved axially to the right (e.g., towards the second cover 513) to engage the second sun gear 512 and the second cover 513, thereby activating the second planetary gear set 518. The first synchronizer 534 is moved axially to the left (e.g., towards the first cover 533) to engage the first sun gear 532 and the first cover 533, thereby activating the second planetary gear set 528.The electric axle 500 achieves a first reduction ratio R1 through the engagement of the third helical gear 508 and the external serration of the second ring gear 516, a second reduction ratio R2 through the engagement of the second sun gear 512 and the second cover 513, a third reduction ratio R3 through the engagement of the first sun gear 532 and the first cover 533, a fourth reduction ratio R4 through the engagement of the first helical gear 538 and the second helical gear 542, and a fifth reduction ratio R5 through the engagement of the ring gear 546 and the pinion gear 540.

[0045] The first reduction ratio R1 is the quotient of the number of teeth Z1 of the third helical gear 508 and the number of external splines Z2 of the second ring gear 516. The second reduction ratio R2 corresponds to the first planetary gear set ratio. Since the second planetary gear set 518 is active, the second planetary gear set is the quotient of the number of internal splines ZR1 of the second ring gear 516 and the number of teeth ZS1 of the second sun gear 512 plus one. The third reduction ratio R3 corresponds to the first planetary gear set ratio. Since the first planetary gear set 528 is active, the first planetary gear set ratio is the quotient of the number of internal splines ZR2 of the first ring gear and the number of teeth ZS2 of the first sun gear 532 plus one.The fourth reduction ratio R4 is the quotient of the number of teeth Z4 of the second helical gear 542 and the number of teeth Z3 of the first helical gear 538. The fifth reduction ratio R5 is the quotient of the number of teeth Z6 of the ring gear 546 and the number of teeth Z5 of the pinion 540. The total reduction ratio of the electric axle 500 is the product of the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4, and the fifth reduction ratio R5.

[0046] Fig. Figure 6B shows a mechanical force path 601, while the one in Fig. Figure 5 shows the electric multi-speed and multi-reduction axle in operation. The mechanical force path 400 unfolds as follows when the second synchronizer 514 and the first synchronizer 534 are moved axially to the right: The mechanical force is transmitted from the electric motor 502 to the motor shaft 504; from the motor shaft 504 to the input shaft 506; from the input shaft 506 to the third helical gear 508; from the third helical gear 508 to the second ring gear 516; from the second ring gear 516 to the first planetary gear set 520; from the first planetary gear set 520 to the second sun gear 512; from the second sun gear 512 to the intermediate shaft 522; from the intermediate shaft 522 to the first ring gear 530; from the first ring gear 530 to the first planetary gear set 526; from the first planetary gear set 526 to the first sun gear 532 and to the first planet carrier 536; from the first planet carrier 536 to the first sun gear 532;from the first sun gear 532 to the first helical gear 538; from the first helical gear 538 to the second helical gear 542; from the second helical gear 542 to the pinion 540; from the pinion 540 to the ring gear 546; from the ring gear 546 to the differential 548; and from the differential 548 to the downstream components.

[0047] The second synchronizer 514 is moved axially to the right (e.g., towards the second cover 513) to engage the second sun gear 512 and the second cover 513, thereby activating the second planetary gear set 518. The first synchronizer 534 is moved axially to the right (e.g., towards the first planet carrier 536) to engage the first sun gear 532 and the first planet carrier 536, thereby deactivating the second planetary gear set 528. The electric shaft 500 reaches the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4, and the fifth reduction ratio R5.The electric axle 500 achieves a first reduction ratio R1 through the engagement of the third helical gear 508 and the external serration of the second ring gear 516, a second reduction ratio R2 through the engagement of the second sun gear 512 and the second cover 513, a third reduction ratio R3 through the engagement of the first sun gear 532 and the first planet carrier 536, a fourth reduction ratio R4 through the engagement of the first helical gear 538 and the second helical gear 542, and a fifth reduction ratio R5 through the engagement of the ring gear 546 and the pinion 540.

[0048] The first reduction ratio R1 is the quotient of the number of teeth Z1 of the third helical gear 508 and the number of external splines Z2 of the second ring gear 516. The second reduction ratio R2 corresponds to the first planetary gear set ratio. Since the second planetary gear set 518 is active, the second planetary gear set is the quotient of the number of internal splines ZR1 of the second ring gear 516 and the number of teeth ZS1 of the second sun gear 512 plus one. The third reduction ratio R3 corresponds to the first planetary gear set ratio. Since the first planetary gear set 528 is inactive, the first planetary gear set ratio is 1:1. The fourth reduction ratio R4 is the quotient of the number of teeth Z4 of the second helical gear 542 and the number of teeth Z3 of the first helical gear 538.The fifth reduction ratio R5 is a quotient of the number of teeth Z6 of the ring gear 546 and the number of teeth Z5 of the pinion 540. The total reduction of the electric axle 500 is the product of the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4 and the fifth reduction ratio R5.

[0049] Fig. Figure 6C shows a mechanical force path 603, while the one in Fig. Figure 5 shows the electric multi-speed and multi-reduction axle in operation. The mechanical force path 400 unfolds as follows when the second synchronizer 514 and the first synchronizer 534 are moved axially to the left: The mechanical force is transmitted from the electric motor 502 to the motor shaft 504; from the motor shaft 504 to the input shaft 506; from the input shaft 506 to the third helical gear 508; from the third helical gear 508 to the second ring gear 516; from the second ring gear 516 to the second planetary gear set 520; from the second planetary gear set 520 to the second planet carrier 510 and to the second sun gear 512; from the second sun gear 512 to the second planet carrier 510; from the second planet carrier 510 to the intermediate shaft 522; from the intermediate shaft 522 to the first ring gear 530; from the first ring gear 530 to the first planetary gear set 526;from the first planetary gear set 526 to the first planet carrier 536 and to the first sun gear 532; from the first planet carrier 536 to the first sun gear 532; from the first sun gear 532 to the first helical gear 538; from the first helical gear 538 to the second helical gear 542; from the second helical gear 542 to the pinion 540; from the pinion 540 to the ring gear 546; from the ring gear 546 to the differential 548; and from the differential 548 to the downstream components.

[0050] The second synchronizer 514 is moved axially to the left (e.g., towards the second planet carrier 510) to engage the second sun gear 512 and the second planet carrier 510, thereby deactivating the second planetary gear set 518. The first synchronizer 534 is moved axially to the left (e.g., towards the first cover 533) to engage the first sun gear 532 and the first cover 533, thereby activating the second planetary gear set 528. The electric shaft 500 reaches the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4, and the fifth reduction ratio R5.The electric axle 500 achieves a first reduction ratio R1 through the engagement of the third helical gear 508 and the external serration of the second ring gear 516, a second reduction ratio R2 through the engagement of the second sun gear 512 and the second planet carrier 510, a third reduction ratio R3 through the engagement of the first sun gear 532 and the first planet carrier 536, a fourth reduction ratio R4 through the engagement of the first helical gear 538 and the second helical gear 542, and a fifth reduction ratio R5 through the engagement of the ring gear 546 and the pinion 540.

[0051] The first reduction ratio R1 is the quotient of the number of teeth Z1 of the third helical gear 508 and the number of external splines Z2 of the second ring gear 516. The second reduction ratio R2 corresponds to the first planetary gear set ratio. Since the second planetary gear set 518 is inactive, the second planetary gear set ratio is 1:1. The third reduction ratio R3 corresponds to the first planetary gear set ratio. Since the first planetary gear set 528 is active, the first planetary gear set ratio is the quotient of the number of internal splines ZR2 of the first ring gear 530 and the number of teeth ZS2 of the first sun gear 532 plus one. The fourth reduction ratio R4 is the quotient of the number of teeth Z4 of the second helical gear 542 and the number of teeth Z3 of the first helical gear 538.The fifth reduction ratio R5 is a quotient of the number of teeth Z6 of the ring gear 546 and the number of teeth Z5 of the pinion 540. The total reduction of the electric axle 500 is the product of the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4 and the fifth reduction ratio R5.

[0052] Fig. Figure 6D shows a mechanical force path 605, while the one in Fig. Figure 5 shows the electric multi-speed and multi-reduction axle in operation. The mechanical force path 400 unfolds as follows when the second synchronizer 514 is moved axially to the left and the first synchronizer 534 is moved axially to the right: The mechanical force is transmitted from the electric motor 502 to the motor shaft 504; from the motor shaft 504 to the input shaft 506; from the input shaft 506 to the third helical gear 508; from the third helical gear 508 to the second ring gear 516; from the second ring gear 516 to the second planetary gear set 520; from the second planetary gear set 520 to the second planet carrier 510 and to the second sun gear 512; from the second sun gear 512 to the second planet carrier 510; from the second planet carrier 510 to the intermediate shaft 522; from the intermediate shaft 522 to the first ring gear 530; from the first ring gear 530 to the first planetary gear set 526;from the first planetary gear set 526 to the first planet carrier 536; from the first planet carrier 536 to the first helical gear 538; from the first helical gear 538 to the second helical gear 542; from the second helical gear 542 to the pinion 540; from the pinion 540 to the ring gear 546; from the ring gear 546 to the differential 548; and from the differential 548 to the downstream components.

[0053] The second synchronizer 514 is moved axially to the left (e.g., towards the second planet carrier 510) to engage the second sun gear 512 and the second planet carrier 510, thereby deactivating the second planet gear set 518. The first synchronizer is moved axially to the right (e.g., towards the first planet carrier 536) to engage the first sun gear 532 and the first planet carrier 536, thereby deactivating the second planet gear set 528.The electric axle 500 achieves a first reduction ratio R1 through the engagement of the third helical gear 508 and the external serration of the second ring gear 516, a second reduction ratio R2 through the engagement of the second sun gear 512 and the second planet carrier 510, a third reduction ratio R3 through the engagement of the first sun gear 532 and the first planet carrier 536, a fourth reduction ratio R4 through the engagement of the first helical gear 538 and the second helical gear 542, and a fifth reduction ratio R5 through the engagement of the ring gear 546 and the pinion 540.

[0054] The first reduction ratio R1 is a quotient of the number of teeth Z1 of the third helical gear 508 and the number of external serrations Z2 of the second ring gear 516. The second reduction ratio R2 corresponds to the first planetary gear set ratio. Since the second planetary gear set 518 is inactive, the second planetary gear set ratio is 1:1. The third reduction ratio R3 corresponds to the first planetary gear set ratio. Since the first planetary gear set 528 is inactive, the first planetary gear set ratio is 1:1. The fourth reduction ratio R4 is a quotient of the number of teeth Z4 of the second helical gear 542 and the number of teeth Z3 of the first helical gear 538. The fifth reduction ratio R5 is a quotient of the number of teeth Z6 of the ring gear 546 and the number of teeth Z5 of the pinion 540.The overall reduction ratio of the electric axle 500 is the product of the first reduction ratio R1, the second reduction ratio R2, the third reduction ratio R3, the fourth reduction ratio R4 and the fifth reduction ratio R5.

[0055] It goes without saying that the ones in the Fig. 1, Fig. 3 and Fig. The five illustrated electric axle systems are examples, and deviations from these exemplary systems do not deviate from the scope of this disclosure. For example, the electric axle systems may comprise fewer or more components, as long as each of the electric axle systems is feasible based on the adaptability of an electric axle system.

[0056] Fig. Figure 7 shows an example procedure 700 for the operation of an electric axle system, such as the one mentioned above in relation to Fig. 3 and Fig. 5 described electric multi-speed and multiple reduction axles. Procedure 700 can be executed by a control unit and stored as instructions in a memory. The instructions for executing procedure 700 can be executed by the control unit in conjunction with signals received from vehicle sensors, such as those described above with reference to Fig. 1 are described. The control unit can use actuators of the system (for example, the synchronizers) to adjust the operation of the system according to the procedure described below.

[0057] In the case of 702, method 700 involves the axial movement of a corresponding synchronizer. To achieve different reduction ratios, the respective synchronizer can be moved axially. The respective synchronizer can be moved axially toward a planet carrier of a respective planetary gear set system or toward a housing cover via an actuator when a sensor receives signals indicating that axial movement of the respective synchronizer is required. Moving the synchronizer axially toward the planet carrier achieves a different reduction ratio than moving the synchronizer toward the housing cover. The direction in which the respective synchronizer changes is based on the configuration of the electric multi-speed and multi-reduction shaft.

[0058] For example, the respective synchronizer is on the left side of the [unclear text] in the Fig. 3 and Fig. The electrical axle system is arranged as shown in Figure 5. Accordingly, the housing cover is located to the left of the synchronizer, and the planet carrier of the respective planetary gear set system is located to the right of the synchronizer. Therefore, the respective synchronizer is moved axially to the left towards the cover and axially to the right towards the planet carrier, as required. In another example, the respective synchronizer is located on the right side of the housing shown in Figure 5. Fig. The electrical axle system is arranged as shown in section 5. Accordingly, the housing cover is located to the right of the synchronizer, and the planet carrier of the respective planetary gear set system is located to the left of the synchronizer. Therefore, the respective synchronizer is moved axially to the right towards the cover and axially to the left towards the planet carrier, as required.

[0059] In instrument 704, method 700 comprises engaging a sun gear of the respective planetary gear set system with one of the planet carriers or the cover to achieve different reduction ratios of the planetary gear set system. The respective planetary gear set system is deactivated by moving the respective synchronizer axially toward the planet carrier and engaging the sun gear and the planet carrier of the respective planetary gear set system to achieve one reduction ratio. Conversely, the respective planetary gear set system is activated by moving the respective synchronizer axially toward the cover and engaging the sun gear and the cover to achieve a different reduction ratio. The reduction ratio achieved with the planetary gear set system active differs from the reduction ratio achieved with the planetary gear set system inactive.

[0060] In an example of an electric axle system (e.g. Fig. 3 and Fig. 5), in which a first planetary gear set is located on the left side of the housing of the electric axle system, the first planetary gear set is deactivated when a first synchronizer is moved axially to the right to engage a first sun gear and a first planet carrier of the first planetary gear set, and activated when the first synchronizer is moved axially to the left to engage the first sun gear and a first cover of the housing. In another example of the in Fig. In the electrical axle system shown in Figure 5, in which a second planetary gear set is located on the right side of the electrical axle system housing, the second planetary gear set is deactivated when a second synchronizer is moved axially to the left to engage a second sun gear and a second planet carrier, and activated when the second synchronizer is moved axially to the right to engage the second sun gear and a second cover. Method 700 then terminates.

[0061] Fig. Figure 8 shows a series of electric axes 800 based on various arrangements of the electric multi-speed and multiple reduction axe. The electric multi-speed and multiple reduction axe can be embodiments of the one described in the Fig. 1, Fig. 3 and Fig. The electric axles shown in Figure 5 are 100, 300, and 500. In general, the electric multi-speed and multi-reduction axle may comprise a housing with at least one cover surrounding the electric multi-speed and multi-reduction axle system, an electric motor rotatably coupled to a motor shaft, the motor shaft being connected to an input shaft via splined connections and a carrier, no more than two planetary gear sets, each planetary gear set comprising a ring gear, a sun gear, planet gears, and a planet carrier, no more than two synchronizers, each synchronizer being coupled to a corresponding sun gear and axially movable to engage the sun gear with one of the at least one cover of the housing or planet carrier of a corresponding planetary gear set, and at least two helical gears.wherein at least one helical gear is arranged over another helical gear, whereby the at least two helical gears can be brought into mesh with each other, and a pinion which is coupled to a helical gear via splined connections and is in mesh with a ring gear, wherein the ring gear is coupled to a differential.

[0062] The series of electric axles 800 can comprise a first transmission 801 with a first arrangement, a second transmission 803 with a second arrangement, and a third transmission 805 with a third arrangement of the electric multi-speed and multi-reduction axle. Each of the first transmissions 801, second transmission 803, and third transmission 805 comprises a housing that includes at least one first cover 817, which is arranged on one side of the respective transmission and surrounds the respective transmission, the arrangement of the first cover being the same for each of the first transmissions, second transmissions, and third transmissions. The first transmission 801, the second transmission 803, and the third transmission 805 further comprise an electric motor 802, which is rotatably coupled to a motor shaft 804, the motor shaft being coupled to an input shaft 806 via splined connections and a carrier.The electric motor 802 is arranged on the opposite side of the respective gearbox relative to the first cover 817.

[0063] The first gearbox 801, the second gearbox 803, and the third gearbox 805 further comprise a pair of helical gears arranged on the same side of the respective gearbox as the first cover 817. The pair of helical gears comprises a first helical gear 812, arranged in an upper half, and a second helical gear 814, arranged in a lower half of the respective gearbox, meshing with each other, and neither the first helical gear nor the second helical gear being coupled to the input shaft 806. The first gearbox 801, the second gearbox 803, and the third gearbox 805 further comprise a pinion 816, arranged on the same side of the respective gearbox as the first cover 817 and coupled to the second helical gear 814 via splined connections.The pinion 816 engages with a ring gear 820, the ring gear being coupled to a differential 822 in a central area of ​​the respective transmission.

[0064] The first gearbox 801, the second gearbox 803, and the third gearbox 805 differ from each other in the number of covers, the number of planetary gear sets, the number of synchronizers, and the number of helical gears contained in the respective gearboxes. Furthermore, the first gearbox 801, the second gearbox 803, and the third gearbox 805 differ from each other due to components coupled with the overlapping components contained in each gearbox.

[0065] More precisely, the first gearbox 801 and the second gearbox 803 comprise a first housing 830, which is identical for both gearboxes, although the arrangement of the first and second gearboxes differs. The third gearbox 805 has a different housing because the motor is arranged differently (e.g., in the lower part of the third gearbox), and the third gearbox is equipped with an additional planetary gear set, an additional synchronizer, and a cover compared to the first gearbox 801 and the second gearbox 803.

[0066] Accordingly, the electric motor 802 is arranged in the upper half of the first gearbox 801 and the second gearbox 803. In contrast to the second gearbox 803 and the third gearbox 805, the first gearbox 801 further comprises the input shaft 806, which is coupled to an output shaft 808, and the first helical gear 812, which is coupled to the output shaft via splines on the same side of the respective gearbox as the first cover 817. The input shaft 806 of the second gearbox 803 and the third gearbox 805 is not coupled to the output shaft 808. Likewise, the first helical gear 812 of the second gearbox 803 and the third gearbox 805 is not coupled to the output shaft via splines on the same side of the respective gearbox as the first cover.Rather, the input shaft 806 and the first helical gear 812 are coupled to various components in the second gearbox 803 and the third gearbox 805. Neither the second gearbox 803 nor the third gearbox 805 contains the output shaft 808 in their respective configurations.

[0067] In contrast to the first gearbox 801, the second gearbox 803 and the third gearbox 805 additionally include a first planetary gear set 810, comprising a first ring gear, a first sun gear, a first planet carrier, and a first planetary gear set, as well as a first synchronizer 818. Compared to the second gearbox 803 and the third gearbox 805, the first gearbox 801 does not include any planetary gear set systems or a synchronizer.

[0068] The first planetary gear set 810 is located in the upper half and on the same side as the first cover 817 of the respective gearbox. The first synchronizer 818 is located in an upper half and is arranged on the same side as the first cover 817 of the respective gearbox and is coupled to the first sun gear of the first planetary gear set 810. The first helical gear 812 is coupled to the first planet carrier via splines in both the second gearbox 803 and the third gearbox 805. Therefore, the first helical gear 812 is not coupled to the first planet carrier via splines in the first gearbox 801, since the first gearbox does not contain any planetary gear sets. In contrast to the first gearbox 801 and the third gearbox 805, the second gearbox 803 additionally includes the input shaft 806, which is coupled to the first ring gear of the first planetary gear set 810 via splines.The input shaft 806 is not connected to the first ring gear via splined connections in either the first gearbox 801 or the third gearbox 805.

[0069] In contrast to the first gearbox 801 and the second gearbox 803, the third gearbox 805 includes an input shaft 806 coupled to a third helical gear 824 located on the opposite side of the third gearbox relative to the first cover 817 and situated in the lower half of the third gearbox. Neither the first gearbox 801 nor the second gearbox 803 includes the third helical gear 824. Thus, the first gearbox 801 and the second gearbox 803 are configured such that the input shaft 806 is not coupled to the third helical gear 824, which is located on the opposite side of the respective gearbox relative to the first cover 817 and is not situated in a lower half of the respective gearbox.

[0070] The third gearbox 805 further comprises a second housing 832, which includes the first cover 817 and a second cover 827, which is arranged on a different side of the third gearbox relative to the first cover. The third gearbox 805 also includes the electric motor 802, which is located in the lower half of the third gearbox, and the third helical gear, which meshes with the external splines of a second ring gear of a second planetary gear set 826. Neither the first gearbox 801 nor the second gearbox 803 includes the second cover 827, with the electric motor 802 located in the lower half of the respective gearbox, or the second planetary gear set 826.Therefore, the first gearbox 801 and the second gearbox 803 are configured such that the third helical gear 824 does not engage with the external serrations of the second ring gear of the second planetary gear set system 826, since neither the first gearbox nor the second gearbox is configured with the third helical gear 824 and the second planetary gear set system 826.

[0071] The second planetary gear set 826 is located in the upper half and on the same side as the second cover 827 of the third gear set. The second planetary gear set 826 comprises the second ring gear, a second planet gear set, a second planet carrier, and a second sun gear. The third gear set 805 further comprises a second synchronizer 828, which is coupled to the second sun gear of the second planetary gear set 826, the second planet carrier of the second planetary gear set engaging with an intermediate shaft 834 via splined connections, and the intermediate shaft 834 being coupled via splined connections to the first ring gear of the first planetary gear set 810.

[0072] Neither the first gearbox 801 nor the second gearbox 803 includes the second synchronizer 828 or the intermediate shaft 834. Accordingly, the first gearbox 801 and the second gearbox 803 are configured such that the second synchronizer 828 is not coupled to the second sun gear of the second planetary gear set 826, the second planet carrier of the second planetary gear set is not engaged with the intermediate shaft 834 via splined connections, and the intermediate shaft 834 is not coupled to the first ring gear of the first planetary gear set 810, since the first gearbox and the second gearbox are not configured with the second synchronizer 828 and the intermediate shaft 834, and the first gearbox is not configured with the first planetary gear set 810.

[0073] The technical effect of an electric multi-speed and multiple reduction axle system and an adaptable configuration that changes based on a number of synchronizers and a number of synchronizers integrated into the electric multi-speed and multiple reduction axle system is that multiple speeds and reduction capabilities are possible while achieving a required level of compactness of the electric axle system.

[0074] The disclosure also provides support for an electric multi-speed and multiple reduction axle system comprising: a housing with at least one cover surrounding the electric multi-speed and multiple reduction axle system; an electric motor rotatably coupled to a motor shaft, the motor shaft being connected to an input shaft via splined connections and a carrier; not more than two planetary gear sets, each planetary gear set comprising a ring gear, a sun gear, planet gears, and a planet carrier; not more than two synchronizers, each synchronizer being coupled to a corresponding sun gear and axially movable to engage the sun gear with one of the at least one cover of the housing or the planet carrier of a corresponding planetary gear set; and at least two helical gears.wherein at least one helical gear is arranged over another helical gear, whereby the at least two helical gears can be brought into mesh with each other, and a pinion which is coupled to a helical gear via splined connections and is in mesh with a ring gear, wherein the ring gear is coupled to a differential.

[0075] In a first example of the system, the at least one cover comprises a first cover located on one side of the electric multi-speed and multiple reduction axle system, wherein the first cover is located in an upper half of the electric multi-speed and multiple reduction axle system.In a second example of the system, which optionally includes the first example, the at least two helical gears comprise a first helical gear and a second helical gear meshing with the first helical gear and coupled to the pinion, wherein the first helical gear is located on the same side as the first cover in the upper half of the electric multi-speed and multiple reduction axle system, and the second helical gear is located on the same side as the first cover and in a lower half of the electric multi-speed and multiple reduction axle system.In a third example of the system, which optionally includes one or both of the first and second examples, the electric motor, motor shaft and one end of the input shaft are located on an opposite side of the electric multi-speed and multiple reduction axle system relative to the first cover and in the upper half of the electric multi-speed and multiple reduction axle system.

[0076] In a fourth example of the system, which optionally includes one or more or all of the first to third examples, the system with no more than two planetary gear sets comprises a first planetary gear set located on the same side as the first cover and in the upper half of the electrical multi-gear and multiple reduction axle system, comprising a first sun gear, a first planetary gear set, a first ring gear, and a first planet carrier, wherein the no more than two synchronizers comprise a first synchronizer located on the same side as the first cover and in the upper half of the electrical multi-gear and multiple reduction axle system.In a fifth example of the system, which optionally includes one or more or all of the first to fourth examples, the input shaft is coupled to an output shaft which is coupled to the first helical gear, the input shaft is coupled to the first ring gear of the first planetary gear set system, and the first planet carrier is coupled to the first helical gear of the first planetary gear set system.

[0077] In a sixth example of the system, which optionally includes one, more, or all of the first five examples, the electric motor, motor shaft, and input shaft are located on a opposite side of the electric multi-gear and multiple reduction axle system relative to the first cover and in a lower half of the electric multi-gear and multiple reduction axle system. In a seventh example of the system, which optionally includes one, more, or all of the first six examples, the at least two helical gears further include a third helical gear located on the same side as a second cover and in the lower half of the electric multi-gear and multiple reduction axle system, and coupled to the input shaft via splined connections.In an eighth example of the system, which optionally includes one or more or all of the first to seventh examples, the system with no more than two planetary gear sets additionally includes a second planetary gear set located on the same side as the second cover and in the upper half of the electric multi-gear and multi-reduction axle system, comprising a second sun gear, a second planetary gear set, a second ring gear and a second planet carrier.

[0078] In a ninth example of the system, which optionally includes one, more, or all of the first through eighth examples, the no more than two synchronizers include a second synchronizer located on the same side as the second cover and in the upper half of the electric multi-gear and multi-reduction axle system. In a tenth example of the system, which optionally includes one, more, or all of the first through ninth examples, the third helical gear engages with the internal spline of the second ring gear of the second planetary gear set system, the second planet carrier engages with an intermediate shaft, and the intermediate shaft is coupled to the first ring gear of the first planetary gear set system.

[0079] The disclosure also provides support for a method for operating a modular electric multi-speed and multi-reduction axle, comprising: axially moving a respective synchronizer towards a planet carrier of a respective planetary gear set system or a cover of a housing and engaging a sun gear of the respective planetary gear set system with the planet carrier or the cover to achieve different reduction ratios of the respective planetary gear set system.In a first example of the procedure, the respective planetary gear set system is deactivated in response to the axial movement of the respective synchronizer towards the planet carrier and the engagement of the sun gear and the planet carrier of the respective planetary gear set system, and the respective planetary gear set system is activated in response to the axial movement of the respective synchronizer towards the cover and the engagement of the sun gear and the cover.

[0080] The disclosure also relates to a series of axle systems comprising: a first gearbox, a second gearbox, and a third gearbox, each of the first, second, and third gearboxes comprising: a housing with at least one first cover arranged on one side of the respective gearbox and circumferentially enclosing the respective gearbox, the arrangement of the first cover being the same for each of the first, second, and third gearboxes; an electric motor rotatably coupled to a motor shaft, the motor shaft being coupled to an input shaft via splined connections and a support, and the electric motor being arranged on a side of the respective gearbox opposite the first cover; a pair of helical gears arranged on the same side of the respective gearbox as the first cover; and a first helical gear arranged in an upper half.and a second helical gear arranged in a lower half of the respective transmission, which mesh with each other, wherein neither the first helical gear nor the second helical gear is coupled to the input shaft, and a pinion arranged on the same side of the respective transmission as the first cover and coupled to the second helical gear via splined connections and meshing with a ring gear, wherein the ring gear is connected to a differential in a central area of ​​the respective transmission.

[0081] In a first example of the system, the first gearbox and the second gearbox further comprise: the electric motor, which is located in the upper half of the respective gearbox; the electric motor is not located in the lower half of the respective gearbox; the housing does not include a second cover, which is located on a different side of the respective gearbox relative to the first cover; a third helical gear does not mesh with the external splined teeth of a second ring gear of a second planetary gear set system; the second planetary gear set is not located in the upper half and on the same side as the second cover of the respective gearbox; a second synchronizer is not coupled to a second sun gear of the second planetary gear set system; and a second planet carrier does not mesh with an intermediate shaft via splined teeth.and wherein the intermediate shaft is not coupled via splines to a first ring gear of a first planetary gear set system. In a second example of the system, which optionally includes the first example, the first transmission further comprises: the input shaft coupled to an output shaft, the first helical gear coupled via splines to the output shaft on the same side of the respective transmission as the first cover, wherein the input shaft is not coupled to the first ring gear of the first planetary gear set system, which is located in the upper half and is arranged on the same side as the first cover, wherein the first helical gear is not coupled via splines to a first planet carrier of the first planetary gear set system, and wherein the input shaft is not coupled to the third helical gear.which is located on the opposite side of the respective gearbox relative to the first cover and is situated in the lower half of the respective gearbox, wherein a first synchronizer is not located in the upper half and is situated on the same side as the first cover of the respective gearbox and is coupled to a first sun gear of the first planetary gear set system.

[0082] In a third example of the system, which optionally includes one or both of the first and second examples, the second and third gearboxes further comprise: the input shaft is not coupled to the output shaft, and the first helical gear is not coupled to the output shaft via splines on the same side of the respective gearbox as the first cover; the first planetary gear set system is located in the upper half and is arranged on the same side as the first cover of the respective gearbox, wherein the first planetary gear set system comprises the first ring gear, the first sun gear, the first planet carrier, and a first planetary gear set; the first synchronizer is located in the upper half and is arranged on the same side as the first cover of the respective gearbox and is coupled to the first sun gear of the first planetary gear set system.and wherein the first helical gear is coupled to the first planet carrier via splined connections.

[0083] In a fourth example of the system, which optionally includes one or more or all of the first to third examples, the second transmission includes the input shaft being coupled via splined connections to the first ring gear of the first planetary gear set system and not coupled to the third helical gear, which is located on the opposite side of the respective relative to the first cover and is situated in the lower half of the respective transmission, and the third transmission includes the input shaft being coupled to the third helical gear.

[0084] In a fifth example of the system, which optionally includes one or more or all of the first to fourth examples, the third gearbox further comprises: the housing further comprises the second cover, which is arranged on a different side of the respective gearbox, wherein the electric motor is located in the lower half of the respective gearbox and the electric motor is not located in the upper half of the respective gearbox; the third helical gear meshes with external spline teeth of the second ring gear of the second planetary gearbox, wherein the second planetary gear set system is located in the upper half, is arranged on the same side as the second cover of the respective gearbox, and comprises the second ring gear, a second planetary gear set, the second planet carrier, and the second sun gear, as well as the second synchronizer, which is coupled to the second sun gear of the second planetary gear set system.In a sixth example of the system, which optionally includes one or more or all of the first to fifth examples, the third gear further comprises: the second planet carrier, which engages with the intermediate shaft via splined teeth, and the intermediate shaft, which is coupled to the first ring gear of the first planetary gear set system via splined teeth.

[0085] Fig.Figures 1-6D and 8 show example configurations with the relative arrangement of the various components. If these elements are in direct contact with each other or directly coupled, they can be described as being in direct contact or directly coupled, respectively, in at least one example. Similarly, elements depicted as adjacent or side by side can be adjacent or side by side in at least one example. For instance, components that are in planar contact with each other can be described as being in planar contact. As a further example, elements that are separated from each other, with only a gap between them and that have no other components, can be described as such in at least one case.In yet another example, elements that are displayed above / below each other, on opposite sides, or to the left / right of each other can be described as such, in relation to each other.

[0086] Furthermore, in at least one example, as illustrated in the figures, a topmost element or the highest point of an element can be referred to as the "top" of the component, and a bottommost element or the lowest point of the element can be referred to as the "bottom" of the component. The terms top / bottom, upper / lower, above / below used here can refer to a vertical axis of the figures and can be used to describe the positioning of elements within the figures relative to one another. For example, in one instance, elements shown above other elements are positioned vertically above them. As another example, the shapes of the elements depicted in the figures can be described as such (e.g., circular, straight, flat, curved, rounded, beveled, angled, etc.).Furthermore, the depicted elements that intersect each other can be referred to as intersecting elements or mutually intersecting elements in at least one example. In addition, an element depicted inside or outside another element can be described as such.

[0087] Features described as axial can be approximately parallel to a datum axis unless otherwise specified. Features described as counter-rotating can be approximately perpendicular to the datum axis unless otherwise specified. Features described as radial can extend around an axis, such as the datum axis, or a component or feature previously described as radial to a datum axis, or extend radially outward unless otherwise specified.

[0088] It should be noted that the example control and estimation routines contained herein can be used with various powertrain, electric drive, and / or vehicle system configurations. The control methods and routines disclosed herein can be stored as executable instructions in non-volatile memory and can be executed by the control system, which includes the control unit, in combination with the various sensors, actuators, and other transmission and / or vehicle hardware, in conjunction with the electronic control unit. Thus, the described actions, operations, and / or functions can graphically represent code programmed into non-volatile memory of the computer-readable storage medium in the vehicle and / or the powertrain control system.The various actions, operations, and / or functions shown can be performed in the sequence presented, in parallel, or omitted in some cases. Accordingly, the processing sequence is not strictly necessary to achieve the features and benefits of the examples described here; it serves only for better illustration and description. One or more of the actions, operations, and / or functions shown can be executed repeatedly, depending on the specific strategy used. One or more of the process steps described here can also be omitted if desired.

[0089] It is understood that the configurations and routines disclosed herein are exemplary and that these specific embodiments are not to be considered limiting, as numerous variations are possible. Unless expressly stated otherwise, the terms "first," "second," "third," etc., do not denote any order, position, quantity, or significance, but serve only to distinguish the individual elements. The subject matter of this 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 properties disclosed herein.

[0090] Unless otherwise stated, the term "approximately" means plus or minus five percent of the range.

[0091] The following claims specifically indicate certain combinations and subcombinations that are considered novel and not obvious. These claims may refer to "one" element, "a first" element, or the equivalent thereof. Such claims are to be understood as including one or more such elements, with two or more such elements neither required nor excluded. 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 they have a broader, narrower, the same, or different scope than the original claims, are also considered to be included in the subject matter of the present disclosure.

Claims

[1] Electric multi-speed and multi-reduction axle system, comprising: a housing with at least one cover that completely encloses the electrical multi-gear and multiple reduction axle system; an electric motor rotatably coupled to a motor shaft, wherein the motor shaft is connected to an input shaft via splined connections and a support; no more than two planetary gear sets, each planetary gear set comprising a ring gear, a sun gear, planet gears and a planet carrier; no more than two synchronizers, each synchronizer being coupled to a corresponding sun gear and being axially movable to engage the sun gear with one of the at least one cover of the housing or a planet carrier of a corresponding planetary gear set system; at least two helical gears, wherein at least one helical gear is arranged over another helical gear, enabling the at least two helical gears to mesh with each other; and a pinion which is coupled to a helical gear via a splined connection and engages with a ring gear, the ring gear being coupled to a differential. [2] Electric multi-speed and multiple reduction axle system according to claim 1, wherein the at least one cover comprises a first cover arranged on one side of the electric multi-speed and multiple reduction axle system, wherein the first cover is arranged in an upper half of the electric multi-speed and multiple reduction axle system. [3] Electric multi-speed and multiple reduction axle system according to claim 2, wherein the at least two helical gears comprise a first helical gear and a second helical gear which engages with the first helical gear and is coupled to the pinion, wherein the first helical gear is arranged on the same side as the first cover and in the upper half of the electric multi-speed and multiple reduction axle system and the second helical gear is arranged on the same side as the first cover and in the lower half of the electric multi-speed and multiple reduction axle system. [4] Electric multi-gear and multiple reduction axis system according to claim 2 or 3, wherein the electric motor, the motor shaft and an end of the input shaft are arranged on an opposite side of the electric multi-gear and multiple reduction axis system relative to the first cover and in the upper half of the electric multi-gear and multiple reduction axis system. [5] Electric multi-gear and multiple reduction axle system according to any one of claims 2 to 4, wherein the no more than two planetary gear sets comprise a first planetary gear set system arranged on the same side as the first cover and in the upper half of the electric multi-gear and multiple reduction axle system and comprising a first sun gear, a first planetary gear set, a first ring gear and a first planet carrier, and wherein the no more than two synchronizers comprise a first synchronizer arranged on the same side as the first cover and in the upper half of the electric multi-gear and multiple reduction axle system. [6] Electric multi-speed and multi-reduction axle system according to claim 5, wherein the input shaft is coupled to an output shaft coupled to the first helical gear, the input shaft is coupled to the first ring gear of the first planetary gear set system and the first planet carrier is coupled to the first helical gear of the first planetary gear set system. [7] Electric multi-speed and multiple reduction axle system according to any one of claims 2 to 6, wherein the electric motor, the motor shaft and the input shaft are arranged on an opposite side of the electric multi-speed and multiple reduction axle system relative to the first cover and in a lower half of the electric multi-speed and multiple reduction axle system. [8] Electric multi-speed and multiple reduction axle system according to one of the preceding claims, comprising at least the features of claim 3, wherein the at least two helical gears further comprise a third helical gear arranged on the same side as a second cover and in the lower half of the electric multi-speed and multiple reduction axle system and coupled to the input shaft via splined connections. [9] Electric multi-speed and multiple reduction axle system according to claim 8, wherein the no more than two planetary gear sets further comprise a second planetary gear set system arranged on the same side as the second cover and in the upper half of the electric multi-speed and multiple reduction axle system and comprising a second sun gear, a second planetary gear set, a second ring gear and a second planet carrier. [10] Electric multi-speed and multiple reduction axle system according to claim 9, wherein the no more than two synchronizers comprise a second synchronizer which is arranged on the same side as the second cover and in the upper half of the electric multi-speed and multiple reduction axle system. [11] Electric multi-speed and multi-reduction axle system according to claim 9 or 10, wherein the third helical gear engages with the internal teeth of the second ring gear of the second planetary gear set system, the second planet carrier engages with an intermediate shaft and the intermediate shaft is coupled to the first ring gear of the first planetary gear set system. [12] Series of axle systems, comprising: a first gearbox, a second gearbox, and a third gearbox, each of the first gearbox, the second gearbox, and the third gearbox comprising the following: a housing comprising at least one first cover arranged on one side of each gearbox and surrounding the gearbox, wherein one position of a first cover is the same for each of the first gearbox, the second gearbox and the third gearbox; an electric motor rotatably coupled to a motor shaft, wherein the motor shaft is coupled to an input shaft via splined connections and a support, and wherein the electric motor is arranged on an opposite side of the respective gearbox relative to the first cover; a pair of helical gears arranged on the same side of the respective gearbox as the first cover, comprising a first helical gear located in an upper half and a second helical gear located in a lower half of the respective gearbox, meshing with each other, wherein neither the first helical gear nor the second helical gear is coupled to the input shaft; and a pinion which is arranged on the same side of the respective gearbox as the first cover and is coupled to the second helical gear via splined connections and engages with a ring gear, the ring gear being coupled to a differential in a central area of ​​the respective gearbox. [13] Series of electric axles according to claim 12, wherein the first gearbox and the second gearbox further comprise: the electric motor, which is located in the upper half of the respective gearbox; the electric motor, which is not located in the lower half of the respective gearbox; the housing that does not include a second cover located on a different side of the respective gearbox relative to the first cover; wherein a third helical gear does not engage with the external teeth of a second ring gear of a second planetary gear set system and the second planetary gear set system is not located in the upper half and on the same side as the second cover of the respective gearbox, wherein a second synchronizer is not coupled to a second sun gear of the second planetary gear set system and a second planet carrier is not engaged with an intermediate shaft via splined connections; and wherein the intermediate shaft is not coupled to a first ring gear of a first planetary gear set system via splined connections. [14] Series of electric axles according to claim 13, wherein the first transmission further comprises: wherein the input shaft is coupled to an output shaft; wherein the first helical gear is coupled to the output shaft via splined connections on the same side of the respective gearbox as the first cover; wherein the input shaft is not coupled to the first ring gear of the first planetary gear set system, which is located in the upper half and on the same side as the first cover; wherein the first helical gear is not coupled to a first planet carrier of the first planetary gear set system via splined connections; wherein the input shaft is not coupled to the third helical gear, which is located on the opposite side of the respective gearbox relative to the first cover and is located in the lower half of the respective gearbox; wherein a first synchronizer is not located in the upper half and is located on the same side as the first cover of the respective gearbox and is coupled to a first sun gear of the first planetary gear set system.

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