Multi-speed electric drive axle using multi-lay shaft transmission

Abstract

The electric drive axle includes an electric motor having a motor shaft rotatable about an axis, a differential, and a transmission. The transmission transmits rotational power between the motor shaft and the differential. The multi-speed reducer includes an input shaft and at least three axial gears. The input shaft is rotatably coupled to the motor shaft. Each of the at least three axial gears is coaxial with the input shaft and rotatable relative to the input shaft at at least one of a first speed ratio and a second speed ratio. The input shaft is axially movable along the axis between a first position where a first one of the at least three axial gears is rotatably coupled to the input shaft and a second position where a second one of the at least three axial gears is rotatably coupled to the input shaft.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 442,471, filed February 1, 2023, and U.S. Provisional Patent Application No. 63 / 407,007, filed September 15, 2022. The entire disclosure of each of the above applications is incorporated herein by reference. [Technical Field]

[0002]

[0002] The present disclosure relates to a multi-speed electric drive axle using a multi-lay shaft transmission. [Background technology]

[0003]

[0003] This section provides background information related to the present disclosure that is not necessarily prior art.

[0004] Electric drive axles are becoming increasingly popular in automotive vehicle drivelines. There is growing interest in electric drive axles that use multi-speed transmissions. One drawback of such electric drive axles has been that, until now, it has been difficult to install the multi-speed transmission on a vehicle without affecting either the passenger compartment space or vehicle clearance. Therefore, there is a need in the art for an improved electric drive axle with a multi-speed transmission that is relatively compact. Summary of the Invention

[0005]

[0005] This section provides a general overview of the disclosure, but is not an exhaustive disclosure of its entire scope or all of its features.

[0006] In one aspect, the present disclosure provides an electric drive axle including a housing assembly, an electric motor, a differential assembly, and a transmission. The electric motor is coupled to the housing assembly and has a motor shaft rotatable about a motor axis. The differential assembly is received in the housing assembly and includes a differential input member rotatable about an output shaft and a pair of differential output members rotatable about the output shaft. The transmission is received in the housing assembly and transmits rotational power between the motor shaft and the differential input members. The transmission has an input shaft rotatably coupled to the motor shaft and axially movable along the motor axis, a first reduction gear set, a second reduction gear set, and a coupling sleeve. The first reduction gear set has a first intermediate input gear and a first intermediate output gear. The first intermediate output gear is axially slidably and rotatably disposed on the input shaft. The first intermediate output gear is meshingly engaged with the first intermediate input gear and rotatable about an intermediate axis parallel to the motor shaft. The second reduction gear set includes a second intermediate input gear, a second intermediate output gear, a first intermediate gear, a second intermediate gear, a third intermediate gear, and a fourth intermediate gear. The input shaft is rotatable and axially slidable relative to the second intermediate input gear, the third intermediate gear, and the fourth intermediate gear. The first intermediate gear is meshedly engaged with the second intermediate input gear. The second intermediate gear is coupled to the first intermediate gear for rotation therewith and meshedly engaged with the third intermediate gear. The fourth intermediate gear is meshedly engaged with the second intermediate output gear. A coupling sleeve is coupled to the input shaft for rotation about the input shaft but for translation with the input shaft along the motor axis. The input shaft is movable between a first position in which the input shaft is rotatably coupled to the first intermediate input gear and the coupling sleeve is rotatably decoupled from at least one of the third intermediate gear and the fourth intermediate gear, and a second position in which the input shaft is rotatably decoupled from the first intermediate input gear, the input shaft is rotatably coupled to the second intermediate input gear, and the coupling sleeve rotatably couples the third intermediate gear and the fourth intermediate gear to one another.

[0007] In another aspect, the present disclosure provides an electric drive axle including a housing assembly, an electric motor, a differential assembly, and a transmission. The electric motor is coupled to the housing assembly and has a motor shaft rotatable about a motor axis. The differential assembly is received in the housing assembly and includes a differential input member rotatable about an output shaft and a pair of differential output members rotatable about the output shaft. The transmission is received in the housing assembly and transmits rotational power between the motor shaft and the differential input members. The transmission has an input shaft rotatably coupled to the motor shaft and axially movable along the motor axis, a multi-speed reducer including a first reduction gear set, a second reduction gear set, and a connecting sleeve. The first reduction gear set has a first intermediate input gear and a first intermediate output gear. The first intermediate output gear is axially slidably and rotatably disposed on the input shaft. The first intermediate output gear is meshingly engaged with the first intermediate input gear and rotatable about an intermediate axis parallel to the motor shaft. The second reduction gear set includes a second intermediate input gear, a second intermediate output gear, a first intermediate gear, and a second intermediate gear. The second intermediate input gear is axially slidably and rotatably coupled to the input shaft. The first intermediate gear is axially slidably and rotatably disposed on the input shaft. The second intermediate gear is axially slidably and rotatably disposed on the input shaft. The second intermediate output gear is meshingly engaged with the second intermediate gear and coupled to the first intermediate output gear for co-rotation about an intermediate axis. A coupling sleeve is rotatably received on the input shaft but axially fixed to the input shaft. The input shaft is movable between a first position in which the input shaft is rotatably coupled to the first intermediate input gear and the coupling sleeve is rotatably decoupled from at least one of the first intermediate gear and the second intermediate gear, and a second position in which the input shaft is rotatably decoupled from the first intermediate input gear and the coupling sleeve rotatably couples the first intermediate gear and the second intermediate gear to one another.

[0008] In yet another aspect, the present disclosure provides an electric drive axle including a housing assembly, an electric motor, a differential assembly, and a transmission. The electric motor is coupled to the housing assembly and has a motor shaft rotatable about a motor axis. The differential assembly is received in the housing assembly and includes a differential input member rotatable about an output shaft and a pair of differential output members rotatable about the output shaft. The transmission is received in the housing assembly and transfers rotational power between the motor shaft and the differential input members. The transmission has a multi-speed reducer selectively operable at a first speed ratio and a second speed ratio. The multi-speed reducer has an input shaft and at least three axial gears. The input shaft is rotatably coupled to the motor shaft. Each of the at least three axial gears is coaxial with the input shaft and rotatable relative to the input shaft at at least one of the first and second speed ratios. The input shaft is axially movable along the motor axis between a first position in which a first one of the at least three axial gears is rotatably coupled to the input shaft and a second position in which a second one of the at least three axial gears is rotatably coupled to the input shaft.

[0009] In yet another aspect, the present disclosure provides an electric drive axle including a housing assembly, an electric motor, a differential assembly, a mounting plate, a transmission, a first bearing, and a second bearing. The housing assembly has a housing member defining a first bearing mount. The electric motor is coupled to the housing assembly and has a motor shaft rotatable about a motor axis. The differential assembly is received in the housing assembly and includes a differential input member rotatable about an output shaft and a pair of differential output members rotatable about the output shaft. The mounting plate is coupled to the housing assembly and defines a second bearing mount. The transmission is received in the housing assembly and transfers rotational power between the motor shaft and the differential input member. The transmission has a compound gear including a lay shaft, a first intermediate gear, and a second intermediate gear coupled to each other for common rotation about an intermediate shaft. The first bearing is received in the first bearing mount and supports a first end of the lay shaft for rotation about the intermediate shaft relative to the housing member. A second bearing is mounted in the second bearing mount and supports the second end of the lay shaft for rotation about the intermediate axis relative to the mounting plate. A lubrication gallery is formed in the mounting plate. The lubrication gallery is in fluid communication with the first and second bearing mounts.

[0010] In yet another aspect, the present disclosure provides an electric drive axle including a housing assembly, a transmission, and a park lock mechanism. The housing assembly has first and second housing members cooperating to define a transmission cavity between the first and second housing members. The second housing member defines a second mount and a pivot pin aperture. The transmission is received in the transmission cavity. The transmission has a gear supported by bearings received in the bearing mount. The park lock mechanism includes a park lock gear coupled for rotation with elements of the transmission, a pivot pin, a park pawl, a spring, and a park pawl plunger assembly. The pivot pin is received in the pivot pin aperture and is rotatable relative to the second housing member about a pivot axis. The park pawl is coupled to the pivot pin for common rotation about the pivot axis between an engaged position in which the park pawl is engaged with the park lock gear and a disengaged position in which the park pawl is disengaged from the park lock gear. The spring biases the park pawl out of engagement with the park lock gear. The park lock plunger assembly includes an input member, a plunger, and a compliance spring. The input member is disposed along an actuation axis. The plunger is slidably disposed on the input member and is movable along the actuation axis between a first position and a second position. The actuation axis may be parallel to the pivot axis. Movement of the plunger from the first position toward the second position causes corresponding movement of the park pawl toward the engaged position. Placement of the plunger in the second position allows the spring to move the park pawl to the disengaged position. The compliance spring is disposed coaxially on the input member and biases the head of the input member away from the plunger.

[0011] In yet another form, the present disclosure provides a method for assembling an electric drive axle, the method including providing a first housing member; assembling a transmission to the first housing member, wherein the transmission includes a gear supported on a bearing; providing a second housing member, wherein the second housing member defines a bearing mount; and installing a park lock mechanism in the second housing member, wherein the park lock mechanism has a park lock gear, a pivot pin, a park pole, a spring, and a park lock plunger assembly, the park lock gear is coupled for rotation with elements of the transmission, the pivot pin is received in the pivot pin aperture and is rotatable relative to the second housing member about a pivot axis, the park pole is coupled to the pivot pin for common rotation about the pivot axis between an engaged position where the park pole is engaged with the park lock gear and a disengaged position where the park pole is disengaged from the park lock gear, and the spring is adapted to engage the park pole to disengage from the park lock gear. the park lock plunger assembly has an input member, a plunger, and a compliance spring, the input member is disposed along an actuation axis, the plunger is slidably disposed on the input member and is movable along the actuation axis between a first position and a second position, the actuation axis being parallel to a pivot axis of the plunger, movement of the plunger from the first position toward the second position causes corresponding movement of the park pawl toward the engaged position, and placement of the plunger in the second position enables the spring to move the park pawl to the disengaged position, the compliance spring is coaxially disposed on the input member and biases the head of the input member away from the plunger; installing bearings in bearing mounts; and assembling the second housing member to the first housing member to enclose the transmission, the park lock gear, the pivot pin, the park pawl, and the plunger assembly within a housing assembly formed by the first and second housing members.

[0012] In a further aspect, the present disclosure provides a vehicle driveline component including a housing assembly, a multi-speed reducer received in the housing assembly, and an actuator assembly. The multi-speed reducer has a movable element movable along a shift axis between a first position and a second position. Disposing the movable element in the first position causes the multi-speed reducer to operate at a first reduction ratio, while disposing the movable element in the second position causes the multi-speed reducer to operate at a second reduction ratio different from the first reduction ratio. The actuator assembly includes an actuator motor, a screw, an actuator output member, a coupler, and at least one coupler pad. The screw is driven by the actuator motor about a screw axis parallel to the shift axis. The actuator output member has a first end and a second end opposite the first end. The movable element of the multi-speed reducer is axially fixed to the first end of the axially movable member but is rotatable relative to the first end of the axially movable member. The second end of the axially movable member defines a pocket. The coupler is threadably coupled to the screw and received in the pocket. Each of the at least one coupler pads is received in the pocket and attached to one of the coupler and the axially movable member. Each of the at least one coupler pads has a first surface that abuts an associated surface of the axially movable member and a second surface that abuts an associated surface of the coupler. The second surface of each of the at least one coupler pad is curved such that contact between the coupler and each of the at least one coupler pad occurs along an associated line extending in a plane that includes the screw axis.

[0013] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.

[0014]

[0014] The drawings described herein are intended only to illustrate selected embodiments rather than all possible implementations and are not intended to limit the scope of the present disclosure. [Brief explanation of the drawings]

[0015] [Figure 1]

[0015] FIG. 1 is a perspective view of an exemplary electric drive axle constructed in accordance with the teachings of the present disclosure. [Figure 2]

[0016] FIG. 2 is a cross-sectional view taken along line 2-2 of FIG. [Figure 3]

[0017] 2 is an exploded perspective view of a portion of the electric drive axle of FIG. 1 illustrating in greater detail the housing assembly, transmission, and gear case of the differential assembly. [Figure 4]

[0018] 2 is a cross-sectional view of a portion of the electric drive axle of FIG. 1 taken through the motor shaft of the electric motor. [Figure 5]

[0019] 2 is a schematic diagram of a portion of the electric drive axle of FIG. 1 illustrating the transmission in more detail. [Figure 6]

[0020] FIG. 2 is a perspective view of a portion of the electric drive axle of FIG. 1 illustrating the transmission in more detail. [Figure 7]

[0021] FIG. 2 is a cross-sectional view of a portion of the transmission taken along the motor shaft. [Figure 8]

[0022] FIG. [Figure 9]

[0023] FIG. 1 is a cross-sectional view of a portion of the transmission taken through the motor shaft and the intermediate shaft of the first compound gear. [Figure 10]

[0024] FIG. 2 is an exploded perspective view of a multi-speed input portion of the transmission. [Figure 11]

[0025] 8 is an enlarged view of FIG. 7 illustrating the input shaft of the multi-speed input section of the transmission in a high speed position. [Figure 12]8 is an enlarged view of FIG. 7 illustrating the input shaft of the multi-speed input portion of the transmission in a neutral position. [Figure 13] 8 is an enlarged view of FIG. 7 illustrating the input shaft of the multi-speed input portion of the transmission in a low speed position. [Figure 14]

[0026] FIG. 2 is a perspective view of a portion of the electric drive axle of FIG. 1 illustrating a portion of the transmission including the mounting plate. [Figure 15]

[0027] FIG. 10 is a cross-sectional view taken through a portion of an electric drive axle illustrating one of the layshafts of the transmission as mounted between a mounting plate and a portion of the housing assembly. [Figure 16]

[0028] 2 is a perspective view of a portion of the electric drive axle of FIG. 1 illustrating in greater detail an actuator assembly for operating the multi-speed input portion of the transmission and the park lock mechanism. [Figure 17]

[0029] 2 is a cross-sectional view of a portion of the electric drive axle of FIG. 1 illustrating the connection between the actuator assembly and the input shaft. [Figure 18]

[0030] FIG. 2 is a perspective view of the electric drive axle of FIG. 1 illustrating the actuator assembly in more detail. [Figure 19]

[0031] 2 is a perspective view of a portion of the electric drive axle of FIG. 1 illustrating a portion of the actuator assembly in greater detail. [Figure 19A]

[0032] FIG. 10 is a cross-sectional view of a portion of the actuator assembly taken in a plane that includes both the shift axis about which the input shaft rotates and the axis of rotation of the sliding screw along which the input shaft translates. [Figure 19B]

[0033] FIG. 1 is an exploded perspective view illustrating an axially movable member of the output assembly and a coupler of the actuator assembly, where the coupler is exploded from the axial end of the axially movable member. [Figure 19C]

[0034] FIG. 10 is a cross-sectional view of a portion of the actuator assembly taken perpendicular to the axis of rotation of the sliding screw. [Figure 19D]

[0035] FIG. 10 is a partial cross-sectional view of a portion of another actuator assembly illustrating a coupler pad coupled to a coupler and attached to an axially movable member. [Figure 19E]

[0036] FIG. 2 is a perspective view of a coupler pad. [Figure 19F] FIG. 2 is a perspective view of a coupler pad. [Figure 19G]

[0037] FIG. 19E is a cross-sectional view of a portion of the actuator assembly of FIG. 19D. [Figure 20]

[0038] FIG. 2 is a perspective view of the park lock mechanism. [Figure 21]

[0039] 2 is a perspective view of a portion of the electric drive axle of FIG. 1 illustrating the park lock mechanism in more detail. [Figure 22]

[0040] FIG. 10 is a cross-sectional view taken through a portion of the park lock mechanism illustrating the park pole plunger assembly in conjunction with the guide and park pole. [Figure 23]

[0041] FIG. 1 is a schematic diagram of an alternatingly constructed actuator assembly. [Figure 24]

[0042] FIG. 10 is a schematic diagram of a portion of another constructed multi-speed electric drive axle illustrating an alternating constructed transmission. DETAILED DESCRIPTION OF THE INVENTION

[0016]

[0043] Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.

[0017]

[0044] 1 and 2, an illustrative electric drive axle constructed in accordance with the teachings of the present disclosure is generally designated by the reference numeral 10. The multi-speed electric drive axle 10 includes several major assemblies or components, including a housing assembly 12, an electric motor 14, a transmission 16, a differential assembly 18, and a pair of axle shafts 20.

[0018]

[0045] 2 and 3 , the housing assembly 12 of the example provided includes first and second housing members 30 and 32, respectively, and a pair of axle tubes 34 in which the axle shaft 20 is rotatably disposed. The housing assembly 12 is configured to accommodate beaming loads, thereby providing a "beam" or "rigid" axle configuration for the multi-speed electric drive axle 10. However, it should be appreciated that the housing assembly 12 may be configured differently, for example, to configure the multi-speed electric drive axle 10 for use with an independent suspension.

[0019]

[0046] The first and second housing members 30 and 32 have a "clamshell" configuration and cooperate to form a carrier housing defining a gear case having a transmission cavity 38 and a differential cavity 40 intersecting the differential cavity 40. Each of the first and second housing members 30 and 32 may define a coupling flange 44, a differential bearing mount 46, and an axle tube mount 48. The first housing member 30 may additionally include a motor mount 50. The coupling flanges 44 may abut against one another, and threaded fasteners may be used to secure the coupling flanges 44 to one another. A gasket or sealant (not shown) may be disposed between the first and second housing members 30 and 32 (e.g., contacting adjacent surfaces of the coupling flanges 44) to additionally sealingly couple the first and second housing members 30 and 32 to one another. Each differential bearing mount 46 is formed in the vehicle body side of an associated one of the first and second housing members 30 and 32 and is configured to receive therein a differential bearing 54 that supports the differential assembly 18 for rotation about an output shaft 58. Each axle tube mount 48 defines an axle tube aperture configured to receive therein an associated one of the axle tubes 34.

[0020]

[0047] Each of the axle tubes 34 may be received in an associated one of the axle tube apertures and fixedly coupled to an associated one of the axle tube mounts 48 in any desired manner. In the example shown, the axle tubes 34 are press-fit into the axle tube apertures, and conventional weld slugs (not specifically shown) are used to prevent both axial and rotational movement of the axle tubes 34 along or about the output shaft 58 relative to the first and second housing members 30 and 32.

[0021]

[0048] Referring to FIG. 4 , electric motor 14, which may be configured as any type of electric motor, includes a motor housing 64, a stator 66 received within and fixedly coupled to motor housing 64, a rotor 68 received within stator 66 and rotatable relative to stator 66 about a motor axis 70, and a motor output shaft 72 fixedly coupled to rotor 68. Motor housing 64 may define motor bearing mounts (not specifically shown) and seal mounts. Motor output shaft 72 extends through motor housing 64 along motor axis 70 and may optionally extend into transmission cavity 38 in housing assembly 12. Motor output shaft 72 may be hollow and may define a plurality of first internal spline teeth 80. Motor bearings 82 may be received between motor housing 64 and motor output shaft 72 and may support motor output shaft 72 for rotation about motor axis 70 relative to motor housing 64. A rotary shaft seal 84 may be mounted on the seal mount to form a seal between the motor housing 64 and the motor output shaft 72 that prevents fluid communication between the transmission cavity 38 and the interior of the motor housing 64 through a motor shaft aperture in the motor housing 64. Fasteners (not specifically shown) may be used to fixedly couple the motor housing 64 to the motor mount 50 on the first housing member 30. Alternatively, the motor housing 64 may be unitarily and integrally formed with the first housing member 30. The motor output shaft 72 may extend through or be aligned with the motor shaft aperture.

[0022]

[0049] 5 and 6, the transmission 16 in the example provided is a multi-speed transmission, although it should be understood that the transmission 16 can be any type of transmission, including a single-speed transmission. The particular transmission 16 shown includes a mounting plate 90, a multi-speed input portion 92, and a single-speed output portion 94. The mounting plate 90 will be described in more detail below, but for now it will suffice to say that the mounting plate 90 is received within the transmission cavity 38 and fixedly coupled to the first housing member 30, with a substantial portion of the multi-speed input portion 92 disposed between the first housing member 30 and the mounting plate 90.

[0023]

[0050] 5 and 7 , the multi-speed input portion 92 includes a first gear 100, a second gear 102, a third gear 104, a first compound gear 106, an input shaft 108, and a connecting sleeve 110. The first gear 100 can have gear teeth in the form of helical gear teeth disposed about the periphery of a first gear hub 112. The first gear hub 112 can be hollow and can define a plurality of second internal spline teeth 114. A bearing 116 is mounted between the first housing member 30 and the first gear hub 112 and supports the first gear 100 for rotation about the motor shaft 70. The second gear 102 can have gear teeth in the form of helical gear teeth disposed about the periphery of a second gear hub 122. The second gear hub 122 can be hollow and can define a plurality of third internal spline teeth 124. A pair of bearings 126 are mounted between the mounting plate 90 and the second gear hub 122 and support the second gear 102 both axially along the motor shaft 70 and radially about the motor shaft 70. The first gear 100 is disposed along the motor shaft 70 between the motor output shaft 72 and the second gear 102. Optionally, a portion of the first gear hub 112 may be concentrically received within a portion of the second gear hub 122.

[0024]

[0051] The third gear 104 can have gear teeth in the form of helical gear teeth disposed around a third gear hub 132. The third gear hub 132 can be hollow and define a plurality of first flank teeth 135 and a plurality of fourth internal spline teeth 134 formed on or in an axial end face of the third gear hub 132 facing or adjacent to the second gear 102. Bearings 136a and 136b are used to rotatably support the third gear 104 for rotation about the motor shaft 70. Bearing 136a is mounted between the mounting plate 90 and the third gear hub 132 adjacent to the second gear 102, while bearing 136b is mounted between the third gear hub 132 and the gear case on the axial end of the third gear 104 opposite bearing 136a.

[0025]

[0052] 5, 8, and 9, the first compound gear 106 includes a first lay shaft 140, a first intermediate gear 142, and a second intermediate gear 144. The first lay shaft 140 may be hollow and may be supported on either side by first and second bearings 146a and 146b, respectively, for rotation about a respective first intermediate shaft 148 that is parallel to but offset (i.e., not coincident) from the motor shaft 70. The first bearing 146a may be disposed between a first intermediate bearing mount 150 formed by the first housing member 30 and a first end of the first lay shaft 140, while the second bearing 148b may be disposed between a second intermediate bearing mount 152 formed by the mounting plate 90 and a second end opposite the first end of the first lay shaft 140. The first intermediate gear 142 is fixedly coupled to the first lay shaft 140 for rotation therewith about a first intermediate axis 148 and includes gear teeth meshingly engaged with the gear teeth of the first gear 100. The second intermediate gear 144 is fixedly coupled to the first lay shaft 140 for rotation therewith about the first intermediate axis 148 and includes gear teeth meshingly engaged with the gear teeth of the second gear 102. It should be appreciated that the first gear 100, the second gear 102, and the first compound gear 106 can form a reduction gear set.

[0026]

[0053] 7 and 10 , input shaft 108 is concentrically received through first, second, and third gear hubs 112, 122, and 132 and is rotatable about motor shaft 70. Input shaft 108 includes a plurality of first external spline teeth 160 disposed on a first axial end of input shaft 108 that is disposed within motor output shaft 72, a plurality of second external spline teeth 162 spaced from first external spline teeth 160 along motor shaft 70, and a circumferential rib 164 disposed along motor shaft 70 between first external spline teeth 160 and second external spline teeth 162. A lubrication hole 166 may be formed through input shaft 108, and a plurality of lubrication passages 168 may be formed through input shaft 108 to intersect lubrication hole 166 and extend radially through input shaft 108 at desired locations. A lubrication nozzle may be received in an axial end of the input shaft 108 proximate the third gear 104 and configured to input a flow of pressurized lubrication fluid into the lubrication bore 166. The pressurized lubrication fluid in the lubrication bore 166 may be routed to a lubrication passage 168 to cool and / or lubricate various components, such as bearings or sliding interfaces, and optionally to conduct the pressurized lubrication fluid into the motor output shaft 72, where the pressurized lubrication fluid may be used to cool and / or lubricate various components of the electric motor 14. In the example provided, the lubrication nozzle is attached to an auxiliary cover attached to the side of the second housing member 32 opposite the transmission cavity 38, and the lubrication nozzle does not contact or seal against the input shaft 108.

[0027]

[0054] Various bearings may be used to provide radial support to the input shaft 108 while allowing axial movement of the input shaft 108 along the motor axis 70. In the example provided, a first needle bearing 170 is disposed between the first gear hub 112 and a first cylindrical bearing surface formed on the input shaft 108, while a second needle bearing 172 is disposed between the third gear hub 132 and a second cylindrical bearing surface formed on the input shaft 108.

[0028]

[0055] The coupling sleeve 110 may be concentrically received about the input shaft 108 and may be rotatable relative to the input shaft 108 about the motor shaft 70. The coupling sleeve 110 may define a shoulder that may abut a first side of a circumferential rib 164 on the input shaft 108. An internal snap ring may be received in a groove formed in the coupling sleeve 110 and may abut a second side of the circumferential rib 164 opposite the shoulder. As such, translation of the input shaft 108 along the motor shaft 70 will cause corresponding translation of the coupling sleeve along the motor shaft 70. The coupling sleeve 110 defines a plurality of third external spline teeth 180 and a plurality of second surface teeth 182. The third external spline teeth 180 are meshingly engaged with the third internal spline teeth 124 formed on the second gear hub 122, thereby coupling the coupling sleeve 110 to the second gear 102 in a manner that prevents relative rotation but allows axial sliding or translational movement of the coupling sleeve 110 relative to the second gear 102.

[0029]

[0056] Input shaft 108 is movable along motor axis 70 between a high speed position (shown in FIG. 11 ), a neutral position (shown in FIG. 12 ), and a low speed position (shown in FIG. 13 ). First external spline teeth 160 on input shaft 108 are meshingly engaged with first internal spline teeth 80 on motor output shaft 72 (thereby coupling input shaft 108 to motor output shaft 72 for rotation therewith about motor axis 70) in each of the high speed, neutral, and low speed positions.

[0030]

[0057] 11 , the first external spline teeth 160 on the input shaft 108 are engaged only with the first internal spline teeth 80 on the motor output shaft 72, the second external spline teeth 162 on the input shaft 108 are engaged with the fourth internal spline teeth 134 formed on the third gear 104, and the second flank teeth 182 on the coupling sleeve 110 are spaced apart and disengaged from the first flank teeth 135 on the third gear 104. As a result, rotational power output from the electric motor 14 ( FIG. 1 ) through the motor output shaft 72 is input to the input shaft 108 and transmitted to the third gear 104, driving the third gear 104 at the rotational speed of the electric motor 14 ( FIG. 1 ).

[0031]

[0058] 12, the first external spline teeth 160 on the input shaft 108 are engaged only with the first internal spline teeth 80 on the motor output shaft 72, the second external spline teeth 162 on the input shaft 108 are spaced apart from and disengaged with the fourth internal spline teeth 134 formed on the third gear 104, and the second face teeth 182 on the coupling sleeve 110 are spaced apart from and disengaged with the first face teeth 135 on the third gear 104. As a result, rotational power output from the electric motor 14 (FIG. 1) through the motor output shaft 72 is input to the input shaft 108 but is not transmitted to any of the first, second, and third gears 100, 102, and 104.

[0032]

[0059] 13, the first external spline teeth 160 on the input shaft 108 are engaged with both the first internal spline teeth 80 on the motor output shaft 72 and the second internal spline teeth 114 on the first gear 100, the second external spline teeth 162 on the input shaft 108 are spaced apart and disengaged from the fourth internal spline teeth 134 formed on the third gear 104, and the second face teeth 182 on the coupling sleeve 110 are engaged with the first face teeth 135 on the third gear 104. As a result, rotational power output from the electric motor 14 (FIG. 1) through the motor output shaft 72 is input to the input shaft 108 and transmitted to the first gear 100 to drive the first intermediate gear 142 (FIG. 8) to provide the first reduction. A second intermediate gear 144 (FIG. 8), rotating with the first intermediate gear 142 (FIG. 8), drives the second gear 102 to provide the second reduction. Because the coupling sleeve 110 is rotatably coupled to both the second gear 102 (via the mating engagement of the third external spline teeth 180 with the third internal spline teeth 124) and the third gear 104 (via the mating engagement of the second surface teeth 182 with the first surface teeth 135), the third gear 104 rotates at the rotational speed of the second gear 102. It should be appreciated that the first gear 100, the second gear 102, and the third gear 104 are coaxial with the input shaft 108 and rotatable relative to the input shaft 108 at at least one of a first speed ratio and a second speed ratio. Additionally, the input shaft 108 is axially movable along the motor axis 70 between a first position in which a first one of the at least three axial gears (i.e., the first gear 100, the second gear 102, and the third gear 104) is rotatably coupled to the input shaft 108, and a second position in which a second, different one of the at least three axial gears is rotatably coupled to the input shaft.

[0033]

[0060] 5 and 8 , single speed output section 94 receives rotational power from third gear 104 and includes an output gear 200 rotatable about output shaft 58. Optionally, single speed output section 94 may include one or more reducers between third gear 104 and output gear 200. In the example provided, single speed output section 94 includes a pair of second compound gears 210 between third gear 104 and output gear 200, providing single speed output section 94 with two gear reducers.

[0034]

[0061] Each of the second compound gears 210 includes a second lay shaft 212, a third intermediate gear 214, and a fourth intermediate gear 216. The second lay shaft 212 may be hollow and may be supported on both sides by first and second bearings 220a and 220b, respectively, to rotate about a respective second intermediate shaft 222 that is parallel to but offset (i.e., not coincident with) both the motor shaft 70 and the output shaft 58. The first bearing 220a may be disposed between a first intermediate bearing mount formed by the first housing member 30 and a first end of the second lay shaft 212, while the second bearing 220b may be disposed between a second intermediate bearing mount formed by the second housing member 32 and a second end of the second lay shaft 212 opposite the first end. The third intermediate gear 214 is fixedly coupled to the second lay shaft 212 for rotation therewith about the second intermediate axis 222 and includes gear teeth meshingly engaged with the gear teeth of the third gear 104. The fourth intermediate gear 216 is fixedly coupled to the second lay shaft 212 for rotation therewith about the second intermediate axis 222 and includes gear teeth meshingly engaged with the gear teeth of the output gear 200. In the example provided, the second compound gear 210 is positioned along the second intermediate axis 222 such that the third intermediate gear 214 is disposed farther from the first gear 100 than the fourth intermediate gear 216. Such a configuration allows the transmission 16 to be relatively compact axially (e.g., along the output shaft 58).

[0035]

[0062] 5 and 8 , the differential assembly 18 may include a differential input member 230 coupled to the output gear 200 for rotation therewith, and a pair of differential output members 232 rotatable relative to the differential input member 230 about the output shaft 58. The differential assembly 18 may be configured in any desired manner. For example, the differential assembly 18 may be configured using a bevel gear set having (straight) bevel side gears and a differential pinion, and the differential input member 230 may be a differential case that houses the side gears and differential pinions. In the example provided, the differential assembly 18 is configured as a planetary or epicyclic differential assembly having an internal gear (not specifically shown), a sun gear (not specifically shown), a planet carrier (not specifically shown), and multiple sets of planet gears (not specifically shown). The internal gear may be fixedly coupled to the output gear 200 of the transmission 16 (e.g., formed unitarily and integrally with the output gear 200). The sun gear is concentrically disposed within the internal gear and is rotatable about the output shaft 58. The planet carrier is rotatable about the output shaft 58. Each of the planet gear sets includes one or more planet gears meshed with both the internal gear and the sun gear and journaled by the planet carrier. In situations where a planet gear set includes two or more planet gears, each of the planet gears meshes with another one of the planet gears, one of the planet gears meshes with the internal gear, and a different one of the planet gears meshes with the sun gear. In the example shown, each planet gear set includes a first planet gear meshingly engaged with the internal gear and journaled by the planet carrier, and a second planet gear meshingly engaged with both the first planet gear and the sun gear and also journaled by the planet carrier. In this configuration, the sun gear and planet carrier are the differential output member 232 of the differential assembly 18. The differential bearing 54 may be mounted radially between a gear case formed on the planet carrier and a hub (not specifically shown) to support the differential input member 230 for rotation about the output shaft 58.In the example shown, the differential bearing 54 is a tapered roller bearing that provides additional support to the differential assembly 18 axially along the output shaft 58 .

[0036]

[0063] 2 and 5 , each of the axle shafts 20 is received through a corresponding one of the axle tubes 34 and is coupled for rotation with a corresponding one of the differential output members 232. Various bearings (not specifically shown) may be used to support the axle shafts 20 relative to the housing assembly 12. In the example provided, the multi-speed electric drive axle 10 has a “full-floating” axle configuration in which the axle shafts 20 are rotatably coupled to wheel hubs 250 that are supported (axially and rotatably) on the axle tubes 34 such that the axle shafts 20 transmit rotational torque between the differential assembly 18 and associated vehicle wheels (not shown) but do not support the weight of the vehicle. However, it should be appreciated that the multi-speed electric drive axle 10 may be configured differently and may have any desired configuration (e.g., semi-floating, three-quarter floating, independent).

[0037]

[0064] 3, 9, and 14, the mounting plate 90 includes a mounting plate body 260, a flange member 262, a plurality of bearing mounts (bearing mount 264a, bearing mount 264b, and second intermediate bearing mount 152), and a lubrication gallery 266. The flange member 262 is fixedly coupled to and extends around the periphery of the mounting plate body 260. The flange member 262 is configured to abut an interior or interior surface of the first housing member 30. A plurality of threaded fasteners may be received through the flange member 262 and threadably engage corresponding threaded holes (not specifically shown) in the first housing member 30 to secure the mounting plate 90 to the first housing member 30. A positioning means, such as one or more dowel pins or a pair of roll pins, may be used to position or locate the mounting plate 90 relative to the first housing member 30. The mounting plate body 260 may be contoured to form a space or cavity that can accommodate the gear teeth of the third gear 104 and the first intermediate gear 142 .

[0038]

[0065] Bearing mount 264a is disposed on a first side of mounting plate body 260 (i.e., the side facing first housing member 30) and is configured to receive one of the bearings 126 that support second gear 102. Bearing mount 164b is disposed on a second, opposite side of mounting plate body 260 (i.e., the side facing second housing member 32) and is configured to receive one of the bearings (i.e., bearing 136a) that support third gear 104. Second intermediate bearing mount 152 is formed on the first side of mounting plate body 260 and is configured to receive bearing 146b that supports first lay shaft 140 of first compound gear 106.

[0039]

[0066] 14 and 15 , lubrication gallery 266 includes an inlet port 270, one or more fluid passages (e.g., fluid passages 272, 274, and 276), and one or more fluid outlets (e.g., outlet nozzle 278 and / or one or more outlet orifices (not specifically shown)). Inlet port 270 is configured to be fluidly coupled to a source or stream of pressurized lubrication fluid. In the example provided, inlet port 270 is fluidly coupled to a hose 280 that provides pressurized lubrication fluid to lubrication gallery 266. The fluid passages are generally configured to route pressurized lubrication fluid through mounting plate 90 between inlet port 270 and the fluid outlets. In the example provided, first fluid passage 272 receives pressurized lubrication fluid from inlet port 270 and routes the pressurized lubrication fluid to second and third fluid passages 274 and 276, respectively, and to outlet nozzle 278. The outlet nozzle 278 supplies pressurized lubricating fluid to both the second intermediate bearing mount 152 (for lubrication of both the second bearing 146b and the teeth of the second intermediate gear 144) and the hollow interior of the first lay shaft 140 (i.e., the longitudinal passage in the first lay shaft 140). Pressurized lubricating fluid traveling through the first lay shaft 140 may be routed into the first intermediate bearing mount 150 and used to lubricate both the first bearing 146a and the teeth of the first intermediate gear 142. The outlet orifice may be positioned and sized to provide lubrication in desired areas, such as the teeth of the bearing 146b and / or the third gear 104. Additionally or alternatively, one or more of the fluid passages in the mounting plate 90 may route pressurized lubricating fluid into the first housing member 30, for example, for lubrication of various bearings (e.g., bearings mounted in the first housing member 30 and supporting the second compound gear 210) and / or gear mesh.

[0040]

[0067] 16-19, the multi-speed input portion 92 of the transmission 16 may further include an actuator assembly 300 configured to move the input shaft 108 between a high speed position, a neutral position, and a low speed position. The actuator assembly 300 may be configured in any desired manner, but in the particular example provided, includes an output assembly 300, a slide screw 304, a coupler 306, first and second actuator bearings 308 and 310, and an actuator motor 312.

[0041]

[0068] The output assembly 300 may include a bearing 320 and an axially movable member 322. The bearing 320 may be received on the input shaft 108 and may abut against a shoulder formed on the input shaft 108. The axially movable member 322 may extend between the motor shaft 70 and the rotational axis of the sliding screw 304 and may define bearing apertures and coupler mounts 330 disposed on opposite ends thereof. The bearing 320 may be received in the bearing apertures and fixedly coupled to the axially movable member 322 in any desired manner. In the example provided, an internal snap ring is mounted in a snap ring groove formed in the axially movable member 332 concentric with the bearing aperture b4 and on the axial end of the bearing 320 opposite the axial end that abuts against the shoulder on the input shaft 108. Therefore, the axially movable member 322 is coupled to the input shaft 108 in a manner that prevents relative axial movement between the axially movable member 322 and the input shaft 108, but allows rotation of the input shaft 108 relative to the axially movable member 322.

[0042]

[0069] The slide screw 304 is rotatably disposed about a slide screw axis and includes a slide screw input 340 and an externally threaded portion 342 .

[0043]

[0070] 19A-19C , the coupler 306 can have a mounting flange 352 and an internally threaded hub 350 that can be attached to the coupler mount 330. The internally threaded hub 350 can be threaded onto the externally threaded portion 342 of the lead screw 304. It should be appreciated that the mounting flange 352 and the coupler mount 330 can be configured in any desired shape. In the example provided, the mounting flange 352 has a non-circular cross-sectional area (viewed perpendicular to the longitudinal axis of the internally threaded hub 350), and the coupler mount 330 defines a pocket 330a into which a portion of the mounting flange 352 is received such that the mounting flange 352 is axially and non-rotatably coupled to the coupler mount 330. Therefore, rotation of the lead screw 304 causes corresponding translation of both the coupler 306 and the output assembly 300.

[0044]

[0071] Optionally, one or more coupler pads 1000 may be coupled to the mounting flange 352 and may extend from one or both sides of the mounting flange 352. The coupler pads 1000 may contact the inner surface of the pocket 330a in the coupler mount 330. The coupler pads 1000 may be used for various purposes, such as to help direct the forces transmitted between the coupler 306 and the axially movable member 322 in a desired manner and / or to provide vibration damping between the coupler 306 and the axially movable member 322.

[0045]

[0072] 19B and 19D-19G, the coupler pad 1000 can include a pad member 900 and a protrusion 902. The pad member 900 has a first surface 1002 that abuts the inner surface of the pocket 330a and a second surface 1004 that abuts an associated axial front or rear surface of the coupler 306. One of the first and second surfaces 1002 and 1004 of the pad member 1002 is curved so that contact between each coupler pad 1000 and one of the coupler 306 and axially movable members 322 occurs on an associated line that extends in a plane P that includes the rotation axis SA of the slide screw 304 and is parallel to the shift axis (i.e., the axis along which movement causes shifting, which in the example provided is the motor shaft 70). The protrusion 902 may be configured to be received in an aperture 908 that may be formed in the coupler 306 or the coupler mount 330 such that the protrusion 902 is coupled to the coupler 306 or the coupler mount 330 with a snap or interference fit. In the example provided, the protrusion 902 fits into an aperture 908 formed in the coupler 306.

[0046]

[0073] First and second bearings 308 and 310 may be mounted to the gear case and may support the sliding screw 304 for rotation about the sliding screw axis.

[0047]

[0074] The actuator motor 312 is configured to provide rotational power for driving the sliding screw 304 about the sliding screw axis. The actuator motor 312 can be directly coupled to the sliding screw input, or a reducer, such as a reduction gear set, can be disposed between the actuator motor 312 and the sliding screw input. In the example provided, a reduction gear set utilizing bevel gearing is used. More specifically, the reduction gear set includes an actuator input gear 360 driven directly by the actuator motor 312 about an axis perpendicular to the sliding screw axis, and an actuator output gear 362 meshingly engaged with the actuator input gear 360 and rotatable about the sliding screw axis. It should be appreciated that the reduction gear set can be configured differently and need not utilize bevel gearing. The actuator output gear 362 can be coupled to the sliding screw input in any desired manner. For example, the actuator output gear 362 can be directly coupled to the sliding screw input such that the sliding screw 304 rotates directly with the actuator output gear 362. Alternatively, a torsionally resilient coupling may be used between the actuator output gear 362 and the sliding screw input 340 to provide compliance in one or both rotational directions between the actuator output gear 362 and the sliding screw 304. In the example provided, the torsionally resilient coupling allows the actuator output gear 362 to rotate in cases where the input shaft 108 is not allowed to translate (e.g., due to 1) tooth-to-tooth contact between one of the sets of external splines on the input shaft and one of the sets of internal splines on one of the first or third gears, or between the first and second flank teeth, or 2) the magnitude of the torque applied through the input shaft 108, i.e., torque load).

[0048]

[0075] 16 and 19-22, a park lock mechanism 400 may be incorporated into the multi-speed electric drive axle 10 (FIG. 1). In the example provided, the park lock mechanism 400 is configured to prevent rotation of the third gear 104, thereby preventing rotation of the differential input member 230 (FIG. 5), and thereby preventing rotation of the differential output member 232 (FIG. 5). The park lock mechanism 400 may include a park lock gear 402, a pivot pin 404, a park pole 406, and a park lock plunger assembly 408.

[0049]

[0076] The park lock gear 402 may be fixedly coupled to the third gear 104 and may define a plurality of park lock teeth and a plurality of valleys 420 each circumferentially disposed between an associated pair of the park lock teeth. The pivot pin 404 may be received in a pivot pin aperture formed in the second housing member 32 and may be rotatable about a pivot axis relative to the second housing member 32. In the example provided, the pivot pin 404 is mounted on a bracket 424.

[0050]

[0077] The park pole 406 includes a pole body 430 coupled to the pivot pin 404 for rotation about a pivot axis, and a pole member 432 fixedly coupled to the pole body 430. The pole body 430 is pivotable relative to the park lock gear 402 between a first or locked position in which the park pole 406 is received in the valley 420, thereby preventing rotation of both the park lock gear 402 and the third gear 104 about the motor shaft 70, and a second or unlocked position in which the park pole 406 is disengaged from the park lock gear 402 and does not prevent rotation of the park lock gear 402 about the motor shaft 70. The park pole 406 may optionally include a guide structure 438 that may be attached to the second housing member 32. The guide structure 438 may have a guide member that can guide the pole body 430 as it moves between the first and second positions. Movement of the guide structure 438 caused by corresponding movement of the plunger 450 can cause corresponding pivotal movement of the pole body 430 about the pivot pin 404 .

[0051]

[0078] A biasing spring, such as torsion spring 440, may be used to bias the pole body 430 to the second position. In the example provided, the torsion spring 440 is received on the pivot pin 404 and has a spirally wound portion disposed between two arms. A first end of the arms is attached to the bracket 424, while the other end of the arms is attached to the pole body 430. A feature, such as a head or washer, may be formed on or coupled to the pivot pin 404 to hook the spirally wound portion of the torsion spring 440 onto the pivot pin 404 on the side of the bracket 424 opposite the park pole 406.

[0052]

[0079] The park lock plunger assembly 408 may include a plunger 450, an input member 452, and a compliance spring 454. The plunger 450 is movable along an axis parallel to the motor shaft 70 and has a generally cylindrical first plunger portion, a generally cylindrical second plunger portion, and a tapered transition portion between the first and second plunger portions. The first plunger portion has a first diameter, the second plunger portion is spaced from the first plunger portion and has a second, larger diameter, and the transition portion is disposed between the first and second plunger portions and tapers such that the transition portion has a frustoconical outer surface. The plunger 450 may be translated between a first plunger position in which the first plunger portion contacts the park pole 406 and a second plunger position in which either the transition portion or the second plunger portion contacts the park pole 406. The first plunger position is sized such that the pole body 430 of the park pole 406 is disposed in the second position when the first plunger portion is engaged (in direct contact) with the pole body 430. Translation of the plunger 450 from the first plunger position to the second plunger position brings a relatively larger portion of the plunger 450 into contact with the pole body 430, which pivots the pole body 430 toward the second pole position.

[0053]

[0080] The input member 452 is movable about the translational axis of the plunger 450 and can be moved in any desired manner. In the example provided, an electric park lock motor 460 and a manual park lock input lever 462 are provided as alternative or redundant inputs for operating the park lock mechanism 400, while an output lever 464 is used to coordinate the movement of the input member 452. More specifically, the output lever 464 is coupled to the input member 452 and pivotally coupled to the second housing member 32 for movement between a first input position and a second input position. The manual park lock input lever 462 is fixedly coupled to a portion of the output lever 464 that extends through the second housing member 32 (i.e., such that the manual park lock input lever 462 is disposed outside the gear case). Pivoting movement of the manual park lock input lever 462 about its pivot axis causes corresponding pivoting movement of the output lever 464 about its pivot axis. The electric parking lock motor 460 includes an output shaft 470 mounted to the outer surface of the second housing member 32 and extending into the transmission cavity 38. An intermediate lever 472 is coupled to the output shaft 470 of the electric parking lock motor 460 and can be moved by the electric parking lock motor 460 about the axis of rotation of the output shaft 470 between a first intermediate lever position and a second intermediate lever position. The end of the intermediate lever 472 opposite the output shaft 470 includes a pin received in a slotted aperture in the output lever 464. Movement of the intermediate lever 472 from the first intermediate lever position to the second intermediate lever position (in response to rotation of the output shaft 470) causes pivotal movement of the output lever 464 about its pivot axis from the first input position to the second input position. The slotted aperture in the output lever 464 allows the output lever 464 to be moved about its pivot axis from the first input position to the second input position without corresponding movement of the intermediate lever 472.

[0054]

[0081] The compliance spring 454 is disposed between the input member 452 and the plunger 450 and enables the pole body 430 to push the plunger 450 away from the pole body 430 when the output lever 464 is disposed in the second input position. It should be appreciated that disposing the output lever 464 in the second input position places the input member 452 in a position that would normally position the plunger 450 in the second plunger position. However, in situations where the pole member 432 falls into or is otherwise unable to remain in the valley 420, the park pole 406 can translate the plunger 450 toward the compliance spring 454, compressing the compliance spring 454 so that the park lock gear 402 can rotate.

[0055]

[0082] Substantial portions of both the actuator assembly 300 and the park lock mechanism 400 may be assembled to the second housing member 32 before the second housing member 32 is assembled to the first housing member 30 to close the transmission cavity 38 and the differential cavity 40. In this regard, all or a portion of the reduction gear set (e.g., actuator input gear 360 and actuator output gear 362 in the example provided), bearings 308 and 310, slide screw 304, torsionally resilient coupling (if included), and optionally coupler 306 and / or actuator motor 312 of the actuator assembly 300 may be installed in the second housing member 32 before attaching the second housing member 32 to the first housing member 30. Additionally or alternatively, all of the components of the park lock mechanism 400, except for the park lock gear 402, may be assembled to the second housing member 32 before attaching the second housing member 32 to the first housing member 30.

[0056]

[0083] 23 , the actuator assembly 300a includes an actuator transmission 500 that transfers rotational power between the actuator motor 312 and a coupler 306a. In this example, the sliding screw 304a is non-rotatably but axially slidably coupled to the housing assembly 12a, and the actuator output gear 502 of the actuator transmission 500 is fixedly coupled to the coupler 306a. Therefore, the actuator motor 312 can be operated to rotatably drive the actuator output gear 502. Because the coupler 306a is fixedly coupled to the actuator output gear 502 and threadably coupled to the sliding screw 304a, rotation of the actuator output gear 502 causes corresponding rotation of the coupler 306a, which in turn causes translation of the sliding screw 304a along the motor shaft 70. The sliding screw 304a can be coupled to the input shaft 108 in a manner that allows relative rotation but prevents relative axial movement along the motor shaft 70. In the example provided, bearing 504 is mounted between sliding screw 304a and input shaft 108. Bearing 504 is configured to transmit thrust loads along motor shaft 70 between sliding screw 304a and input shaft 108, and can optionally rotatably support radial loads transmitted between sliding screw 304a and input shaft 108. If desired, lubricant (represented by arrow A) can be routed through sliding screw 304a into the hollow interior of input shaft 108. Optionally, sensor 510 can be mounted to housing assembly 12 and configured to sense the position of sliding screw 304a along motor shaft 70 and generate a sensor signal accordingly.

[0057]

[0084] 24 illustrates a portion of another multi-speed electric drive axle 10b. The transmission 16b of the multi-speed electric drive axle 10b is configured with a planetary arrangement having a sun gear 600, a planet carrier 602, a plurality of planet gears 604, and a ring gear 606 fixedly coupled to the housing assembly 12. Each of the planet gears 604 may be a single gear journaled by the planet carrier 602 and meshingly engaged with both the sun gear 600 and the ring gear 606. Alternatively, each of the planet gears 604 may include two or more gears meshed together and journaled by the planet carrier 602, with one of the gears meshingly engaged with the sun gear 600 and another of the gears meshingly engaged with the ring gear 606. The input shaft 108 is slidable between a first position in which the input shaft 108 is rotatably coupled only to the sun gear 600 so that the transmission 16b operates at a first speed ratio, and a second position in which the input shaft 108 is rotatably coupled to both the sun gear 600 and the planet carrier 602 so that the transmission 16b operates at a second speed ratio different from the first speed ratio.

[0058]

[0085] 25, the transmission 16d includes an auxiliary reduction stage 698 having first and second intermediate gears 700 and 702, respectively, and a lay shaft gear pair having a first lay shaft gear 704 meshingly engaged with the first intermediate gear 700 and a second lay shaft gear 706 coupled to the first lay shaft gear 704 for rotation therewith and meshingly engaged with the second intermediate gear 702. The first and second intermediate gears 700 and 702 are rotatably mounted on the input shaft 108, with a mating spline portion 714 formed on the first intermediate gear 700 and a mating spline portion 712 formed on the second intermediate gear 702.

[0059]

[0086] When the input shaft 108 is positioned in the first position, a splined portion 720 on the motor output shaft 72 engages with a splined portion 730 formed on the input shaft 108, thereby rotatably coupling the input shaft 108 to the motor output shaft 72, another splined portion 732 on the input shaft 108 engages with a mating splined portion 742 on the first drive gear 744, thereby rotatably coupling the first drive gear 744 to the input shaft 108, a splined portion 750 on the input shaft 108 is disengaged from the mating splined portion 714 of the first intermediate gear 700, and a splined portion 752 on the coupling sleeve 754 is engaged only with the mating splined portion 712 of the second intermediate gear 702. As a result, the auxiliary reduction stage 698 is not used to transmit rotational power between the electric motor 14 and the differential assembly 18. It should be appreciated that although the splined portion 752 on the coupling sleeve 754 is engaged with the mating splined portion 712 of the second intermediate gear 702, rotational power is not transmitted between the second intermediate gear 702 and the input shaft 108 because the coupling sleeve 754 is rotatable relative to the input shaft 108. It should be appreciated that the first drive gear 744 is meshingly engaged with an intermediate gear 744 a fixed to the lay shaft, and the lay shaft output gear is meshingly engaged with an output gear fixedly coupled to the lay shaft and coupled to the differential input member 230 for common rotation.

[0060]

[0087] Movement of the input shaft 108 from the first position to the second position disengages the splined portion 732 on the input shaft 108 from the mating splined portion 742 on the drive gear 744, but leaves the splined portion 720 on the motor output shaft 72 engaged with the mating splined portion 730 on the input shaft 108, leaves the splined portion 750 on the input shaft 108 disengaged from the mating splined portion 714 of the first intermediate gear 700, and leaves the splined portion 752 on the coupling sleeve 754 engaged only with the mating splined portion 712 of the second intermediate gear 702. In this position, no rotational power is transferred between the drive gear 744 and the motor output shaft 72, and therefore, the transmission 16d operates in a “neutral” condition such that no rotational power is transferred between the differential input member 230 and the motor output shaft 72.

[0061]

[0088] Movement of the input shaft 108 from the second position to the third position engages the spline portion 750 on the input shaft 108 with the mating spline portion 714 of the first intermediate gear 700 and engages the spline portion 752 on the connecting sleeve 754 with the mating spline portion 760 on the second drive gear 762, while simultaneously keeping the spline portion 720 on the motor output shaft 72 engaged with the mating spline portion 730 on the input shaft 108, keeping the spline portion 732 on the input shaft 108 disengaged from the mating spline portion 742 on the drive gear 744, and keeping the spline portion 752 on the connecting sleeve 754 engaged with the mating spline portion 712 of the second intermediate gear 702. In this position, rotational power provided by the motor output shaft 72 is transferred to the first intermediate gear 700 (via a splined portion 750 on the input shaft 108 and a mating splined portion 714 of the first intermediate gear 700). The auxiliary reduction stage 698 performs speed reduction and torque multiplication functions, with a first speed reduction and torque multiplication function provided by the first intermediate gear 200 and the first lay shaft gear 204 and a second speed reduction and torque multiplication function provided by the second lay shaft gear 206 and the second intermediate gear 702. A coupling sleeve 754 rotatably couples the second intermediate gear 702 to a second drive gear 762 to drive the second drive gear 762 about the motor shaft 70. It should be appreciated that when the input shaft 108 is positioned in the third position, the second drive gear 762 is driven at a reduced speed compared to the rotational speed of the first drive gear 744 when the input shaft 108 is in the first position because the auxiliary reduction stage 698 is actively used to transfer rotational power between the motor output shaft 72 and the differential assembly 18 when the input shaft 108 is in the third position (i.e., the second drive gear 762 is operated at a reduced rotational speed compared to the rotational speed of the motor output shaft 72 due to the speed reduction provided by the auxiliary reduction stage 698). It should be appreciated that the second drive gear 762 is drivingly engaged with another intermediate gear 762 a fixed to the lay shaft, thereby driving the lay shaft and the lay shaft output gear.

[0062]

[0089] It should be appreciated that the first intermediate input gear 744, the second intermediate input gear 700, the third intermediate gear 702, and the fourth intermediate gear 762 are coaxial with the input shaft 108 and are rotatable relative to the input shaft 108 at at least one of a first speed ratio and a second speed ratio. Additionally, the input shaft 108 is axially movable along the motor axis 70 between a first position in which a first one of the at least three axial gears (i.e., the first intermediate input gear 744, the second intermediate input gear 700, the third intermediate gear 702, and the fourth intermediate gear 762) is rotatably coupled to the input shaft 108 and a second position in which a second, different one of the at least three axial gears is rotatably coupled to the input shaft.

[0063]

[0090] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, may be interchangeable and used in selected embodiments even if not specifically shown or described. The same may also be modified in many ways. Such variations are not to be considered a departure from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. An electric drive axle (10), comprising: a housing assembly (12); an electric motor (14) coupled to the housing assembly (12) and having a motor shaft (72) rotatable about a motor axis (70); a differential assembly (18) received in the housing assembly (12), wherein the differential assembly (18) has a differential input member (230) rotatable about an output shaft (58) and a pair of differential output members (232) rotatable about the output shaft (58); a transmission (16) received in the housing assembly (12) and transmitting rotational power between the motor shaft (72) and the differential input member (230); wherein the transmission (16) includes an input shaft (108) rotatably coupled to the motor shaft (72) and axially movable along the motor shaft (70); a multi-speed reducer (92) including a reduction gear set (100, 106, 102), an output gear (104), and a connecting sleeve (110), wherein the reduction gear set (100, 106, 102) includes an intermediate input gear (100) and an intermediate output gear (102), and the connecting sleeve (110) is coaxially disposed on the input shaft (108); the coupling sleeve (110) is axially fixed to the input shaft (108) but rotatable about the input shaft (108), the input shaft (108) being movable along the motor axis (70) between a first position in which the output gear (104) is coupled to the input shaft (108) to rotate therewith, and a second position in which the intermediate input gear (100) is coupled to the input shaft (108) to rotate therewith, the coupling sleeve (110) rotatably coupling the intermediate output gear (102) to the output gear (104) when the input shaft (108) is in the second position; An electric drive axle (10).

2. 2. The electric drive axle of claim 1, wherein the input shaft is movable along the output shaft to a neutral position between the first position and the second position, and when the input shaft is in the neutral position, the coupling sleeve is rotatably decoupled from the intermediate output gear, and the input shaft is rotatably decoupled from both the intermediate input gear and the output gear.

3. 2. The electric drive axle of claim 1, wherein the transmission further includes a single speed section having a transmission output gear rotatably coupled to the differential input member, the single speed section receiving rotational power from the output gear of the multi-speed reducer.

4. 4. The electric drive axle of claim 3, wherein the single speed portion includes a first intermediate gear meshingly engaged with the output gear of the multi-speed reducer and a second intermediate gear coupled to the first intermediate gear for rotation therewith, the second intermediate gear meshingly engaged with the transmission output gear.

5. 5. The electric drive axle of claim 4, wherein the single speed portion includes a third intermediate gear meshingly engaged with the output gear of the multi-speed reducer, and a fourth intermediate gear coupled to the third intermediate gear for rotation therewith, the fourth intermediate gear meshingly engaged with the transmission output gear.

6. 2. The electric drive axle of claim 1, further comprising an actuator assembly having an axially movable member, the input shaft being axially fixed to the axially movable member but rotatable relative to the axially movable member.

7. 7. The electric drive axle of claim 6, wherein the actuator assembly includes at least one bearing disposed between the input shaft and the axially movable member.

8. The electric drive axle (10) of claim 7, wherein the at least one bearing (320) comprises a pair of thrust bearings (320a).

9. 7. The electric drive axle of claim 6, wherein the actuator assembly includes an actuator having an actuator motor, a screw driven by the actuator motor, and a coupler threadedly coupled to the screw and engaged with the axially movable member.

10. 10. The electric drive axle of claim 9, wherein a pocket is formed in the axially movable member, and a portion of the coupler is received in the pocket to couple the axially movable member to the coupler for movement with the coupler along the axis of rotation of the thread.

11. 11. The electric drive axle of claim 10, wherein the pocket and the portion of the coupler have mating non-circular cross-sectional shapes taken perpendicular to the axis of rotation of the threads.

12. The intermediate input gear (100) has a first set of internal splines (114), the intermediate output gear (102) has a second set of internal splines (124), the output gear (104) has a third set of internal splines (134), the input shaft (108) has a first set of external splines (160) engageable with the first set of internal splines (114) to rotatably couple the intermediate input gear and the input shaft (108) together, and the coupling sleeve (1 2. The electric drive axle of claim 1, wherein the connecting sleeve and the intermediate output gear have a second set of external splines meshingly engaged with the second set of internal splines to rotatably couple the connecting sleeve and the intermediate output gear, and the input shaft has a third set of external splines engagable with the third set of internal splines to rotatably couple the input shaft to the output gear.

13. 2. The electric drive axle of claim 1, wherein the output gear has a first set of engagement features and the coupling sleeve has a second set of engagement features engageable with the first set of engagement features to rotatably couple the coupling sleeve to the output gear.

14. The electric drive axle (10) of claim 13, wherein the first and second sets of engagement features (135, 182) comprise face teeth.

15. 2. The electric drive axle of claim 1, wherein the housing assembly includes a carrier housing and a pair of axle tubes, the carrier housing being formed by a pair of housing members joined together across a plane transverse to the output shaft, each of the housing members defining an axle tube mount, and each of the axle tubes being received in a corresponding one of the axle tube mounts.

16. 2. The electric drive axle of claim 1, further comprising a pair of wheel hubs and a pair of axle shafts, each of the wheel hubs rotatably mountable on the housing assembly, and each of the axle shafts rotatably coupling one of the differential output members to a corresponding one of the wheel hubs.

17. 2. The electric drive axle of claim 1, further comprising: an actuator assembly having an actuator motor; a screw non-rotatably but axially slidably coupled to the housing assembly; a coupler threadedly coupled to the screw; and an actuator transmission transmitting rotational power between the actuator motor and the coupler, the actuator transmission being driven by the actuator motor and having an actuator output gear rotatable about a longitudinal axis of the screw, the coupler being fixedly coupled to the actuator output gear.

18. An electric drive axle (10), comprising: a housing assembly (12); an electric motor (14) coupled to the housing assembly (12) and having a motor shaft (72) rotatable about a motor axis (70); a differential assembly (18) received in the housing assembly (12), wherein the differential assembly (18) has a differential input member (230) rotatable about an output shaft (58) and a pair of differential output members (232) rotatable about the output shaft (58); a transmission (16d) received in the housing assembly (12) and transmitting rotational power between the motor shaft (72) and the differential input member (230); wherein the transmission (16d) includes an input shaft (108) rotatably coupled to the motor shaft (72) and axially movable along the motor axis (70); a first reduction gear set (744, 744a); a second reduction gear set (698, 762, 762a, 704, 706); and a coupling sleeve (706). 54), the first reduction gear set (744, 744a) has a first intermediate input gear (744) and a first intermediate output gear (744a), the first intermediate output gear (744a) is axially slidably and rotatably disposed on the input shaft (108), the first intermediate output gear (744a) is meshingly engaged with the first intermediate input gear (744) and is rotatable about an intermediate axis parallel to the motor shaft (70), and the second reduction gear set (698, 762, 762a, 704,706) has a second intermediate input gear (700), a second intermediate output gear (762a), a first intermediate gear (704), a second intermediate gear (706), a third intermediate gear (702), and a fourth intermediate gear (762), and the input shaft (108) is rotatable and axially slidable relative to the second intermediate input gear (700), the third intermediate gear (702), and the fourth intermediate gear (762), and the first The intermediate gear (704) is meshingly engaged with the second intermediate input gear (700), the second intermediate gear (706) is coupled to the first intermediate gear (704) for rotation therewith, and meshingly engaged with the third intermediate gear (702), the fourth intermediate gear (762) is meshingly engaged with the second intermediate output gear (762a), and the coupling sleeve (754) is coupled to the input shaft (702). a motor shaft (700) coupled to the input shaft (108) for rotation about the first intermediate input gear (744) but translational movement therewith along the motor axis (70), the input shaft (108) being movable between a first position in which the input shaft (108) is rotatably coupled to the first intermediate input gear (744) and the coupling sleeve (754) is rotatably decoupled from at least one of the third intermediate gear (702) and the fourth intermediate gear (762), and a second position in which the input shaft (108) is rotatably decoupled from the first intermediate input gear (744), the input shaft (108) is rotatably coupled to the second intermediate input gear (700), and the coupling sleeve (754) rotatably couples the third intermediate gear (702) and the fourth intermediate gear (762) to one another; An electric drive axle (10).

19. An electric drive axle (10), comprising: a housing assembly (12); an electric motor (14) coupled to the housing assembly (12) and having a motor shaft (72) rotatable about a motor axis (70); a differential assembly (18) received in the housing assembly (12), wherein the differential assembly (18) has a differential input member (230) rotatable about an output shaft (58) and a pair of differential output members (232) rotatable about the output shaft (58); a transmission (16; 16d) received in the housing assembly (12) and transmitting rotational power between the motor shaft (72) and the differential input member (230); wherein the transmission (16) has a multi-speed reducer (92) selectively operable at a first speed ratio and a second speed ratio, the multi-speed reducer (92) having an input shaft (108) and at least three axial gears (100, 102, 104; 744, 762, 702, 750), the input shaft (108) being rotatably coupled to the motor shaft (72) and the at least three axial gears (100, 102, 104; 744, 762, 702, 750) each of the at least three axial gears (100, 102, 104; 744, 762, 702, 750) is coaxial with the input shaft (108) and rotatable relative to the input shaft (108) at at least one of the first and second speed ratios, the input shaft (108) being movable axially along the motor axis (70) between a first position in which a first one of the at least three axial gears (100, 102, 104; 744, 762, 702, 750) is rotatably coupled to the input shaft (108) and a second position in which a second one of the at least three axial gears (100, 102, 104; 744, 762, 702, 750) is rotatably coupled to the input shaft (108); An electric drive axle (10).

20. An electric drive axle (10), comprising: A housing assembly (12) having a housing member (30), wherein said housing member (30) defines a first bearing mount (150); an electric motor (14) coupled to the housing assembly (12) and having a motor shaft (72) rotatable about a motor axis (70); a differential assembly (18) received in the housing assembly (12), wherein the differential assembly (18) has a differential input member (230) rotatable about an output shaft (58) and a pair of differential output members (232) rotatable about the output shaft (58); a mounting plate (90) coupled to said housing assembly (12), wherein said mounting plate (90) defines a second bearing mount (152); a transmission (16) received in the housing assembly (12) and transmitting rotational power between the motor shaft (72) and the differential input member (230), wherein the transmission (16) has a compound gear (106) including a lay shaft (140), a first intermediate gear (142), and a second intermediate gear (144) coupled together for common rotation about an intermediate shaft (148); a first bearing (146a) received in the first bearing mount (150) and supporting a first end of the lay shaft (140) for rotation about the intermediate axis (148) relative to the housing member (30); a second bearing (146b) mounted in the second bearing mount (152) and supporting a second end of the lay shaft (140) for rotation about the intermediate axis (148) relative to the mounting plate (90); a lubrication gallery (266) formed in the mounting plate (90), the lubrication gallery (266) being in fluid communication with the first and second bearing mounts (150, 152).

21. 21. The electric drive axle (10) of claim 20, wherein a longitudinal passage is formed in the layshaft (140), and the lubrication gallery (266) is in fluid communication with the longitudinal passage.

22. 21. The electric drive axle of claim 20, wherein the transmission has a multi-speed reducer including an intermediate input gear rotatable about an input shaft parallel to the intermediate shaft and in driving engagement with the first intermediate gear, and an intermediate output gear rotatable about the input shaft and in meshing engagement with the second intermediate gear.

23. 23. The electric drive axle (10) of claim 22, wherein the multi-speed reducer includes an output gear (104) rotatable about the input shaft (70), the output gear (104) coupled to the intermediate output gear (102) for rotation therewith when the multi-speed reducer is operated at a first speed ratio.

24. 24. The electric drive axle (10) of claim 23, wherein the output gear (104) is rotatable relative to the intermediate output gear (102) when the multi-speed reducer is operated at a second speed ratio.

25. 25. The electric drive axle of claim 24, wherein the multi-speed reducer includes an input shaft movable along the input shaft, the input shaft coupled to the intermediate input gear for common rotation about the input shaft when the multi-speed reducer is operated at the first speed ratio, the input shaft coupled to the compound gear, and the input shaft coupled to the output gear for common rotation about the input shaft when the multi-speed reducer is operated at the second speed ratio.

26. 24. The electric drive axle of claim 23, further comprising a third bearing received in a bearing mount formed in the mounting plate, the third bearing supporting the output gear for rotation about the input shaft relative to the mounting plate.

27. 27. The electric drive axle (10) of claim 26, wherein the lubrication gallery (266) includes a fluid passage (274) in fluid communication with the bearing mount (164b) in the mounting plate (90).

28. 21. The electric drive axle (10) of claim 20, wherein the first intermediate gear (142) extends outwardly of the mounting plate (90).

29. An electric drive axle (10), comprising: A housing assembly (12) having first and second housing members (30, 32) cooperating to define a transmission cavity (38) between the first and second housing members (30, 32), wherein the second housing member (32) defines a second mount and pivot pin (404) aperture; a transmission received in said transmission cavity (38), wherein said transmission has gears supported by bearings, said bearings being received in bearing mounts; Park lock mechanism (400) The parking lock mechanism (400) comprises: a park lock gear (402) coupled to rotate with the transmission elements; a pivot pin (404) received in the pivot pin aperture and rotatable relative to the second housing member (32) about a pivot axis; a park pole (406) coupled to the pivot pin (404) for co-rotation about the pivot axis between an engagement position where the park pole (406) is engaged with the park lock gear (402) and a disengagement position where the park pole (406) is disengaged from the park lock gear (402); a spring (440) biasing the park pole (406) out of engagement with the park lock gear (402); a park lock plunger assembly (408) having an input member, a plunger (450), and a compliance spring (454), wherein the input member is disposed along an actuation axis, the plunger (450) is slidably disposed on the input member and is movable along the actuation axis between a first position and a second position, the actuation axis being parallel to the pivot axis, movement of the plunger from the first position toward the second position causes corresponding movement of the park pawl (406) toward the engaged position, and placement of the plunger in the second position enables the spring to move the park pawl (406) to the disengaged position, and the compliance spring (454) is coaxially disposed on the input member and biases a head of the input member away from the plunger (450); An electric drive axle (10).

30. 30. The electric drive axle (10) of claim 29, wherein the park lock mechanism (400) further includes a park lock actuator coupled to the second housing member (32) and selectively operable to translate the input member along the actuation axis.

31. 31. The electric drive axle (10) of claim 30, wherein the park lock actuator includes a lever pivotable about a lever axis perpendicular to the actuation axis, the lever coupled to the input member such that pivotal movement of the lever causes corresponding translation of the input member.

32. 32. The electric drive axle (10) of claim 31, wherein the park lock actuator further includes a locking mechanism having a latch engageable with the lever to prevent pivotal movement of the lever about the lever axis.

33. 33. The electric drive axle of claim 32, wherein the parking lock mechanism further comprises a guide structure attached to the second housing member, the guide structure configured to guide the plunger for movement between the first position and the second position.

34. 34. The electric drive axle (10) of claim 33, wherein the locking mechanism is attached to the guide structure (438).

35. 32. The electric drive axle (10) of claim 31, wherein the park lock actuator further includes a park lock motor having a motor output member rotatable about a motor axis, the motor output member coupled to the lever such that rotation of the motor output member about the motor axis causes corresponding rotation of the lever about the lever axis.

36. 32. The electric drive axle (10) of claim 31, wherein the park lock actuator further includes a manual input lever coupled to the lever for rotation therewith about the lever axis.

37. A method for assembling an electric drive axle (10), said method comprising: providing a first housing member; assembling a transmission to the first housing member, wherein the transmission includes gears supported on bearings; providing a second housing member (32), wherein said second housing member (32) defines a bearing mount; a park lock mechanism (400) installed in the second housing member (32), wherein the park lock mechanism (400) has a park lock gear (402), a pivot pin (404), a park pole (406), a spring, and a park lock plunger assembly (408), wherein the park lock gear (402) is coupled to rotate with elements of the transmission, the pivot pin (404) is received in a pivot pin aperture and is rotatable relative to the second housing member (32) about a pivot axis, the park pole (406) is coupled to the pivot pin (404) to rotate in common about the pivot axis between an engaged position where the park pole (406) is engaged with the park lock gear (402) and a disengaged position where the park pole (406) is disengaged from the park lock gear (402), and the spring is adapted to disengage the park pole (406) from engagement with the park lock gear (402). the park lock plunger assembly (408) includes an input member, a plunger (450), and a compliance spring (454), the input member disposed along an actuation axis, the plunger (450) slidably disposed on the input member and movable along the actuation axis between a first position and a second position, the actuation axis being parallel to the pivot axis of the plunger (450), movement of the plunger from the first position toward the second position causes corresponding movement of the park pole (406) toward the engaged position, and placement of the plunger in the second position enables the spring to move the park pole (406) to the disengaged position, and the compliance spring (454) is coaxially disposed on the input member and biases the head of the input member away from the plunger (450); installing the bearings in the bearing mounts and assembling the second housing member (32) to the first housing member (30, 32) to enclose the transmission, the park lock gear (402), the pivot pin (404), the park pole (406), and the park lock plunger assembly within a housing assembly (12) formed by the first and second housing members (30, 32); A method comprising:

38. 1. A vehicle driveline component comprising: a housing assembly (12); a multi-speed reducer (92) received in the housing assembly (12), wherein the multi-speed reducer has a movable element (108) movable along a shift axis (70) between a first position and a second position, wherein disposing the movable element (108) in the first position causes the multi-speed reducer to operate at a first reduction ratio, and disposing the movable element (108) in the second position causes the multi-speed reducer to operate at a second reduction ratio different from the first reduction ratio; an actuator assembly (300) having an actuator motor (312), a screw (304), an actuator output member (322), a coupler (306), and at least one coupler pad (1000), wherein the screw (304) is driven by the actuator motor (312) about a rotational axis of the screw (304) parallel to the shift axis (70), and the actuator output member (322) has a first end and and a second end opposite the first end, the movable element (108) of the multi-speed reducer (92) being axially fixed to the first end of an axially movable member (322) but rotatable relative to the first end of the axially movable member (322), the second end of the axially movable member (322) defining a pocket (330a), the coupler (306) being threadably coupled to the screw (304), and the pocket and each of the at least one coupler pads (1000) is received in the pocket (330a) and attached to one of the coupler (306) and the axially movable member (322), and each of the at least one coupler pads (1000) has a first surface (1002) that abuts an associated surface (1004) of the axially movable member (322) and an associated surface (1004) of the coupler (306). and a second surface (1006) abutting against the first surface (1008) of the at least one coupler pad (1000), wherein one of the first and second surfaces (1002, 1006) of each of the at least one coupler pad (1000) is curved such that contact between the other of the coupler (306) and the axially movable member (322) and each of the at least one coupler pad (1000) occurs over an associated line (1010) extending in a plane (P) containing the screw axis (SA); A vehicle driveline component comprising:

39. 39. The vehicle driveline component of claim 38, wherein at least one of the coupler pads includes a pad member having the first and second surfaces formed thereon, and a protrusion received in a recess formed in the one of the coupler and the axially movable member.

40. 40. The vehicle driveline component of claim 38, wherein each of the at least one coupler pads engages the coupler to prevent rotation of the coupler relative to the axially movable member.

Images