Electric drive module configured as a beam axle

Abstract

This invention relates to an electric drive module configured as a beam axle. [Solution] The carrier housing 50e of the electric drive module 10e includes a central section 310 and a pair of end covers 312. The central section 310 defines an axle tube fitting 56 and first and second flanges parallel to and spaced apart from the output shaft, respectively. Each of the end covers 312 defines an associated motor fitting 58, which is configured to receive therein one associated electric motor assembly 14 and to house each one pinion gear and a pair of compound gears of the transmission. The end covers 312 cooperate with the central section 310 to form an internal cavity into which a differential and a single or common transmission output gear are received.

Description

Cross - reference to related applications

[0001]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 161218, filed Mar. 15, 2021; U.S. Provisional Patent Application No. 63 / 178985, filed Apr. 23, 2021; and U.S. Provisional Patent Application No. 63 / 220204, filed Jul. 9, 2021. The disclosures of the applications referenced above are incorporated by reference as if fully and specifically set forth herein.

Technical Field

[0002]

[0002] The present invention relates to an electric drive module configured as a beam axle.

Background Art

[0003]

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

[0004]

[0004] The demand for electric commercial delivery vehicles is increasing. One challenge faced by vehicle manufacturers is the integration of electric propulsion into vehicle skeletons that were developed for and continue to support powertrains including internal combustion engines. Various solutions have been proposed, but none of these solutions have been widely commercially accepted.

Summary of the Invention

[0005]

[0005] This section provides a general overview of the present disclosure and is not an exhaustive disclosure of its full scope or all of its features.

[0006]

[0006] In one embodiment, the present disclosure provides an electric drive module comprising a housing, a pair of axle tubes, an electric motor, a transmission, a first bearing, and a differential. The housing has a motor mount and a pair of axle tube mounts. The motor mount defines the motor output shaft axis. The axle tube mount is parallel to the motor output shaft axis and is arranged along the output shaft offset therefrom. The pair of axle tubes are received in the axle tube mount and are fixedly coupled to the housing. The electric motor has a motor output shaft and is mounted in the motor mount such that the motor output shaft is rotatable about the motor output shaft axis. The transmission includes a pinion gear received in the housing and coupled to the motor output shaft to rotate together, a pair of first compound gears, and a transmission output gear rotatable about the output shaft. Each of the first compound gears has a first gear that meshes and engages with the pinion gear and a second gear that is fixedly coupled to the first gear. The first composite gear transmits rotational power between the pinion gear and the transmission output gear. The first bearing is coupled to the housing and the transmission output gear and supports the transmission output gear axially along the output shaft and radially around the output shaft. The differential has a differential input member fixedly coupled to the transmission output gear and a pair of differential output members rotatable relative to the differential input member about the output shaft.

[0007]

[0007] In another embodiment, the present disclosure provides an electric drive module comprising a motor assembly, an output gear, a differential assembly, a transmission assembly, a housing assembly, and a heat exchanger. The motor assembly comprises a stator, a rotor, a motor output shaft, and a motor controller. The rotor is housed in the stator and is rotatable relative to the stator about the axis of the motor output shaft. The motor output shaft is coupled to the rotor to rotate together with it. The motor controller is configured to control the rotational speed of the rotor relative to the stator. The motor controller includes an inverter. The output gear is rotatable about the output shaft. The differential assembly comprises a differential input member and a pair of differential output members. The differential input member is coupled to the output gear to rotate together with it about the output shaft. Each of the differential output members is rotatable about the output shaft relative to the differential input member. The transmission is configured to transmit rotational power between the motor output shaft and the output gear. The housing assembly comprises a first housing portion and a second housing portion. The transmission is at least partially housed in the first housing portion. The second housing portion has a first axial end and a heat exchanger fitting. The first axial end of the second housing portion is removably attached to the first housing portion. The second housing portion houses the stator, the rotor, and at least a portion of the motor controller, including the inverter. The housing assembly defines a sump, a pump fitting, and a filter fitting. The sump is configured to hold a first fluid used in the electric drive module to lubricate the motor assembly, the differential assembly, and the transmission, and to cool the motor assembly. The heat exchanger is mounted on the heat exchanger fitting on the second housing portion. The heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet. The pump fitting is in fluid communication with the sump. A first internal gallery in the housing assembly fluidly couples the pump fitting to the inlet on the filter fitting.A second internal gallery in the housing assembly fluid-couples its outlet on a filter fixture to the heat exchanger inlet. A third internal gallery in the housing assembly fluid-couples directly to at least one heat exchanger outlet. A first portion of the first fluid delivered through the third internal gallery is directed into at least one of the stator and rotor to cool the motor assembly. A second portion of the first fluid delivered through the third internal gallery is directed into the first housing portion to lubricate at least one of the transmission and differential assemblies.

[0008]

[0008] In another embodiment, the present disclosure provides an electric drive module comprising a motor assembly, an output gear, a differential assembly, a transmission, a housing assembly, a pump, and a heat exchanger. The motor assembly comprises a stator, a rotor, a motor output shaft, and a motor controller. The rotor is housed in the stator and is rotatable relative to the stator about the axis of the motor output shaft. The motor output shaft is coupled to the rotor to rotate together with it. The motor controller is configured to control the rotational speed of the rotor relative to the stator. The motor controller includes an inverter. The output gear is rotatable about the output shaft. The differential assembly comprises a differential input member and a pair of differential output members. The differential input member is coupled to the output gear to rotate together with it about the output shaft. Each of the differential output members is rotatable about the output shaft relative to the differential input member. The transmission is configured to transmit rotational power between the motor output shaft and the output gear. The housing assembly comprises a first housing portion, a second housing portion, and a cover. The transmission is at least partially housed in the first housing portion. The second housing portion has a first axial end and a heat exchanger fitting. The first axial end of the second housing portion is removablely attached to the first housing portion. The second housing portion houses the stator, the rotor, and at least a portion of the motor controller, including the inverter. A cover closes the end of the second housing portion opposite to the first housing portion. The housing assembly defines a sump configured to hold a first fluid. The first fluid is used in the electric drive module to lubricate the motor assembly, the differential assembly, and the transmission, and to cool the motor assembly. A pump is coupled to the housing assembly so that the pump is fluidly coupled to the sump and receives the first fluid from there. The pump is configured to discharge the flow of the first fluid. The heat exchanger is mounted to a heat exchanger fitting on the second housing portion. The heat exchanger has a heat exchanger inlet, a first heat exchanger outlet, and a second heat exchanger outlet.A first internal gallery is formed in the housing assembly. The first gallery receives at least a portion of the flow of a first fluid. The first internal gallery is fluid-coupled directly to the heat exchanger inlet so that the first fluid discharged from the first internal gallery is received into the heat exchanger. A second internal gallery is formed in the housing assembly. The second internal gallery is fluid-coupled directly to the outlet of the first heat exchanger so that a first portion of the first fluid discharged from the heat exchanger is received into the second internal gallery. The first portion of the first fluid is directed into the first housing portion to lubricate at least one of the transmission and differential assemblies. A third internal gallery is formed in the cover. The third internal gallery is fluid-coupled directly to the outlet of the second heat exchanger so that a second portion of the first fluid discharged from the heat exchanger is directed into the cover. The first fluid exiting the cover is directed into at least one of the stator and rotor to cool the motor assembly.

[0009]

[0009] In another embodiment, the present disclosure provides an electric drive module comprising a beam axle housing, a differential assembly, a pair of axle shafts, a multiphase electric motor, and a transmission. The beam axle housing has a central portion and a pair of axle tubes fixedly coupled to the central portion and extending laterally from the lateral sides thereof. The differential assembly has a differential input member received in the central portion and rotatable about an output shaft relative to the central portion, and a pair of differential output members rotatable about an output shaft relative to the differential input member. Each of the pair of axle shafts is received in one of the axle tubes and coupled to one of the differential output members to rotate together about an output shaft. The multiphase motor assembly has a motor housing, a stator, a rotor, and an inverter. The motor housing is fixedly coupled to the central portion of the beam axle housing. The stator has a stator core and a plurality of field windings wound around the stator core. Each of the field windings is associated with a different electrical phase. The stator is housed within the motor housing and fixedly coupled to it. The rotor is rotatable relative to the stator about the motor output shaft axis. The rotor has the motor output shaft. The inverter is housed within the motor housing and electrically coupled to the field windings. The inverter is configured to control the supply of power to each of the field windings. The transmission is housed within the central section and transmits rotational power between the motor output shaft and the differential input member.

[0010]

[0010] In another embodiment, the present disclosure provides an electric drive module comprising a carrier housing, a pair of axle tubes, a differential assembly, a first transmission housing, a first motor assembly, a first transmission, and a pair of axle shafts. The carrier housing defines a pair of axle tube apertures. Each of the pair of axle tubes is received into the associated one of the pair of axle tube apertures and is fixedly coupled to the carrier housing. The differential assembly is rotatably mounted to the carrier housing and has a pair of differential output members. The first transmission housing is removably coupled to the carrier housing. The first motor assembly comprises a first motor housing and a first electric motor having a first stator and a first rotor. The first motor housing is coupled to the first transmission housing. The first stator is fixedly coupled to the first motor housing. The first rotor is received in the first stator and has a first motor output shaft rotatable about the axis of the first motor output shaft. The first transmission is housed in the first transmission housing and transmits rotational power between the first motor output shaft and the differential assembly. Each of the pair of axle shafts extends through the associated one of the pair of axle tubes and is driven-engaged to the corresponding one of the differential output members.

[0011]

[0011] In a further embodiment, the present disclosure provides an electric drive module comprising a beam axle housing, a differential assembly, a pair of axle shafts, a pair of multiphase motor assemblies, and a pair of transmissions. The beam axle housing comprises a central portion and a pair of axle tubes. The central portion comprises two clamshell halves, each defining an axle tube aperture. Each axle tube is received in the axle tube aperture and is fixedly coupled to the associated clamshell halves such that the axle tube extends laterally from the lateral sides of the central portion. The differential assembly comprises a differential input member received in the central portion and rotatable about an output shaft relative to the central portion, and a pair of differential output members rotatable about an output shaft relative to the differential input member. Each of the pair of axle shafts is received in the associated axle tube and coupled to the associated differential output member to rotate together about an output shaft. Each multiphase motor assembly comprises a motor housing, a stator, a rotor, and an inverter. The motor housing is fixedly coupled to the central portion of the beam axle housing. The stator has a stator core and multiple field windings wound around the stator core. Each of the field windings is associated with a different electrical phase. The stator is received within the motor housing and fixedly coupled thereto. The rotor is rotatable relative to the stator about the motor output shaft axis and includes the motor output shaft. The inverter is housed within the motor housing and electrically coupled to the field windings. The inverter is configured to control the supply of power to each of the field windings. Each transmission is received within the central portion and transmits rotational power between one of the motor output shafts and a differential input member.

[0012]

[0012] Further areas of applicability will become apparent from the descriptions provided herein. The descriptions and specific examples in this summary are for illustrative purposes only and are not intended to limit the scope of this disclosure.

[0013]

[0013] The drawings described herein are intended to illustrate selected embodiments only, and not all possible implementations, and are not intended to limit the scope of this disclosure. [Brief explanation of the drawing]

[0014] [Figure 1]

[0014] This is a front perspective view of an exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 2]

[0015] Figure 1 is a rear perspective view of the electric drive module. [Figure 3]

[0016] Figure 1 is a perspective view of a portion of the electric drive module, in which a portion of the housing assembly has been removed to better illustrate the transmission, differential assembly, and portion of the electric motor assembly. [Figure 4]

[0017] This is a cross-sectional view of a portion of the electric drive module shown in Figure 1. [Figure 5]

[0018] Figure 1 is a perspective view of a portion of an electric drive module illustrating the configuration of an axle tube assembly. [Figure 6]

[0019] This is a cross-sectional view of a portion of the electric drive module in Figure 1, seen through the axle tube assembly and the wheel mounting fixture on the axle shaft. [Figure 7]

[0020] This is a front perspective view of a second illustrative electric drive module constructed in accordance with the teachings of this disclosure. [Figure 8]

[0021] Figure 7 shows a cross-sectional view seen through the electric drive module, illustrating the transmission. [Figure 9] Figure 7 shows a cross-sectional view seen through the electric drive module, illustrating the transmission. [Figure 10]

[0022] This is a front perspective view of a third illustrative electric drive module constructed in accordance with the teachings of this disclosure. [Figure 11]

[0023] It is a rear perspective view of the electric drive module of FIG. 10. [Figure 12]

[0024] It is a side elevation view of the electric drive module of FIG. 10. [Figure 13]

[0025] It is a cross-sectional view of a part of the electric drive module of FIG. 10. [Figure 14]

[0028] It is a rear perspective view of a fourth exemplary electric drive module constructed in accordance with the teachings of the present disclosure. [Figure 15] It is a rear perspective view of a fourth exemplary electric drive module constructed in accordance with the teachings of the present disclosure. [Figure 16]

[0029] It is a side elevation view of the electric drive module of FIG. 14. [Figure 17]

[0030] It is a cross-sectional view of a part of the electric drive module of FIG. 14. [Figure 18]

[0031] It is a front perspective view of a part of a fifth exemplary electric drive module constructed in accordance with the teachings of the present disclosure. [Figure 19]

[0032] It is a side elevation view of the electric drive module of FIG. 18. [Figure 20]

[0033] It is a cross-sectional view taken along line 20-20 of FIG. 19. [Figure 21]

[0034] It is a cross-sectional view taken along line 21-21 of FIG. 19. [Figure 22]

[0035] It is a cross-sectional view taken along line 22-22 of FIG. 19. [Figure 23]

[0036] It is a rear perspective view of a sixth exemplary electric drive module constructed in accordance with the teachings of the present disclosure. [Figure 24] It is a rear perspective view of a sixth exemplary electric drive module constructed in accordance with the teachings of the present disclosure. [Figure 25]

[0037] It is a side elevation view of the electric drive module of FIG. 23. [Figure 26]

[0038] It is a cross-sectional view taken along line 26-26 of FIG. 25. [Figure 27]

[0039] This is a cross-sectional view along line 27-27 in Figure 25. [Figure 27A]

[0040] This is a perspective view of an electric drive module that uses two electric drive assemblies, similar to the one in Figure 23. [Figure 28]

[0041] This is a rear perspective view of a seventh exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 29] This is a rear perspective view of a seventh exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 30]

[0042] This is a side elevation view of the electric drive module shown in Figure 28. [Figure 31]

[0043] This is a cross-sectional view along line 31-31 in Figure 30. [Figure 32]

[0044] This is a cross-sectional view along line 32-32 in Figure 30. [Figure 33]

[0045] This is a cross-sectional view along line 33-33 in Figure 30. [Figure 34]

[0046] This is a rear perspective view of a portion of an eighth exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 35] This is a rear perspective view of a portion of an eighth exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 36]

[0047] This is a side elevation view of the electric drive module shown in Figure 34. [Figure 37]

[0048] This is a cross-sectional view along line 37-37 in Figure 36. [Figure 38]

[0049] This is a cross-sectional view along line 38-38 in Figure 36. [Figure 39]

[0050] This is a cross-sectional view along line 39-39 in Figure 36. [Figure 40]

[0051] This is a rear perspective view of a portion of a ninth exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 41]

[0052] This is a front perspective view of a portion of the electric drive module shown in Figure 40. [Figure 42]

[0053] This is a side elevation view of the electric drive module shown in Figure 40. [Figure 43]

[0054] This is a cross-sectional view along line 43-43 in Figure 42. [Figure 44]

[0055] This is a cross-sectional view along line 44-44 in Figure 42. [Figure 45]

[0056] This is a cross-sectional view along line 45-45 in Figure 42. [Figure 46]

[0057] A rear perspective view of a portion of a tenth exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 47] This is a rear perspective view of a portion of a tenth exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 48]

[0058] This is a front perspective view of a portion of the electric drive module shown in Figure 46. [Figure 49] Figure 46 is a front perspective view of a portion of the electric drive module. [Figure 50]

[0059] This is a rear perspective view of a portion of an eleventh exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 51] This is a rear perspective view of a portion of an eleventh exemplary electric drive module constructed in accordance with the teachings of this disclosure. [Figure 52]

[0060] This is a cross-sectional view of a part of the electric drive module shown in Figure 50. [Figure 53]

[0061] is a perspective view of an electric drive module using a banjo housing, similar to that shown in Figure 50. [Figure 54]

[0062] This is a perspective view of another electric drive module, similar to the one in Figure 53, but using two motor assemblies. [Modes for carrying out the invention]

[0015]

[0063] The corresponding reference numbers indicate the corresponding parts through several figures in the drawing.

[0016]

[0064] Referring to Figures 1-3, an illustrative electric drive module constructed in accordance with the teachings of this disclosure is shown overall by reference no. 10. The electric drive module 10 may include a housing assembly 12, an electric motor assembly 14, a transmission 16, a differential 18, and a pair of axle shaft assemblies 20. The electric motor assembly 14 may be similar to those described in International Patent Application Publication WO2020 / 219955, published on 29 October 2020, and International Patent Application PCT / US2020 / 062541, filed on 30 November 2020, and their disclosures are incorporated by reference as if they were described in detail herein. Briefly, the electric motor assembly 14 comprises an electric motor 26 and a lubrication and cooling system 28. The electric motor 26 is a multiphase electric motor and includes a stator S which may have a stator core SC and multiple field windings FW, an inverter I, and a rotor R which has a motor output shaft 30 (Figure 3) rotatable about a motor output shaft axis 32 parallel to the output shaft 34 of the electric drive module 10. Each of the field windings FW is wound around the stator core SC and is associated with a different phase of power. The inverter I is electrically coupled to the field windings FW and is configured to control the supply of power to each of the field windings FW. The inverter I is mounted in a motor housing that houses the stator S and the rotor R. The lubrication and cooling system 28 includes a pump 40 (Figure 2), a cooling system heat exchanger 42 (Figure 2), and other components (not particularly shown) that direct and control the flow of fluid through the electric motor 26, transmission 16, and differential gear 18 for the purpose of cooling and / or lubricating the various components of the electric motor assembly 14, transmission 16, and differential gear 18.

[0017]

[0065] Referring to Figures 2 and 4, the housing assembly 12 is a beam axle and may include a central portion or carrier housing 50 and a pair of axle tube assemblies 52. The carrier housing 50 may be formed as two or more components that are assembled together and may define a pair of axle tube mounts 56, a motor mount 58, and an internal cavity 60 capable of receiving a transmission 16 and a differential 18. Each of the axle tube mounts 56 may have a tubular portion 64 fixedly coupled to a wall portion 66 (for example, formed integrally with it). One or more gussets 68 may be coupled to the tubular portion 64 and the wall portion 66. The tubular portions 64 may be arranged concentrically around the output shaft 34. The electric motor assembly 14 is fixedly coupled to the motor mount 58 such that the motor output shaft 30 (Figure 3) is located within the internal cavity 60.

[0018]

[0066] In the specific example provided, the carrier housing 50 comprises a first housing member 70 and a second housing member 72, which are configured as a mating clamshell half. The first housing member 70 and the second housing member 71 are fastened to each other via a number of threaded fasteners (not shown in particular). The first housing member 70 and the second housing member 72 are separated from each other around a plane P that intersects the output shaft 34. As shown, the plane P is perpendicular to the output shaft 34, but it should be noted that the plane P can be oriented in different ways. The motor mount 58 is disposed on the first housing member 70 in the example shown.

[0019]

[0067] Referring to Figures 4-6, each of the axle tube assemblies 52 may include an axle tube 80 and an axle tube flange 82. Each axle tube 80 can be received into one associated tubular portion 64 of an axle tube fitting 56 and can be fixed and coupled to the carrier housing 50 in any desired manner. In the provided example, the axle tube 80 engages with the tubular portion 64 of the axle tube fitting 56 in an interference fit so that bending loads are transmitted through the axle tube 80 to the carrier housing 50. One or more slag welds 86 (Figure 2) can be used to prevent movement of the axle tube 80 both rotationally about the output shaft 34 relative to the carrier housing 50 and axially along the output shaft 34. The axle tube flange 82 may be formed as a separate part and can be coupled to the opposite end of the axle tube 80 on the carrier housing 50 in any desired manner. In the provided example, the axle tube flange 82 is friction welded to the axle tube 80.

[0020]

[0068] Referring to Figure 3, the transmission 16 may include a pinion gear 90, a pair of compound gears 92, and a transmission output gear 94. The pinion gear 90 can be coupled to the motor output shaft 30 to rotate together. Each of the compound gears 92 may include a first gear 96 that meshes with the pinion gear 90 and a second gear 98 that is rotatably coupled to the first gear 96. The transmission output gear 94 is arranged concentrically around the output shaft 34 and meshes with the second gear 98. In the provided example, each of the pinion gear 90, the first gear 96, the second gear 98, and the transmission output gear 94 are helical gears, but it should be noted that other types of gear tooth profiles, such as spur gears, can be used as substitutes for some or all of the gears in the transmission 16.

[0021]

[0069] Referring to Figure 4, the first bearing 100 can be used to support the transmission output gear 94 axially along the output shaft 34 and radially with respect to the carrier housing 50 with respect to the output shaft 34. In the provided example, the first bearing 100 is a four-point angular contact bearing having a first race 102 disposed on the carrier housing 50, a second race 104 disposed on the transmission output gear 94, and a plurality of rolling elements 106 disposed between the first race 102 and the second race 104. The first race 102 may comprise a pair of race members 110 and 112 that can be received on a tubular segment 114 formed on the first housing member 70. Race member 112 can abut against a shoulder 116 on the first housing member 70. Multiple threaded fasteners 120 and disc spring washers 122 can be used to fix the race members 110 and 112 to the first housing member 70 and to apply a preload force on the first bearing 100. The second race 104 can be formed entirely or partially directly on the transmission output gear 94.

[0022]

[0070] Returning to Figure 3, each of the composite gears 92 can be supported by a second bearing 130 and a third bearing 132. Each second bearing 130 is configured to support the composite gear 92 axially along the rotation axis of the composite gear 92 and radially about the rotation axis of the composite gear 92 against the second housing member 72 (Figure 4). Each third bearing 132 is configured to support the composite gear 92 radially about the rotation axis of the composite gear 92 against the first housing member 70.

[0023]

[0071] The shaft 140 can be non-rotatably coupled to each of the compound gears 92 and can extend from the second gear 98 in a direction away from the first gear 96. If desired, the shaft 140 can be integrally and unibodyly formed with the second gear 98. The park lock gear 142 can be non-rotatably coupled to each of the shafts 140. The park lock gear 142 can be engaged by a parking pawl (not shown) to prevent rotation of the transmission output gear 94. In the example shown, the second bearing 130 is positioned along the axis of rotation of the compound gear between the park lock gear 142 and the second gear 98.

[0024]

[0072] Returning to Figure 4, the differential 18 may include a differential input member 150 coupled to the transmission output gear 94 for rotation together, and a pair of differential output members 152 rotatable about the output shaft 34 relative to the differential input member 150. In the provided example, the differential input member 150 is a differential case, the differential 18 includes a differential gear set 158, and the differential output members 152 are gears in the differential gear set 158. The differential case may have a flange 160 that abuts against the transmission output gear 94. A number of threaded fasteners 162 are received through the flange 160 and screwed into the transmission output gear 94 to fix and couple the differential input member 150 to the transmission output gear 94. The threaded fasteners 162 fitted through the flange 160 are arranged radially outward of the threaded fasteners 120 that secure the first race 102 of the first bearing 100 to the first housing member 70. This configuration allows the transmission 16, the first bearing 100, the disc spring washer 122, and the threaded fastener 120 to be assembled to the first housing member 70, and then the differential 18 to be assembled to the transmission output gear 94.

[0025]

[0073] Optionally, the differential 18 may include a limited-slip or locking mechanism. In the example shown, the differential 18 is an electronically locked differential having a dog clutch 170 and an electromagnet 172. The dog clutch 170 includes a first dog 174 coupled axially slidably but immobilely to a differential input member 150, and a second dog 176 coupled immobilely to one of the differential output members 152. The electromagnet 172 can operate to drive the first dog 174 along the output shaft 34 to engage with the second dog 176, thereby suppressing the speed difference between the differential output members 152. A spring 178 may be disposed between the first dog 174 and the second dog 176 and can bias the first dog 174 away from the second dog 176 when the electromagnet 172 is not operating.

[0026]

[0074] While the first bearing 100 has been described as directly supporting the transmission output gear 94 to rotate on the housing assembly 12, and thereby indirectly supporting the differential 18 to rotate relative to the housing assembly 12, it is understood that the electric drive module 10 can be constructed somewhat differently. For example, the differential input member 150 can be supported on a pair of bearings mounted on the housing assembly in the manner shown in Figures 10-13.

[0027]

[0075] In Figures 4 and 6, each of the axle shaft assemblies 20 may include an axle shaft 180, a bearing mount 182, and a bearing set 184. The axle shaft 180 has a shaft member 190 that is non-rotatably coupled to one of the relevant differential output members 152, and a wheel mount 192. The bearing mount 182 can be received coaxially around the shaft member 190. The bearing set 184 is disposed on the shaft member 190 with respect to a shoulder 196 formed on the shaft member 190. The bearing set 184 is radially disposed between the shaft member 190 and the bearing mount 182. In the example shown, the bearing set 184 comprises a pair of tapered roller bearings, the outer bearing races of the tapered roller bearings are integrally and unified with the bearing mount 182. A wedding ring 200 can be fitted onto the shaft member 190 to prevent axial movement of the inner bearing races of the tapered roller bearings along the shaft member 190. The tone ring 206 can be attached to the shaft member 190. A threaded fastener 210 can be used to secure the bearing mount 182 to the axle tube flange 82. In the provided example, the threaded fastener 210 also secures the caliper mount 212 and dust shield 214 to the bearing mount 182 and the axle tube flange 82.

[0028]

[0076] Referring to Figures 7–9, another electric drive module constructed in accordance with the teachings of this disclosure is shown overall by reference no. 10a. Electric drive module 10a is generally similar to electric drive module 10 (Figure 1) described in detail above, except for the configuration of transmission 16a and a modified form to a carrier housing 50a for housing transmission 16a. Transmission 16a employs further reduction between the second gear 98 and the transmission output gear 94 so that the second gear 98 does not directly mesh with the transmission output gear 94. More specifically, transmission 16a includes a second compound gear 250 having a third gear 252 that meshes and engages with the second gear 98 of compound gear 92, and a fourth gear 254 that is non-rotatably coupled to the third gear 252 and meshes and engages with the transmission output gear 94. To support the composite gear 250 in the axial and rotational directions relative to the carrier housing 50a, fourth and fifth bearings (not shown), which may be similar to the second bearing 130 and the third bearing 132 (Figure 3), can be used.

[0029]

[0077] Referring to Figures 10–13, another illustrative electric drive module constructed in accordance with the teachings of this disclosure is shown overall by reference no. 10b. Electric drive module 10b may be generally similar to electric drive module 10 (Figure 1), except for the configuration of the housing assembly 12b and the differential 18b. More specifically, the differential 18b may include a differential input member 150, which can be configured as a differential case capable of housing a plurality of differential pinions (not shown), and a pair of side gears 152b that serve as differential output members. The differential input member 150 is fixedly coupled to the transmission output gear 94. A pair of bearings 300 support the differential input member 150 relative to the housing assembly 12b. In the provided example, the bearings 300 are tapered roller bearings, but it should be noted that the bearings 300 can be configured differently, for example, as angular contact bearings. The tapered roller bearings can be preloaded in their respective axial directions in any desired manner, such as shims. Optionally, a bearing adjuster configuration is used to preload one of the bearings 300 axially. The bearing adjuster configuration includes a threaded adjustment bushing having threads that screw into housing threads formed in the housing assembly. The adjustment bushing is tightened against one of the outer bearing races of each of the bearings 300 to apply a desired clamping force to one of each of the bearings 300. A clip coupled to the housing assembly with a threaded fastener engages with the adjustment bushing to prevent rotation of the adjustment bushing relative to the housing assembly. Optionally, a speed sensor can be used to sense the rotational speed of the differential input member 150. In the example provided, the speed sensor includes a sensor target coupled to the differential input member 150 to rotate together, and a sensor that senses the sensor target when it rotates. In the example provided, the sensor is a Hall effect sensor and is mounted to the housing assembly.

[0030]

[0078] Figures 14-17 illustrate an electric drive module 10c, which is similar to that in Figures 10-13, except for the configuration of the carrier housing 50c.

[0031]

[0079] Figures 18–22 illustrate yet another electric drive module 10d constructed in accordance with the teachings of this disclosure. The electric drive module 10d is similar to those in Figures 14–17, except that the carrier housing 50d is configured to house two electric motor assemblies 14 and two transmissions 16. It should be noted that each of the electric motor assemblies 14 can drive its own pinion gear (not shown in particular), and the pinion gear can then drive a pair of compound gears 92. However, the two transmissions 16 have a single or common transmission output gear 94 engaged by two pairs of compound gears 92. In the particular example provided, the motor output shafts 32 are parallel to each other, and the output shaft 34 is disposed between the motor output shafts 32.

[0032]

[0080] Figures 23–27 illustrate another electric drive module 10e which is generally similar to the electric drive module 10d in Figures 18–22, except for the configuration of the carrier housing 50e. In this example, the carrier housing 50e includes a central section 310 and a pair of end covers 312. The central section 310 defines an axle tube fitting 56 and first and second flanges (not shown) parallel to and spaced apart from the output shaft, respectively. Each of the end covers defines an associated motor fitting 58, which is configured to receive therein one associated electric motor assembly 14 and to house each of a pinion gear 90 and a pair of compound gears 92 of the transmission 16. The end covers 312 cooperate with the central section 310 to form an internal cavity 60 which receives a differential (not shown) and a single or common transmission output gear (not shown).

[0033]

[0081] Figure 27A illustrates an electric drive module 10e' similar to that in Figure 23, except that two electric motor assemblies 14 are located on a common side of the carrier housing 50e and are mounted on the lateral sides of a single end cover 312'. In this regard, the motor output shafts 32 coincide with each other and are located on a common side of the output shaft 34. Each electric motor assembly 14 can be used to drive its own transmission 16, or it can be used to drive a transmission common to both electric motor assemblies 14. A cover CV can be used to close the carrier housing 50e on the side of the carrier housing 50e opposite the end cover 312'. Alternatively, the end cover 312' or cover CV can be formed integrally with the carrier housing 50e.

[0034]

[0082] Figures 28-33 illustrate examples of electric drive modules that are generally similar to the embodiments shown in Figures 14-17.

[0035]

[0083] Figures 34–39 illustrate further examples of electric drive modules constructed in accordance with the teachings of this disclosure. The electric drive module 10g comprises a carrier housing 50g including a central section 310g and an end cover (not shown in particular). The central section 310g defines an axle tube fitting 56 and a flange 320 parallel to and spaced apart from the output shaft. The end cover defines an associated motor fitting, which is configured to receive an electric motor assembly 14 and to house a pinion gear 90 and a pair of compound gears 92 of a transmission 16. The end cover cooperates with the central section 310g to form an internal cavity 60 into which a differential 18 and a transmission output gear 94 are received.

[0036]

[0084] Figures 40–45 illustrate an example of an electric drive module that is generally similar to the embodiments shown in Figures 34–39, except that the carrier housing 50h is configured such that the central section 310h defines an axle tube mount 56, a motor mount 58, and a flange 320. The motor mount 58 is configured to receive an electric motor assembly 14 and to house the pinion gear 90 and a pair of compound gears 92 of the transmission 16. The flange 320 is parallel to and spaced apart from the output shaft. An end cover (not shown) is configured as a conventional axle cover and is attached to the flange 320 to close the internal cavity 60.

[0037]

[0085] Figures 46–49 illustrate an electric drive module similar to those in Figures 23–27, but with a laminated plate heat exchanger directly positioned on each motor housing of the electric motor assembly. Two elbows protruding from each heat exchanger are used to deliver cooling fluid to and from each heat exchanger. Pump fittings for mounting a pump and filter fittings for mounting a filter can be incorporated into one or both of the end covers. The pump can draw fluid from a sump that can be located in the relevant end cover, optionally in the carrier housing, and optionally in the opposite end cover. The pump can discharge pressurized fluid that can be sent to a filter through a gallery inside the end cover. The pressurized fluid exiting the filter can be sent to the heat exchanger(s) through a gallery inside the housing assembly. In the example shown, an internal gallery for fluid connection of the filter to the heat exchanger is formed in the end cover and motor housing. The pressurized fluid is cooled in the heat exchanger and delivered through the inverter and the rest of the electric motor assembly housed in the motor housing.

[0038]

[0086] Referring to Figures 50-52, another vehicle drive component 10f constructed in accordance with the teachings of this disclosure is illustrated. The vehicle drive component 10f is generally similar to the vehicle drive component 10 (Figure 1), except for the configuration of the housing assembly 12f and the lubrication and cooling system 28f.

[0039]

[0087] The housing assembly 12f comprises a carrier housing 400, a carrier housing 50f which includes a cover 402, a transmission housing 404, and a motor housing 406. The carrier housing 400 is configured to house a differential 18 (Figure 4) and includes an axle tube fitting 56 which receives an axle tube assembly 52. ​​As shown in the example in Figure 1, at least one bearing 100 (Figure 4) is mounted on the housing assembly 12f to directly support one of the differential 18 (Figure 4) and the differential input member 150 (Figure 4) to rotate relative to the housing assembly 12f about an output shaft 34 (Figure 4). The cover 402 is mounted on the first side of the carrier housing 400 and can close the first side of the internal cavity (not shown) formed by the carrier housing 400. The transmission housing 404 can be mounted on the second side of the carrier housing 400, opposite to the first side, and can close the second side of the internal cavity. The transmission housing 404 is configured to house various components of the transmission 16 (Figure 3), such as the pinion gear 90 (Figure 3) and the compound gear 92 (Figure 3). The transmission housing 404 is also configured integrally with both the pump fitting 410 and the filter fitting 412. The pump 40 is configured to be mounted in the pump fitting 410. The pump fitting 410 fluid-couples the suction side of the pump 40 to a sump (not shown), allowing the pump 40 to draw fluid from the sump S. The filter 418 is configured to be mounted in the filter fitting 412. The high-pressure fluid discharged by the pump 40 is sent through an outlet formed in the pump fitting 410, then to a first internal gallery 420 in the transmission housing 404, and then to an inlet in the filter fitting 412, which directs the pressurized fluid into the inlet of the filter 418. The fluid passes through the filter 418, is discharged from the filter 418 into the outlet of the filter fitting 412, and flows into the second internal gallery 424 which is integrally and unified with the transmission housing 404.The transmission housing 404 further defines a third internal gallery 428, which is integrally formed with the transmission housing 404 and configured to receive fluids used to lubricate and / or cool the transmission 16 (Figure 3), the differential 18 (Figure 4), and various components of the electric motor 26, including the rotor 430 of the electric motor 26.

[0040]

[0088] The motor housing 406 is fixedly coupled to the transmission housing 404 and extends substantially parallel to one of the axle tube assemblies 52. The motor housing 406 houses an electric motor assembly 14, including an electric motor 26 and an inverter 434. The fourth internal gallery 438 and the fifth internal gallery 442 are formed integrally and unified with the motor housing 406, respectively. The fourth internal gallery 438 is fluidically coupled to the second internal gallery 424 in the transmission housing 404, and the fifth internal gallery 442 is fluidly coupled to the third internal gallery 428 in the transmission housing 404. One or more gaskets or seals can be used to seal between the transmission housing 404 and the motor housing 406, between the second internal gallery 424 and the fourth internal gallery 438, and between the third internal gallery 428 and the fifth internal gallery 442.

[0041]

[0089] The motor housing cover 402 closes the end of the motor housing 406 opposite to the transmission housing 404 and is configured to direct fluid into the electric motor assembly 14 (e.g., the field windings FW of the stator 446 and the inverter 434 of the electric motor 26) for cooling and / or lubrication. The motor housing cover 402 can define a sixth internal gallery 450 that can be coupled to a coolant intake conduit 462 formed on the inverter mounting fixture 464 of the inverter 434 for fluid communication. The fluid directed through the coolant intake conduit in the inverter mounting fixture 464 can be directed to cool a number of power semiconductors 468 in the inverter 434 and to various cooling channels 470 formed longitudinally through the body or core of the stator 446. One or more gaskets and / or seals (not particularly shown) can seal between the motor housing 406 and the motor housing cover 402, and optionally between the sixth internal gallery 450 and the coolant intake conduit 462.

[0042]

[0090] The cooling system heat exchanger 42f can be mounted in the motor housing 406 and can close the opening in the motor housing 406 that houses the inverter 434. The cooling system heat exchanger 42f may have a first fluid inlet 480 that can be fluid-connected to a fourth internal gallery 438 in the motor housing 406, a first fluid outlet 482 that can be fluid-connected to a fifth internal gallery 442, and a second fluid outlet 484 that can be fluid-connected to a sixth internal gallery 450. One or more gaskets and / or seals (not particularly shown) can seal between the motor housing 406 and the cooling system heat exchanger 42f, between the first fluid inlet 480 and the fourth internal gallery 438, between the first fluid outlet 482 and the fifth internal gallery 442, and between the second fluid outlet 484 and the sixth internal gallery 450.

[0043]

[0091] During operation, the pump 40 can draw fluid from the sump S. The pressurized fluid exiting the pump 40 can be transmitted through the first internal gallery 420 to the filter fitting 412, where at least a portion of the pressurized fluid can be sent through the filter 418. The fluid exiting the filter 418 is sent through the second internal gallery 424 and the fourth internal gallery 438 to the first fluid inlet 480 in the cooling system heat exchanger 42f. This fluid is circulated through the cooling system heat exchanger 42f, allowing heat in the fluid to be released into the cooling fluid, which is also circulated through the cooling system heat exchanger 42f. The cooled (pressurized, filtered) fluid can exit the cooling system heat exchanger 42f through the first fluid outlet 482 and the second fluid outlet 484. The fluid passing through the first fluid outlet 482 is sent through the fifth internal gallery 442 and the third internal gallery 428, and the fluid passing through the second fluid outlet 484 is sent through the sixth internal gallery 450.

[0044]

[0092] The example in Figure 53 is similar to those in Figures 50-52, except that the housing assembly is formed as a banjo housing. In this regard, the carrier housing CH includes the output shaft 34 and is formed from two housing segments H1 and H2 that fit together along a plane that divides the carrier housing CH into a substantially symmetrical upper and lower half. The cover CVR is fixedly coupled to the rear end of the carrier housing CH, and the carrier CA is fixedly coupled to the front end of the carrier housing CH. The differential assembly DA is rotatably mounted inside the carrier CA, and the transmission housing 404 is mounted outside the carrier CA.

[0045]

[0093] The example in Figure 54 is similar to the example in Figure 53, but uses two electric motor assemblies 14 mounted on the outside of the carrier CA.

[0046]

[0094] The foregoing description of embodiments has been presented for illustrative and explanatory purposes only. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally interchangeable and can be used in selected embodiments, even if not specifically shown or described, where applicable, although they are not limited to that particular embodiment. The same can also be modified in many ways. Such modifications should not be considered deviations from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. An electric drive module, A motor assembly comprising a stator, a rotor, a motor output shaft, and a motor controller, wherein the rotor is received in the stator and is rotatable relative to the stator about the axis of the motor output shaft, the motor output shaft is coupled to the rotor to rotate together with it, the motor controller is configured to control the rotational speed of the rotor relative to the stator, and the motor controller includes an inverter. An output gear that can rotate around the output shaft, A differential assembly having a differential input member and a pair of differential output members, wherein the differential input member is coupled to the output gear so as to rotate together about the output shaft, and each of the pair of differential output members is rotatable about the output shaft relative to the differential input member. A transmission configured to transmit rotational power between the motor output shaft and the output gear, A housing assembly having a first housing portion and a second housing portion, wherein the transmission is at least partially housed in the first housing portion, the second housing portion has a first axial end and a heat exchanger fitting, the first axial end of the second housing portion is removably attached to the first housing portion, the second housing portion houses the stator, the rotor and at least a portion of the motor controller including the inverter, the housing assembly defines a sump, a pump fitting and a filter fitting, the sump is configured to hold a first fluid used in the electric drive module to lubricate the motor assembly, the differential assembly and the transmission and to cool the motor assembly. A heat exchanger mounted on the heat exchanger mounting fixture on the second housing portion, wherein the heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet. An electric drive module comprising, wherein the pump fitting is in fluid communication with the sump, a first internal gallery in the housing assembly fluidly couples the pump fitting to an inlet on the filter fitting, a second internal gallery in the housing assembly fluidly couples the outlet on the filter fitting to the heat exchanger inlet, a third internal gallery in the housing assembly fluidly couples directly to at least one heat exchanger outlet, a first portion of the first fluid delivered through the third internal gallery is directed to at least one of the stator and the rotor to cool the motor assembly, and a second portion of the first fluid delivered through the third internal gallery is directed to the first housing portion to lubricate at least one of the transmission and the differential assembly.

2. The electric drive module according to claim 1, wherein the housing assembly further comprises a cover, the cover being attached to a second axial end of the second housing portion, the second axial end of the second housing portion being opposite to the first axial end, a fourth internal gallery in the housing assembly being fluid-coupled to the at least one heat exchanger outlet, and at least a portion of the first fluid delivered through the fourth internal gallery being directed into the motor assembly to cool the motor assembly.

3. The electric drive module according to claim 2, wherein the motor assembly includes an inverter mounting fixture, the inverter mounting fixture is configured to direct a first portion of the first fluid transmitted through the fourth internal gallery through the inverter.

4. The electric drive module according to claim 3, wherein the inverter mounting fixture is configured to direct a second portion of the first fluid transmitted through the fourth internal gallery through the stator.

5. The electric drive module according to claim 1, wherein the inverter includes an electrolytic capacitor, and a portion of the heat exchanger, which is received in the second housing portion, is adjacent to the electrolytic capacitor.

6. The electric drive module according to claim 1, wherein the housing assembly includes a pipe, the first housing portion defines a pipe fitting, and the pipe is received in the pipe fitting and fixedly coupled to the first housing portion.

7. The electric drive module according to claim 6, wherein the housing assembly further includes a third housing portion, the first and third housing portions having a mating flange and cooperating to define a central cavity in which the differential assembly is disposed.

8. The electric drive module according to claim 7, wherein a bearing is disposed in one of the first and third housing portions, and the bearing directly supports one of the output gear and the differential input member to rotate about the output shaft.

9. The electric drive module according to claim 1, further comprising a pair of shafts, each of the pair of shafts being coupled to a related one of the differential output members to rotate together, the housing assembly including a third housing portion, the first and third housing portions having fitting flanges, and the shafts passing through the third housing portion.

10. The electric drive module according to claim 9, wherein the third housing portion defines a pair of pipe fittings, and the housing assembly further comprises a pair of pipes, each of the pair of pipes being received into one of the corresponding pipe fittings and fixedly coupled to the third housing portion.

11. The electric drive module according to claim 9, wherein at least one bearing is mounted on the housing assembly to directly support one of the output gear and the differential input member for rotation around the output shaft.

12. An electric drive module, A motor assembly comprising a stator, a rotor, a motor output shaft, and a motor controller, wherein the rotor is received in the stator and is rotatable relative to the stator about the axis of the motor output shaft, the motor output shaft is coupled to the rotor to rotate together with it, the motor controller is configured to control the rotational speed of the rotor relative to the stator, and the motor controller includes an inverter. An output gear that can rotate around the output shaft, A differential assembly having a differential input member and a pair of differential output members, wherein the differential input member is coupled to the output gear so as to rotate together about the output shaft, and each of the pair of differential output members is rotatable about the output shaft relative to the differential input member. A transmission configured to transmit rotational power between the motor output shaft and the output gear, A housing assembly comprising a first housing portion, a second housing portion, and a cover, wherein the transmission is at least partially housed in the first housing portion, the second housing portion has a first axial end and a heat exchanger fitting, the first axial end of the second housing portion is removably attached to the first housing portion, the second housing portion houses the stator, the rotor, and at least a portion of the motor controller including the inverter, the cover closes the end of the second housing portion opposite to the first housing portion, the housing assembly defines a sump configured to hold a first liquid, the first liquid used in the electric drive module to lubricate the motor assembly, the differential assembly, and the transmission, and to cool the motor assembly. A pump coupled to the housing assembly and fluid-coupled to the sump, from which the first liquid is received, wherein the pump is configured to discharge the flow of the first fluid, A heat exchanger mounted on the heat exchanger mounting fixture on the second housing portion, wherein the heat exchanger has a heat exchanger inlet, a first heat exchanger outlet, and a second heat exchanger outlet. The heat exchanger is equipped with a first internal gallery formed in the housing assembly, the first internal gallery receiving at least a portion of the flow of the first fluid, the first internal gallery being directly fluid-coupled to the heat exchanger inlet so that the first fluid discharged from the first internal gallery is received into the heat exchanger, and a second internal gallery formed in the housing assembly, the second internal gallery being directly fluid-coupled to the first heat exchanger outlet so that a first portion of the first fluid discharged from the heat exchanger is received into the second internal gallery. An electric drive module wherein the first portion of the first fluid is directed into the first housing portion to lubricate at least one of the transmission and the differential assembly, a third internal gallery is formed in the cover, the third internal gallery is fluid-coupled directly to the outlet of the second heat exchanger such that the second portion of the first fluid discharged from the heat exchanger is directed into the cover, and the first fluid exiting the cover is directed into at least one of the stator and the rotor to cool the motor assembly.

13. The electric drive module according to claim 12, wherein the motor assembly includes an inverter mounting fixture, the inverter mounting fixture is configured to direct a first portion of the first fluid transmitted through the third internal gallery through the inverter.

14. The electric drive module according to claim 13, wherein the inverter mounting fixture is configured to direct a second portion of the first fluid transmitted through the third internal gallery through the stator.

15. The electric drive module according to claim 12, wherein the inverter includes an electrolytic capacitor, and a portion of the heat exchanger, which is received in the second housing portion, is adjacent to the electrolytic capacitor.

16. The electric drive module according to claim 12, wherein the housing assembly includes a pipe, the first housing portion defines a pipe fitting, and the pipe is received in the pipe fitting and fixedly coupled to the first housing portion.

17. The electric drive module according to claim 16, wherein the housing assembly further includes a third housing portion, the first and third housing portions having a mating flange and cooperating to define a central cavity in which the differential assembly is disposed.

18. The electric drive module according to claim 17, wherein a bearing is disposed in one of the first and third housing portions, and the bearing directly supports one of the output gear and the differential input member to rotate about the output shaft.

19. The electric drive module according to claim 12, further comprising a pair of shafts, each of the pair of shafts being coupled to a related one of the differential output members to rotate together, the housing assembly including a third housing portion, the first and third housing portions having fitting flanges, and the shafts passing through the third housing portion.

20. The electric drive module according to claim 19, wherein the third housing portion defines a pair of pipe fittings, and the housing assembly further comprises a pair of pipes, each of the pair of pipes being received into one of the corresponding pipe fittings and fixedly coupled to the third housing portion.

21. The electric drive module according to claim 19, wherein at least one bearing is mounted on the housing assembly to directly support one of the output gear and the differential input member for rotation around the output shaft.

22. An electric drive module, A beam axle housing having a central portion and a pair of axle tubes fixedly connected to the central portion and extending laterally from the lateral sides thereof, A differential assembly having a differential input member received in the central portion and rotatable about the output shaft relative to the central portion, and a pair of differential output members rotatable about the output shaft relative to the differential input member, A pair of axle shafts, each of which is received in a related one of the pair of axle tubes and coupled to a related one of the differential output members to rotate together about the output shaft, A multiphase motor assembly comprising a motor housing, a stator, a rotor, and an inverter, wherein the motor housing is fixedly coupled to the central portion of the beam axle housing; the stator has a stator core and a plurality of field windings wound around the stator core, each of the field windings relating to a different electrical phase; the stator is received in the motor housing and fixedly coupled thereto; the rotor is rotatable relative to the stator about the motor output shaft axis; the rotor has a motor output shaft; the inverter is housed in the motor housing and electrically coupled to the field windings; and the inverter is configured to control the supply of power to each of the field windings. A transmission is received in the central portion and transmits rotational power between the motor output shaft and the differential input member. An electric drive module equipped with the following features.

23. The electric drive module according to claim 22, wherein the central portion includes two clamshell halves, and each of the pair of axle tubes is fixedly coupled to the associated one of the two clamshell halves.

24. The electric drive module according to claim 23, wherein each of the pair of axle tubes is an individual component assembled into the associated one of the clamshell halves.

25. The electric drive module according to claim 22, wherein the central portion includes a first housing member defining a pair of axle tube apertures, each of the pair of axle tubes being received in a related one of the pair of axle tube apertures, and the differential input member being rotatably mounted on the first housing member.

26. The electric drive module according to claim 25, wherein the central portion includes the first housing member and a second housing member detachably coupled to the motor housing, and the transmission is at least partially disposed within the second housing member.

27. An electric drive module, A carrier housing defining a pair of axle tube apertures, A pair of axle tubes, each of which is received into a related one of the pair of axle tube apertures and fixedly coupled to the carrier housing; a differential assembly rotatably mounted to the carrier housing, wherein the differential assembly has a pair of differential output members; A first transmission housing is detachably coupled to the carrier housing, A first motor assembly comprising a first motor housing and a first electric motor having a first stator and a first rotor, wherein the first motor housing is coupled to the first transmission housing, the first stator is fixedly coupled to the first motor housing, and the first rotor has a first motor output shaft that is received in the first stator and is rotatable about a first motor output shaft axis. A first transmission, housed in the first transmission housing and transmitting rotational power between the first motor output shaft and the differential assembly; a pair of axle shafts, each of which extends through a related one of the pair of axle tubes and is driven-engaged to a corresponding one of the differential output members; An electric drive module equipped with the following features.

28. The electric drive module according to claim 27, further comprising a pump and a heat exchanger, wherein the pump is mounted on the first transmission housing, the heat exchanger is mounted on the first motor housing, the first transmission housing defines a sump, the pump draws lubricant from the sump and discharges a pressurized flow of lubricant, and at least a portion of the pressurized flow of lubricant is directed through the heat exchanger.

29. The electric drive module according to claim 28, further comprising a filter attached to the first transmission housing, wherein the flow of pressurized lubricant is delivered through the filter before the heat exchanger.

30. A second transmission housing is detachably coupled to the carrier housing on the side of the carrier housing opposite to the first transmission housing, A second motor assembly comprising a second motor housing and a second electric motor having a second stator and a second rotor, wherein the second motor housing is coupled to the second transmission housing, the second stator is fixedly coupled to the second motor housing, and the second rotor has a second motor output shaft that is received in the second stator and is rotatable about the axis of the second motor output shaft. The electric drive module according to claim 27, further comprising a second transmission housed in the second transmission housing and transmitting rotational power between the second motor output shaft and the differential assembly.

31. The electric drive module according to claim 30, wherein the first and second motor output shafts are parallel to each other, and the output shaft is disposed between the first motor output shaft and the second motor output shaft.

32. The electric drive module according to claim 30, further comprising a pair of heat exchangers, each of which is fixedly coupled to the corresponding one of the first and second motor housings.

33. The electric drive module according to claim 30, further comprising a pair of inverters, each of which is housed in one of the first and second motor housings and electrically coupled to a set of field windings on one of the first and second stators.

34. The electric drive module according to claim 33, further comprising a pair of cooling and lubrication systems, each of which includes a pump that draws lubricant from a sump defined by the carrier housing, the first transmission housing, and the second transmission housing and generates a pressurized flow of lubricant, and a heat exchanger that receives the pressurized flow of lubricant, wherein the lubricant discharged from the heat exchanger is directed to one of the first and second electric motors and one of the first and second transmissions.

35. The electric drive module according to claim 27, further comprising an inverter housed in the first motor housing, wherein the inverter is electrically coupled to a set of field windings of the first stator.

36. The electric drive module according to claim 15, further comprising a cooling and lubrication system having a pump, a filter, and a heat exchanger, wherein the pump draws lubricant from a sump defined by the carrier housing and the first transmission housing to generate a pressurized flow of lubricant, the heat exchanger receives the pressurized flow of lubricant, and the lubricant discharged from the heat exchanger is directed to the inverter, the first electric motor, and the first transmission.

37. The electric drive module according to claim 36, wherein a plurality of lubricant galleries are formed in the first transmission housing and the first motor housing, and pressurized lubricant is delivered between the pump and the heat exchanger through only a portion of the lubricant galleries.

38. An electric drive module, A beam axle housing having a central portion and a pair of axle tubes, wherein the central portion has two clamshell halves, each of the two clamshell halves defining an axle tube aperture, and each of the pair of axle tubes being received in the axle tube aperture and fixedly coupled to the corresponding one of the two clamshell halves such that the pair of axle tubes extend laterally from the lateral surfaces on both sides of the central portion. A differential assembly having a differential input member received in the central portion and rotatable about the output shaft relative to the central portion, and a pair of differential output members rotatable about the output shaft relative to the differential input member, A pair of axle shafts, each of which is received in a related one of the pair of axle tubes and coupled to a related one of the differential output members to rotate together about the output shaft, A pair of multiphase motor assemblies, each multiphase motor assembly comprising a motor housing, a stator, a rotor, and an inverter, wherein the motor housing is fixedly coupled to the central portion of the beam axle housing, the stator comprises a stator core and a plurality of field windings wound around the stator core, each of the field windings relating to a different electrical phase, the stator is received in the motor housing and fixedly coupled thereto, the rotor is rotatable relative to the stator about the motor output shaft axis, the rotor has a motor output shaft, the inverter is housed in the motor housing and electrically coupled to the field windings, and the inverter is configured to control the supply of power to each of the field windings. A pair of transmissions, where each transmission is received in the central portion and transmits rotational power between one of the motor output shafts and the differential input member. An electric drive module equipped with the following features.

39. The electric drive module according to claim 38, wherein the motor output shafts are parallel to each other, and the output shafts are disposed between the motor output shafts.

40. The electric drive module according to claim 38, further comprising a pair of inverters, each of which is housed in one of the motor housings and electrically coupled to a set of field windings on one of the stators.

Images