An electric drive module configured as a beam axle

Abstract

An electrically operated electric drive module for use in a vehicle framework configured for a power train including an internal combustion engine. The electrically operated electric drive module enables a vehicle to be converted to an electrically propelled vehicle in a cost-effective manner that is relatively low in weight.

Description

Cross - Reference to Related Applications

[0001]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 161218, filed on March 15, 2021, U.S. Provisional Patent Application No. 63 / 178985, filed on April 23, 2021, and U.S. Provisional Patent Application No. 63 / 220204, filed on July 9, 2021. The disclosures of the applications referenced above are incorporated by reference as if fully and particularly 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 form, the present disclosure provides an electric drive module including 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 a motor output shaft axis. The axle tube mounts are disposed along an output axis that is parallel to and offset from the motor output shaft axis. The pair of axle tubes are received in the axle tube mounts and fixedly coupled to the housing. The electric motor has a motor output shaft and is mounted to the motor mount such that the motor output shaft is rotatable about the motor output shaft axis. The transmission is received in the housing and includes a pinion gear coupled to the motor output shaft for co-rotation, a pair of first compound gears, and a transmission output gear rotatable about the output axis. Each of the first compound gears has a first gear meshingly engaged with the pinion gear and a second gear fixedly coupled to the first gear. The first compound gears transmit 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 axis and radially about the output axis. 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 axis.

[0007]

[0007] In another form, the present disclosure provides an electric drive module including a motor assembly, an output gear, a differential assembly, a transmission assembly, a housing assembly, and a heat exchanger. The motor assembly has a stator, a rotor, a motor output shaft, and a motor controller. The rotor is received within the stator and is rotatable relative to the stator about the motor output shaft axis. The motor output shaft is coupled to the rotor for co-rotation. 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 an output shaft. The differential assembly has a differential input member and a pair of differential output members. The differential input member is coupled to the output gear for co-rotation about the output shaft. Each of the differential output members is rotatable relative to the differential input member about the output shaft. The transmission is configured to transmit rotational power between the motor output shaft and the output gear. The housing assembly has a first housing portion and a second housing portion. The transmission is at least partially received within the first housing portion. The second housing portion has a first axial end and a heat exchanger fixture. 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 fixture, and a filter fixture. The sump is configured to hold a 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. The heat exchanger is attached to the heat exchanger fixture on the second housing portion. The heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet. The pump fixture is in fluid communication with the sump. A first internal gallery in the housing assembly fluidly couples the pump fixture to an inlet on the filter fixture.The second internal gallery in the housing assembly fluidly couples an outlet on the filter fixture to the heat exchanger inlet. The third internal gallery in the housing assembly is fluidly coupled directly to at least one heat exchanger outlet. A first portion of the first fluid sent 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 sent through the third internal gallery is directed into the first housing portion to lubricate at least one of the transmission and differential assembly.

[0008] In another form, the present disclosure provides an electric drive module including a motor assembly, an output gear, a differential assembly, a transmission, a housing assembly, a pump, and a heat exchanger. The motor assembly has a stator, a rotor, a motor output shaft, and a motor controller. The rotor is received within the stator and is rotatable relative to the stator about the motor output shaft axis. The motor output shaft is coupled to the rotor for co-rotation. 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 an output shaft. The differential assembly has a differential input member and a pair of differential output members. The differential input member is coupled to the output gear for co-rotation 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 has a first housing portion, a second housing portion, and a cover. The transmission is at least partially received within the first housing portion. The second housing portion has a first axial end and a heat exchanger fixture. 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 the first housing portion. The housing assembly defines a sump configured to hold a first liquid. The first liquid is used within the electric drive module to lubricate the motor assembly, the differential assembly, and the transmission and to cool the motor assembly. The pump is coupled to the housing assembly such that the pump is fluidly coupled to the sump and receives the first liquid therefrom. The pump is configured to discharge a flow of the first fluid. The heat exchanger is attached to the heat exchanger fixture 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 within the housing assembly. The first gallery receives at least a portion of the flow of a first fluid. The first internal gallery is fluidly coupled directly to a heat exchanger inlet such that the first fluid discharged from the first internal gallery is received into the heat exchanger. A second internal gallery is formed within the housing assembly. The second internal gallery is fluidly coupled directly to a first heat exchanger outlet such 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 a first housing portion to lubricate at least one of a transmission and a differential assembly. A third internal gallery is formed within the cover. The third internal gallery is fluidly coupled directly to a second heat exchanger outlet such 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 a stator and a rotor to cool a motor assembly.

[0009]

[0009] In another form, the present disclosure provides an electric drive module including a beam axle housing, a differential assembly, a pair of axle shafts, a polyphase 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 lateral sides on both 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 the output shaft relative to the differential input member. Each of the pair of axle shafts is received in a respective one of the axle tubes and coupled to a respective one of the differential output members for co-rotation about the output shaft. The polyphase 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 received in and fixedly coupled to the motor housing. The rotor is rotatable relative to the stator about a 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. The inverter is configured to control the supply of power to each of the field windings. The transmission is received in the central portion and transmits rotational power between the motor output shaft and the differential input member.

[0010] In another form, the present disclosure provides an electric drive module including 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 within a respective one of the pair of axle tube apertures and 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 has 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 within the first stator and has a first motor output shaft rotatable about a first motor output shaft axis. The first transmission is received within 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 a respective one of the pair of axle tubes and is drivingly engaged with a corresponding one of the differential output members.

[0011]

[0011] In a further form, the present disclosure provides an electric drive module including a beam axle housing, a differential assembly, a pair of axle shafts, a pair of polyphase motor assemblies, and a pair of transmissions. The beam axle housing has a central portion and a pair of axle tubes. The central portion includes two clam shell halves, each of which defines an axle tube aperture. Each of the axle tubes is received in the axle tube aperture and fixedly coupled to an associated one of the clam shell halves such that the axle tubes extend laterally from lateral sides on both sides of the central portion. 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 the output shaft relative to the differential input member. Each of the pair of axle shafts is received in an associated one of the axle tubes and coupled to an associated one of the differential output members for co-rotation about the output shaft. Each polyphase 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 received in the motor housing and fixedly coupled thereto. The rotor is rotatable relative to the stator about a motor output shaft axis and includes the motor output shaft. The inverter is housed in 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 in the central portion and transmits rotational power between an associated one of the motor output shafts and the differential input member.

[0012]

[0012] 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.

[0013] [

[0013] The drawings described in this specification are for illustrative purposes only of selected embodiments and not for all possible implementations, and are not intended to limit the scope of the present disclosure.] [[Brief Description of the Drawings]]

[0014]

Figure 1

[0014] A front perspective view of an exemplary electric drive module constructed in accordance with the teachings of the present disclosure.]

Figure 2

[0015] A rear perspective view of the electric drive module of FIG. 1.

Figure 3

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

Figure 4

[0017] A cross-sectional view of a portion of the electric drive module of FIG. 1.

Figure 5

[0018] A perspective view of a portion of the electric drive module of FIG. 1 illustrating the construction of the axle tube assembly.

Figure 6

[0019] A cross-sectional view of a portion of the electric drive module of FIG. 1 taken through the axle tube assembly and wheel attachment on the axle shaft.

Figure 7

[0020] [

[0014] A front perspective view of a second exemplary electric drive module constructed in accordance with the teachings of the present disclosure.]

Figure 8

[0021] A cross-sectional view taken through the electric drive module of FIG. 7, illustrating the transmission.

Figure 9

Figure 10

[0022] [

[0014] A front perspective view of a third exemplary electric drive module constructed in accordance with the teachings of the present 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

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

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

Figure 27A

Figure 28

Figure 29

Figure 30

Figure 31

Figure 32

Figure 33

Figure 34

Figure 35

Figure 36

Figure 37

Figure 38

Figure 39

Figure 40

Figure 41

Figure 42

[0053] It is a side elevation view of the electric drive module of FIG. 40.

Figure 43

[0054] It is a cross-sectional view taken along line 43-43 of FIG. 42.

Figure 44

[0055] It is a cross-sectional view taken along line 44-44 of FIG. 42.

Figure 45

[0056] It is a cross-sectional view taken along line 45-45 of FIG. 42.

Figure 46

[0057] It is a rear perspective view of a portion of a tenth exemplary electric drive module constructed in accordance with the teachings of the present disclosure.

Figure 47

Figure 48

[0058] It is a front perspective view of a portion of the electric drive module of FIG. 46.

Figure 49

Figure 50

[0059] It is a rear perspective view of a portion of an eleventh exemplary electric drive module constructed in accordance with the teachings of the present disclosure.

Figure 51

Figure 52

[0060] It is a cross-sectional view of a portion of the electric drive module of FIG. 50.

Figure 53

[0061] It is similar to that of FIG. 50, but is a perspective view of an electric drive module using a banjo housing.

Figure 54

[0062] It is similar to that of FIG. 53, but is a perspective view of another electric drive module using two motor assemblies.

DETAILED DESCRIPTION OF THE INVENTION

[0015]

[0063] Corresponding reference numerals indicate corresponding parts throughout several views of the drawings.

[0016]

[0064] Referring to FIGS. 1-3, an exemplary electric drive module constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10. The electric drive module 10 can 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 can be similar to that described in International Patent Application Publication No. WO2020 / 219955 published on October 29, 2020 and International Patent Application No. PCT / US2020 / 062541 filed on November 30, 2020, the disclosures of which are incorporated by reference as if set forth in detail herein. Briefly, the electric motor assembly 14 includes an electric motor 26 and a lubrication and cooling system 28. The electric motor 26 is a polyphase electric motor and includes a stator S that can have a stator core SC and a plurality of field windings FW, an inverter I, and a rotor R having a motor output shaft 30 (FIG. 3) rotatable about a motor output shaft axis 32 parallel to the output axis 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 within a motor housing that houses the stator S and the rotor R. The lubrication and cooling system 28 includes a pump 40 (FIG. 2), a cooling system heat exchanger 42 (FIG. 2), and other components (not particularly shown) for directing and controlling the flow of fluid through the electric motor 26, the transmission 16, and the differential 18 for the purpose of cooling and / or lubricating various components of the electric motor assembly 14, the transmission 16, and the differential 18.

[0017]

[0065] Referring to FIGS. 2 and 4, the housing assembly 12 can be a beam axle and includes a central portion or carrier housing 50 and a pair of axle tube assemblies 52. The carrier housing 50 can be formed as two or more components assembled to each other, and can define a pair of axle tube attachments 56, a motor attachment 58, and an internal cavity 60 capable of receiving the transmission 16 and the differential 18. Each of the axle tube attachments 56 can include a tubular portion 64 fixedly coupled (e.g., integrally formed therewith) to a wall portion 66. One or more gussets 68 can be coupled to the tubular portion 64 and the wall portion 66. The tubular portions 64 can be arranged concentrically about the output shaft 34. The electric motor assembly 14 is fixedly coupled to the motor attachment 58 such that the motor output shaft 30 (FIG. 3) is disposed within the internal cavity 60.

[0018]

[0066] In a particular example provided, the carrier housing 50 includes a first housing member 70 and a second housing member 72 configured as mating clam shell halves. The first housing member 70 and the second housing member 71 are fixed to each other via a plurality of threaded fasteners (not particularly shown). The first housing member 70 and the second housing member 72 are divided from each other about 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 recognized that the plane P can be oriented differently. The motor attachment 58 is disposed on the first housing member 70 in the example shown.

[0019]

[0067] Referring to FIGS. 4 - 6, each of the axle tube assemblies 52 can include an axle tube 80 and an axle tube flange 82. Each axle tube 80 can be received within a respective one of the tubular portions 64 of the axle tube fixture 56 and can be fixedly coupled to the carrier housing 50 in any desired manner. In the example provided, the axle tube 80 engages the tubular portion 64 of the axle tube fixture 56 by interference fit such that bending loads are transmitted through the axle tube 80 to the carrier housing 50. One or more plug welds 86 (FIG. 2) can be used to prevent movement of the axle tube 80 in both the rotational direction about the output shaft 34 and the axial direction along the output shaft 34 relative to the carrier housing 50. The axle tube flange 82 can be formed as a separate component and can be coupled to the end of the axle tube 80 on the opposite side of the carrier housing 50 in any desired manner. In the example provided, the axle tube flange 82 is friction welded to the axle tube 80.

[0020]

[0068] Referring to FIG. 3, the transmission 16 can 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 for co - rotation. Each of the compound gears 92 can include a first gear 96 meshed with the pinion gear 90 and a second gear 98 rotationally coupled to the first gear 96. The transmission output gear 94 is disposed concentrically about the output shaft 34 and is meshed with the second gear 98. In the example provided, each of the pinion gear 90, the first gear 96, the second gear 98, and the transmission output gear 94 is a helical gear, but it should be recognized that other types of gear tooth profiles, such as spur gears, can be used as an alternative for some or all of the gears of the transmission 16.

[0021]

[0069] Referring to FIG. 4, the first bearing 100 can be used to support the transmission output gear 94 axially along the output shaft 34 and radially about the output shaft 34 with respect to the carrier housing 50. In the example provided, 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 can 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. The race member 112 can abut against a shoulder 116 on the first housing member 70. A plurality of threaded fasteners 120 and washer springs 122 can be used to fix the race members 110 and 112 to the first housing member 70 and apply a preload force on the first bearing 100. The second race 104 can be formed completely or partially directly on the transmission output gear 94.

[0022]

[0070] Returning to FIG. 3, each of the compound gears 92 can be supported by a second bearing 130 and a third bearing 132. Each second bearing 130 is configured to support the compound gear 92 axially along the axis of rotation of the compound gear 92 and radially about the axis of rotation of the compound gear 92 with respect to the second housing member 72 (FIG. 4). Each third bearing 132 is configured to support the compound gear 92 radially about the axis of rotation of the compound gear 92 with respect to 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 unitarily 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 pole (not shown) to prevent rotation of the transmission output gear 94. In the example shown, the second bearing 130 is disposed along the axis of rotation of the compound gear at a location between the park lock gear 142 and the second gear 98.

[0024]

[0072] Returning to FIG. 4, the differential device 18 can 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 example provided, the differential input member 150 is a differential case, the differential device 18 includes a differential gear set 158, and the differential output members 152 are gears in the differential gear set 158. The differential case can have a flange 160 that abuts the transmission output gear 94. A plurality of threaded fasteners 162 are received through the flange 160 and threaded into the transmission output gear 94 to fixedly couple the differential input member 150 to the transmission output gear 94. The threaded fasteners 162 fitted through the flange 160 are disposed radially outside of the threaded fasteners 120 that fix the first race 102 of the first bearing 100 to the first housing member 70. Configuring in this way enables the transmission 16, the first bearing 100, the disc spring washer 122, and the threaded fasteners 120 to be assembled to the first housing member 70, and then enables the differential device 18 to be assembled to the transmission output gear 94.

[0025]

[0073] Optionally, the differential 18 can include a limited slip or locking mechanism. In the example shown, the differential 18 is an electronically lockable differential having a dog clutch 170 and an electromagnet 172. The dog clutch 170 includes a first dog 174 that is axially slidable but non-rotatably coupled to the differential input member 150, and a second dog 176 that is non-rotatably coupled to one of the differential output members 152. The electromagnet 172 can be operated to drive the first dog 174 along the output shaft 34 to engage the second dog 176, thereby suppressing the speed difference between the differential output members 152. A spring 178 can 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] The first bearing 100 has been described as directly supporting the transmission output gear 94 for rotation on the housing assembly 12, thereby indirectly supporting the differential 18 for rotation relative to the housing assembly 12, but 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 FIGS. 10-13.

[0027]

[0075] In FIGS. 4 and 6, each of the axle shaft assemblies 20 can include an axle shaft 180, a bearing mount 182, and a bearing set 184. The axle shaft 180 has a shaft member 190 non-rotatably coupled to a related one of the differential output members 152 and a wheel mount 192. The bearing mount 182 can be coaxially received around the shaft member 190. The bearing set 184 is disposed on the shaft member 190 relative to a shoulder 196 formed on the shaft member 190. The bearing set 184 is disposed radially 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, and the outer bearing race of the tapered roller bearing is integrally and monolithically formed 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 race of the tapered roller bearing along the shaft member 190. A tone ring 206 can be attached to the shaft member 190. A screw fastener 210 can be used to secure the bearing mount 182 to the axle tube flange 82. In the example provided, the threaded fastener 210 also secures a caliper mount 212 and a dust shield 214 to the bearing mount 182 and the axle tube flange 82.

[0028]

[0076] Referring to FIGS. 7-9, another electric drive module constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10a. The electric drive module 10a is generally similar to the electric drive module 10 (FIG. 1) described in detail above, except for the configuration of the transmission 16a and the modified form to the carrier housing 50a for housing the transmission 16a. The transmission 16a uses additional reduction between the second gear 98 and the transmission output gear 94 such that the second gear 98 does not directly mesh with the transmission output gear 94. More specifically, the transmission 16a includes a second compound gear 250 having a third gear 252 that meshes and engages with the second gear 98 of the 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. Fourth and fifth bearings (not shown), similar to the second bearing 130 and the third bearing 132 (FIG. 3), can be used to support the compound gear 250 axially and rotationally with respect to the carrier housing 50a.

[0029]

[0077] Referring to FIGS. 10-13, another exemplary electric drive module constructed in accordance with the teachings of the present disclosure is generally indicated by reference numeral 10b. The electric drive module 10b can be generally similar to the electric drive module 10 (FIG. 1), except for the configuration of the housing assembly 12b and the differential 18b. More specifically, the differential 18b can include a differential input member 150 that can be configured as a differential case for housing a plurality of differential pinions (not specifically 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 with respect to the housing assembly 12b. It should be recognized that in the example provided, the bearings 300 comprise tapered roller bearings, but 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 with shims.Optionally and a bearing adjuster structure Sei which is used to apply an axial preload to one of the bearings 300. The bearing adjuster structure Sei wa includes an adjustment bushing with threads In the Li formed in a housing assembly In the mountain and screwed into a housing screw Mountain . The adjustment bushing Gu is tightened against each outer bearing race of the bearings 300 to apply a desired clamping force to each of the bearings 300. A threaded fastener couples the housing assembly Gu wa to a clip To the Su which engages the adjustment bushing To the Li to prevent rotation of the adjustment bushing relative to the housing assembly Pu ga . Optionally, a speed sensor To the Gu can be used to sense the rotational speed of the differential input member 150. In the illustrated example, the speed sensor To the Li includes a sensor target Of the Gu coupled to the differential input member 150 for co-rotation Sa , and a sensor Sa wa which senses the sensor target To and as it rotates To ga . In the provided example, the sensor To is a Hall effect sensor Sa and and is attached to the housing assembly Sa wa . To the Li

[0030]

[0078] Figures 14 - 17 illustrate an electric drive module 10c which is similar to that of 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 the present disclosure. The electric drive module 10d is similar to those of FIGS. 14 - 17, except that the carrier housing 50d is configured to accommodate two electric motor assemblies 14 and two transmissions 16. Each of the electric motor assemblies 14 can drive respective pinion gears (not particularly shown), and it should be recognized that the pinion gears can in turn 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 shaft axes 32 are parallel to each other, and the output shaft 34 is disposed between the motor output shaft axes 32.

[0032]

[0080] Figures 23 - 27 illustrate another electric drive module 10e that is generally similar to the electric drive module 10d of FIGS. 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 a vehicle axle tube mount 56 and first and second flanges (not particularly shown) that are parallel to and spaced from the output shaft. Each of the end covers defines an associated motor mount 58, and the associated motor mount 58 is configured to receive an associated one of the electric motor assemblies 14 therein and is configured to accommodate one pinion gear 90 and a pair of compound gears 92 of each of the transmissions 16. The end covers 312 cooperate with the central section 310 to form an internal cavity 60 in which a differential (not particularly shown) and a single or common transmission output gear (not particularly shown) are received.

[0033]

[0081] FIG. 27A illustrates an electric drive module 10e' that is similar to that of FIG. 23, except that two electric motor assemblies 14 are disposed on a common side of a carrier housing 50e and are attached to lateral side surfaces on both sides of a single end cover 312'. In this regard, the motor output shaft axes 32 are aligned with each other and are disposed on a common side surface of the output shaft 34. Each of the electric motor assemblies 14 can be used to drive its respective transmission 16 or can be used to drive a transmission that is common to both electric motor assemblies 14. A cover CV can be used to close the carrier housing 50e on the side surface of the carrier housing 50e opposite the end cover 312'. Alternatively, the end cover 312' or the cover CV can be integrally and monolithically formed with the carrier housing 50e.

[0034]

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

[0035]

[0083] FIGS. 34 - 39 illustrate further examples of electric drive modules constructed in accordance with the teachings of the present disclosure. The electric drive module 10g has a carrier housing 50g that includes a central section 310g and an end cover (not particularly shown). The central section 310g defines an axle tube mount 56 and a flange 320 that is parallel to and spaced from the output shaft. The end cover defines an associated motor mount that is configured to receive an electric motor assembly 14 therein and is configured to accommodate the pinion gear 90 of the transmission 16 and a pair of compound gears 92. The end cover cooperates with the central section 310g to form an internal cavity 60 in which the differential 18 and the 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 embodiment illustrated in Figures 34 - 39, except that the carrier housing 50h is configured such that the central section 310h defines the axle tube fixture 56, the motor fixture 58, and the flange 320. The motor fixture 58 is configured to receive the electric motor assembly 14 therein and to accommodate the pinion gear 90 of the transmission 16 and a pair of compound gears 92. The flange 320 is parallel to and spaced 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 are similar to those of Figures 23 - 27 and illustrate an electric drive module in which a stacked - plate type heat exchanger is positioned directly on each motor housing of the electric motor assembly. Two elbows protruding from each of the heat exchangers are used to send cooling fluid inside and outside each heat exchanger. A pump fixture to which a pump can be attached and a filter fixture to which a filter can be attached can be incorporated into one or both of the end covers. The pump can draw fluid from a sump that can be located optionally in a related one of the end covers, optionally in the carrier housing, and optionally in the opposite end cover. The pump can discharge pressurized fluid that can be sent through a gallery inside the end cover to the filter. The pressurized fluid exiting the filter can be sent through a gallery inside the housing assembly to the heat exchanger(s). In the example shown, an internal gallery fluid - connecting the filter to the heat exchanger is formed in the end cover and the motor housing. The pressurized fluid is cooled in the heat exchanger and sent through other parts of the electric motor assembly housed in the inverter and the motor housing.

[0038]

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

[0039]

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

[0040]

[0088] The motor housing 406 is fixedly coupled to the transmission housing 404 and extends generally parallel to one of the axle tube assemblies 52. The motor housing 406 houses the electric motor assembly 14 including the electric motor 26 and the inverter 434. A fourth internal gallery 438 and a fifth internal gallery 442 are integrally and integrally formed with the motor housing 406, respectively. The fourth internal gallery 438 is fluidly communicatively coupled to the second internal gallery 424 in the transmission housing 404, and the fifth internal gallery 442 is fluidly communicatively 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, to seal between the second internal gallery 424 and the fourth internal gallery 438, and to seal 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 the transmission housing 404 and is configured to direct fluid into the electric motor assembly 14 (e.g., the field winding FW of the stator 446 of the electric motor 26 and the inverter 434) to cool and / or lubricate the electric motor assembly 14. The motor housing cover 402 can define a sixth internal gallery 450 that can be fluidly coupled in communication with a coolant suction conduit 462 formed on the inverter fixture 464 of the inverter 434. Fluid directed through the coolant suction conduit in the inverter fixture 464 can be directed to cool a plurality of power semiconductors 468 in the inverter 434 and to various cooling flow paths 470 formed longitudinally through the body or core of the stator 446. One or more gaskets and / or seals (not specifically 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 suction conduit 462.

[0042]

[0090] The cooling system heat exchanger 42f can be attached to the motor housing 406 and can close an opening in the motor housing 406 in which the inverter 434 is housed. The cooling system heat exchanger 42f can have a first fluid inlet 480 that can be fluidly coupled in communication with a fourth internal gallery 438 in the motor housing 406, a first fluid outlet 482 that can be fluidly coupled in communication with a fifth internal gallery 442, and a second fluid outlet 484 that can be fluidly coupled in communication with the sixth internal gallery 450. One or more gaskets and / or seals (not specifically shown) can seal between the motor housing 406 and the cooling system heat exchanger 42f and between the first fluid inlet 480 and the fourth internal gallery 438, the first fluid outlet 482 and the fifth internal gallery 442, and the second fluid outlet 484 and the sixth internal gallery 450.

[0043]

[0091] During operation, pump 40 can draw fluid from sample S. The pressurized fluid exiting pump 40 can be conveyed through the first internal gallery 420 to the filter fixture 412, where at least a portion of the pressurized fluid can be sent through filter 418. The fluid exiting 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, enabling the heat in the fluid to be discarded to the cooling fluid that 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 of FIG. 53 is similar to those of FIGS. 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, H2 that are mated along a plane that bisects the carrier housing CH into a substantially symmetric upper half 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 of FIG. 54 is similar to the example of FIG. 53, but uses two electric motor assemblies 14 mounted outside the carrier CA.

[0046]

[0094] The foregoing description of the embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. The individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in the selected embodiment, even if not specifically shown or described. The same also can be changed in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure. The invention described in the original claims of the present application is appended below. [1] An electric drive module, comprising A motor assembly having 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 motor output shaft axis, the motor output shaft is coupled to the rotor for co-rotation, 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 rotatable about an 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 for co-rotation 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 received within the first housing portion, the second housing portion has a first axial end and a heat exchanger fixture, 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 fixture, and a filter fixture, the sump is configured to hold a 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 heat exchanger attached to the heat exchanger fixture on the second housing portion, wherein the heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet, comprising, the pump fixture is in fluid communication with the sump, a first internal gallery in the housing assembly fluidly couples the pump fixture to an inlet on the filter fixture, a second internal gallery in the housing assembly fluidly couples an outlet on the filter fixture to the heat exchanger inlet, a third internal gallery in the housing assembly is directly fluidly coupled to the at least one heat exchanger outlet, a first portion of the first fluid sent through the third internal gallery is directed to at least one of the stator and the rotor to cool the motor assembly, a second portion of the first fluid sent through the third internal gallery is directed to the first housing portion to lubricate at least one of the transmission and the differential assembly, an electric drive module. [2] 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 on the opposite side of the first axial end, a fourth internal gallery in the housing assembly being fluidly coupled to the at least one heat exchanger outlet, and at least a portion of the first fluid sent through the fourth internal gallery being directed into the motor assembly to cool the motor assembly, the electric drive module according to [1]. [3] The motor assembly includes an inverter fixture, the inverter fixture being configured to direct a first portion of the first fluid conveyed through the fourth internal gallery through the inverter, the electric drive module according to [2]. [4] The inverter fixture is configured to direct a second portion of the first fluid conveyed through the fourth internal gallery through the stator, the electric drive module according to [3]. [5] The inverter includes an electrolytic capacitor, a portion of the heat exchanger received in the second housing portion being adjacent to the electrolytic capacitor, the electric drive module according to [1]. [6] The housing assembly includes a tube, the first housing portion defining a tube fixture, the tube being received in the tube fixture and fixedly coupled to the first housing portion, the electric drive module according to [1]. [7] The housing assembly further includes a third housing portion, the first and third housing portions having mating flanges that cooperate to define a central cavity in which the differential assembly is disposed, the electric drive module according to [6]. [8] A bearing is disposed in one of the first and third housing portions, the bearing directly supporting one of the output gear and the differential input member for rotation about the output shaft, the electric drive module according to [7]. [9] Further comprising a pair of shafts, each of the pair of shafts being coupled to a respective one of the differential output members for co-rotation, the housing assembly including a third housing portion, the first and third housing portions having mating flanges, the shafts passing through the third housing portion, the electric drive module according to [1].

[10] The third housing portion defines a pair of pipe fittings, the housing assembly further comprising a pair of pipes, each of the pair of pipes being received in a respective one of the pipe fittings and fixedly coupled to the third housing portion, the electric drive module according to [9].

[11] At least one bearing is attached to the housing assembly so as to directly support one of the output gear and the differential input member for rotation about the output shaft, the electric drive module according to [9].

[12] An electric drive module, A motor assembly having 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 a motor output shaft axis, the motor output shaft being coupled to the rotor for co-rotation, the motor controller being configured to control the rotational speed of the rotor relative to the stator, the motor controller including an inverter, An output gear rotatable about an 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 for co-rotation about the output shaft, each of the pair of differential output members being 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, a second housing portion, and a cover, wherein the transmission is at least partially received within the first housing portion, the second housing portion has a first axial end and a heat exchanger fixture, 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 the first housing portion, the housing assembly defines a sump configured to hold a first liquid, the first liquid being 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 fluidly coupled to the sump to receive the first liquid therefrom, wherein the pump is configured to discharge a flow of the first fluid, A heat exchanger attached to the heat exchanger 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, An electric drive module, comprising 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 fluidly coupled directly to the heat exchanger inlet such that the first fluid discharged from the first internal gallery is received into the heat exchanger; a second internal gallery formed in the housing assembly, the second internal gallery being fluidly coupled directly to the first heat exchanger outlet such 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 being directed into the first housing portion to lubricate at least one of the transmission and the differential assembly; and a third internal gallery formed in the cover, the third internal gallery being fluidly coupled directly to the second heat exchanger outlet such that a second portion of the first fluid discharged from the heat exchanger is directed into the cover, the first fluid exiting the cover being directed into at least one of the stator and the rotor to cool the motor assembly.

[13] The electric drive module according to

[12] , wherein the motor assembly includes an inverter fixture 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

[13] , wherein the inverter 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

[12] , wherein the inverter includes an electric field capacitor, and a portion of the heat exchanger received in the second housing portion is adjacent to the electric field capacitor.

[16] The electric drive module according to

[12] , wherein the housing assembly includes a tube, the first housing portion defining a tube fixture, the tube being received in the tube fixture and fixedly coupled to the first housing portion.

[17] The housing assembly further includes a third housing portion, wherein the first and third housing portions have mating flanges and cooperate to define a central cavity in which the differential assembly is disposed, the electric drive module according to

[16] .

[18] A bearing is disposed in one of the first and third housing portions, the bearing directly supporting one of the output gear and the differential input member for rotation about the output shaft, the electric drive module according to

[17] .

[19] Further comprising a pair of shafts, each of the pair of shafts being coupled to a respective one of the differential output members for co-rotation, the housing assembly including a third housing portion, the first and third housing portions having mating flanges, the shafts passing through the third housing portion, the electric drive module according to

[12] .

[20] The third housing portion defines a pair of pipe fittings, the housing assembly further comprising a pair of pipes, each of the pair of pipes being received in a respective one of the pipe fittings and fixedly coupled to the third housing portion, the electric drive module according to

[19] .

[21] At least one bearing is attached to the housing assembly to directly support one of the output gear and the differential input member for rotation about the output shaft, the electric drive module according to

[19] .

[22] An electric drive module, A beam axle housing having a central portion and a pair of axle tubes fixedly coupled to the central portion and extending laterally from lateral sides thereof on both sides, A differential assembly received in the central portion and having a differential input member rotatable about an 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, wherein each of the pair of axle shafts is received in a respective one of the pair of axle tubes and coupled to a respective one of the differential output members for co-rotation about the output shaft, A polyphase motor assembly having 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 is associated with a different electrical phase, the stator is received in and fixedly coupled to the motor housing, the rotor is rotatable relative to the stator about a 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 received in the central portion and configured to transmit rotational power between the motor output shaft and the differential input member comprising an electric drive module.

[23] The electric drive module according to

[22] , wherein the central portion includes two clam shell halves, and each of the pair of axle tubes is fixedly coupled to a respective one of the two clam shell halves.

[24] The electric drive module according to

[23] , wherein each of the pair of axle tubes is an individual component assembled in the respective one of the clam shell halves.

[25] The electric drive module according to

[22] , wherein the central portion includes a first housing member defining a pair of axle tube apertures, each of the pair of axle tubes is received in a respective one of the pair of axle tube apertures, and the differential input member is rotatably mounted on the first housing member.

[26] The electric drive module according to

[25] , wherein the central portion includes a second housing member removably coupled to the first housing member and the motor housing, and the transmission is at least partially disposed in the second housing member.

[27] An electric drive module comprising a carrier housing defining a pair of axle tube apertures, A pair of axle tubes, wherein each of the pair of axle tubes is received within a respective one of the pair of axle tube apertures, fixedly coupled to the carrier housing, and a differential assembly rotatably mounted to the carrier housing, wherein the differential assembly has a pair of differential output members, A first transmission housing removably coupled to the carrier housing, A first motor assembly having a first motor housing, 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, the first rotor is received within the first stator, and has a first motor output shaft rotatable about a first motor output shaft axis, A first transmission received within the first transmission housing and transmitting rotational power between the first motor output shaft and the differential assembly, and a pair of axle shafts, wherein each of the pair of axle shafts extends through a respective one of the pair of axle tubes and is drivingly engaged with a corresponding one of the differential output members, An electric drive module comprising.

[28] Further comprising a pump and a heat exchanger, wherein the pump is attached to the first transmission housing, the heat exchanger is attached to the first motor housing, the first transmission housing defines a sump, the pump draws lubricant from the sump and discharges a pressurized lubricant flow, and at least a portion of the pressurized lubricant flow is directed through the heat exchanger, the electric drive module according to

[27] .

[29] Further comprising a filter attached to the first transmission housing, wherein the pressurized lubricant flow is sent through the filter prior to the heat exchanger, the electric drive module according to

[28] .

[30] A second transmission housing removably coupled to the carrier housing on a side surface of the carrier housing opposite the first transmission housing, A second motor assembly having 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, the second rotor is received within the second stator, and has a second motor output shaft rotatable about a second motor output shaft axis, further comprising a second transmission received within the second transmission housing and transmitting rotational power between the second motor output shaft and the differential assembly, the electric drive module according to

[27] .

[31] The first and second motor output shaft axes are parallel to each other, and the output shaft is disposed between the first motor output shaft axis and the second motor output shaft axis, the electric drive module according to

[30] .

[32] Further comprising a pair of heat exchangers, each of the pair of heat exchangers being fixedly coupled to a relevant one of the first and second motor housings, the electric drive module according to

[30] .

[33] Further comprising a pair of inverters, each of the pair of inverters being received within a relevant one of the first and second motor housings and electrically coupled to a set of field windings on a relevant one of the first and second stators, the electric drive module according to

[30] .

[34] Further comprising a pair of cooling and lubrication systems, each of the pair of cooling and lubrication systems having 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 lubricant flow, and a heat exchanger that receives the pressurized lubricant flow, wherein the lubricant discharged from the heat exchanger is directed to a relevant one of the first and second electric motors and a relevant one of the first and second transmissions, the electric drive module according to

[33] .

[35] Further comprising an inverter received within the first motor housing, the inverter being electrically coupled to a set of field windings of the first stator, the electric drive module according to

[27] .

[36] 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, generates a pressurized flow of lubricant, and 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, the electric drive module according to

[15] .

[37] A plurality of lubricant galleries are formed in the first transmission housing and the first motor housing, and the pressurized lubricant is sent between the pump and the heat exchanger through only a portion of the lubricant gallery, the electric drive module according to

[36] .

[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 clam shell halves, each of the two clam shell halves defines an axle tube aperture, and each of the pair of axle tubes is received in the axle tube aperture and is fixedly coupled to a related one of the two clam shell halves such that the pair of axle tubes extends laterally from lateral sides on both sides of the central portion, A differential assembly having a differential input member received in the central portion and rotatable about an output shaft with respect to the central portion, and a pair of differential output members rotatable about the output shaft with respect to the differential input member, A pair of axle shafts, wherein each of the pair of axle shafts is received in a related one of the pair of axle tubes and is coupled to a related one of the differential output members for co-rotation about the output shaft, A pair of polyphase motor assemblies, where each polyphase motor assembly has a motor housing, a stator, a rotor, and an inverter, the motor housing being fixedly coupled to the central portion of the beam axle housing, the stator having a stator core and a plurality of field windings wound around the stator core, each of the field windings being associated with a different electrical phase, the stator being received in and fixedly coupled to the motor housing, the rotor being rotatable relative to the stator about a motor output shaft axis, the rotor having a motor output shaft, the inverter being housed in the motor housing and electrically coupled to the field windings, the inverter being 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 an associated one of the motor output shafts and the differential input member, An electric drive module comprising the same.

[39] The motor output shaft axes are parallel to each other, and the output shaft is disposed between the motor output shaft axes. The electric drive module according to

[38] .

[40] Further comprising a pair of inverters, each of the pair of inverters being received in an associated one of the motor housings and electrically coupled to a set of field windings on an associated one of the stators. The electric drive module according to

[38] .

Claims

1. An electric drive module, comprising: a motor assembly having a stator, a rotor, a motor output shaft, and a motor controller, wherein the rotor is received within the stator and is rotatable relative to the stator about a motor output shaft axis, the motor output shaft is coupled to the rotor for co-rotation, 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 rotatable about an 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 for co-rotation about the output shaft, and each of the pair of differential output members is rotatable relative to the differential input member about the output shaft; 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 received within the first housing portion, the second housing portion has a first axial end and a heat exchanger fixture, 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 fixture, and a filter fixture, 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 attached to the heat exchanger fixture on the second housing portion, wherein the heat exchanger has a heat exchanger inlet and at least one heat exchanger outlet; comprising, the pump fixture is in fluid communication with the sump, a first internal gallery in the housing assembly fluidly couples the pump fixture to an inlet on the filter fixture, a second internal gallery in the housing assembly fluidly couples an outlet on the filter fixture to a heat exchanger inlet, a third internal gallery in the housing assembly is directly fluidly coupled to the at least one heat exchanger outlet, a first portion of a first fluid sent 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 sent through the third internal gallery is directed to the first housing portion to lubricate at least one of the transmission and the differential assembly. The housing assembly further comprises a cover, the cover is attached to a second axial end of the second housing portion, the second axial end of the second housing portion is on the opposite side of the first axial end, a fourth internal gallery in the housing assembly is fluidly coupled to the at least one heat exchanger outlet, and at least a portion of the first fluid sent through the fourth internal gallery is directed into the motor assembly to cool the motor assembly, an electric drive module. Claim 2 The motor assembly includes an inverter fixture, the inverter fixture is configured to direct a first portion of the first fluid conveyed through the fourth internal gallery through the inverter, the electric drive module according to claim 1. Claim 3 The inverter fixture is configured to direct a second portion of the first fluid conveyed through the fourth internal gallery through the stator, the electric drive module according to claim 2. Claim 4 The inverter includes an electric field capacitor, and a portion of the heat exchanger received in the second housing portion is adjacent to the electric field capacitor, the electric drive module according to claim 1. Claim 5 The housing assembly includes an axle tube, the first housing portion defines an axle tube fixture, the axle tube is received in the axle tube fixture and fixedly coupled to the first housing portion. The electric drive module according to claim 1.

6. The housing assembly further includes a third housing portion, the first and third housing portions have mating flanges and cooperate to define a central cavity in which the differential assembly is disposed. The electric drive module according to claim 5.

7. 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 for rotation about the output shaft. The electric drive module according to claim 6.

8. The electric drive module further includes a pair of shafts, each of the pair of shafts is coupled to a related one of the differential output members for co-rotation, the housing assembly includes a third housing portion, the first and third housing portions have mating flanges, and the shafts penetrate the third housing portion. The electric drive module according to claim 1.

9. The third housing portion defines a pair of axle tube fixtures, the housing assembly further includes a pair of axle tubes, each of the pair of axle tubes is received in a related one of the axle tube fixtures and fixedly coupled to the third housing portion. The electric drive module according to claim 8.

10. At least one bearing is attached to the housing assembly to directly support one of the output gear and the differential input member for rotation about the output shaft. The electric drive module according to claim 8.

11. An electric drive module, A motor assembly having 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 a motor output shaft axis, the motor output shaft is coupled to the rotor for co-rotation, 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 rotatable about an 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 for co-rotation 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, a second housing portion, and a cover, wherein the transmission is at least partially received within the first housing portion, the second housing portion has a first axial end and a heat exchanger mount, the first axial end of the second housing portion is removably attached to the first housing portion, the second housing portion houses at least a portion of the motor controller including the stator, the rotor, and the inverter, the cover closes the end of the second housing portion opposite the first housing portion, the housing assembly defines a sump configured to hold a first fluid, the first fluid being 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 fluidly coupled to the sump to receive the first fluid therefrom, wherein the pump is configured to discharge a flow of the first fluid, A heat exchanger attached to the heat exchanger mount 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, comprising 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 fluidly coupled to the heat exchanger inlet such that the first fluid discharged from the first internal gallery is received into the heat exchanger; a second internal gallery formed in the housing assembly, the second internal gallery being directly fluidly coupled to the first heat exchanger outlet such 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 being directed into the first housing portion to lubricate at least one of the transmission and the differential assembly; a third internal gallery formed in the cover, the third internal gallery being directly fluidly coupled to the second heat exchanger outlet such that a second portion of the first fluid discharged from the heat exchanger is directed into the cover, the first fluid exiting the cover being directed into at least one of the stator and the rotor to cool the motor assembly. The motor assembly includes an inverter fixture configured to direct a first portion of the first fluid conveyed through the third internal gallery through the inverter, an electric drive module. **Claim 12** The electric drive module according to claim 11, wherein the inverter fixture is configured to direct a second portion of the first fluid conveyed through the third internal gallery through the stator. **Claim 13** The electric drive module according to claim 11, wherein the inverter includes an electric field capacitor, and a portion of the heat exchanger received in the second housing portion is adjacent to the electric field capacitor. **Claim 14** The electric drive module according to claim 11, wherein the housing assembly includes an axle tube, the first housing portion defining an axle tube fixture, the axle tube being received in the axle tube fixture and fixedly coupled to the first housing portion. **Claim 15** The housing assembly further includes a third housing portion, and the first and third housing portions have mating flanges and cooperate to define a central cavity in which the differential assembly is disposed. The electric drive module according to claim 14.

16. 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 for rotation about the output shaft. The electric drive module according to claim 15.

17. The electric drive module according to claim 11, further comprising a pair of shafts, each of the pair of shafts being coupled to a respective one of the differential output members for co-rotation, the housing assembly including a third housing portion, the first and third housing portions having mating flanges, and the shafts passing through the third housing portion.

18. The third housing portion defines a pair of axle tube attachments, the housing assembly further comprising a pair of axle tubes, each of the pair of axle tubes being received in a respective one of the axle tube attachments and fixedly coupled to the third housing portion. The electric drive module according to claim 17.

19. At least one bearing is attached to the housing assembly to directly support one of the output gear and the differential input member for rotation about the output shaft. The electric drive module according to claim 17.

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