# US 11,999,227 B2 · Electric drive axle with a gearbox and gearbox operating method > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,999,227 B2 - Document ID: US11999227B2 - Status: Granted - Kind: B2 - Application number: 18/303,374 - Filed: 2023-04-19 - Published: 2023-10-26 - Granted: 2024-06-04 - Earliest claimed: 2022-04-22 - Assignees: Dana Automotive Systems Group, LLC - Applicants: Dana Automotive Systems Group, LLC - Inventors: Eric M. Engerman; Andy Perakes - Web page: https://patentgrep.com/patent/US11999227B2 ## CPC - B60K 17/08: of mechanical type - B60K 1/00: Arrangement or mounting of electrical propulsion units (B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00) - B60K 17/02: characterised by arrangement, location, or kind of clutch - F16H 37/082: {and additional planetary reduction gears} - F16H 61/682: with interruption of drive - B60K 2001/001: {one motor mounted on a propulsion axle for rotating right and left wheels of this axle} - B60Y 2200/91: Electric vehicles - F16H 3/66: composed of a number of gear trains without drive passing from one train to another - F16H 2200/0021: specially adapted for electric vehicles - F16H 2200/0034: the gear ratios comprising two forward speeds - F16H 2200/2007: with two sets of orbital gears - F16H 2200/2035: with two engaging means - F16H 2200/2064: using at least one positive clutch, e.g. dog clutch - F16H 2200/2094: using positive clutches, e.g. dog clutches - F16H 2200/2097: comprising an orbital gear set member permanently connected to the housing, e.g. a sun wheel permanently connected to the housing - B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES - F16H: GEARING - B60Y: INDEXING SCHEME RELATING TO ASPECTS CROSS-CUTTING VEHICLE TECHNOLOGY ## Abstract Methods and systems for an electric drive axle are provided. An electric drive axle, in one example, includes an electric machine rotationally coupled to a gearbox which includes a higher range planetary gear set coupled to a lower range planetary gear set via a clutch. The clutch is configured to selectively rotationally couple an input gear to a sun gear in each of the higher range planetary gear set and the lower range planetary gear set in different positions or selectively rotationally couple a carrier in the higher range planetary gear set to a carrier and a sun gear in the lower range planetary gear set in different positions. ## Claims ### Claim 1 An electric drive axle, comprising: an electric machine rotationally coupled to a gearbox, the gearbox comprising: a clutch selectively coupled to a first planetary gear set and a second planetary gear set; wherein the clutch is configured to: in a first position corresponding to a lower gear ratio mode, rotationally couple a carrier in the first planetary gear set to a carrier in the second planetary gear set; and in a second position corresponding to a higher gear ratio mode, rotationally couple the carrier in the first planetary gear set to a sun gear in the second planetary gear set; and wherein the carrier of the second planetary gear set is coupled to an output gear of the gearbox. ### Claim 2 (depends on 1) The electric drive axle of claim 1, wherein the first and second planetary gear sets are coaxially arranged. ### Claim 3 (depends on 2) The electric drive axle of claim 2, wherein the electric machine and the first and second planetary gear sets are coaxially arranged. ### Claim 4 (depends on 1) The electric drive axle of claim 1, wherein the clutch is a multi-position dog clutch. ### Claim 5 (depends on 1) The electric drive axle of claim 1, wherein at least one of the first and second planetary gear sets is a simple planetary gear set. ### Claim 6 (depends on 1) The electric drive axle of claim 1, wherein the output gear is directly coupled to a differential. ### Claim 7 (depends on 6) The electric drive axle of claim 6, wherein a rotational axis of the differential is parallel to a rotational axis of the electric machine. ### Claim 8 (depends on 1) The electric drive axle of claim 1, further comprising a controller including instructions stored in memory that when executed cause the controller to: transition the gearbox between the higher gear ratio mode and the lower gear ratio mode. ### Claim 9 (depends on 8) The electric drive axle of claim 8, wherein the gearbox is transitioned between the higher gear ratio mode and the lower gear ratio mode based on operator interaction with a range mode selector. ### Claim 10 (depends on 8) The electric drive axle of claim 8, wherein the gearbox is transitioned between the higher gear ratio mode and the lower gear ratio mode based on vehicle speed and/or load. ### Claim 11 (depends on 1) The electric drive axle of claim 1, wherein the electric machine is an electric motor-generator. ### Claim 12 (depends on 1) The electric drive axle of claim 1, wherein the electric drive axle is a beam axle. ### Claim 13 (depends on 1) The electric drive axle of claim 1, wherein the clutch is the only clutch in the gearbox. ### Claim 14 A method for operation of an electric drive axle, comprising: operating a clutch in a gearbox to transition the gearbox between a higher gear ratio mode and a lower gear ratio mode; wherein the electric drive axle comprises: an electric machine rotationally coupled to the gearbox, the gearbox comprising: the clutch selectively coupled to a first planetary gear set and a second planetary gear set; and wherein the clutch is configured to: in a lower gear ratio position, rotationally couple a carrier in the first planetary gear set to a carrier in the second planetary gear set; and in a higher gear ratio position, rotationally couple the carrier in the first planetary gear set to a sun gear in the second planetary gear set; and wherein the clutch is the only clutch in the gearbox. ### Claim 15 (depends on 14) The method of claim 14, wherein the clutch is a dog clutch. ### Claim 16 An electric drive axle, comprising: an electric motor rotationally coupled to a gearbox, the gearbox comprising: a first planetary gear set arranged coaxial to a second planetary gear set; and a clutch configured to: in a first position corresponding to a higher gear ratio mode, rotationally couple an input gear to a sun gear in the first planetary gear set and rotationally decouple the input gear from a sun gear in the second planetary gear set; and in second position corresponding to a lower gear ratio mode, rotationally couple the input gear to the sun gear in the second planetary gear set and rotationally decouple the sun gear in the first planetary gear set from the input gear. ### Claim 17 (depends on 16) The electric drive axle of claim 16, further comprising a differential rotationally coupled to the first planetary gear set, wherein a rotational axis of the differential is parallel to a rotational axis of the electric motor. ### Claim 18 (depends on 16) The electric drive axle of claim 16, wherein the clutch is a dog clutch. ### Claim 19 (depends on 16) The electric drive axle of claim 16, wherein the gearbox includes an output gear coupled to a carrier of the first planetary gear set.