Active oil flow control in electric drive unit

An electric drive unit comprising:

• a electric motor including a rotor, a stator, a first gear set operationally engaged with a first end of the rotor and a second gear set operationally engaged with a second end of the rotor;
• a first oil flow circuit adapted to provide oil flow to the first gear set and the second gear set of the electric motor;
• a second oil flow circuit adapted to provide oil flow to the rotor of the electric motor;
• a third oil flow circuit adapted to provide oil flow to end turn spray baffles of the electric motor;
• a fourth oil flow circuit adapted to provide oil flow to the stator of the electric motor;
• a fifth oil flow circuit adapted to provide oil flow to an air gap between the stator and the rotor within the electric motor;
• an oil delivery system adapted to supply pressurized oil to the first, second, third, fourth and fifth oil flow circuits, the oil delivery system including a main sump and a heat exchanger positioned between the main sump and the oil flow control module;
• and
• an oil flow control module positioned between the electric motor and the oil delivery system and adapted to provide independent active control of oil flow within the first, second, third, fourth and fifth oil flow circuits within the electric motor
• the oil flow control module including:
• a temperature control rotary spool valve adapted to selectively:
• route oil flow from the oil delivery system to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module prior to the oil passing through the heat exchanger;
• and
• route oil flow from the oil delivery system to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module after the oil passes through the heat exchanger;
• the temperature control rotary spool valve adapted to meter the ratio of oil that does not pass through the heat exchanger to the oil that passes through the heat exchanger to control a temperature of the oil routed to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module;
• a temperature control bypass circuit adapted to selectively allow oil flow from the oil delivery system to bypass the temperature control rotary spool valve;
• an integrated pressure side filter;
• and
• a filter bypass circuit adapted to selectively allow oil flow to bypass the integrated pressure side filter.

A vehicle having an electric drive unit, the electric drive unit comprising:

• a electric motor including a rotor, a stator, a first gear set operationally engaged with a first end of the rotor and a second gear set operationally engaged with a second end of the rotor;
• a first oil flow circuit adapted to provide oil flow to the first gear set and the second gear set of the electric motor;
• a second oil flow circuit adapted to provide oil flow to the rotor of the electric motor;
• a third oil flow circuit adapted to provide oil flow to end turn spray baffles of the electric motor;
• a fourth oil flow circuit adapted to provide oil flow to the stator of the electric motor;
• a fifth oil flow circuit adapted to provide oil flow to an air gap between the stator and the rotor within the electric motor;
• an oil delivery system adapted to supply pressurized oil to the first, second, third, fourth and fifth oil flow circuits, the oil delivery system including a main sump and a heat exchanger positioned between the main sump and the oil flow control module;
• and
• an oil flow control module positioned between the electric motor and the oil delivery system and adapted to provide independent active control of oil flow within the first, second, third, fourth and fifth oil flow circuits within the electric motor
• the oil flow control module including:
• a temperature control rotary spool valve adapted to selectively:
• route oil flow from the oil delivery system to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module prior to the oil passing through the heat exchanger;
• and
• route oil flow from the oil delivery system to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module after the oil passes through the heat exchanger;
• the temperature control rotary spool valve adapted to meter the ratio of oil that does not pass through the heat exchanger to the oil that passes through the heat exchanger to control a temperature of the oil routed to the at least two of the plurality of oil flow circuits within the electric motor that are controlled by the oil flow module;
• a temperature control bypass circuit adapted to selectively allow oil flow from the oil delivery system to bypass the temperature control rotary spool valve;
• an integrated pressure side filter:
• a filter bypass circuit adapted to selectively allow oil flow to bypass the integrated pressure side filter;
• and
• one of:
• a first linear spool valve and a first linear force solenoid, the first linear force solenoid adapted to selectively actuate the first linear spool valve and the first linear spool valve adapted to selectively control a flow of oil within the first oil flow circuit and actively control oil flow to the first and second gear sets of the electric motor, a second linear spool valve and a second linear force solenoid, the second linear force solenoid adapted to selectively actuate the second linear spool valve and the second linear spool valve adapted to selectively control a flow of oil within the second oil flow circuit and actively control oil flow to the rotor of the electric motor, and a third linear spool valve and a third linear force solenoid, the third linear force solenoid adapted to selectively actuate the third linear spool valve and the third linear spool valve adapted to selectively control a flow of oil within the fifth oil flow circuit and actively control oil flow to the air gap between the stator and the rotor within the electric motor;
• or
• a flow control rotary spool valve adapted to selectively and independently control a flow of oil within the first oil flow circuit, the second oil flow circuit and the third oil flow circuit, the flow control rotary spool valve positioned within a machined bore of a housing of the oil flow control module, sealed within the machined bore by a top plate and actuated by an actuator, and a pump positioned within the machined bore adjacent the flow control rotary spool valve, the pump adapted to pull oil from the main sump and feed pressurized oil to the flow control rotary spool valve, the pump including:
• a gerotor rotationally supported within the machined bore within the oil flow control module, coaxial with the flow control rotary spool valve, the machined bore in communication with the main sump at a point adjacent to the gerotor, a port plate positioned within the machined bore between and coaxial with the gerotor and the flow control rotary spool valve, the port plate including a port adapted to channel oil flow from the gerotor at an outer periphery of the machined bore to a central oil passage within the flow control rotary spool valve, an anti-rotational key adapted to prevent rotational movement of the port plate and allow axial float of the port plate within the machined bore of the oil flow control module, and a motor adapted to rotate the gerotor within the machined bore;
• wherein, rotation of the gerotor pulls oil from the main sump and pushes pressurized oil through the port plate to the flow control rotary spool valve.