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US 2026/0071670 A1Published application
Modular and adaptable multi-speed and multi-reduction axle
AssigneeDana Heavy Vehicle Systems Group, LLC
InventorsSaket KALE, Anand WAKODE
Life of this patent
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Abstract
Systems and methods for a modular multi-speed and multi-reduction electric axle, comprising an electric motor rotationally coupled to a motor shaft, the motor shaft being coupled to an input shaft via splines, no more than two planetary gearset systems that comprise an annulus gear, planet gears, planet carriers, and a cover, no more than two synchronizers that are coupled to a respective sun gear and axially moveable to engage the sun gear with one of a cover or planet carrier of the respective planetary gearset system, at least two helical gears that engage with each other; and a pinion gear that engages with a ring gear, the ring gear being coupled to a differential.
Claims19
A multi-speed and multi-reduction electric axle system, comprising:
- a housing with at least one cover that circumferentially encloses a transmission assembly of the multi-speed and multi-reduction electric axle system;
- an electric motor rotationally coupled to a motor shaft, the motor shaft being coupled to an input shaft via splines and a carrier;
- no more than two planetary gearset systems, each planetary gearset system comprising an annulus gear, a sun gear, planet gears, and a planet carrier;
- no more than two synchronizers wherein each synchronizer is coupled to a respective sun gear and axially moveable to engage the sun gear with one of the at least one cover of the housing or planet carrier of a respective planetary gearset system;
- at least two helical gears, wherein at least one helical gear of the at least two helical gears is positioned above another helical gear of the at least two helical gears enabling the at least two helical gears to engage with each other;
- and
- a pinion gear that is coupled to one helical gear via a spline and engages with a ring gear, the ring gear being coupled to a differential,
- wherein the at least one cover comprises a first cover located on one side of the multi-speed and multi-reduction electric axle system, the first cover being located in a top half of the multi-speed and multi-reduction electric axle system,
- wherein the at least two helical gears includes a first helical gear and a second helical gear that engages with the first helical gear and is coupled to the pinion gear, the first helical gear being located on a same side as the first cover and in the top half of the multi-speed and multi-reduction electric axle system and the second helical gear being located on the same side as the first cover and in a bottom half of the multi-speed and multi-reduction electric axle system, and
- wherein the at least two helical gears further include a third helical gear located on the same side as a second cover and in the bottom half of the multi-speed and multi-reduction electric axle system and coupled to the input shaft via splines.
7 more elements
2-3. (canceled)
(canceled)
A method for operation of a modular multi-speed and multi-reduction electric axle, comprising:
- axially moving a respective synchronizer toward one of a planet carrier of a respective planetary gearset system or a cover of a housing;
- and
- engaging a sun gear of the respective planetary gearset system with one of the planet carrier or the cover to achieve different reduction ratios of the respective planetary gearset system,
- wherein the respective planetary gearset system is rendered inactive in response to axially moving the respective synchronizer toward the planet carrier and engaging the planet carrier of the planetary gearset system, and wherein the respective planetary gearset system is rendered active in response to axially moving the respective synchronizer toward the cover and engaging the cover.
1 more element
(canceled)
A line of axle systems, comprising:
- a first transmission, a second transmission, and a third transmission, each of the first transmission, the second transmission, and the third transmission comprising:
- a housing comprising at least a first cover positioned on one side of a respective transmission that circumferentially encloses the respective transmission, a position of a first cover being the same for each of the first transmission, the second transmission, and the third transmission;
- an electric motor rotationally coupled to a motor shaft, the motor shaft being coupled to an input shaft via splines and a carrier and the electric motor being positioned on an opposite side of the respective transmission relative to the first cover;
- a pair of helical gears positioned on a same side of the respective transmission as the first cover and comprising a first helical gear positioned in a top half and a second helical gear positioned in a bottom half of the respective transmission that engage with each other and neither of the first helical gear and the second helical gear is coupled to the input shaft;
- and
- a pinion gear positioned on the same side of the respective transmission as the first cover and coupled to the second helical gear via a spline and engages with a ring gear, the ring gear being coupled to a differential in a center region of the respective transmission.
3 more elements
Dependencies are inferred from the claim text.