Multi-speed transaxle for electric and hybrid vehicle application

An electric drive module for transferring torque to wheels of an electric or hybrid motor vehicle, comprising:

• a housing defining a motor chamber and a gearbox chamber disposed adjacent to one another and arranged along a common axis;
• an electric motor including a rotatable rotor disposed within the motor chamber;
• a planetary gearset disposed within the gearbox chamber adjacent the electric motor and including a first member driven by the rotor in response to an energizing of the electric motor, and a second member;
• a synchronizer disposed within the gearbox chamber and operable to restrict a third member of the planetary gearset from rotation when the electric drive module operates at a first drive ratio, the synchronizer transferring energy from the rotating rotor to the third member during a shift between the first drive ratio and a second drive ratio to match the rotational speeds of the rotor and the second member;
• a reduction unit including an input member being driven by the second member and further including an output member being driven at a reduced speed relative to the input member;
• and
• a differential assembly having an input driven by the output member, a first differential output driving a first output shaft, and a second differential output driving a second output shaft,
• a shift sleeve axially translatable between a first position grounding the third member to a housing and a second position drivingly interconnecting the third member and the second member,
• a shift fork extending radially from the shift sleeve for axially moving the shift sleeve between the first drive ratio and the second drive ratio, and
• an actuator rod attached to the shift fork for moving the shift fork axially.

An electric drive module for transferring drive torque to first and second wheels of an electric or hybrid motor vehicle, the electric drive module comprising:

• a housing defining a motor chamber and a gearbox chamber disposed adjacent to one another and arranged along a common axis;
• an electric motor disposed within the motor chamber for driving a rotor shaft in response to an energizing of the electric motor;
• and
• a gearbox disposed within the gearbox chamber and including a planetary gearset disposed adjacent the electric motor, a reduction unit, a synchronizer assembly and a differential, the planetary gearset including a first rotary member driven by the rotor shaft and second and third rotary members, the reduction unit including an input member coupled for rotation with the second rotary member of the planetary gearset and an output member driven at a reduced speed relative to the input member, the differential including an input component driven by the output member of the reduction unit, a first output component drivingly connected to the first wheel, and a second output component drivingly connected to the second wheel, the synchronizer assembly including a hub fixed for rotation with the third rotary member of the planetary gearset, a shift sleeve coupled for rotation with and sliding axial movement on the hub between at least two positions, a first non-rotary clutch member, a second rotary clutch member fixed to the input member of the reduction unit, a first synchronizer operably disposed between the first clutch member and the shift sleeve and a second synchronizer operably disposed between the second clutch member and the shift sleeve, wherein the shift sleeve is operable in a first position to couple the third member of the planetary gearset to the first clutch member and establish a first speed ratio drive connection between the rotor shaft and the input member of the reduction unit, and wherein the shift sleeve is operable in a second position to couple the third member of the planetary gearset to the second clutch member and establish a second speed ratio drive connection between the rotor shift and the input member of the reduction unit,
• a shift fork extending radially from the shift sleeve for axially moving the shift sleeve between the first drive ratio and the second drive ratio, and
• an actuator rod attached to the shift fork for moving the shift fork axially.