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CN-122029066-A - Drive module assembly

CN122029066ACN 122029066 ACN122029066 ACN 122029066ACN-122029066-A

Abstract

A drive module assembly for use in a vehicle includes a housing defining a housing interior, and an electric machine including a rotor and a stator. The drive module assembly also includes a differential rotatably coupled to the rotor, a first input shaft rotatably coupled to the differential, a second input shaft rotatably coupled to the differential, a first countershaft rotatably coupled to the first input shaft, a second countershaft rotatably coupled to the second input shaft, a first output shaft rotatably coupled to the first countershaft, and a second output shaft rotatably coupled to the second countershaft. The differential is configured to receive rotational torque from the electric machine and to transfer rotational torque from the electric machine to the first and second input shafts.

Inventors

  • Shi Yuanchong
  • C.B. Campton

Assignees

  • 博格华纳公司

Dates

Publication Date
20260512
Application Date
20240829
Priority Date
20230830

Claims (20)

  1. 1. A drive module assembly for use in a vehicle, the drive module assembly comprising: A housing defining a housing interior; An electric motor, which comprises a motor body, A rotor disposed in the housing interior and extending along a rotor axis, and A stator disposed about the rotor axis such that the stator surrounds the rotor; a differential rotatably coupled to the rotor; a first input shaft rotatably coupled to the differential; A second input shaft rotatably coupled to the differential; A first countershaft rotatably coupled to the first input shaft; a second countershaft rotatably coupled to the second input shaft; A first output shaft rotatably coupled to the first countershaft, and A second output shaft rotatably coupled to the second countershaft; Wherein the differential is configured to receive rotational torque from the electric machine and to transfer rotational torque from the electric machine to the first and second input shafts.
  2. 2. The drive module assembly of claim 1, wherein the differential is directly coupled to the rotor.
  3. 3. The drive module assembly according to any one of claims 1 and 2, wherein the differential is directly coupled to the first and second input shafts.
  4. 4. The drive module assembly of any one of the preceding claims, further comprising a first bearing coupled to the first input shaft and configured to support rotation of the first input shaft, and a second bearing coupled to the second input shaft and configured to support rotation of the second input shaft.
  5. 5. The drive module assembly of any of the preceding claims, wherein the first input shaft has a first input diameter of less than 32 millimeters, and wherein the second input shaft has a second input diameter of less than 32 millimeters.
  6. 6. The drive module assembly of claim 5, wherein the first input diameter is less than 29 millimeters, and wherein the second input shaft has a second input diameter that is less than 29 millimeters.
  7. 7. The drive module assembly according to any one of claims 4 to 6, wherein the first bearing has a first bearing diameter of less than 43 millimeters, and wherein the second bearing has a second bearing diameter of less than 43 millimeters.
  8. 8. The drive module assembly of claim 7, wherein the first bearing diameter is less than 41 millimeters, and wherein the second bearing diameter is less than 41 millimeters.
  9. 9. The drive module assembly according to any one of the preceding claims, further comprising a first and a second driven gear rotatably coupled to the first input shaft and the first countershaft and configured to transmit rotational torque from the first input shaft to the first countershaft, the second driven gear rotatably coupled to the second input shaft and the second countershaft and configured to transmit rotational torque from the second input shaft to the second countershaft.
  10. 10. The drive module assembly according to any one of the preceding claims, further comprising a first output gear rotatably coupled to the first countershaft and the first output shaft and configured to transmit rotational torque from the first countershaft to the first output shaft, and a second output gear rotatably coupled to the second countershaft and the second output shaft and configured to transmit rotational torque from the second countershaft to the second output shaft.
  11. 11. The drive module assembly according to any one of the preceding claims, wherein the first and second input shafts extend along an input axis, the first and second auxiliary shafts extend along an auxiliary shaft axis, and wherein the first and second output shafts extend along an output axis.
  12. 12. The drive module assembly of claim 11, wherein the input axis, the countershaft axis, and the output axis are parallel to one another.
  13. 13. The drive module assembly according to any one of claims 11 and 12, wherein the input axis, the countershaft axis, and the output axis are offset from one another.
  14. 14. The drive module assembly according to any one of claims 11 to 13, wherein the secondary axis is disposed between the input axis and the output axis.
  15. 15. The drive module assembly according to any one of the preceding claims, wherein the rotor defines a rotor interior, and wherein the differential is disposed in the rotor interior.
  16. 16. The drive module assembly of claim 15, wherein the first input shaft and the second input shaft are disposed in the rotor interior.
  17. 17. The drive module assembly according to any one of the preceding claims, wherein the first and second input shafts have a peak speed of greater than 20,000 RPM.
  18. 18. A vehicle comprising two of the drive module assemblies according to any one of the preceding claims.
  19. 19. A vehicle comprising the drive module assembly of any one of the preceding claims, wherein the vehicle comprises an internal combustion engine.
  20. 20. A vehicle comprising the drive module assembly of any one of the preceding claims, wherein the vehicle is devoid of an internal combustion engine.

Description

Drive module assembly Cross reference to related applications The present application claims priority and ownership from U.S. provisional application No. 63/535,553 filed on 8/30 of 2023, which is hereby incorporated by reference in its entirety. Technical Field The present disclosure relates generally to drive module assemblies and, in particular, drive module assemblies for use in vehicles. Background Conventional drive module assemblies include an electric machine configured to transmit rotational torque to wheels of a vehicle. To assist in transmitting rotational torque to the wheels of the vehicle, conventional drive module assemblies include gears and differentials to ultimately transmit rotational torque from the electric machine to the wheels of the vehicle to permit maneuvering of the vehicle. As hybrid and battery electric vehicles become more popular, the need for efficient and reliable drive module assemblies has become increasingly important. One of the major challenges in designing drive module assemblies for hybrid and battery electric vehicles is achieving high efficiency while maintaining compact size and low weight. Hybrid and battery electric vehicles typically have limited space available for the drive module assembly, and any added weight may reduce the travel and performance of the vehicle. In recent years, advances in motor technology and power electronics have led to the development of more compact and efficient drive module assemblies. However, in recent years, there has been a limit to the input speed of drive module assemblies including planetary gear systems due to the ability of the bearings used in the drive module assemblies. Further, in a drive module assembly that includes a countershaft, there has been a limit to the achievable gear ratios due to the size of the various components (such as the diameter of the input shaft). Additionally, as it is desired to reduce the overall size of the drive module assembly, the various components of the drive module assembly must be smaller. However, reducing the size of the various components limits the performance of the drive module assembly, such as reducing the torque capacity of the drive module assembly. Accordingly, there remains a need for a drive module assembly that is lighter and more compact, while also having improved efficiency and improved performance while overcoming the drawbacks set forth above. Disclosure of Invention A drive module assembly for use in a vehicle includes an electric machine and a housing defining a housing interior. The electric machine includes a rotor disposed in the housing interior and extending along a rotor axis, and a stator disposed about the rotor axis about the rotor such that the stator surrounds the rotor. The drive module assembly additionally includes a differential rotatably coupled to the rotor, a first input shaft rotatably coupled to the differential, and a second input shaft rotatably coupled to the differential. The drive module assembly further includes a first countershaft rotatably coupled to the first input shaft, a second countershaft rotatably coupled to the second input shaft, a first output shaft rotatably coupled to the first countershaft, and a second output shaft rotatably coupled to the second countershaft. The differential is configured to receive rotational torque from the electric machine and to transfer rotational torque from the electric machine to the first and second input shafts. Drawings Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings. FIG. 1 is a cross-sectional view of a drive module assembly including a housing, an electric machine including a rotor and a stator, a differential, a first input shaft, a second input shaft, a first countershaft, a second countershaft, a first output shaft, and a second output shaft. Fig. 2 is a graph illustrating the relationship of gear ratio as a function of first drive gear base circle diameter. Fig. 3 is a graph illustrating the relationship of gear ratio as a function of center distance between the input axes of the first and second input shafts and the countershaft axes of the first and second countershafts. FIG. 4 is an exemplary flow chart for reducing the size of a drive module assembly. Detailed Description Referring to the drawings, wherein like numerals indicate like parts throughout the several views, a drive module assembly 10 for use in a vehicle is shown in cross-sectional view in fig. 1. The vehicle may comprise an internal combustion engine and is thus a hybrid vehicle. The vehicle may also be a battery electric vehicle without an internal combustion engine. It should be appreciated that the vehicle may include one or more drive module assemblies 10, such as two drive module assemblies, described below. The drive module assembly 10 includes a