Drivetrain system having an axle assembly

A drivetrain system including an axle assembly that may have an electric motor module, a gear reduction module, a drive pinion, a differential assembly, an auxiliary shaft, and a shift collar. The shift collar may selectively couple the auxiliary shaft, the drive pinion, and the gear reduction module in various combinations.

TECHNICAL FIELD

This disclosure relates to a drivetrain system that may include an axle assembly. The axle assembly may include an electric motor module, a gear reduction module, a drive pinion, a differential assembly, an auxiliary shaft, and a shift collar. The shift collar may selectively couple the auxiliary shaft, the drive pinion, and the gear reduction module in various combinations.

BACKGROUND

An axle assembly having an electric motor module is disclosed in U.S. Patent Publication No. 2019/0054816.

SUMMARY

In at least one embodiment, a drivetrain system is provided. The drivetrain system may include an axle assembly that has an electric motor module, a gear reduction module, a drive pinion, a differential assembly, an auxiliary shaft, and a shift collar. The gear reduction module may be operatively connected to the electric motor module. The drive pinion may be rotatable about a first axis. The differential assembly may be rotatable about a second axis and may engage the drive pinion. The auxiliary shaft may be rotatable about the first axis and may be spaced apart from the drive pinion. The shift collar may be rotatable about the first axis with the auxiliary shaft and may selectively couple the auxiliary shaft to the drive pinion, the gear reduction module, or the drive pinion and the gear reduction module.

In at least one embodiment, a drivetrain system is provided. The drivetrain system may include an axle assembly that has an electric motor module, a gear reduction module, a drive pinion, a differential assembly, an auxiliary shaft, and a shift collar. The gear reduction module may be operatively connected to the electric motor module. The drive pinion may be rotatable about a first axis. The differential assembly may be rotatable about a second axis and may engage the drive pinion. The auxiliary shaft may be rotatable about the first axis and may be spaced apart from the drive pinion. The shift collar may be rotatable about the first axis and may be configured to selectively couple the gear reduction module to the auxiliary shaft or the drive pinion.

DETAILED DESCRIPTION

Referring toFIG. 1, an example of a drivetrain system10is shown. The drivetrain system10may include an axle assembly12. The axle assembly12may be provided with a motor vehicle like a truck, bus, farm equipment, mining equipment, military transport or weaponry vehicle, or cargo loading equipment for land, air, or marine vessels. The motor vehicle may include a trailer for transporting cargo in one or more embodiments. The axle assembly12may provide torque to one or more traction wheel assemblies that may include a tire mounted on a wheel. The wheel may be mounted to a wheel hub that may be rotatable about an axis.

One or more axle assemblies may be provided with the vehicle. As is best shown with reference toFIGS. 1 and 2, the axle assembly12may include a housing assembly20, a drive pinion22, an electric motor module24, a gear reduction module26, an auxiliary shaft28, a shift mechanism30, a differential assembly32, and at least one axle shaft34.

Referring toFIG. 1, the housing assembly20may receive various components of the axle assembly12. In addition, the housing assembly20may facilitate mounting of the axle assembly12to the vehicle. In at least one configuration, the housing assembly20may include an axle housing40and a differential carrier42. In addition, the housing assembly20may include portions that may receive and/or facilitate mounting of the electric motor module24, the shift mechanism30, or both.

The axle housing40may receive and may support the axle shafts34. In at least one embodiment, the axle housing40may include a center portion50and at least one arm portion52.

The center portion50may be disposed proximate the center of the axle housing40. The center portion50may define a cavity that may receive the differential assembly32. A lower region of the center portion50may at least partially define a sump portion that may contain a first lubricant. Splashed lubricant may flow down the sides of the center portion50and may flow over various internal components of the axle assembly12and gather in the sump portion.

One or more arm portions52may extend from the center portion50. For example, two arm portions52may extend in opposite directions from the center portion50and away from the differential assembly32. The arm portions52may have substantially similar configurations. For example, the arm portions52may each have a hollow configuration or tubular configuration that may extend around and may receive a corresponding axle shaft34and may help separate or isolate the axle shaft34or a portion thereof from the surrounding environment. An arm portion52or a portion thereof may be integrally formed with the center portion50. Alternatively, an arm portion52may be separate from the center portion50. In such a configuration, each arm portion52may be attached to the center portion50in any suitable manner, such as by welding or with one or more fasteners. An arm portion may rotatably support an associated wheel hub. It is also contemplated that the arm portions52may be omitted.

Referring toFIGS. 1 and 2, the differential carrier42, which may also be called a carrier housing, may be mounted to the center portion50of the axle housing40. The differential carrier42may support the differential assembly32. In at least one configuration, the differential carrier42may facilitate mounting of the electric motor module24.

Referring toFIG. 2, the drive pinion22may provide torque to a ring gear that may be provided with the differential assembly32. Moreover, the drive pinion22may help operatively connect the gear reduction module26to the differential assembly32. The drive pinion22may extend along and may be rotatable about a first axis60. In addition, the drive pinion22may extend through a hole in the differential carrier42. In at least one configuration, the drive pinion22may include a gear portion70and a shaft portion72.

The gear portion70may be disposed at or near an end of the shaft portion72. The gear portion70may have a plurality of teeth that may mate or mesh with corresponding teeth on the ring gear. The gear portion70may be integrally formed with the shaft portion72or may be provided as a separate component that may be fixedly disposed on the shall portion72.

The shaft portion72may extend from the gear portion70in a direction that extends away from the axle housing40. The shaft portion72may be rotatably supported by one or more drive pinion bearings and may include a drive pinion spline74, which is best shown inFIG. 3.

Referring toFIG. 3, the drive pinion spline74may be disposed near an end of the shaft portion72that may be disposed opposite the gear portion70. The drive pinion spline74may include a plurality of teeth. The teeth may be disposed substantially parallel to the first axis60and may mate with a corresponding spline on a shift collar of the shift mechanism30as will be discussed in more detail below.

Referring toFIG. 2, the electric motor module24may provide torque to the differential assembly32via the drive pinion22, the gear reduction module26, and the shift mechanism30. In at least one configuration, the electric motor module24may be mounted to the differential carrier42and may be axially positioned between the axle housing40and the gear reduction module26. In at least one configuration, the electric motor module24may include a stator80, a rotor82, and at least one rotor bearing assembly84.

The stator80may be fixedly positioned with respect to the housing assembly20. For example, the stator80may extend around the first axis60and may not rotate about the first axis60. The stator80may include windings that may be electrically connected to an electrical power source, such as a battery, capacitor, or the like. An inverter may electrically connect the electric motor module24and the electrical power source.

The rotor82may be rotatable about the first axis60with respect to the differential carrier42and the stator80. For example, the rotor82may be spaced apart from the stator80but may be disposed close to the stator80. The rotor82may include magnets or ferromagnetic material that may facilitate the generation of electrical current.

One or more rotor bearing assemblies84may rotatably support the rotor82. In at least one configuration, a rotor bearing assembly84may receive a bearing support wall of the differential carrier42and may be received inside of the rotor82.

A rotor shaft90or rotor coupling may operatively connect the rotor82to the gear reduction module26. For example, the rotor shaft90may extend from the rotor82or may be operatively connected to the rotor82such that the rotor82and the rotor shaft90may be rotatable together about the first axis60. The rotor shaft90may be fixedly coupled to the rotor82at or proximate a first end of the rotor shaft90and may be coupled to the gear reduction module26proximate a second end.

Referring toFIG. 2, the gear reduction module26may transmit torque between the electric motor module24and the drive pinion22.

The gear reduction module26may be provided in various configurations, such as planetary gear set configurations and non-planetary gear set configurations. InFIG. 2, the gear reduction module26has a planetary gear set100. In such a configuration, the gear reduction module26may include a sun gear110, planet gears112, a planetary ring gear114, and a planet gear carrier116.

Referring primarily toFIG. 3, the sun gear110may be disposed proximate the center of the planetary gear set100and may be rotatable about the first axis60. In at least one configuration, the sun gear110may be configured as a hollow tubular body that may include a sun gear hole120, a sun gear spline122, a first gear portion124, and a second gear portion126.

The sun gear hole120may be a through hole that may extend through the sun gear110. The sun gear hole120may extend along and may be centered about the first axis60. The drive pinion22may extend through the sun gear hole120and may be spaced apart from the sun gear110.

The sun gear spline122may facilitate coupling of the sun gear110to a rotor shaft90. In at least one configuration, the sun gear spline122may be disposed opposite the sun gear hole120and may have teeth that may extend away from the sun gear hole120. As such, the sun gear spline122may be received inside the rotor shaft90and may mesh or mate with corresponding teeth on the rotor shaft90. It is also contemplated that the sun gear spline122may be disposed in the sun gear hole120and the rotor shaft90may be received inside the sun gear110.

The first gear portion124may be disposed in the sun gear hole120. Teeth of the first gear portion124may be arranged around the first axis60, may extend toward the first axis60, and may be configured to mesh with teeth of a shift collar170as will be discussed in more detail below.

The second gear portion126may be disposed opposite the sun gear hole120and may have teeth that may extend away from the sun gear hole120. The teeth of the second gear portion126may mate or mesh with teeth of the planet gears112.

Referring toFIGS. 2 and 3, the planet gears112may be rotatably disposed between the sun gear110and the planetary ring gear114. Each planet gear112may have a hole and a set of teeth. The hole may be a through hole that may extend through the planet gear112. The set of teeth may be disposed opposite the hole. The set of teeth may mesh with teeth of the second gear portion126of the sun gear110and teeth on the planetary ring gear114. The teeth may have any suitable configuration. In the configuration shown, the teeth are provided with a helical configuration however, other tooth configurations may be provided. Each planet gear112may be configured to rotate about a different planet gear axis of rotation. The planet gear axes of rotation may extend substantially parallel to the first axis60.

Referring toFIG. 3, the planetary ring gear114may extend around the first axis60and may receive the planet gears112. The planetary ring gear114may include a set of planetary ring gear teeth that may extend toward the first axis60and may mesh with teeth on the planet gears112. The planetary ring gear114may be stationary with respect to the first axis60. For example, the planetary ring gear114may be received in and may be fixedly disposed on the housing assembly20.

Referring toFIGS. 2 and 3, the planet gear carrier116may be rotatable about the first axis60and may rotatably support the planet gears112. For instance, each planet gear112may be rotatably disposed on a corresponding pin that may extend from the planet gear carrier116. In at least one configuration, the planet gear carrier116may include a planet gear carrier hole130, a planet gear carrier ring132, and a planet gear carrier gear portion134.

Referring toFIG. 3, the planet gear carrier hole130may be a through hole that may extend through planet gear carrier116. The planet gear carrier hole130may extend along and may be centered about the first axis60.

The planet gear carrier ring132may extend around the first axis60and may at least partially define the planet gear carrier hole130. The planet gear carrier ring132may be received in and may be rotatably supported by a support bearing140.

The planet gear carrier gear portion134may be disposed in the planet gear carrier ring132and may extend into the planet gear carrier hole130. Teeth of the planet gear carrier gear portion134may be arranged around the first axis60and may extend toward the first axis60.

Referring toFIGS. 1-3, the auxiliary shaft28may protrude from the housing assembly20. For example, the auxiliary shaft28may protrude from the housing assembly20and may extend away from the electric motor module24and the axle housing40. In at least one configuration, the auxiliary shaft28may be rotatable about the first axis60. The auxiliary shaft28may function as an output from the axle assembly12, an input to the axle assembly12, or combinations thereof. For example, the auxiliary shaft28may function as an output or a power take-off (PTO) that may transfer power or torque from the axle assembly12to an auxiliary device150that may be operatively connected to the auxiliary shaft28. Examples of an auxiliary device150include but are not limited to a pump, ladder, vacuum, blower, compressor, winch, mechanical arm, compactor, boom, grapple, tree spade, dump truck bed lift, or the like. The auxiliary shaft28may also function as an input that may receive power or torque from an auxiliary device150, such as engine like an internal combustion engine. As is best shown inFIG. 3, the auxiliary shaft28may be spaced apart from the drive pinion22. In at least one configuration, the auxiliary shaft28may include an auxiliary shaft spline160.

The auxiliary shaft spline160may mate or selectively mate with a corresponding spline on a shift collar of the shift mechanism30as will be discussed in more detail below. For example, the auxiliary shaft spline160may include a plurality of teeth that may be disposed substantially parallel to the first axis60and that may permit axial movement of the shift collar along the first axis60.

Referring toFIGS. 1-3, the shift mechanism30may help control the transmission of torque through the axle assembly12. In at least one configuration, the shift mechanism30may include a shift collar170, an actuator172, and a linkage174.

Referring toFIG. 3, the shift collar170may selectively couple and decouple components of the axle assembly12such as the drive pinion22, the gear reduction module26, the auxiliary shaft28, or combinations thereof. In at least one configuration, the shift collar170may receive the drive pinion22. The auxiliary shaft28and may be partially received in the planet gear carrier116. In the configuration shown inFIG. 3, the shift collar170may include a shift collar hole180, a first shift collar spline182, a second shift collar spline184, a shift collar groove186, and a shift collar gear188.

The shift collar hole180may extend through the shift collar170and may extend around the first axis60. The shift collar hole180may receive the shaft portion72of the drive pinion22and the auxiliary shaft28.

The first shift collar spline182may be disposed in the shift collar hole180and may be axially positioned near a first end of the shift collar170. The first shift collar spline182may extend toward the first axis60and may mate or mesh with the drive pinion spline74of the drive pinion22. The mating splines may allow the shift collar170to move in an axial direction along the first axis60while inhibiting rotation of the shift collar170about the first axis60with respect to the drive pinion22. Thus, the shift collar170may be rotatable about the first axis60with the drive pinion22when the shift collar170is coupled to the drive pinion22such that the first shift collar spline182mates or meshes with the drive pinion spline74of the drive pinion22.

The second shift collar spline184may be disposed in the shift collar hole180and may be axially positioned near a second end of the shift collar170. The second shift collar spline184may extend toward the first axis60and may mate or mesh with a spline of the auxiliary shaft28. The mating splines may allow the shift collar170to move in an axial direction along the first axis60while inhibiting rotation of the shift collar170about the first axis60with respect to the auxiliary shaft28. Thus, the shift collar170may be rotatable about the first axis60with the auxiliary shaft28when the shift collar170is coupled to the auxiliary shaft28such that the second shift collar spline184mates or meshes with the auxiliary shaft spline160of the auxiliary shaft28.

The shift collar groove186may face away from the first axis60and may extend around the first axis60. The shift collar groove186may receive the linkage174.

The shift collar gear188may be disposed between the first end and the second end of the shift collar170. The shift collar gear188may have at least one set of teeth that may be arranged around the first axis60and that may extend away from the first axis60. In the configuration shown inFIG. 3, the shift collar gear188includes a first set of teeth190and a second set of teeth192. An annular groove200may be provided between the first set of teeth190and the second set of teeth192. The annular groove200may extend around the first axis60and may separate the first set of teeth190and the second set of teeth192.

Referring toFIG. 1, the actuator172may be configured to move the shift collar170along the first axis60. The actuator172may be of any suitable type. For example, the actuator172may be an electrical, electromechanical, pneumatic or hydraulic actuator.

Referring toFIG. 3, the linkage174may operatively connect the actuator172to the shift collar170. For example, the linkage174may be configured as a shift fork that may extend from the shift collar170to the actuator172. In at least one configuration, the linkage174may be received in the shift collar groove186.

A control system may be provided with the drivetrain system10. The control system may include one or more electronic controllers, such as a microprocessor-based controller. The control system may control operation of the axle assembly12. For example, the controller may receive signals from various sensors, such as rotational speed sensors that may provide signals indicative of the rotational speed of a wheel, the axle shaft34, the drive pinion22, the sun gear110, the rotor82, or combinations thereof. In addition, the control system may control the actuator172and thereby control movement of the shift collar170.

Referring toFIG. 2, the differential assembly32may be at least partially received in the center portion50of the housing assembly20. The differential assembly32may transmit torque to the wheels and permit the wheels to rotate at different velocities. The differential assembly32may be operatively connected to the axle shafts34and may permit the axle shafts34to rotate at different rotational speeds in a manner known by those skilled in the art. The differential assembly32may have a ring gear210that may have teeth the mate or mesh with the teeth of the gear portion70of the drive pinion22. Accordingly, the differential assembly32may receive torque from the drive pinion22via the ring gear210and transmit torque to the axle shafts34.

Referring toFIGS. 1 and 2, the axle shafts34may transmit torque from the differential assembly32to corresponding wheel hubs and wheels. Two axle shafts34may be provided such that each axle shaft34extends through a different arm portion52of axle housing40. The axle shafts34may extend along and may be rotatable about the second axis220. Each axle shaft34may have a first end and a second end. The first end may be operatively connected to the differential assembly32. The second end may be disposed opposite the first end and may be operatively connected to a wheel. Optionally, gear reduction may be provided between an axle shaft34and a wheel.

Referring toFIGS. 3-19, operation of the drivetrain system10will now be discussed in more detail. In these figures, the straight arrowed lines represent the transmission of torque. InFIGS. 3-14, the shift collar170may be rotatable about the first axis60with the auxiliary shaft28and may selectively couple the auxiliary shaft28to the drive pinion22, the gear reduction module26, or the drive pinion22and the gear reduction module26. InFIGS. 15-19, the shift collar may selectively couple the gear reduction module26to the auxiliary shaft28or the drive pinion22.

Referring toFIGS. 3-6, the auxiliary shaft28is configured to function as an output or power take-off and is operatively connected to at least one auxiliary device150.

InFIG. 3, the shift collar170is shown in a first position. In the first position, the shift collar170may couple the drive pinion22and the auxiliary shaft28such that the drive pinion22, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74and the second shift collar spline184may mate or mesh with the auxiliary shaft spline160. The shift collar170may be decoupled from the gear reduction module26when the shift collar170is in the first position. For instance, the shift collar gear188may be spaced apart from and may not mate or mesh with the second gear portion126of the sun gear110or the planet gear carrier gear portion134of the planet gear carrier116. Accordingly, the electric motor module24may not provide torque to the drive pinion22or the auxiliary shaft28or receive torque from the drive pinion22or the auxiliary shaft28. The drive pinion22, the shift collar170, and the auxiliary shaft28may be coupled but may not rotate about the first axis60when the vehicle is stationary. The drive pinion22, shift collar170, and the auxiliary shaft28may be coupled and may rotate about the first axis60when the vehicle is coasting and torque is provided from the rotating vehicle wheels to the drive pinion22via the axle shafts34and the differential assembly32.

InFIG. 4, the shift collar170is shown in a second position. In the second position, the shift collar170may couple the drive pinion22, the planet gear carrier116of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the planet gear carrier116, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the second set of teeth192of the shift collar gear188may mate or mesh with the planet gear carrier gear portion134. The second position may also be referred to as a low range position in which the gear reduction module26may provide a low range gear ratio.

The electric motor module24may provide torque to the sun gear110via the rotor shaft90, the sun gear110may provide torque to the planet gear carrier116via the planet gears112, and the planet gear carrier116may provide torque to the drive pinion22and the auxiliary shaft28via the shift collar170when the shift collar is in the second position and the electrical power source provides electrical power to the electric motor module24. In addition, it is contemplated that the electric motor module24may receive torque or may act as a generator that may charge the electrical power source when the vehicle is coasting, in which case torque may be provided from the rotating vehicle wheels to the drive pinion22via the axle shafts34and the differential assembly32, and thus the drive pinion22may provide torque to the auxiliary shaft28and to the electric motor module24via the planet gear carrier116of the gear reduction module26when the shift collar170is in the second position. The shift collar170may be decoupled from the sun gear110when the shift collar170is in the second position.

InFIG. 5, the shift collar170is shown in a third position. In the third position, the shift collar170may couple the drive pinion22, the sun gear110of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the sun gear110, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the first set of teeth190of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The third position may also be referred to as a high range position in which the gear reduction module26may provide a high range gear ratio. The high range gear ratio may provide a different gear reduction ratio or lesser gear reduction ratio than the low range gear ratio. As a nonlimiting example, the high range gear ratio may provide a 1:1 gear ratio. The second drive gear ratio may facilitate faster vehicle cruising or a cruising gear ratio that may help improve fuel economy.

The electric motor module24may provide torque to the sun gear110via the rotor shaft90and the sun gear110may provide torque to the drive pinion22and the auxiliary shaft28via the shift collar170when the shift collar is in the third position and the electrical power source provides electrical power to the electric motor module24. In addition, it is contemplated that the electric motor module24may receive torque or may act as a generator that may charge the electrical power source when the vehicle is coasting, in which case torque may be provided from the rotating vehicle wheels to the drive pinion22via the axle shafts34and the differential assembly32and thus the drive pinion22may provide torque to the auxiliary shaft28and to the electric motor module24via the sun gear110of the gear reduction module26when the shift collar170is in the third position. The shift collar170may be decoupled from the planet gear carrier116when the shift collar170is in the third position.

InFIG. 6, the shift collar170is shown in a fourth position. In the fourth position, the shift collar170may couple the sun gear110of the gear reduction module26to the auxiliary shaft28such that the sun gear110, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160and the second set of teeth192of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The fourth position may also be a high range position in which the gear reduction module26may provide a high range gear ratio or the same gear ratio as the third position. The drive pinion22may be decoupled from the shift collar170when the shift collar170is in the fourth position. For example, the first shift collar spline182may be decoupled from and may not mate or mesh with the drive pinion spline74.

The electric motor module24may provide torque to the sun gear110via the rotor shaft90and the sun gear110may provide torque to the auxiliary shaft28via the shift collar170when the shift collar is in the fourth position and the electrical power source provides electrical power to the electric motor module24. Accordingly, the fourth position may be employed when the vehicle is stationary and it is desired to provide power to the auxiliary shaft28. In addition, it is contemplated that shift collar170may be configured to provide torque to the auxiliary shaft28via the planet gear carrier116rather than the sun gear110when the shift collar170is decoupled from the drive pinion22.

Referring toFIGS. 7-10, the auxiliary shaft28may be configured to function as an input and may receive torque from an auxiliary device150, such as an internal combustion engine. For instance, the auxiliary device150may be a torque source that is connected in a series hybrid configuration. The shift collar positions inFIGS. 7-10match those shown inFIGS. 3-6, but the torque transmission paths are different since the auxiliary shaft28may function as an input rather than an output.

InFIG. 7, the shift collar170is shown in a first position. In the first position, the shift collar170may couple the drive pinion22and the auxiliary shaft28such that the drive pinion22, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74and the second shift collar spline184may mate or mesh with the auxiliary shaft spline160. The shift collar170may be decoupled from the gear reduction module26when the shift collar170is in the first position. For instance, the shift collar gear188may be spaced apart from and may not mate or mesh with the second gear portion126of the sun gear110or the planet gear carrier gear portion134of the planet gear carrier116. Accordingly, the electric motor module24may not provide torque to the drive pinion22or the auxiliary shaft28and may not receive torque from the drive pinion22or the auxiliary shaft28. The auxiliary device150may therefore provide torque to propel the vehicle and regenerative torque may not be provided to the electric motor module24when the vehicle is coasting.

InFIG. 8, the shift collar170is shown in a second position. In the second position, the shift collar170may couple the drive pinion22, the planet gear carrier116of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the planet gear carrier116, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the second set of teeth192of the shift collar gear188may mate or mesh with the planet gear carrier gear portion134. The second position may also be referred to as a low range position in which the gear reduction module26may provide a low range gear ratio. Accordingly, the auxiliary device150may provide torque to propel the vehicle and regenerative torque to the electric motor module24such that the electric motor module24may act as a generator that may charge the electrical power source. In addition, regenerative torque may be provided to the electric motor module24via the low range gear ratio when the vehicle is coasting.

InFIG. 9, the shift collar170is shown in a third position. In the third position, the shift collar170may couple the drive pinion22, the sun gear110of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the sun gear110, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the first set of teeth190of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The third position may also be referred to as a high range position in which the gear reduction module26may provide a high range gear ratio as previously discussed. Accordingly, the auxiliary device150may provide torque to propel the vehicle and may provide regenerative torque to the electric motor module24such that the electric motor module24may act as a generator that may charge the electrical power source. In addition, regenerative torque may be provided to the electric motor module24via the high range gear ratio when the vehicle is coasting.

InFIG. 10, the shift collar170is shown in a fourth position. In the fourth position, the shift collar170may couple the sun gear110of the gear reduction module26to the auxiliary shaft28such that the sun gear110, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160and the second set of teeth192of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The fourth position may also be a high range position in which the gear reduction module26may provide a high range gear ratio or the same gear ratio as the third position. The drive pinion22may be decoupled from the shift collar170when the shift collar170is in the fourth position. Accordingly, the auxiliary device150may not provide torque to propel the vehicle and may provide regenerative torque to the electric motor module24such that the electric motor module24may act as a generator that may charge the electrical power source. In addition, it is contemplated that shift collar170may be configured to provide regenerative torque to the electric motor module24via the low range gear ratio when the shift collar170is decoupled from the drive pinion22.

Referring toFIGS. 11-14, the auxiliary shaft28may be configured to function as an input and may receive torque from an auxiliary device150, such as an internal combustion engine. For instance, the auxiliary device150may be a torque source that is connected in a parallel hybrid configuration. The shift collar positions inFIGS. 11-14match those shown inFIGS. 7-10, but the torque transmission paths may differ.

InFIG. 11, the shift collar170is shown in a first position. In the first position, the shift collar170may couple the drive pinion22and the auxiliary shaft28such that the drive pinion22, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74and the second shift collar spline184may mate or mesh with the auxiliary shaft spline160. The shift collar170may be decoupled from the gear reduction module26when the shift collar170is in the first position. For instance, the shift collar gear188may be spaced apart from and may not mate or mesh with the second gear portion126of the sun gear110or the planet gear carrier gear portion134of the planet gear carrier116. Accordingly, the electric motor module24may not provide torque to the drive pinion22or the auxiliary shaft28and may not receive torque from the drive pinion22or the auxiliary shaft28. The auxiliary device150may therefore provide torque to propel the vehicle and regenerative torque may not be provided to the electric motor module24when the vehicle is coasting.

InFIG. 12, the shift collar170is shown in a second position. In the second position, the shift collar170may couple the drive pinion22, the planet gear carrier116of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the planet gear carrier116, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the second set of teeth192of the shift collar gear188may mate or mesh with the planet gear carrier gear portion134. The second position may also be referred to as a low range position in which the gear reduction module26may provide a low range gear ratio. Accordingly, the electric motor module24, the auxiliary device150, or both may provide torque to propel the vehicle. In addition, regenerative torque may be provided to the electric motor module24via the low range gear ratio when the vehicle is coasting.

InFIG. 13, the shift collar170is shown in a third position. In the third position, the shift collar170may couple the drive pinion22, the sun gear110of the gear reduction module26, and the auxiliary shaft28such that the drive pinion22, the sun gear110, the shift collar170, and the auxiliary shaft28may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, the second shift collar spline184may mate or mesh with the auxiliary shaft spline160, and the first set of teeth190of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The third position may also be referred to as a high range position in which the gear reduction module26may provide a high range gear ratio as previously discussed. Accordingly, the electric motor module24, the auxiliary device150, or both may provide torque to propel the vehicle. In addition, regenerative torque may be provided to the electric motor module24via the high range gear ratio when the vehicle is coasting.

InFIG. 14, the shift collar170is shown in a fourth position. The fourth position inFIG. 14may be the same as the fourth position and description associated withFIG. 10.

Referring toFIGS. 15-19, the shift collar170′ is shown with a different configuration than the shift collar170previously discussed. In the configuration shown, the shift collar gear188of the shift collar170′ may include a third set of teeth194in addition to the first set of teeth190and the second set of teeth192. The second set of teeth192may be positioned between the first set of teeth190and the third set of teeth194. A second annular groove202may be provided between the second set of teeth192and the third set of teeth194. The second annular groove202groove may extend around the first axis60and may separate the second set of teeth192from the third set of teeth194. InFIGS. 15-19, the auxiliary shaft28is configured to function as an output or power take-off and may be operatively connected to at least one auxiliary device150at previously discussed. In addition, the shift collar170′ may be configured to selectively couple the gear reduction module26to the drive pinion22or the auxiliary shaft28inFIGS. 15-19, which may differ from the configurations shown inFIGS. 3-14in which the shift collar170remains coupled to the auxiliary shaft28.

InFIG. 15, the shift collar170′ is shown in a first neutral position. The shift collar170′ may be coupled to the drive pinion22such that the shift collar170′ and the drive pinion22may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74. The shift collar170′ may be decoupled from the gear reduction module26and may be decoupled from the auxiliary shaft28when the shift collar170′ is in the first neutral position. For instance, the shift collar gear188may be spaced apart from and may not mate or mesh with the first gear portion124of the sun gear110or the planet gear carrier gear portion134of the planet gear carrier116, and the second shift collar spline184may be spaced apart from and may not mate or mesh with the auxiliary shaft spline160. The drive pinion22and the shift collar170′ may rotate about the first axis60when the vehicle is coasting and torque is provided from the rotating vehicle wheels to the drive pinion22via the axle shafts34and the differential assembly32.

InFIG. 16, the shift collar170′ is shown in a low range position. The shift collar170′ may couple the drive pinion22to the planet gear carrier116of the gear reduction module26such that the drive pinion22, the planet gear carrier116, and the shift collar170′ may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, and the third set of teeth194of the shift collar gear188may mate or mesh with the planet gear carrier gear portion134. The gear reduction module26may provide a low range gear ratio in the low range position. The electric motor module24may provide torque to the sun gear110via the rotor shaft90, the sun gear110may provide torque to the planet gear carrier116via the planet gears112, and the planet gear carrier116may provide torque to the drive pinion22via the shift collar170′ when the shift collar is in the low range position and the electrical power source provides electrical power to the electric motor module24. The shift collar170′ may be decoupled from the auxiliary shaft28and the sun gear110when the shift collar170′ is in the low range position.

InFIG. 17, the shift collar170′ is shown in a high range position. The shift collar170′ may couple the drive pinion22to the sun gear110of the gear reduction module26such that the drive pinion22, the sun gear110, and the shift collar170′ may be rotatable together about the first axis60. For example, the first shift collar spline182may mate or mesh with the drive pinion spline74, and the first set of teeth190of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110. The gear reduction module26may provide a high range gear ratio in the high range position. The electric motor module24may provide torque to the sun gear110via the rotor shaft90, and the sun gear110may provide torque to the drive pinion22via the shift collar170′ when the shift collar is in the high range position and the electrical power source provides electrical power to the electric motor module24. The shift collar170′ may be decoupled from the auxiliary shaft28and the planet gear carrier116when the shift collar170′ is in the high range position.

InFIG. 18, the shift collar170′ is shown in a second neutral position. The shift collar170′ may be coupled to the sun gear110such that the shift collar170′ and the sun gear110may be rotatable together about the first axis60. For example, the second set of teeth192of the shift collar170′ may mate or mesh with the sun gear spline122of the sun gear110. The shift collar170′ may be decoupled from the drive pinion22and may be decoupled from the auxiliary shaft28when the shift collar170′ is in the second neutral position. For instance, the first shift collar spline182may be spaced apart from and may not mate or mesh with the drive pinion spline74and the second shift collar spline184may be spaced apart from and may not mate or mesh with the auxiliary shaft spline160of the auxiliary shaft28.

InFIG. 19, the shift collar170′ is shown in an auxiliary drive position. The shift collar170′ may couple the sun gear110of the gear reduction module26to the auxiliary shaft28such that the auxiliary shaft28, the sun gear110, and the shift collar170′ may be rotatable together about the first axis60. For example, the third set of teeth194of the shift collar gear188may mate or mesh with the first gear portion124of the sun gear110and the second shift collar spline184may mate or mesh with the auxiliary shaft spline160. The electric motor module24may provide torque to the sun gear110via the rotor shaft90, and the sun gear110may provide torque to the auxiliary shaft28via the shift collar170′ when the shift collar170′ is in the auxiliary drive position and the electrical power source provides electrical power to the electric motor module24. The shift collar170′ may be decoupled from the drive pinion22and the planet gear carrier116when the shift collar170′ is in the auxiliary drive position.