# Patent

## Title
Electric drive unit with modular motor assembly

## Abstract

An electric drive module for a motor vehicle includes an electric motor assembly having a cartridge housing containing a stator, a rotor, and a rotor shaft. The rotor shaft is supported by the cartridge housing. The electric motor assembly is positioned within an axle housing. A reduction unit includes an input member being driven by the rotor shaft and includes an output member driven at a reduced speed relative to the input member. A differential assembly includes 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.

## Background
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 61/255,124, filed on Oct. 27, 2009. The entire disclosure of the above application is incorporated herein by reference.


FIELD
The present disclosure relates to electric drive systems for motor vehicles. More specifically, the present disclosure relates to a two-speed electric drive module for electric and hybrid vehicles.
BACKGROUND
Automobile manufacturers are actively working to develop alternative powertrain systems in an effort to reduce the level of pollutants exhausted into the air by conventional vehicles equipped with internal combustion engines. Significant development has been directed to electric vehicles and fuel cell vehicles. These alternative powertrain systems are still under development. In addition, several different hybrid electric vehicles have recently been offered for sale. Many of the hybrid vehicles are equipped with an internal combustion engine and an electric motor that can be operated independently or in combination to drive the vehicle.
There are two typical types of hybrid vehicles, namely, series-hybrid and parallel-hybrid. In a series-hybrid vehicle, power is delivered to the wheels by the electric motor which draws electrical energy from the battery. The engine is used in series-hybrid vehicles to drive a generator which supplies power directly to the electric motor or charges the battery when the state of charge falls below a predetermined value. In parallel-hybrid vehicles, the electric motor and the engine can be operated independently or in combination pursuant to the running conditions of the vehicle. Typically, the control strategy for such parallel-hybrid vehicles utilizes a low-load mode where only the electric motor is used to drive the vehicle, a high-load mode where only the engine is used to drive the vehicle, and an intermediate-assist mode where the engine and electric motor are both used to drive the vehicle. Regardless of the type of hybrid drive system used, hybrid vehicles are highly modified versions of conventional vehicles that are expensive due to the componentry, required control systems, and specialized packaging requirements.
Hybrid powertrains have also been adapted for use in four-wheel drive vehicles and typically utilize the above-noted parallel-hybrid powertrain to drive the primary wheels and a second electric motor to drive the secondary wheels. Obviously, such a four-wheel drive system is extremely expensive and difficult to package. Thus, a need exists to develop solely electrically powered or hybrid powertrains for use in four-wheel drive vehicles that utilize many conventional powertrain components so as to minimize specialized packaging and reduce cost.
SUMMARY OF THE INVENTION
An electric drive module for a motor vehicle includes an electric motor assembly having a cartridge housing containing a stator, a rotor, and a rotor shaft. The rotor shaft is supported by the cartridge housing. The electric motor assembly is positioned within an axle housing. A reduction unit includes an input member being driven by the rotor shaft and includes an output member driven at a reduced speed relative to the input member. A differential assembly includes 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 method of assembling electric drive modules for motor vehicles having different track widths includes positioning an electric motor assembly within an axle housing. A reduction unit is positioned within the axle housing and includes an input member driven by the electric motor assembly rotor shaft and has an output member driven at a reduced speed relative to the input member. A differential assembly is positioned within the axle housing and includes 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. One of a plurality of covers having different axial dimensions is selected based on a vehicle track width. The second output shaft is extended through an aperture in the cover. The cover is coupled to the axle housing.
An electric module for a motor vehicle includes an axle housing including a removable cover fixed to a body. An electric motor assembly including a stator, a rotor and a rotor shaft is positioned within the axle housing. A reduction unit includes an input member being driven by the rotor shaft and having an output member being driven at a reduced speed relative to the input member. A differential assembly includes 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. The first output shaft, the second output shaft and the rotor are coaxially arranged. A resolver is operable to output a signal indicative of the speed of the rotor shaft. The resolver includes a resolver stator stationarily coupled to the axle housing body and the resolver rotor fixed for rotation with the rotor shaft. Removal of the cover does not disturb the resolver.
Further areas of applicability of the present disclosure will become apparent from the detailed description provided hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the present disclosure, are intended for purposes of illustration only since various changes and modifications within the fair scope of this particular disclosure will become apparent to those skilled in the art.



DRAWINGS
The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
FIG. 1 is a schematic view showing a hybrid powertrain for a four-wheel drive vehicle in accordance with the present disclosure;
FIG. 2 is a schematic view of an alternative arrangement for the hybrid powertrain of the present disclosure;
FIG. 3 is a schematic view of an alternative arrangement electric powertrain of the present disclosure;
FIG. 4 is a sectional view of an electric drive module associated with the powertrains of FIGS. 1-3;
FIG. 5 is a sectional view of an alternate electric drive module configured for use in a vehicle having a different track width;
FIG. 6 is a sectional view of another alternate electric drive module configured for use in a vehicle having a different track width;
FIG. 7 is a sectional view of another alternate electric drive module having the axes of rotation of the output shafts offset from an axis of rotation of the electric motor rotor; and
FIG. 8 is a schematic of another alternate electric drive module including a planetary gearset.



Corresponding reference numerals indicate corresponding parts throughout the several views of the drawings.
DETAILED DESCRIPTION
Example embodiments will now be described more fully with reference to the accompanying drawings.
The present disclosure is related to an electric drive module assembly including an electric motor. More particularly, the electric drive module is controlled for delivering motive power (i.e., drive torque) to a pair of ground-engaging wheels. The compact arrangement of the electric motor, a single speed gearbox or an optional two-speed gear box permits the use of the electric drive module in substitution for a conventional axle assembly. As such, conventional rear-wheel drive and front-wheel drive powertrains can be used in combination with the electric drive module so as to establish a hybrid drive system for a four-wheel drive vehicle. Alternatively, the electric drive module may be used in vehicles powered solely by batteries as well. Accordingly, various features and functional characteristics of the electric drive module will be set forth below in a manner permitting those skilled in relevant arts to fully comprehend and appreciate the significant advantages the present disclosure provides.
Referring to FIG. 1, a four-wheel drive powertrain for a hybrid electric vehicle 10 is shown to include a first powered driveline 12 and a second powered driveline 14. First powered driveline 12 includes an internal combustion engine 16, a transmission 18, a drive shaft 20, and an axle assembly 22 connecting a pair of wheels 24. Engine power is delivered to a differential unit 26 associated with axle assembly 22 through transmission 18 and drive shaft 20. The drive torque delivered to differential unit 26 is transferred through axleshafts 28 and 30 to wheels 24. Second powered driveline 14 includes an electric drive module 32 which drives a second pair of wheels 34 through axleshafts 36 and 40.
In the particular layout shown in FIG. 1, first powered driveline 12 delivers power to rear wheels 24 while second powered driveline 14 delivers power to front wheels 34. Obviously, those skilled in the art would understand that the opposite powertrain arrangement can be utilized such that electric drive module 32 supplies power to the rear wheels. To better illustrate this arrangement, FIG. 2 shows electric drive module 32 supplying power to rear wheels 24 through axleshafts 28 and 30 while engine power is supplied to front wheels 34 through a transaxle 18A and axleshafts 36 and 40. Regardless of the particular arrangement, hybrid vehicle 10 includes two distinct powered drivelines capable of both independent and combined operation to drive the vehicle.
As shown in FIG. 3, it is also contemplated that electric drive module 32 may be the sole source of motive power for vehicle 10. An internal combustion engine would not be present. Accordingly, front wheels 34 receive torque through axleshafts 36 and 40 provided by electric drive module 32.
FIGS. 1-3 also depict a controller 37 in communication with a battery 39, vehicle sensors 41, electric drive module 32 as well as the engine and transmission, if present. Concurrent control of engine 16, transmission 18 and electric drive module 32 is described in issued U.S. Pat. Nos. 6,595,308 and 6,604,591, which are herein incorporated by reference.
Referring now to FIG. 4, electric drive module 32 will be described in detail. Electric drive module 32 may be configured as a single speed or multi-speed power transmission device. Furthermore, the axis of electric motor rotor rotation may be co-axial with or offset from an axis of output shaft rotation from electric drive module 32. A co-axial single speed version is depicted in FIG. 4.
Electric drive module 32 includes a multi-section housing assembly 42 defining a motor chamber 44 and a gearbox chamber 46 separated by a radial support wall 48. A cover 50 is fixed to housing assembly 42 via fasteners 52. An electric variable speed motor assembly 54 is located within motor chamber 44. Motor assembly 54 includes a cartridge housing 56, a wound stator 58 secured to cartridge housing 56, a rotor 60 and a rotor shaft 62. Rotor shaft 62 is supported for rotation at its opposite ends by bearing assemblies 64 mounted to cartridge housing 56. In this manner, the relative positioning between stator 58 and rotor 60 may be accurately maintained throughout the operational life of electric drive module 32. Further benefits arise from bearings 64 being coupled to common cartridge housing 56. Accurate alignment of rotor shaft 62 and rotor 60 relative to cartridge housing 56 and stator 58 is maintained.
Motor assembly 54 may be assembled and tested at a location remote from the location where electric drive module 32 is assembled. Furthermore, it is contemplated that motor assembly 54 is tested and approved prior to shipment from the off-site location.
Motor assembly 54 also includes a resolver 65 operable to output a signal indicative of the speed and/or position of rotor shaft 62. A resolver stator 66 is fixed to cartridge housing 56. A resolver rotor 68 is fixed for rotation with rotor shaft 62. The relative position of rotor shaft 62, bearings 64 and cartridge housing 56 assure reliable resolver output. Furthermore, the resolver components 66, 68 are protected from the outside environment by cover 50. Removal of cover 50 does not disturb either resolver stator 66 or resolver rotor 68.
Cartridge housing 56 includes a number of design features to assure that motor assembly 54 is accurately positioned within motor chamber 44. For example, cartridge housing 56 includes a bottom face 72 placed in engagement with a land 74 of support wall 48. Additionally, an outer circumferential surface 76 of cartridge housing 56 is placed in a slip-fit engagement with an inner circumferentially shaped wall 78 defining motor chamber 44. At an opposite end of motor assembly 54, cartridge housing 56 includes a flared portion 82 positioned in engagement with a stepped recess 84 formed in housing assembly 42. To further restrain motor assembly 54 from movement relative to housing assembly 42, cover 50 includes a lip 88 positioned in engagement with an end face 90 of cartridge housing 56. Lip 88 imparts a compressive load on cartridge housing 56 to drive bottom face 72 into engagement with land 74. A dowel 92 fixes cartridge housing 56 to housing assembly 42 and restricts relative rotation therebetween. It should be appreciated that dowel 92 may be positioned at the opposite end of cartridge housing 56 and be alternately fixed to cover 50. A gas or liquid coolant may be pumped into motor chamber 44 to cool motor assembly 54.
Electric drive module 32 further includes a gearbox 98 located within gearbox chamber 46 and which is comprised of a reduction unit 100 and a bevel differential 102. Reduction unit 100 includes a first reduction gearset 104 having a first drive gear 106 in constant meshed engagement with a first driven gear 108 as well as a second reduction gearset 110 having a second drive gear 112 in constant meshed engagement with a second driven gear 114. First drive gear 106 is fixed for rotation with rotor shaft 62 via a splined connection 116. A bearing 118 supports first drive gear 106 for rotation at wall 48. First driven gear 108 and second drive gear 112 are fixed for rotation with a countershaft 120 rotatably supported by bearings 122. Second drive gear 112 is shown as being integrally formed with countershaft 120. Second driven gear 114 is fixed to a casing 126 of bevel differential 102. One end of casing 126 is rotatably supported by a bearing 128. The opposite end of casing 126 includes a snout 130 supported by a bearing 132 and a first drive gear 106. Other bearing arrangements are possible.
Bevel differential 102 further includes a first side gear 138 fixed via a spline connection 140 to a first output shaft 142, a second side gear 144 fixed via a spline connection 146 to a transfer shaft 148, and at least one pair of pinions 150 meshed with side gears 138 and 144. Pinions 150 are rotatably supported on a pinion shaft 152 having its opposite ends located in apertures 154 formed in casing 126. A coupling shaft 156 drivingly interconnects a second output shaft 158 with transfer shaft 148. Coupling shaft 156 extends through rotor shaft 62 and is supported for rotation by a bearing 159 mounted within cover 50.
It should be appreciated that a number of different versions of electric drive module 32 may be constructed to accommodate vehicles having a different track width. Each variation of co-axial electric drive module 32 is designed to include all of the identical components to the other configurations with the exception of cover 50 and coupling shaft 156. FIG. 4 depicts electric drive module 32 including cover 50 defining a dimension “L” from a datum plane at a joint between portions of housing assembly 42 and an extremity of cover 50. FIG. 5 depicts an alternate electric drive module 32a having a cover 50a and a coupling shaft 156a arranged to fit a reduced track width vehicle. Dimension “La” of electric drive module 32a is less than dimension “L” relating to electric drive module 32. In a similar manner, FIG. 6 depicts another electric drive module identified with reference numeral 32b. Electric drive module 32b includes a longer coupling shaft 156b and a cover 50b having an axially extended shape. Dimension “Lb” of electric drive module 32b is longer than dimension “L” of electric drive module 32 shown in FIG. 4. The varying “L” dimensions correspond to varying vehicle track widths. The modular concept described allows for reduced part proliferation, testing and production part approval. A reduced cost family of electric drive modules may be provided.
As shown in FIG. 4, a parking pawl assembly 160 is provided to selectively ground a parking gear 162 fixed for rotation with countershaft 120 to housing assembly 42. Parking gear 162 includes a plurality of teeth selectively engageable with a parking pawl 166. When parking pawl 166 is engaged with parking gear 162, rotation of the components within reduction unit 100 is restricted. Accordingly, movement of vehicle 10 is also restricted.
In accordance with a use of electric drive module 32, output shafts 142 and 158 are adapted to be connected to corresponding ones of front axleshafts 36 and 40 for the hybrid powertrain arrangement shown in FIG. 1 or, alternatively, to corresponding ones of rear axleshafts 28 and 30 for the powertrain arrangement shown in FIG. 2. In this manner, electric drive module 32 functions as an electrically-powered secondary axle assembly which can be controlled independently, or in combination with, the engine-based powertrain. To provide a compact arrangement, a portion transfer shaft 148, coupling shaft 156 and second output shaft 158 extends through tubular rotor shaft 62.
It should be appreciated that an alternate electric drive module 200 may be configured as an offset power transmission device as shown in FIG. 7. Electric drive module 200 may include many of the components previously described in relation to electric drive module 32. In particular, electric drive module 200 is equipped with motor assembly 54. As previously described, motor assembly 54 is preassembled, tested, certified and approved for use in a number of assemblies including electric drive module 200 without the need for testing the motor assembly in each of the final configurations. Furthermore, it is contemplated that electric drive module 200 may include a new multi-piece housing 201 as well as first output shaft 142 and second output shaft 158. To package electric drive module 200 within a different vehicle, it may be useful to have first output shaft 142 and second output shaft 158 rotate about a first axis 202 while rotor shaft 62 rotates about an axis 204 extending parallel to and offset from axis 202.
FIG. 8 provides a schematic of an alternate electric drive module 300. Electric drive module 300 is substantially similar to electric drive module 32 with the exception that a reduction unit 302 replaces reduction unit 300. Reduction unit 302 includes a planetary gearset 304 and a bevel differential 306. Planetary gearset 304 includes a sun gear 308 driven by rotor shaft 62 of motor assembly 54. A first pinion gear 310 is in constant meshed engagement with sun gear 308. A second reduced diameter pinion gear 312 is in constant meshed engagement with a ring gear 314. Pinion gears 310, 312 are supported for rotation on a carrier 316. Ring gear 314 is fixed to housing assembly 42. Carrier 316 provides the output from planetary gearset 304 and is fixed for rotation with a casing 318 of bevel differential 306. Electric drive module 300 includes the beneficial features previously described in relation to electric drive module 32 such as use of motor assembly 54 having cartridge housing 56, among others. It is contemplated that the countershaft arrangement depicted in FIG. 7 may be replaced with a planetary gearset similar to planetary gearset 304 described and shown in FIG. 8.
The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

## Claims

1. A method of assembling electric drive modules for motor vehicles having different track widths, the method comprising:
providing a vehicle track width;
positioning an electric motor assembly within an axle housing;
positioning a reduction unit including an input member being driven by the electric motor assembly and having an output member being driven at a reduced speed relative to the input member within the axle housing; and
positioning a differential assembly within the axle housing, the differential assembly including 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;
selecting one of a plurality of covers having different axial dimensions based on the vehicle track width;
extending the second output shaft through an aperture in the cover; and
coupling the cover to the axle housing.

2. The method of claim 1 further including a transfer shaft being driven by the second differential output and one of a plurality of coupling shafts drivingly interconnecting the transfer shaft and the second output shaft.

3. The method of claim 2 further including selecting the one of a plurality of coupling shafts based on the vehicle track width.

4. The method of claim 3 further including positioning a stator, a rotor, and a rotor shaft of the electric motor assembly in a cartridge housing.

5. The method of claim 4 further including extending the one of a plurality of coupling shafts through the rotor shaft.

6. The method of claim 1 further including supporting the second output shall by the cover.

7. The method of claim 1 further including testing the electric motor assembly prior to assembly within the axle housing.

8. The method of claim 1 further including clamping a cartridge housing of the electric motor assembly into engagement with the axle housing when the cover is coupled to the axle housing.

9. The method of claim 1 further including aligning axes of rotation of the first and second output shafts with an axis of rotation of a rotor of the electric motor assembly.

10. The method of claim 1 further including aligning axes of rotation of the first and second output shafts and positioning an axis of rotation of a rotor of the electric motor assembly offset from the output shaft axes.

11. A method of assembling an electric drive module for use in a motor vehicle having a track width dimension to drive a pair of wheels, the method comprising:
determining a desired track width dimension for the motor vehicle;
providing an axle housing having an axial dimension, the axle housing defining a gearbox chamber, an open-ended motor chamber, and a support wall therebetween;
installing a gearbox assembly within the gearbox chamber, the gearbox assembly including a differential unit and a reduction unit, the reduction unit including a tubular input member rotatably supported in an aperture extending through the support wall and an output member driven at a reduced speed relative to the input member, the differential unit including a differential input driven by the output member, a first differential output driving a first output shaft adapted to drive one of the wheels, and a second differential output driving a transfer shaft extending through the input number into the motor chamber;
installing an electric motor assembly within the motor chamber, the electric motor assembly including a cartridge housing non-rotatably fixed to the support wall, a stator fixed to the cartridge housing and a rotor shaft rotatably supported by the cartridge housing and fixed for rotation with the input member of the reduction unit;
providing a plurality of coupling shafts having different axial lengths;
providing a plurality of covers having different axial lengths;
selecting one of the coupling shafts having a desired shaft length and coupling the selected coupling shaft for rotation with the transfer shaft;
selecting one of the covers having a desired cover length based on the desired track width dimension;
extending the selecting coupling shaft through an aperture in the selected cover and attaching the selected cover to the axle housing to enclose the motor chamber; and
coupling the selected coupling shaft to a second output shaft adapted to drive the other one of the wheels.

12. The method of claim 11 further including extending the selected coupling shaft through the rotor shaft.

13. The method of claim 11 further including extending the second output shaft within a tubular portion of the selected coupling shaft.

14. The method of claim 13 further including rotatably supporting the tubular portion of the selected coupling shaft on the selected cover.

15. The method of claim 11 wherein the cartridge housing of the electric motor assembly has a face surface disposed in mating engagement with a wall surface of the support wall.

16. The method of claim 15 further comprising providing an annular lip on the cartridge housing and engaging the annular lip against a stepped surface of the axle housing.

17. The method of claim 16 further comprising providing the cover with an axially extending projection and engaging the axially-extending projection against an end face of the cartridge housing.

18. A method of assembling an electric drive module for a motor vehicle having a track width dimension, the method comprising:
determining a desired vehicle track width;
positioning an electric motor assembly within a motor chamber of an axle housing;
positioning a reduction unit within a gearbox chamber of the axle housing, the reduction unit including an input member being driven by the electric motor assembly and an output member being driven at a reduced speed relative to the input member; and an output member being driven at a reduced speed relative to the input member,
positioning a differential assembly within the gearbox chamber of the axle housing, the differential assembly including a differential input driven by the output member, a first differential output driving a first output shaft, and a second differential output driving a transfer shaft;
selecting one of a plurality of covers each having a different axial dimension based on the vehicle track width;
extending the transfer shaft through an aperture in the selected cover; and
coupling the selected cover to the axle housing to enclose the motor chamber.

19. The method of claim 18 further including providing a plurality of coupling shafts each having a different axial dimension.

20. The method of claim 19 further including selecting one of the plurality of coupling shafts based on the vehicle track width and coupling the selected coupling shaft to the transfer shaft and a second output shaft.

21. The method of claim 18 further including testing the electric motor assembly prior to assembly within the axle housing.

22. The method of claim 18 further including clamping a cartridge housing of the electric motor assembly into engagement with portions of the motor chamber in the axle housing when the selected cover is coupled to the axle housing.