FIELD

The present disclosure relates to electric drive axles, and more particularly to a multi-speed gearbox for an electric drive axle.

BACKGROUND

Electric and hybrid-electric vehicles utilize an electric power source in communication with an electric motor to provide drive, or augmented drive, to the vehicle. Electric vehicles have several characteristics superior to conventional internal combustion engine driven vehicles. For example, electric motors produce fewer vibrations than internal combustion engines, and electric motors achieve maximum torque more quickly than internal combustion engines.

It would be desirable to produce an electric drive axle having a gear arrangement and differential which generates a plurality of gear ratios, and yet remains compact in size and weight.

SUMMARY

In concordance and agreement with the present disclosure, an electric drive axle having a gear arrangement and differential which generates a plurality of gear ratios, and yet remains compact in size and weight, has surprisingly been discovered.

The present disclosure provides for an electric drive axle for a vehicle. In one embodiment, an electric drive axle, comprises: an electric motor having an output shaft; at least one of a gear and a planetary gear set operably connected to the output shaft, wherein the planetary gear set includes a sun gear, a planet carrier having a plurality of planet gears disposed therein, and an annulus; a differential operably connected to the at least one of the gear and the planetary gear set; and at least one clutch disposed between the electric motor and the differential, wherein the at least one clutch is configured to facilitate a plurality of gear ratios between the electric motor and the differential.

As aspects of certain embodiments, the electric drive axle further comprises an idler shaft disposed parallel to the output shaft, the planetary gear set is selectively coupled to the idler shaft by the at least one clutch.

As aspects of certain embodiments, the idler shaft is fixedly coupled to a stationary structure.

As aspects of certain embodiments, the planet carrier of the planetary gear set is selectively coupled to the idler shaft by the at least one clutch.

As aspects of certain embodiments, the annulus of the planetary gear set is coupled to at least one of a gear disposed about the idler shaft and the at least one clutch.

In another embodiment, an electric drive axle, comprises: an electric motor including a first shaft, wherein a first gear and a second gear are disposed about the first shaft; a second shaft disposed parallel to the first shaft, wherein a third gear and a fourth gear are disposed about the second shaft; a differential operably connected to the electric motor; a first clutch disposed between the electric motor and the differential, wherein the first clutch is configured to facilitate a first gear ratio of the electric drive axle; and a second clutch disposed between the electric motor and the differential, wherein the second clutch is configured to facilitate a second gear ratio of the electric drive axle.

As aspects of certain embodiments, the first clutch is configured to selectively couple one of the first gear and the second gear to the first shaft.

As aspects of certain embodiments, the second clutch is configured to selectively couple one of the first gear and the second gear to the first shaft.

As aspects of certain embodiments, the first clutch is configured to selectively coupled one of the third gear and the fourth gear to the second shaft.

As aspects of certain embodiments, the second clutch is configured to selectively couple one of the third gear and the fourth gear to the second shaft.

As aspects of certain embodiments, at least one of the first and second clutches is one of a sliding collar clutch, a one-way clutch, a wet clutch having a plurality of clutch plates, a dog clutch, and a dog clutch with a synchronizer.

As aspects of certain embodiments, the second clutch is concentrically disposed about the first clutch.

As aspects of certain embodiments, the electric drive axle further comprises a third shaft disposed parallel to at least one of the first and second shafts.

As aspects of certain embodiments, a fifth gear is disposed about one of the second shaft and the third shaft.

As aspects of certain embodiments, a sixth gear is disposed about one of the second shaft and the third shaft.

As aspects of certain embodiments, at least one of the fifth gear and the sixth gear is in operably coupled with at least one of a planetary gear set and the differential.

As aspects of certain embodiments, at least one planetary gear set is disposed between the electric motor and the differential.

As aspects of certain embodiments, the at least one planetary gear set is coupled to at least one of the differential and a fifth gear, and wherein the fifth gear is in meshed engagement with at least one of the third and fourth gears.

As aspects of certain embodiments, the differential is another planetary gear set coupled to the at least one planetary gear set.

In yet another embodiment, an electric drive axle, comprises: an electric motor having an output shaft; a first planetary gear set operably connected to the output shaft, wherein the first planetary gear set includes a sun gear, a planet carrier having a plurality of planet gears disposed therein, and an annulus; a second planetary gear set operably connected to the output shaft, wherein the second planetary gear set includes a sun gear, a planet carrier having a plurality of planet gears disposed therein, and an annulus; a differential operably connected to at least one of the first and second planetary gear sets; and at least one clutch disposed between the electric motor and the differential, wherein the at least one clutch is configured to facilitate a plurality of gear ratios between the electric motor and the differential.

As aspects of certain embodiments, at least one of the sun gear, the planet carrier, and the annulus of the first planetary gear set is selectively coupled to the electric motor by the at least one clutch.

As aspects of certain embodiments, at least one of the sun gear, the planet carrier, and the annulus of the second planetary gear set is selectively coupled to the electric motor by the at least one clutch.

As aspects of certain embodiments, at least one of the sun gear, the planet carrier, and the annulus of the second planetary gear set is selectively coupled to the first planetary gear set by the at least one clutch.

In another embodiment, an electric drive axle, comprises: an electric motor; a first shaft having a first gear coupled thereon; a second gear disposed about the first shaft; a differential operably connected to at least one of the first and second gears; and a movable member coupled to the first shaft and configured to selectively couple one of the first and second gears to the first shaft, wherein the movable member is translatable between a first position and a second position, wherein the movable member in the first position is configured to facilitate a first gear ratio between the electric motor and the differential, and wherein the movable member in the second position is configured to facilitate a second gear ratio between the electric motor and the differential.

As aspects of certain embodiments, the movable member is a collar disposed about the first shaft.

As aspects of certain embodiments, the movable member is coupled to the first shaft by a splined engagement.

