US 11,750,063 B2
Electric drive module configured as a beam axle
Matthew A. Umerley, Shelby Township, MI (US); Frederick E. Zink, Capac, MI (US); Jonathan P. Prichard, Harrison Township, MI (US); James P. Downs, South Lyon, MI (US); Gregory A. Marsh, Waterford, MI (US); Matthew T. Blakeman, Newport, MI (US); Steven Grider, Grosse Pointe Park, MI (US); and Paul J. Valente, Berkley, MI (US)
Assigned to American Axle & Manufacturing, Inc., Detroit, MI (US)
Appl. No. 17/790,254
Filed by American Axle & Manufacturing, Inc., Detroit, MI (US)
PCT Filed Mar. 15, 2022, PCT No. PCT/US2022/020286
§ 371(c)(1), (2) Date Jun. 30, 2022,
PCT Pub. No. WO2022/197642, PCT Pub. Date Sep. 22, 2022.
Claims priority of provisional application 63/220,204, filed on Jul. 9, 2021.
Claims priority of provisional application 63/178,985, filed on Apr. 23, 2021.
Claims priority of provisional application 63/161,218, filed on Mar. 15, 2021.
Prior Publication US 2023/0128748 A1, Apr. 27, 2023
Int. Cl. H02K 7/00 (2006.01); H02K 7/116 (2006.01); H02K 11/33 (2016.01); B60K 1/02 (2006.01); H02K 9/19 (2006.01)
CPC H02K 7/116 (2013.01) [B60K 1/02 (2013.01); H02K 9/19 (2013.01); H02K 11/33 (2016.01)] 12 Claims
OG exemplary drawing
 
1. An electric drive module comprising:
a motor assembly having a stator, a rotor, a motor output shaft and a motor controller, the rotor being received in the stator and being rotatable relative to the stator about a motor output shaft axis, the motor output shaft being coupled to the rotor for rotation therewith, the motor controller being configured to control a rotational speed of the rotor relative to the stator, the motor controller including an inverter;
an output gear that is rotatable about an output axis;
a differential assembly having a differential input member and a pair of differential output members, the differential input member being coupled to the output gear for rotation therewith about the output axis, each of the differential output members being rotatable about the output axis relative to the differential input member;
a transmission that is configured to transmit rotary power between the motor output shaft and the output gear;
a housing assembly having a first housing portion, a second housing portion and a cover, the transmission being at least partly housed in the first housing portion, the second housing portion having a first axial end and a heat exchanger mount, the first axial end of the second housing portion being removably mounted to the first housing portion, the second housing portion housing the stator, the rotor, and at least a portion of the motor controller that includes the inverter, the cover closing an end of the second housing portion that is opposite the first housing portion, wherein the housing assembly defines a sump that is configured to hold a first liquid, the first liquid being employed in the electronic drive module to lubricate the motor assembly, the differential assembly and the transmission and to cool the motor assembly;
a pump coupled to the housing assembly and fluidly coupled to the sump to receive the first liquid therefrom, the pump being configured to discharge a flow of the first fluid; and
a heat exchanger mounted to the heat exchanger mount on the second housing portion, the heat exchanger having a heat exchanger inlet, a first heat exchanger outlet and a second heat exchanger outlet;
wherein a first internal gallery is formed in the housing assembly, the first gallery receiving at least a portion of the flow of the first fluid, the first internal gallery being fluidly coupled directly to the heat exchanger inlet such that the first fluid that is discharged from the first internal gallery is received into the heat exchanger, wherein a second internal gallery is formed in the housing assembly, the second internal gallery being fluidly coupled directly to the first heat exchanger outlet such that a first portion of the first fluid that is discharged from the heat exchanger is received into the second internal gallery, wherein the first portion of the first fluid is directed into the first housing portion for lubricating at least one of the transmission and the differential assembly, wherein a third internal gallery is formed in the cover, the third internal gallery being fluidly coupled directly to the second heat exchanger outlet such that a second portion of the first fluid that is discharged from the heat exchanger is directed into the cover, and wherein the first fluid exiting the cover is directed into the at least one of the stator and the rotor for cooling the motor assembly.