US 11,773,962 B1
Electric drive unit with integrated, variable flow, low-pressure oil cooling system
Matthew Vanderlip, Waterloo (CA); Michael Bradfield, Anderson, IL (US); and Steven Hayslett, Troy, MI (US)
Assigned to BorgWarner Inc., Auburn Hills, MI (US)
Filed by BorgWarner Inc., Auburn Hills, MI (US)
Filed on Mar. 28, 2022, as Appl. No. 17/705,433.
Int. Cl. F16H 57/04 (2010.01); F16H 57/02 (2012.01); H02K 7/10 (2006.01); H02K 9/19 (2006.01); F16H 57/037 (2012.01); H02K 7/116 (2006.01); F16H 57/031 (2012.01)
CPC F16H 57/0476 (2013.01) [F16H 57/037 (2013.01); F16H 57/0424 (2013.01); F16H 57/0436 (2013.01); F16H 57/0443 (2013.01); F16H 57/0471 (2013.01); H02K 7/116 (2013.01); H02K 9/19 (2013.01); F16H 57/031 (2013.01); F16H 57/0417 (2013.01); F16H 57/0483 (2013.01); F16H 2057/02034 (2013.01)] 19 Claims
OG exemplary drawing
 
1. An electric drive unit comprising:
a housing assembly that defines a first cavity, a second cavity, a sump and an upper reservoir, the sump being coupled in fluid communication with the first cavity, the upper reservoir being spaced apart from the sump and the first cavity;
an electric motor received in the first cavity, the electric motor having a stator, a rotor and a motor output shaft, the stator having a stator core, which is fixedly coupled to the housing assembly, and a plurality of windings, the rotor being received within the stator and being rotatable about a rotational axis, the motor output shaft being coupled to the rotor for rotation therewith about the rotational axis;
a differential assembly in the second cavity, the differential assembly having a differential input member, which is rotatable relative to the housing assembly, and first and second differential output members that are rotatable relative to the differential input member;
a first output shaft that is coupled to the first differential output member for rotation therewith;
a second output shaft that is coupled to the second differential output member for rotation therewith;
a transmission received in the second cavity, the transmission being configured to transmit rotary power between the motor output shaft and the differential input member; and
a fluid pump that is configured to draw a lubricant from the sump and provide a flow of the lubricant;
wherein at least a portion of the flow of the lubricant is discharged into the upper reservoir;
wherein the housing assembly defines a plurality of first lubricant supply galleries and a plurality of second lubricant supply galleries, each of the first and second lubricant supply galleries being a conduit that permits lubricant in the upper reservoir to drain due to gravity to an associated component of the electric drive unit to lubricate and/or cool the associated component;
wherein the first lubricant supply galleries intersect the upper reservoir at an associated location that is less than or equal to a first height dimension, wherein the second lubricant supply galleries intersect the upper reservoir at a corresponding location that is greater than or equal to a second height dimension, the second height dimension being larger than the first height dimension.