WO2018060079A1 - Ensemble d'entraînement pour un véhicule - Google Patents

Ensemble d'entraînement pour un véhicule Download PDF

Info

Publication number
WO2018060079A1
WO2018060079A1 PCT/EP2017/074039 EP2017074039W WO2018060079A1 WO 2018060079 A1 WO2018060079 A1 WO 2018060079A1 EP 2017074039 W EP2017074039 W EP 2017074039W WO 2018060079 A1 WO2018060079 A1 WO 2018060079A1
Authority
WO
WIPO (PCT)
Prior art keywords
drive assembly
subframe
removable cover
mounting
vehicle
Prior art date
Application number
PCT/EP2017/074039
Other languages
English (en)
Inventor
Lucia FUSCO
Chris Hughes
Markus HOSE
Original Assignee
Jaguar Land Rover Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Jaguar Land Rover Limited filed Critical Jaguar Land Rover Limited
Priority to DE112017004884.2T priority Critical patent/DE112017004884T5/de
Publication of WO2018060079A1 publication Critical patent/WO2018060079A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/34—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles
    • B60K17/354—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles having separate mechanical assemblies for transmitting drive to the front or to the rear wheels or set of wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/04—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing
    • B60K17/16—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing of differential gearing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/04—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing
    • B60K17/16—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing of differential gearing
    • B60K17/165—Arrangement or mounting of transmissions in vehicles characterised by arrangement, location, or kind of gearing of differential gearing provided between independent half axles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K17/00—Arrangement or mounting of transmissions in vehicles
    • B60K17/34—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles
    • B60K17/356—Arrangement or mounting of transmissions in vehicles for driving both front and rear wheels, e.g. four wheel drive vehicles having fluid or electric motor, for driving one or more wheels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D21/00—Understructures, i.e. chassis frame on which a vehicle body may be mounted
    • B62D21/11—Understructures, i.e. chassis frame on which a vehicle body may be mounted with resilient means for suspension, e.g. of wheels or engine; sub-frames for mounting engine or suspensions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/082—Engine compartments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/24—Superstructure sub-units with access or drainage openings having movable or removable closures; Sealing means therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
    • B60K1/00—Arrangement or mounting of electrical propulsion units
    • B60K2001/001—Arrangement or mounting of electrical propulsion units one motor mounted on a propulsion axle for rotating right and left wheels of this axle

Definitions

  • the present disclosure relates to a drive assembly for a vehicle.
  • a drive assembly for a road vehicle such as a car.
  • a subframe for a vehicle which comprises two longitudinal members configured to be attached to a vehicle body shell and a cross-member, which connects the two longitudinal members and which houses a drive component such as an electric motor.
  • a problem with the arrangement is that the construction of the subframe is quite complex being formed of several different components, including the two longitudinal members and the cross-member, which are bolted together.
  • a second problem is that the subframe has to be dismantled to access the electric motor. It is an aim of the present invention to address disadvantages of the prior art.
  • a drive assembly for a vehicle comprising: a drive mechanism having two output shafts for connection to wheels of the vehicle; a subframe having at least a first mounting feature for mounting the drive assembly at a first side of the body of the vehicle at least a second mounting feature for mounting the drive assembly at a second side of the body of the vehicle; and a removable cover attached to the subframe and covering at least a part of the drive mechanism; wherein the subframe comprises a continuous component extending from the first mounting feature to the second mounting feature and the continuous component has a hole or recess in which at least a part of the drive mechanism resides.
  • the drive mechanism may be supported within the hole or recess of the single continuous component of the subframe, which transfers loads from the drive mechanism to the body of the vehicle in which it is installed. In this way, the number of components and component interfaces is reduced, and so it becomes possible to reduce weight and space taken up within a vehicle. In addition, installation and/or replacement of the drive mechanism is facilitated by having a removable cover.
  • the continuous component comprises a continuous piece of cast metal or a continuous sheet of pressed metal.
  • the drive assembly may comprise a container located within the hole or recess and a seal is provided between the removable cover and the container to enable lubricant to be contained by the removable cover and the container in combination. This provides the advantage that the continuous component does not have to be configured to retain the lubricant and consequently it may be provided with a lighter structure comprising holes.
  • the continuous component of the subframe has a recess in which at least a part of the drive mechanism resides, and the drive assembly comprises a seal between the removable cover and the subframe to enable lubricant to be contained by the removable cover and subframe in combination.
  • the drive mechanism may comprise an electric motor.
  • the drive mechanism may comprise a differential having an input shaft for connection via a driveshaft to an engine mounted remotely from the drive mechanism.
  • the removable cover comprises a plastics material and/or the drive assembly comprises a container located within the hole or recess and the container is formed of a plastics material.
  • the drive assembly comprises a support located over the removable cover, the support being attached to the continuous component of the subframe.
  • the drive assembly comprises bearings supporting the output shafts and the bearings are located between the removable cover and the subframe. By locating the bearings between the removable cover and the subframe simplifies assembly of the drive assembly.
  • the removable cover comprises a plastics material and a metallic structure embedded in the plastics material adjacent to the bearings; and/or the drive assembly comprises a container located within the hole or recess, and the container comprises a plastics material with a metallic structure embedded in the plastics material adjacent to the bearings. This composite structure enables loads to be transferred between the bearings of the drive mechanism and the mounting features while allowing the removable cover and/or the container to be formed of a relatively lightweight (plastics) material.
  • the continuous component defines bearing surfaces for receiving the bearings.
  • the subframe has at least a first two mounting features for mounting the drive assembly, at a first side of the body of the vehicle, and at least a second two mounting features for mounting the drive assembly at a second side of the body of the vehicle.
  • the subframe has a third mounting feature for mounting the drive assembly to the body fore or aft of the drive mechanism. This has the advantage of minimizing the number of fixings necessary to mount the subframe to the body.
  • a vehicle comprising a body and a drive assembly mounted on the body at least the first mounting feature and the second mounting feature.
  • a method of mounting a drive mechanism the drive mechanism having two output shafts for connection to wheels of a vehicle the method comprising: positioning at least a part of a drive mechanism within a hole or a recess formed in a continuous component of a subframe, the continuous component having at least a first mounting feature for mounting the drive assembly at a first side of a body of a vehicle, and at least a second mounting feature for mounting the drive assembly at a second side of the body of the vehicle; and attaching a removable cover to the subframe, the removable cover covering at least a part of the drive assembly.
  • the continuous component comprises a continuous piece of cast metal or a continuous sheet of pressed metal.
  • the method comprises positioning a container within the hole or the recess and providing a seal between the removable cover and the container to enable lubricant to be contained by the removable cover and container in combination.
  • the continuous component of the subframe has a recess in which at least a part of the drive mechanism resides; and the drive assembly comprises a seal between the removable cover and the continuous component to enable lubricant to be contained by the removable cover and continuous component in combination.
  • the drive mechanism may comprise an electric motor.
  • the drive mechanism may comprise a differential.
  • the removable cover comprises a plastics material.
  • the method comprises positioning a support over the removable cover and attaching the support to the continuous component of the subframe.
  • the drive assembly comprises bearings supporting the output shafts and the method comprises positioning the bearings between the removable cover and the subframe.
  • the removable cover comprises a plastics material and metallic structure embedded in the plastics material to provide reinforcement of the plastics material, and the method comprises positioning a part of the removable cover comprising the metallic structure over the bearings.
  • the method comprises positioning the bearings within bearing surfaces defined by the continuous component of the subframe.
  • Fig. 1 shows a vehicle 103 comprising a car that has a drive assembly 101 ;
  • Fig. 2 shows a top view of an example of the drive assembly 101 of Fig. 1 ;
  • Fig. 3 shows a cross-sectional side view of the drive assembly 101 of Fig. 2;
  • Fig. 4 shows a bottom view of the drive assembly 101 of Fig. 2;
  • Fig. 5 shows a cross-sectional view of the drive assembly 101 at plane "A" shown in Fig. 2;
  • Fig. 6 shows a cross-sectional view of the drive assembly 101 at plane "B" shown in Fig. 2;
  • Fig. 7 shows an end view of the drive assembly 101 in the direction of arrow C in Fig. 2;
  • Fig. 8 shows a top view of an alternative example of the drive assembly 101 of Fig. 1 ;
  • Fig. 9 shows a cross-sectional side view of the drive assembly 101 of Fig. 8
  • Fig. 10 shows a cross-sectional view of the drive assembly 101 at plane "D" shown in Fig. 8
  • Fig. 1 1 shows a top view of a second alternative example of the drive assembly 101 of Fig. 1 ;
  • Fig. 12 shows a cross-sectional side view of the drive assembly 101 of Fig. 1 1 ;
  • Fig. 13 shows a second cross-sectional view of the drive assembly 101 at plane "E" shown in Fig. 1 1 ;
  • Fig. 14 shows a third cross-sectional view of the drive assembly 101 at plane "F" shown in Fig. 1 1 ;
  • Fig. 15 shows a flow-chart outlining a method 1500 of mounting a drive mechanism 104
  • Fig. 16 shows schematically a second vehicle 1603 comprising a rear-wheel-drive car that has a drive assembly 101 A;
  • Fig. 17 shows a top view of an example of the drive assembly 101 A of Fig. 16;
  • Fig. 18 shows a cross-sectional side view of the drive assembly 101 A of Fig. 17;
  • Fig. 19 shows a second cross-sectional view of the drive assembly 101 A at plane "G" shown in Fig. 17;
  • Fig. 20 shows a bottom view of a drive assembly
  • Fig. 21 shows a cross section taken at plane "H" shown in Fig.20.
  • the Figures illustrate a drive assembly 101 , 101 A for a vehicle 103, 1603, the drive assembly 101 , 101 A comprising: a drive mechanism 104 having two output shafts 1 13 for connection to wheels 105A of the vehicle 103; a subframe 106, 106A, 106B, 106C having at least a first mounting feature 107 for mounting the drive assembly 101 , 101 A at a first side of the body 102, 1602, at least a second mounting feature 108 for mounting the drive assembly 101 , 101 A at a second side of the body 102, 1602; a removable cover 208, 208A attached to the subframe 106, 106A, 106B, 106C and covering at least a part of the drive mechanism 104, 104A; wherein the subframe 106, 106A, 106B, 106C comprises a continuous component 1 10, 1 10A extending from the first mounting feature 107 to the second mounting feature 108.
  • the continuous component 1 10, 1 1 OA comprises a continuous piece of cast metal or a continuous sheet of pressed metal.
  • the continuous component 1 10, 1 1 OA may be formed of a metal such as steel or aluminium alloy.
  • a vehicle 103 comprising a car that has a drive assembly 101 is shown schematically in Fig. 1 .
  • the car 103 has an engine 1 1 1 which drives front wheels 105B via a transmission 1 12.
  • the car 103 also has rear wheels 105A that are separately driven by a drive mechanism 104 comprising an electric motor 1 14 that forms a part of the drive assembly 101 .
  • the drive mechanism 104 is mounted on a subframe 106, which has a first two mounting features 107 for mounting the drive assembly 101 at a first side of the body 102 of the car 103 and a second two mounting features 108 for mounting the drive assembly 101 at a second side of the body 102.
  • the mounting features 107 and 108 may comprise holes for receiving bushings 1 18 of known types.
  • the bushings 1 18 may be attached to longitudinal beams 120 defined by the body 102 and which extend towards the rear of the vehicle 103. It may be noted that the body 102 may be referred to as a "body in white” or “body shell” and it comprises several pressed metal panels that are welded together.
  • the subframe 106 has a first two mounting features 107 for mounting the drive assembly 101 at a first side of the body 102 of the car 103 and a second two mounting features 108 for mounting the drive assembly 101 at a second side of the body 102
  • the drive assembly 101 may have a first single mounting feature 107 for mounting the drive assembly 101 at a first side of the body 102 of the car 103 and a second single mounting feature 108 for mounting the drive assembly 101 at a second side of the body 102.
  • the subframe 106 may be provided with a third mounting feature arranged to be fixed to the body 102 of the car 103, either fore or aft of the drive mechanism, so that the first mounting feature 107, the second mounting feature 108 and the third mounting feature are positioned at the corners of a triangle.
  • the subframe may comprise a continuous component extending between each of the first, second and third mounting features.
  • the third mounting feature may be positioned in the vicinity of a centerline of the body 102 and closer to the centerline than it is to either of the first or second mounting features. Typically, the third mounting feature is positioned on the centerline of the body 102.
  • the subframe 106 of Fig. 1 comprises a continuous component 1 10 extending from the first two mounting features 107 to the second two mounting features 108 and is formed as a single cast component.
  • the subframe is formed of a single sheet of metal that is cut, for example by laser, and pressed to form the required shape.
  • the drive mechanism 104 has two output shafts 1 13, each of which is connected to a respective rear wheel 105A via universal joints (illustrated by the dashed outline 1 15), a driveshaft (or halfshaft) 1 16 and wheel axles 1 17.
  • the wheel axles 1 17 may be operatively connected to the subframe 106 by a suspension mechanism (not shown) to support the body 102 of the car 103.
  • the front wheels 105B are independently driven from the rear wheels 105A.
  • the vehicle 103 is solely powered by a drive mechanism 104 comprising an electric motor that drives the rear wheels 105A.
  • the subframe 106 is mounted on longitudinal beams located towards the front of the vehicle 103 and a drive mechanism 104 comprising an electric motor that drives the front wheels 105B is mounted on the subframe 106.
  • a subframe 106C is arranged to be mounted towards the rear of a vehicle 1603, and the drive mechanism 104 comprises a differential that is driven by an engine mounted at the front of the vehicle 1603.
  • FIG. 1 An example of the drive assembly 101 of Fig. 1 is shown in Figs. 2, 3, 4, 5, 6 and 7.
  • Fig. 2 shows a top view of the drive assembly 101 ;
  • Fig. 3 shows a cross-sectional side view;
  • Fig. 4 shows a bottom view;
  • Figs. 5 and 6 show cross-sectional views at planes A and B illustrated in Fig. 2;
  • Fig. 7 shows an end view in the direction of arrow C in Fig. 2.
  • the drive mechanism 104 comprises an electric motor 1 14 that has a stator 201 , which may comprise coils, and a rotor 202, which may comprise permanent magnets mounted on a hollow shaft 203.
  • the hollow shaft 203 is operatively connected to a gear and differential mechanism 204 which is arranged to provide equal torque to each of the two output shafts 1 13.
  • the gear and differential mechanism 204 may comprise epicyclical gearing providing a required gear ratio of, for example, 9:1 .
  • a first one of the two output shafts 1 13 is supported by a bearing 205.
  • the other one of the two output shafts 1 13 extends through the hollow shaft 203 and is supported by a bearing 206.
  • the output shafts 1 13 may be provided with female splines for receiving male splines of stub axles 207 providing connection to a respective universal joint 1 15.
  • the subframe 106 of Figs. 2 to 7 defines a hole 401 (which may be best seen in Figs. 4 and 5) in which a part of the drive mechanism 104 resides.
  • the drive assembly 101 of Figs. 2 to 7 comprises a container 301 located within the hole 401 .
  • the container 301 contains at least a part of the drive mechanism 104.
  • the drive assembly 101 also comprises a removable cover 208 that is attached to the subframe 106 and which covers a part of the drive mechanism 104.
  • the removable cover 208 has edges that are configured to extend alongside edges of the container 301 .
  • a seal 501 is provided between the edges of the removable cover 208 and the container 301 to enable containment of lubricant by the removable cover 208 and container 301 in combination.
  • the hole 401 extends through the continuous component 1 10 of the subframe 106 from an upper surface 304 to a lower surface 305 (shown in Fig. 3).
  • the container 301 is able to extend through the continuous component 1 10 of the subframe 106 and beyond the lower surface 305.
  • the container 301 and removable cover 208 are similarly shaped shells which each extend approximately half way around the drive mechanism 104 and which have flanges 210 and 21 1 respectively (shown in Fig. 5), to enable connection of the removable cover 208 to the container 301 and also enable attachment of the removable cover 208 and container 301 to the subframe 106.
  • the removable cover 208 and container 301 are attached to the subframe 106 with fasteners 212.
  • the fasteners 212 may comprise bolts which extend through holes in the flanges 210 and 21 1 of the removable cover 208 and container 301 and into threaded holes provided in the subframe 106.
  • the seal 501 may comprise a bead seal that is located in a groove formed in the flanges 210 provided on the removable cover 208 and/or in the flanges 21 1 provided on the container 301 . As shown in Fig. 5, a second bead seal 501 A may be provided parallel to bead seal 501 with the fastening members 212 located between the two bead seals 501 , 501 A.
  • the container 301 and the removable cover 208 each define a portion of a first opening 302 and a portion of a second opening 303 (shown in Fig. 3) that are provided to allow access to respective ones of the output shafts 1 13.
  • Radial shaft seals 209 are also provided between the removable cover 208 and container 301 within the openings 302 and 303 to maintain lubricant within the container 301 and removable cover 208.
  • the radial shaft seals 209 have an outer cylindrical surface arranged to provide a seal with the removable cover 208 and container 301 and a bore arranged to provide a seal with a respective stub axle 207 connected to the output shafts 1 13.
  • the removable cover 208 and the container 301 may be formed of a plastics material or alternatively may be formed of a metal. If the removable cover 208 and/or container 301 are formed of a plastics material, portions of the removable cover 208 and/or container 301 may be reinforced with a metallic structure about which the plastics material is moulded. Specifically, if the removable cover 208 is formed of a plastic material, portions of the removable cover 208 around the location of the bearings 205 and 206 and extending along the flanges 210 to the locations of the fasteners 212 may be reinforced with a metallic structure 601 , as shown in the cross-section of Fig. 6. Similarly, if the container 301 is formed of a plastics material, portions of the container 301 around the location of the bearings 205 and 206 and extending along the flanges 21 1 may be reinforced with a metallic structure 602.
  • Fig. 6 also shows one of two C-shaped bearing surfaces 603, defined by the continuous component 1 10 of the subframe 106, which are provided to support the container 301 at the positions of the bearings 205, 206.
  • the continuous component 1 10 transmits loads between the bearings 205, 206 and the mounting features 107 and 108.
  • Separate fasteners 213, such as bolts, rivets or clips, may be provided for fastening the removable cover 208 to the container 301 before the removable cover 208 and container 301 are positioned on the subframe 106.
  • the drive mechanism 104 located within the container 310 and removable cover 208, the bearings 205, 206, which support the output shafts 1 13, and the radial shaft seals 209 may be formed as a module. Consequently the module may be installed as a single unit on the subframe 106 by positioning the container 301 in the hole 401 formed in the subframe 106 and fixing the removable cover 208 and container 301 to the subframe 106 with fasteners 212. Stub axles 207 with male splines may then be located through the radial shaft seals 209 and fitted into the female splines provided in the output shafts 1 13.
  • Cables may be positioned through an aperture in the removable cover 208 or container 301 that provide electrical connection to the coils of the stator 201 .
  • the removable cover 208 or container 301 may be provided with an impervious electrical connector connected to the stator 201 and enabling electrical connection to external electrical wiring.
  • FIG. 1 An alternative example of the drive assembly 101 of Fig. 1 is shown in the top view of Fig. 8, cross-sectional side view of Fig. 9 and a second cross-sectional view in Fig. 10, identified as D in Fig. 8.
  • the features of the drive assembly 101 of Figs. 8 to 10 are generally the same as those of Figs. 2 to 7 and they have been labelled using the same reference signs.
  • the drive assembly 101 of Figs. 8 to 10 differs from the drive assembly 101 of Figs. 2 to 7 as follows. Firstly, instead of a hole 401 , the subframe 106A of Figs. 8 to 10 is provided with a recess 901 (shown in Fig. 9) in which the container 301 is located. Thus, a portion of the drive mechanism 104 including the electric motor 1 14 is located within the container 301 within the recess 901 . A portion 902 of the subframe that provides the recess 901 adds to the strength and rigidity of the subframe 106A, when compared with the subframe 106. In addition, it provides mechanical support to the container 301 , which may therefore be formed of thinner and lighter material. As previously mentioned, the container 301 may be formed of a plastics material.
  • the portion 902 of the subframe 106A in which the container 301 resides may be provided with one or more apertures 903 to reduce the weight of the subframe 106A.
  • the container 301 in combination with the removable cover 208 is arranged to contain oil (not shown) that may be provided to lubricate the drive mechanism 104.
  • the drive assembly 101 of Figs. 8 to 10 also comprises a support 801 which extends over the removable cover 208.
  • the support 801 may be formed of a stronger material than the removable cover 208, which again may be formed of a plastics material.
  • the support 801 may be formed of a metal, such as steel or aluminium alloy.
  • the support 801 may have flanges 802 (shown in Figs. 8 and 10) configured to extend over the length of the flanges 210 provided on the removable cover 208.
  • the fasteners 212 may fix the flanges 802 of the support 801 to the subframe 106A and the flanges 210, 21 1 of the removable cover 208 and container 301 may, in this way, be clamped between subframe 106A and the flanges of the support 801 .
  • the support 801 may also have one or more other portions 803 that form a recess 904 (shown in Fig. 9) in which a central portion of the removable cover 208 resides.
  • the support 801 may therefore provide support to the wall of the removable cover 208.
  • the support 801 may also provide additional strength to the subframe 106A.
  • End portions 804 of the support 801 may extend around bearings 205 and 206 and therefore the bearings 205 and 206 may be more rigidly held with respect to the subframe 106A.
  • the support 801 may define one or more apertures 805 in order to reduce the weight of the support 801 .
  • a second alternative example of the drive assembly 101 of Fig. 1 is shown in the top view of Fig. 1 1 ; a cross-sectional side view of Fig. 12; a second cross-sectional view in Fig. 13, which is identified as plane E in Fig. 1 1 ; and a third cross-sectional view in Fig. 14, which is identified as plane F in Fig. 1 1 .
  • the features of the drive assembly 101 of Figs. 1 1 to 14 are generally the same as those of Figs. 2 to 7 and they have been labelled using the same reference signs.
  • the drive assembly 101 of Figs. 1 1 to 14 differs from the drive assembly 101 of Figs. 2 to 7 in that it does not include the container 301 .
  • the subframe 106B of Fig. 1 1 to 14 defines a recess 1201 (shown in Figs. 12 and 13) in which the drive mechanism 104 is fitted directly.
  • the stator 201 may be fixed to the subframe 106B in direct contact with the inner surface of the recess 1201 .
  • the inner surface of the recess 1201 is continuous and therefore, in combination with the removable cover 208, the subframe 106 is arranged to provide a container for retaining a lubricant in which the drive mechanism 104 may be immersed.
  • Bead seals 1301 (shown in Fig. 13) may be provided between the flanges 210 of the removable cover 208 and adjacent surfaces of the subframe 106B.
  • the subframe 106B and the removable cover 208 each define portions of 1 101 openings provided at each of two ends of the drive assembly 101 of Figs. 1 1 to 14, to allow access to the output shafts 1 13.
  • the bearings 205, 206 are positioned between the subframe 106B and the removable cover 208 near to the openings 1 101 .
  • the continuous component 1 10 of the subframe 106B defines C-shaped bearing surfaces 1203 (shown in Figs. 12 and 14) against which the bearings 205, 206 may be directly positioned.
  • Radial shaft seals 209 are also provided at the openings 1 101 .
  • the radial shaft seals 209 have an inner surface for sealing with a stub axle 207 and outer surface that seals against the removable cover 208 and the subframe 106B.
  • a drive assembly 101 as described with reference to Figs. 2 to 7 or Figs. 1 1 to 14 may be provided with a support 801 over the removable cover 208 like the support 801 of Figs. 8 to 10.
  • a flow-chart outlining a method 1500 of mounting a drive mechanism 104 is shown in Fig. 15.
  • a drive mechanism 104 is positioned within a hole 401 or recess 901 , 1201 of a subframe 106, 106A, 106B, wherein the subframe 106, 106A, 106B has at least a first mounting feature 107 for mounting the drive assembly 101 at a first side of a body 102 of a vehicle 103 and at least a second mounting feature 108 for mounting the drive assembly 101 at a second side of the body 102 of the vehicle 103.
  • the subframe 106, 106A, 106B comprises a continuous component 1 10, 1 10A extending from the first mounting feature 107 to the second mounting feature 108.
  • the subframe 106, 106A, 106B has a first two mounting features 107 for mounting the drive assembly 101 at a first side of a body 102 of a vehicle 103 and a second two mounting features 108 for mounting the drive assembly 101 at a second side of the body 102 of the vehicle 103; and the subframe 106, 106A, 106B comprises a continuous component 1 10, 1 10A extending from the first two mounting features 107 to the second two mounting features 108.
  • the drive mechanism 104 may be pre-assembled within the container 301 with the removable cover 208 attached and with the bearings 205, 206 fitted to the output shafts 1 13.
  • the radial shaft seals 209 may also be previously fitted within the openings (such as openings 302 and 303 of Fig. 3) formed at each end of the container 301 and removable cover 208 that provide access to the two output shafts 1 13. However, if the seals 209 are not already fitted, they may be pushed in axially before, or after, the process at block 1502. In the example of Figs.
  • the rotor 202 and stator 201 of the electric motor 1 14 are pre-assembled and connected to the gear and differential mechanism 204, and the bearings 205 and 206 are fitted to the output shafts 1 13.
  • This assembly is then positioned on the subframe 106B at block 1501 of the method 1500, so that the stator 201 rests against the inner surface of the recess 1201 in the subframe 106B and the bearings 205, 206 are located within the C-shaped bearing surfaces 1203 of the subframe 106B.
  • the removable cover 208 may then be fitted over the motor 1 14 and the gear and differential mechanism 204. When fitting the cover 208, cables from the stator 201 may be passed through an orifice in the removable cover 208.
  • the removable cover 208 is attached to the subframe 106, 106A or 106B so that the removable cover 208 covers at least a part of the drive assembly 104.
  • the removable cover 208 may be formed of a plastics material and the flange 210 of the removable cover 208 may be reinforced with steel, and the process at block 1502 may comprise bolting the steel reinforced flange of the removable cover 208 to the subframe 106, 106A or 106B.
  • a support 801 may be located over the removable cover 208 and the flange 210 of the removable cover 208 may be clamped between the support 801 and the subframe 106, 106A or 106B, for example by bolting the support 801 to the subframe 106, 106A or 106B.
  • radial shaft seals 209 are not already fitted, these may be fitted after the process at block 1502 by pushing the seals 209 axially into the openings 302, 303 or 1 101 .
  • the stub axles 207 with male splines may then be inserted axially though the radial shaft seals 209 into female splines provided in the output shafts 1 13 of the drive mechanism 104.
  • a second vehicle 1603 comprising a rear-wheel-drive car is shown schematically in Fig. 16.
  • the car 1603 comprises a drive assembly 101 A mounted on the body 1602 of the car 1603.
  • the drive assembly 101 A comprises a drive mechanism 104A having two output shafts 1613 for connection to wheels 1605A of the car 1603.
  • the drive mechanism 104A comprises a differential 1614 that has an input shaft 1651 driven by an engine 161 1 via a transmission 1612, a drive shaft 1652 and universal joints 1653 and 1654.
  • the differential 1614 may be of a known type for driving the rear wheels of a vehicle.
  • the engine 161 1 is mounted remotely from the drive mechanism
  • the engine 161 1 being mounted in an engine compartment 1655 towards the front of the vehicle 1603 while the drive assembly 101 A is mounted towards the rear of the vehicle 1603.
  • the two rear wheels 1605A of the car 1603 are driven via halfshafts 1616 connected to the output shafts 1613 of the drive mechanism 104A via stub axles 1607 and universal joints 1615.
  • the drive assembly 101 A also comprises a subframe 106C having a first two mounting features 107 for mounting the drive assembly at a first side of the body 1602 of the vehicle 1603 and a second two mounting features 108 for mounting the drive assembly at a second side of the body 1602 of the vehicle 1603.
  • the mounting features 107 and 108 may comprises holes for receiving bushings as described above with regard to the drive assembly 101 of Fig. 1 .
  • a removable cover 208A is attached to the subframe 106C and covers at least a part of the drive mechanism 104A.
  • the subframe 106C of drive assembly 101 A comprises a continuous component 1 10A extending from the first two mounting features 107 to the second two mounting features 108.
  • FIG. 17 An example of the drive assembly 101 A is shown in the top view in Fig. 17, the cross- sectional side view in Fig. 18 and a second cross-sectional view in Fig. 19 through a plane "G" that is identified in Fig. 17.
  • the drive mechanism 104A is located within a container 301 A (shown in Figs. 18 and 19) that has edges sealed against edges of the removable cover 208A.
  • the edges of the removable cover 208A and the container 301 A may be provided with flanges 21 OA and 21 1 A in a similar manner to those of the container 301 and removable cover 208 described above.
  • a bead seal may be provided between the flanges 210A and 21 1 A to enable the container 301 A in combination with the removable cover 208A to contain oil for lubricating the differential 1614.
  • the container 301 A and the removable cover 208A may be attached to the subframe 106C by fasteners 212, such as bolts, located though holes in the flanges 21 OA and 21 1 A, that engage threaded holes in the subframe 106C.
  • the removable cover 208A and container 301 A differ from the removable cover 208 and container 301 of Figs. 2 to 7 in that they define a third opening to allow access to the input shaft 1651 as well as two openings for the output shafts 1613.
  • Each of the three openings is provided with a radial shaft seal 209 that has an outer surface sealing against inner surfaces of the container 301 A and removable cover 208A.
  • Two of the radial shaft seals 209 have an inner surface which seals against a stub axle 1607 fitted to the output shafts 1613 of the differential, and the third radial shaft seal 209 seals against a stub axle 1607A fitted to the input shaft 1651 .
  • Each of the output shafts 1613 and the input shaft 1651 is supported by a respective bearing 205, 206 and 1701 .
  • the continuous component 1 1 OA of the subframe 106C defines C- shaped bearing surfaces 1901 (shown in Fig. 19) at the locations of the bearings 205, 206 and 1701 to provide support for the bearings and to allow loads from the bearings 205, 206 and 1701 to be transferred through the continuous component of the subframe 106C to the mounting features 107 and 108.
  • the container 301 A and the removable cover 208A may be formed of a plastics material that is provided with steel reinforcement at the position of the bearings 205, 206 and 1701 and along the flanges 21 OA and 21 1 B to positions where the container 301 A and removable cover 208A are attached to the subframe 106C, for example by bolts.
  • the container 301 A, and a lower portion of the differential 1614 is located within a hole 1801 in the continuous component 1 1 OA of the subframe 106C.
  • the container 301 A and a lower portion of the differential 1614 may be located within a recess formed in the continuous component 1 10A of the subframe 106C.
  • the lower portion of the differential 1614 may be located within a recessed portion of the continuous component 1 10A of the subframe 106C and therefore the container 301 A may be omitted.
  • the removable cover 208A may be attached directly to the subframe 106 and seal against the subframe 106C.
  • a metal support similar to support 801 of Figs. 8 to 10 may be fitted over the removable cover 208A to provide support to the removable cover (which may be formed of a plastics material) and/or to provide additional strength to the subframe 106C.
  • the drive mechanism is located in a recess in the continuous component forming the subframe.
  • the recess has a main opening to allow the drive mechanism to be installed within the recess.
  • the subframe defines two additional openings which provide access to the output shaft and which contain the radial shaft seals, i.e. the radial shaft seals are completely surrounded by the subframe.
  • Access to supporting surfaces for the bearings of the output shafts is provided via the main opening, and additional fixing elements are provided to fix the bearings in position on the bearing surfaces.
  • the removable cover is sealed against the subframe and does not seal against the radial shaft seals. Therefore, to assemble this alternative drive assembly, the drive mechanism with bearings fitted to the output shafts is passed through the main opening into the recess and the bearings are fixed in place on the bearing surfaces of the subframe. The cover is positioned over the main opening and fixed in place to seal it.
  • the radial shaft seals are inserted into the additional openings in the subframe and then male splines of stub axles may be inserted through the radial shaft seals and into female splines in the output shaft.
  • the subframes 106, 106A, 106B, 106C described above have a first two mounting features 107 for mounting the drive assembly 101 at a first side of the body 102 of the car 103 and a second two mounting features 108 for mounting the drive assembly 101 at a second side of the body 102.
  • the drive assembly 101 has a subframe that has a first single mounting feature 107 for mounting the drive assembly 101 at a first side of the body 102 of the car 103 and a second single mounting feature 108 for mounting the drive assembly 101 at a second side of the body 102.
  • the subframe may be provided with a third mounting feature arranged to be fixed to the body 102 of the car 103, either in front or behind the drive mechanism, so that the first mounting feature 107, the second mounting feature 108 and the third mounting feature define a triangle.
  • the third mounting feature may be positioned in the vicinity of a centerline of the body 102 and closer to the centerline than it is to either of the first or second mounting features.
  • the third mounting feature is positioned on the centerline of the body 102.
  • fig 20 shows a bottom view of a drive assembly 1002.
  • the drive assembly 1002 shown in Fig 20 has three mounting features 107, 108, 109.
  • the drive assembly 1002 has a subframe 106D that has a first single mounting feature 107 for mounting the drive assembly 1002 at a first side of the body 102 of the car 103, a second single mounting feature 108 for mounting the drive assembly 1002 at a second side of the body 102 and a third single mounting feature 109 mounted either fore or aft in the car 103 on a suitable body panel.
  • the third single mounting feature 109 may be placed on the centerline of the vehicle 103 such that the geometry of the three mounts form a symmetrical triangle formation. Alternately the third single mounting feature 109 may be placed slightly off the centerline of the vehicle.
  • a mechanical driveshaft (not shown) may be provided as an input to the embodiment of fig 20, it may be necessary to position the third single mounting feature 109 in a position which would not clash with the mechanical driveshaft.
  • the third single mounting feature 109 may be higher or lower in the vehicle to avoid a mechanical driveshaft (not shown) to suit package constraints.
  • Fig 21 shows a cross section taken at plane "H-H" shown in Fig.20.
  • the subframe 106D provides a continuous component extending from the first mounting feature (107) to both the second mounting feature (108) and the third mounting feature (109).
  • the subframe 106D has a recess formed into it which the container 301 may be located.
  • the container 301 seats into the subframe 106D recess and the removable cover 208B is secured in place over the drive mechanism 104 using the fixings 212A.
  • the fixings 212A could bolt right through the removable cover 208B and the container 301 to screw into a female thread provided in the subframe 106D.
  • the removable cover 208B and the container 301 could be secured together directly using local fixings. Subsequent fixing of the joined container 301 and removable cover 208B to the subframe 106D could be done with other conventional fixings (not shown) from above or below the subframe 106D.
  • the above-described drive assemblies 101 are generally arranged such that the drive mechanism 104, 104A is mounted above an upward facing surface of the respective subframe 106, 106A, 106B, 106C.
  • the drive mechanism (104, 104A) may be mounted below a downward facing surface of the respective subframe 106, 106A, 106B, 106C.
  • the drive mechanism 104, 104A might be detached and lowered from the subframe 106, 106A, 106B, 106C, while the subframe remains attached to the vehicle 103, 1603.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Mechanical Engineering (AREA)
  • Motor Power Transmission Devices (AREA)
  • Arrangement Or Mounting Of Propulsion Units For Vehicles (AREA)
  • Electric Propulsion And Braking For Vehicles (AREA)

Abstract

L'invention concerne un ensemble d'entraînement (101, 101 A) pour un véhicule (103, 1603), un véhicule (103, 1603) et un procédé de montage d'un mécanisme d'entraînement (104, 104A). L'ensemble d'entraînement (101, 101 A) comprend un mécanisme d'entraînement (104, 104A) ayant deux arbres de sortie (113) devant être reliés à des roues (105A, 1605A) du véhicule (103, 1603) et un faux-cadre (106, 106A, 106B, 106C) ayant au moins un premier élément de montage (107) pour monter l'ensemble d'entraînement (101, 101 A) au niveau d'un premier côté de la carrosserie (102, 1602) du véhicule (103, 1603) et au moins un second élément de montage (108) pour monter l'ensemble d'entraînement (101, 101 A) au niveau d'un second côté de la carrosserie (102, 1602) du véhicule (103, 1603). L'ensemble d'entraînement comprend également un couvercle amovible (208, 208A, 208B) fixé au faux-cadre (106, 106A, 106B, 106C) et recouvrant au moins une partie du mécanisme d'entraînement (104, 104A). Le faux-cadre (106, 106A, 106B, 106C) comprend une pièce continue (110, 110A) s'étendant du premier élément de montage (107) au second élément de montage (108), la pièce continue (110, 110A) ayant un trou (401, 1801) ou un renfoncement (1201) dans lequel réside au moins une partie du mécanisme d'entraînement (104, 104 A).
PCT/EP2017/074039 2016-09-29 2017-09-22 Ensemble d'entraînement pour un véhicule WO2018060079A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE112017004884.2T DE112017004884T5 (de) 2016-09-29 2017-09-22 Antriebsanordnung für ein fahrzeug

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1616527.6 2016-09-29
GB1616527.6A GB2554450B (en) 2016-09-29 2016-09-29 A drive assembly for a vehicle

Publications (1)

Publication Number Publication Date
WO2018060079A1 true WO2018060079A1 (fr) 2018-04-05

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ID=57571123

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2017/074039 WO2018060079A1 (fr) 2016-09-29 2017-09-22 Ensemble d'entraînement pour un véhicule

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DE (1) DE112017004884T5 (fr)
GB (1) GB2554450B (fr)
WO (1) WO2018060079A1 (fr)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110891850B (zh) * 2017-07-28 2022-09-02 德纳重型车辆系统集团有限责任公司 电动车桥组件的支架组件

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1527935A1 (fr) * 2003-10-30 2005-05-04 Dana Corporation Procédé de vérification du précharge des paliers d'un module de différentiel
US20110259657A1 (en) * 2010-04-23 2011-10-27 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Vehicle having electric drive
EP2708776A1 (fr) * 2012-09-13 2014-03-19 American Axle & Manufacturing, Inc. Composant de chaîne cinématique avec couvercle structural
EP2720352A1 (fr) * 2011-06-07 2014-04-16 Honda Motor Co., Ltd. Dispositif d'entraînement de véhicule

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7137183B2 (en) * 2002-03-20 2006-11-21 Torque-Traction Technologies, Inc. Drive axle for motor vehicles and method for assembling the same
US9109689B2 (en) * 2013-02-27 2015-08-18 American Axle & Manufacturing, Inc. Axle assembly having banjo beam and strengthened coverpan

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1527935A1 (fr) * 2003-10-30 2005-05-04 Dana Corporation Procédé de vérification du précharge des paliers d'un module de différentiel
US20110259657A1 (en) * 2010-04-23 2011-10-27 Dr. Ing. H.C.F. Porsche Aktiengesellschaft Vehicle having electric drive
EP2720352A1 (fr) * 2011-06-07 2014-04-16 Honda Motor Co., Ltd. Dispositif d'entraînement de véhicule
EP2708776A1 (fr) * 2012-09-13 2014-03-19 American Axle & Manufacturing, Inc. Composant de chaîne cinématique avec couvercle structural

Also Published As

Publication number Publication date
GB201616527D0 (en) 2016-11-16
GB2554450B (en) 2020-01-15
DE112017004884T5 (de) 2019-06-13
GB2554450A (en) 2018-04-04

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