Methods and systems are provided for an electric axle assembly. In one example, a system, includes a cover plate for a head assembly, wherein a cross-member is integrated into the cover plate and configured to attach to a vehicle frame.

An axle disconnect and differential locking system for single or multiple axle vehicles which allows the vehicle to selectively engage and disengage an axle half shaft from the differential side gear. Additionally, the system allows the vehicle to selectively switch between locked and unlocked differential driving modes. The system has a first position, a second position and a third position. At the first position, the system is not meshingly engaged with the differential side gear or the differential case. At the second position, the system is meshingly engaged with the differential side gear but is not meshingly engaged with the differential case. At the third position, the system is engaged with the differential side gear and the differential case. In one embodiment the system is a sliding collar. According to another embodiment, the system includes an axle disconnect collar, a differential locking collar and a biasing member disposed therebetween.

An axle disconnect and differential locking system for single or multiple axle vehicles which allows the vehicle to selectively engage and disengage an axle half shaft from the differential side gear. Additionally, the system allows the vehicle to selectively switch between locked and unlocked differential driving modes. The system has a first position, a second position and a third position. At the first position, the system is not meshingly engaged with the differential side gear or the differential case. At the second position, the system is meshingly engaged with the differential side gear but is not meshingly engaged with the differential case. At the third position, the system is engaged with the differential side gear and the differential case. In one embodiment the system is a sliding collar. According to another embodiment, the system includes an axle disconnect collar, a differential locking collar and a biasing member disposed therebetween.

A method of providing road and vehicle diagnostics. The method includes providing a vehicle axle system having a first axle half shaft housing, a second axle half shaft housing and a differential housing. Attached one or more of said housings is one or more tri-axis accelerometers. In communication with the accelerometers is one or more data processors operably configured to receive and analyze data from the accelerometers. An occurrence of one or more road events is determined by one or more spikes in the Z-direction of said data collected from said accelerometers. A depth of the road event is determined by a magnitude of said positive and negative changes in acceleration of said spike in said Z-direction and a length of road event is determined by a span of said one or more spikes in said Z-direction. Once the road event is identified the time and geographic location of the road event is identified.

A method of providing road and vehicle diagnostics. The method includes providing a vehicle axle system having a first axle half shaft housing, a second axle half shaft housing and a differential housing. Attached one or more of said housings is one or more tri-axis accelerometers. In communication with the accelerometers is one or more data processors operably configured to receive and analyze data from the accelerometers. An occurrence of one or more road events is determined by one or more spikes in the Z-direction of said data collected from said accelerometers. A depth of the road event is determined by a magnitude of said positive and negative changes in acceleration of said spike in said Z-direction and a length of road event is determined by a span of said one or more spikes in said Z-direction. Once the road event is identified the time and geographic location of the road event is identified.

An axle system (150) for a vehicle comprises: —a differential unit (10) including a first housing (24) and a second housing (20) which rotationally receives at least part of said first housing; —at least one drive shaft (11) having one end configured to be connected to a wheel of the vehicle and one end connected to the differential unit (10) and rotationally received in the first housing (24), the drive shaft (11) including at least one joint (110) connecting two portions (114a, 114d) of the drive shaft (11) to transmit rotary motion between said portions; —a first bearing (30) secured around the drive shaft (11), placed between the drive shaft and the first housing (24), having an outer diameter (D30) smaller than the radial dimension (D) of the joint (110); —a second bearing (40) placed between the first housing (24) and the second housing (20); —at least one tightening member (50) to axially lock the first bearing outer ring (32) relative to the first housing (24). The tightening member comprises at least one manoeuvring portion (51) which is arranged in an offset relation relative to the joint (110), when looking axially towards the differential unit (10), so that the tightening member manoeuvring portion (51) is visible and accessible, at least during a tightening phase of an axle system mounting process.

An axle system (150) for a vehicle comprises: —a differential unit (10) including a first housing (24) and a second housing (20) which rotationally receives at least part of said first housing; —at least one drive shaft (11) having one end configured to be connected to a wheel of the vehicle and one end connected to the differential unit (10) and rotationally received in the first housing (24), the drive shaft (11) including at least one joint (110) connecting two portions (114a, 114d) of the drive shaft (11) to transmit rotary motion between said portions; —a first bearing (30) secured around the drive shaft (11), placed between the drive shaft and the first housing (24), having an outer diameter (D30) smaller than the radial dimension (D) of the joint (110); —a second bearing (40) placed between the first housing (24) and the second housing (20); —at least one tightening member (50) to axially lock the first bearing outer ring (32) relative to the first housing (24). The tightening member comprises at least one manoeuvring portion (51) which is arranged in an offset relation relative to the joint (110), when looking axially towards the differential unit (10), so that the tightening member manoeuvring portion (51) is visible and accessible, at least during a tightening phase of an axle system mounting process.

Methods and systems for a locking mechanism in an inter-axle differential are provided. A vehicle system, in one example, includes an electric motor coupled to a clutch assembly in a locking mechanism of an inter-axle differential coupled to a first axle and a second axle, the clutch assembly is configured to selectively disengage the locking mechanism, and in the disengaged configuration the locking mechanism permits speed differentiation between the first and second axles. The system further includes an electric motor brake coupled to the electric motor and configured to selectively apply a brake torque to the electric motor and the electric motor is configured to actuate the clutch assembly.

A through the road (TTR) hybridization strategy is proposed to facilitate introduction of hybrid electric vehicle technology in a significant portion of current and expected trucking fleets. In some cases, the technologies can be retrofitted onto an existing vehicle (e.g., a trailer, a tractor-trailer configuration, etc.). In some cases, the technologies can be built into new vehicles. In some cases, one vehicle may be built or retrofitted to operate in tandem with another and provide the hybridization benefits contemplated herein. By supplementing motive forces delivered through a primary drivetrain and fuel-fed engine with supplemental torque delivered at one or more electrically-powered drive axles, improvements in overall fuel efficiency and performance may be delivered, typically without significant redesign of existing components and systems that have been proven in the trucking industry.

Through-the-road (TTR) hybrid designs using control strategies such as an equivalent consumption minimization strategy (ECMS) or an adaptive ECMS are implemented at the supplemental torque delivering electrically-powered drive axle (or axles) in a manner that follows operational parameters or computationally estimates states of the primary drivetrain and/or fuel-fed engine, but does not itself participate in control of the fuel-fed engine or primary drivetrain. BSFC type data particular to the paired-with fuel-fed engine allows an ECMS implementation (or other similar control strategy) to adapt to efficiency curves for the particular fuel-fed engine and to improve overall efficiencies of the TTR hybrid configuration.