Gearing assembly, vehicle drivetrain and electric wheel hub therewith

Abstract

A gearing assembly includes a rotary input member, a rotary output member, and a gearing arrangement between the input member and the output member selectively able to effect a driving engagement between the input member and the output member through at least a first torque connection having a first gear ratio. A second torque connection has a second gear ratio and a third torque connection having a third gear ratio. The gearing arrangement includes a first engagement member operable selectively to effect the first torque connection in a 1:1 ratio, a first planetary gear stage, and a second planetary gear stage. A second engagement member is operable selectively to effect the second torque connection, and a third engagement member operable selectively to effect the third torque connection, respectively, through one or more of the planetary gear stages.

Claims

1. A gearing assembly, comprising: a rotary input member; a rotary shaft; a gearing arrangement between the rotary input member and the rotary shaft selectively engageable to effect a driving engagement between the rotary input member and the rotary shaft through at least a first torque connection having a first gear ratio, the gearing arrangement including a first engagement member operable selectively to effect the first torque connection in a 1:1 ratio; a second torque connection having a second gear ratio; a third torque connection having a third gear ratio; a first planetary gear stage and a second planetary gear stage; the rotary input member and the rotary shaft are configured as a rotary drive mechanism, to drive the rotary shaft, wherein the first engagement member is located on a first side of the rotary drive mechanism, and the first planetary gear stage, a second engagement member, the second planetary gear stage and a third engagement member are located on a second side of the rotary drive mechanism opposite to said first side, and wherein the drive mechanism is configured as an electric motor; and wherein the second engagement member operable selectively to effect the second torque connection and the third engagement member operable selectively to effect the third torque connection respectively through one or more of the planetary gear stages.

2. The gearing assembly of claim 1, wherein the planetary gear stages are arranged such that the second torque connection is effected through engagement of the first planetary gear stage, and the third torque connection is effected through engagement of the first planetary gear stage and the second planetary gear stage in series.

3. The gearing assembly of claim 1, wherein the gearing arrangement includes the first engagement member being operable selectively to effect the driving engagement between the rotary input member and the rotary shaft in the first gear ratio, the first planetary gear stage and the second engagement member being operable selectively to effect the driving engagement between the rotary input member and the rotary shaft through the first planetary gear stage, and the second planetary gear stage and the third engagement member operable selectively to effect the driving engagement between the rotary input member and the rotary shaft through the first planetary gear stage and the second planetary gear stage in series.

4. The gearing assembly of claim 1, wherein the first engagement member comprises a selectively engageable coupler engageable to effect the driving engagement directly between the rotary input member and the rotary shaft.

5. The gearing assembly of claim 4, wherein the first engagement member is provided with an actuator to effect its selective engagement and disengagement.

6. The gearing assembly of claim 4, wherein the first engagement member includes a first dog clutch arrangement, wherein the first engagement member is provided with a selector hub borne for axial movement relative to the rotary shaft to effect selective engagement with the first dog clutch arrangement.

7. The gearing assembly of claim 1, wherein the first and second planetary gear stages comprises of a first sun gear, a first and second planet gears radially distributed about and meshing with the first sun gear configured to be borne by a common planet carrier co-axially located with the first sun gear, and a common ring gear, configured as an annulus, meshing with the first and second planet gears.

8. The gearing assembly of claim 7, wherein the first and second planetary gear stages are configured to be used as a reduction gear in which the first sun gear being arranged to be driven on an input side of the first and second planetary gear stage, the planet carrier is arranged to rotate on an output side, opposite to the input side, of the first sun gear; and the common ring gear is held non-rotatably.

9. The gearing assembly of claim 1, wherein each planetary gear stage is configured to produce a gear ratio of between 2.5:1 and 3:1.

10. The gearing assembly of claim 1, wherein the second engagement member comprises a selectively engageable coupler arranged to be engageable to effect the driving engagement between the rotary input member and the rotary shaft through the first planetary gear stage.

11. The gearing assembly of claim 1, wherein the second engagement member includes a second dog clutch arrangement.

12. The gearing assembly of claim 1, wherein the third engagement member comprises a selectively engageable coupler arranged to be engageable to effect the driving engagement between the rotary input member and the rotary shaft through the first planetary gear stage and the second planetary gear stage in series.

13. The gearing assembly of claim 1, wherein the third engagement member includes a third dog clutch arrangement.

14. The gearing assembly of claim 1, further including an actuator configured to effect selective engagement of one, other or neither of the second and third engagement members, wherein the actuator comprises a second selector hub borne for axial movement relative to the rotary shaft to effect selective engagement of one, other or neither of the second and third engagement members.

15. The gearing assembly of claim 1, wherein the rotary input member is disposed coaxially with and around the rotary shaft, the rotary shaft extends axially beyond either the first side of the rotary input member the second side of the rotary input member, the first engagement member being disposed with axial extension on the first side of the rotary input member, and the first planetary gear stage, the second engagement member, the second planetary gear stage and the third engagement member being disposed with axial extension on the second side of the rotary input member.

16. The gearing assembly of claim 15, wherein the rotary input member comprises a motor rotor of the electric motor driven by an annular stator, and the motor rotor is an annular rotor disposed coaxially with and around the rotary shaft, the rotary shaft extending axially beyond the annular motor rotor on either the first side of the rotary input member or the second side of the rotary input member.

17. A vehicle drivetrain, comprising: the gearing assembly of claim 1.

18. An electric wheel hub drive, comprising: the gearing assembly of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Some embodiments will now be described by way of example only, and with reference to the following drawing, in which:

(2) FIG. 1 is a schematic cross section of a gearing assembly in accordance with some embodiments.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

(3) Some embodiments include a drive configuration providing three gear ratios including 1:1. An electric rotary drive traction motor rotor is coupled to an output drive shaft either directly, through one planetary gear reduction, or through two planetary gear reductions in series.

(4) In order to deal with the issues raised above relating to regarding accessibility for actuation of the direct coupling, some embodiments the approach of splitting the gearing assembly and placing the direct coupling on a first side of the traction motor and the planetary gear reductions on a second side of the traction motor. This drive configuration, having the high engagement system on one side of the traction motor and the planetary gears and the mid/low engagement system on the other side of the motor allows a simplified mechanism.

(5) FIG. 1 is a schematic cross section of a drive configuration generally denoted 1 including a gearing assembly in accordance with some embodiments. The gearing assembly includes a gearing arrangement that is adapted to engage with and provide rotary output drive to a drive shaft 2. Rotary input 20 is provided from a rotary electric traction motor via a motor rotor 5 driven by an annular stator 6. The motor rotor 5 annularly surrounds the drive shaft 2 which extends axially beyond it on either side. A 1:1 rotor to driveshaft engagement mechanism is disposed to engage upon a first such axial extension on a first side of the traction motor, and a planetary gearing system offering two further ratios, is disposed and in particular two reduction ratios, on a second such axial extension on a second side of the traction motor. High, mid and low dog clutches effect selective engagement of the three ratios, in FIG. 1 all shown disengaged.

(6) The first 1:1 engagement mechanism includes a first, high dog clutch 9 provided with a set of selectively engageable and disengageable dogs to effect a first torque connection between the motor rotor and the driveshaft in a 1:1 ratio. Selective engagement and disengagement is effected by axial movement of a first selector hub 3. The first selector hub 3 has an annular body surrounding the shaft 2 and provided on the left hand side (as shown) with a set of dogs complementarily structured with dogs of the first dog clutch. The selector hub 4 is borne for axial movement relative to the drive shaft by mechanism of a splined connection 7 so that the hub and shaft must turn together but the hub is able to slide axially on the shaft to and fro from the position illustrated in FIG. 1. Axial movement is effected by an operator using the shift fork 8. To engage the 1:1 ratio the selector hub 4 is moved to the left (as shown) and a torque transfer engagement is effected between the high dog clutch 9 and the first selector hub 3 whereby the input of the motor rotor is coupled to the output of the drive shaft in 1:1 ratio.

(7) The other two gear ratios, respectively a mid gear and a low gear, are provided by selective engagement of the planetary gear system disposed on the other side of the traction motor.

(8) First and second planetary gear stages 23, 24 are arranged in series and respectively include a first sun gear 10 meshed with a first planet gear set 14 and a second sun gear 11 meshed with a second planet gear set 15, with a common ring gear 16. Both gear stages 23, 24 are arranged as reduction gears, with the sun gear as the input and the planet carrier as the output, and with the common ring gear held non-rotatably.

(9) A second, mid dog clutch 13 and a third, low dog clutch 12 each provided with a set of selectively engageable and disengageable dogs are provided to effect respectively a second torque connection between the motor rotor and the drive shaft and a third second torque connection between the motor rotor and the drive shaft at the respective second and third ratios. Selective engagement and disengagement to effect a mid gear or low gear connection is effected by axial movement of a second selector hub 17.

(10) The second selector hub 17 has an annular body surrounding the shaft 2 and provided on both sides with a set of dogs complementarily structured with dogs of a respective dog clutch. The second selector hub 17 is borne for axial movement relative to the drive shaft by mechanism of a second splined connection 18 so that the hub and shaft turn together but the hub is able to slide axially on the shaft to and fro from the position illustrated in FIG. 1, in which neither dog clutch is engaged. Axial movement is effected by an operator using the shift fork 19. To engage the mid gear the second selector hub 17 is moved to the right (as shown) and a torque transfer engagement is effected between the mid dog clutch 13 and the complementary dogs on the second selector hub 17 whereby the input of the motor rotor is coupled to the output of the drive shaft via the first planetary gear stage 23 only. To engage the low gear the second selector hub 17 is moved to the left (as shown) and a torque transfer engagement is effected between the low dog clutch 12 and the complementary dogs on the second selector hub 17 whereby the input of the motor rotor is coupled to the output of the drive shaft via the first planetary gear stage 23 and the second planetary gear stage 24 successively in series.

(11) Thus, the system provides three selectable ratios. Using the above configuration the high 9, mid 13 and low 12 dog clutches are used to couple the rotor 5 to the drive shaft 2 respectively directly, through one planetary gear reduction or through two planetary gear reductions in series. As the lowest gear is achieved in the embodiment by using the two reduction stages in series, the ratios of those two stages need not be different and are preferably identical, although they may differ if desired, and other planetary gear arrangements might be considered to achieve mid and low gears.

(12) Advantageously or preferably, the two planetary gear stages 23, 24 are configured with relatively low reduction ratios for example of approximately 2.7:1 per stage. The planet gears are correspondingly small in comparison with the sun gears 10, 11. Two gear stages 23, 24 of approximately 2.7:1 per stage gives a mechanical ratio of approximately 7:1 when the two stages are combined in series, which combined with a typical electrical traction motor range results in a range of approximately 20:1.

(13) The use of a planetary gear reduction with a ratio of approximately 2.7:1 with relatively small planet gears and large sun gears is further advantageous as this enables the space insider the sun gears 10, 11 to house dog clutch components for engaging the mid and low gear ranges.

(14) The drive configuration of this embodiment, by placing the high engagement dog clutch system on one side of the traction motor and the planetary gears and the mid/low engagement dog clutch system on the other side of the motor allows a simplified mechanism. By contrast, keeping the high dog clutch on the same side of the motor as the two planetary gear stages 23, 24 would require a more complex arrangement, for example locating a dog inside a tubular traction motor output shaft with radial slots and pins to allow actuation.

(15) These and other advantageous or preferred embodiments will be apparent from the appended claims.