IP Library Granted Patent US 12697871
Granted Patent B2
US 12697871 · App. 18/346,660 · Granted Aug 4, 2026

Electric axle system with different gear ratios

Inventors: Bruce Falls (Dove Canyon, CA); Oded Nechushtan (Marina Del Rey, CA)
Assignee: Flyer Next, LLC
B60K17/356B60K17/354
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Quick Facts
Patent No.
US 12697871
App. No.
18/346,660
Granted
Aug 4, 2026
Kind
B2
Abstract

The electric axle (e-axle) system having variable gear ratios is disclosed. The e-axle system can include a first axle assembly having one axle gear ratio and a second axle assembly having two or more axle gear ratios that are selectively and independently controlled. In addition, each of the first and second axle assemblies is independently controlled to be in a neutral position.

Claims (51)

1 . An axle system for an electric vehicle, comprising:

a first axle assembly configured to operate in a first gear ratio, the first axle assembly comprising a first electric motor configured to drive a first axle shaft; and

a second axle assembly configured to selectively operate in a second gear ratio and a third gear ratio, the second axle assembly comprising a second electric motor configured to drive a second axle shaft,

wherein the first gear ratio, the second gear ratio, and the third gear ratio are different ratios,

wherein the first axle assembly and the second axle assembly are configured to operate independently of each other, and

wherein the first axle assembly and the second axle assembly are configured to drive the first and second axle shafts simultaneously using the first and second electric motors.

2 . The axle system of claim 1 , wherein the first axle assembly and the second axle assembly are configured to operate in a neutral position, independently of each other, the neutral position being a position in which the first axle shaft or the second axle shaft spins without rotating the first electric motor or the second electric motor, respectively.

3 . The axle system of claim 2 , wherein the first axle assembly is configured to be operated in the neutral position while the second axle assembly is operated in the second gear ratio or the third gear ratio.

4 . The axle system of claim 2 , wherein the second axle assembly is configured to be operated in the neutral position while the first axle assembly is operated in the first gear ratio.

5 . The axle system of claim 1 , wherein:

the first axle assembly and the second axle assembly are coupled to a computing system of the vehicle; and

the computing system is configured to dynamically select between the second gear ratio or the third gear ratio for operation based on sensing data.

6 . The axle system of claim 5 , wherein the sensing data comprises:

operating conditions including at least one of a speed of the vehicle, an acceleration of the vehicle, a deceleration of the vehicle, or a neutral gear selection; and

driving conditions including at least one of a road gradient or a road surface.

7 . The axle system of claim 5 , wherein the first axle assembly further includes a fourth gear ratio that is different from the first, second, and third gear ratios,

wherein the computing system is configured to dynamically select between the first gear ratio, the second gear ratio, and the fourth gear ratio.

8 . The axle system of claim 5 , wherein the computing system is further configured to change between the second gear ratio and the third gear ratio based on the sensing data while allowing a first wheel speed output by the first axle assembly to differ from a second wheel speed output by the second axle assembly.

9 . The axle system of claim 5 , wherein the computing system is further configured to change between the second gear ratio and the third gear ratio based on the sensing data while matching a first wheel speed output by the first axle assembly to a second wheel speed output by the second axle assembly.

10 . The axle system of claim 1 , wherein the first axle assembly is configured to transfer a torque in only the first gear ratio.

11 . The axle system of claim 10 , wherein the second axle assembly is further configured to selectively operate in a fourth gear ratio different from the first, second, and third gear ratios.

12 . An electric vehicle comprising:

a first axle assembly configured to operate in a first gear ratio, the first axle assembly comprising a first electric motor configured to drive a first axle shaft;

a second axle assembly configured to selectively operate in a second gear ratio and a third gear ratio, the second axle assembly comprising a second electric motor configured to drive a second axle shaft; and

a computing system configured to:

control the first axle assembly and the second axle assembly, and

dynamically select between the second gear ratio and the third gear ratio,

wherein the first gear ratio, the second gear ratio, and the third gear ratio are different ratios,

wherein the first axle assembly and the second axle assembly are configured to operate independently of each other, and

wherein the first axle assembly and the second axle assembly are configured to drive the first and second axle shafts simultaneously using the first and second electric motors.

13 . The vehicle of claim 12 , wherein the first axle assembly and the second axle assembly are configured to operate in a neutral position, independently of each other, the neutral position being a position in which the first axle shaft or the second axle shaft spins without rotating the first electric motor or the second electric motor, respectively.

14 . The vehicle of claim 13 , wherein the first axle assembly is configured to be operated in the neutral position while the second axle assembly is operated in the second gear ratio or the third gear ratio.

15 . The vehicle of claim 13 , wherein the second axle assembly is configured to be operated in the neutral position while the first axle assembly is operated in the first gear ratio.

16 . The vehicle of claim 12 , wherein the computing system is configured to dynamically select the second gear ratio or the third gear ratio for operation based on sensing data of the vehicle.

17 . The vehicle of claim 16 , wherein the sensing data comprises:

operating conditions including at least one of a speed of the vehicle, an acceleration of the vehicle, a deceleration of the vehicle, or a neutral gear selection; and

driving conditions including at least one of a road gradient or a road surface.

18 . A computing system for an electric vehicle comprising:

a memory storing instructions; and

one or more processors, coupled to the memory, and configured to dynamically select a first gear ratio and a second gear ratio of a first axle assembly of the vehicle, the first axle assembly comprising a first electric motor configured to drive a first axle shaft,

wherein a second axle assembly of the vehicle has a third gear ratio, the second axle assembly comprising a second electric motor configured to drive a second axle shaft,

wherein the first gear ratio, the second gear ratio, and the third gear ratio are different ratios,

wherein the one or more processors are further configured to control the first axle assembly and the second axle assembly independently of each other, and

wherein the one or more processers are further configured to operate the first and second motors such that they drive the first and second axle shafts simultaneously.

19 . The computing system of claim 18 , wherein the one or more processors are further configured to set the first axle assembly and the second axle assembly in a neutral position, independently of each other, the neutral position being a position in which the first axle shaft or the second axle shaft spins without rotating the first electric motor or the second electric motor, respectively.

20 . The computing system of claim 19 , wherein the first axle assembly is configured to be operated in the neutral position while the second axle assembly is operated in the third gear ratio.

21 . The computing system of claim 19 , wherein the second axle assembly is configured to be operated in the neutral position while the first axle assembly is operated in the first gear ratio or the second gear ratio.

22 . The computing system of claim 18 , wherein the one or more processors are further configured to select between the first gear ratio or the second gear ratio for operation based on sensing data.

23 . The computing system of claim 22 , wherein the sensing data includes:

operating conditions including at least one of a speed of the vehicle, an acceleration of the vehicle, a deceleration of the vehicle, or a neutral gear selection; and

driving conditions including at least one of a road gradient or a road surface.