Wheel assembly with integral electric motor

1. An electric drive wheel assembly ( 20 ) for a vehicle, said assembly ( 20 ) comprising;

a non-rotating spindle ( 26 ) having a first end ( 28 ) for attachment to the vehicle and a second end ( 30 ) spaced from said first end ( 28 ) along a rotational axis (R),

an electric motor ( 22 ) concentric with said spindle ( 26 ) and including a stator ( 34 ) surrounding and secured to said spindle ( 26 ) and a rotor ( 36 ) concentric with said stator ( 34 ) and rotatable about said rotational axis (R) relative to said stator ( 34 ),

said stator ( 34 ) and said rotor ( 36 ) extending a predetermined axial distance (D) along said rotational axis (R),

a carrier ( 54 ) rotatably connected to said spindle ( 26 ) for rotation about said rotational axis (R),

a wheel drive ( 52 ) attached to said carrier ( 54 ) for rotation therewith about said rotational axis (R), and

a planetary gear system ( 62 ) disposed adjacent said carrier ( 54 ) and said wheel drive ( 52 ) for transmitting rotational movement of said rotor ( 36 ) to said carrier ( 54 ),

said assembly ( 20 ) characterized by said wheel drive ( 52 ), said planetary gear system ( 62 ), and said carrier ( 54 ) being interconnected to define a gearbox unit ( 84 ) and said assembly ( 20 ) including a fastener ( 86 ) for removably attaching said gearbox unit ( 84 ) to said spindle ( 26 ) adjacent said second end ( 30 ) of said spindle ( 26 ).

2. An assembly ( 20 ) as set forth in claim 1 wherein said gearbox unit ( 84 ) is at least partially disposed within said predetermined axial distance (D).

3. An assembly ( 20 ) as set forth in claim 1 wherein said planetary gear system ( 62 ) includes a ring gear ( 68 ) non-rotatably attached to said spindle ( 26 ) adjacent said second end ( 30 ) of said spindle ( 26 ).

4. An assembly ( 20 ) as set forth in claim 3 wherein said planetary gear system ( 62 ) includes a sun gear ( 64 ), a plurality of planetary gears ( 66 ), and said ring ( 68 ) gear with said sun gear ( 64 ) engaging said plurality of planetary gears ( 66 ) and said plurality of planetary gears ( 66 ) engaging said ring gear ( 68 ) for reducing rotational speed between said rotor ( 36 ) and said wheel drive ( 52 ).

5. An assembly ( 20 ) as set forth in claim 4 wherein each of said plurality of planetary gears ( 66 ) includes a pin ( 70 ) having a planetary axis (P) for attaching said planetary gear ( 66 ) to said carrier ( 54 ) and further including a planetary bearing ( 72 ) radially disposed between said planetary gear ( 66 ) and said pin ( 70 ) for rotatably supporting said planetary gear ( 66 ) on said pin ( 70 ) for rotation about said planetary axis (P).

6. An assembly ( 20 ) as set forth in claim 4 further including a rotor support ( 40 ) rotatably supported on said spindle ( 26 ) for rotatably supporting said rotor ( 36 ) for rotation about said rotational axis (R).

7. An assembly ( 20 ) as set forth in claim 6 wherein said gear box unit ( 84 ) is disposed about said spindle ( 26 ) between said rotor support ( 40 ) and said second end ( 30 ) of said spindle ( 26 ).

8. An assembly ( 20 ) as set forth in claim 6 wherein said sun gear ( 64 ) includes splined portion ( 76 ) extending axially along said rotational axis (R) and disposed radially about said spindle ( 26 ), and said rotor support ( 40 ) includes a collar ( 42 ) extending axially along said rotational axis (R) and disposed radially about said spindle ( 26 ) for mechanically engaging said sun gear ( 64 ) for transmitting rotational movement therebetween about said rotational axis (R).

9. An assembly ( 20 ) as set forth in claim 1 wherein said carrier ( 54 ) includes a bearing surface ( 78 ) and said gearbox unit ( 84 ) includes at least one hub bearing ( 82 ) disposed between said bearing surface ( 78 ) and said splined portion ( 76 ) of said sun gear ( 64 ).

10. An assembly ( 20 ) as set forth in claim 1 wherein said gearbox unit ( 84 ) includes a rear cover ( 90 ) attached to said carrier ( 54 ).

11. An assembly ( 20 ) as set forth in claim 10 wherein said gearbox unit ( 84 ) includes a flexible member ( 92 ) disposed between said rear cover ( 90 ) and said carrier ( 54 ) for expanding and contracting in response to an internal pressure.

12. An assembly ( 20 ) as set forth in claim 11 wherein said flexible member defines an interior chamber ( 94 ) and an outer chamber ( 96 ) and said rear cover ( 90 ) includes a port ( 98 ) in fluid communication with said outer chamber ( 96 ) for allowing air to flow freely into and out of said outer chamber ( 96 ) as said flexible member expands and contracts.

13. An assembly ( 20 ) as set forth in claim 12 wherein said gearbox unit ( 84 ) includes a front cover bearing ( 60 ) disposed between said front cover ( 56 ) and said spindle ( 26 ) for rotatably supporting said front cover ( 56 ) on said spindle ( 26 ).

14. An assembly ( 20 ) as set forth in claim 1 wherein said wheel drive ( 52 ) includes a front cover ( 56 ) attached to said carrier ( 54 ) for rotation therewith about said rotational axis (R).

15. An assembly ( 20 ) as set forth in claim 14 wherein said front cover ( 56 ) includes a heat absorbing material for absorbing heat from within said gearbox unit ( 84 ).

16. An assembly ( 20 ) as set forth in claim 1 wherein said fastener ( 86 ) includes a retaining nut ( 88 ) in threaded engagement with said second end ( 30 ) of said spindle ( 26 ).

17. An assembly ( 20 ) as set forth in claim 1 wherein said gearbox unit ( 84 ) includes a lubricant for lubricating said planetary gear system ( 62 ) and a plurality of seals ( 100 ) for sealing said lubricant within said gearbox.