Granted Patent B1

US 12,636,945 · App. 19/038,408 · Granted May 26, 2026

Inventors: Eric M. Engerman (Plymouth, MI); Trent Windom (Waterville, OH)

Assignee: DANA AUTOMOTIVE SYSTEMS GROUP, LLC

B60K6/365B60K6/383B60K6/387B60K6/405

Abstract

Claims (65)

1 . A hybrid electric axle system, comprising:

an engine interface assembly comprising:

a one-way clutch rotationally coupled to an input shaft and a gear set that is rotationally coupled to a differential; and

a dog clutch configured to selectively rotationally couple the input shaft and a gear shaft in the gear set;

wherein the input shaft includes a mechanical interface that is configured to receive mechanical power from an internal combustion engine; and

an electric drive assembly including a traction motor that is rotationally coupled to a gear train;

wherein the gear train is rotationally coupled to the differential;

wherein the engine interface assembly and the electric drive assembly are packaged in an axle housing; and

wherein a rotational axis of the engine interface assembly is arranged perpendicular to a rotational axis of the traction motor.

2 . The hybrid electric axle system of claim 1 , wherein:

the dog clutch includes a lock ring with teeth that mate with teeth in the gear shaft; and

the teeth in the lock ring include leading faces that are chamfered.

3 . The hybrid electric axle system of claim 2 , wherein the dog clutch includes an indexing ball and spring that are arranged in a recess in the input shaft.

4 . The hybrid electric axle system of claim 1 , wherein the gear train includes a first planetary gear set that is rotationally coupled to the traction motor and a second planetary gear set that is rotationally coupled to the differential.

5 . The hybrid electric axle system of claim 4 , wherein the first planetary gear set and the second planetary are simple planetary gear sets that each include a grounded ring gear.

6 . The hybrid electric axle system of claim 5 , wherein the traction motor is arranged coaxial to the differential.

7 . The hybrid electric axle system of claim 1 , wherein the one-way clutch is a sprag clutch.

8 . The hybrid electric axle system of claim 1 , wherein the differential is an electronic locking differential.

9 . A method for operation of a hybrid electric axle system, comprising:

selectively rotationally coupling an input shaft and a gear shaft in a gear set via a dog clutch, in response to engagement of a one-way clutch in an engine interface assembly;

wherein the hybrid electric axle system comprises:

the engine interface assembly comprises:

the one-way clutch rotationally coupled to the input shaft and the gear shaft in the gear set that is rotationally coupled to a differential; and

the dog clutch configured to selectively rotationally couple the input shaft and the gear shaft in the gear set;

wherein the input shaft includes a mechanical interface that is configured to receive mechanical power from an internal combustion engine; and

an electric drive assembly including a traction motor that is rotationally coupled to a gear train;

wherein the gear train is rotationally coupled to the differential;

wherein the engine interface assembly and the electric drive assembly are packaged in an axle housing; and

wherein the gear train includes a first simple planetary gear set that is rotationally coupled to the traction motor and a second simple planetary gear set that is rotationally coupled to the differential.

10 . The method of claim 9 , further comprising engaging a parking gear that is directly coupled to the gear shaft.

11 . The method of claim 9 , wherein:

the dog clutch includes a lock ring with teeth that mate with teeth in the gear shaft;

the teeth in the lock ring include leading faces that are chamfered; and

the dog clutch includes an indexing ball and spring that are arranged in a recess in the input shaft.

12 . The method of claim 9 , wherein:

a first ring gear in the first simple planetary gear set is grounded;

a second ring gear in the second simple planetary gear set is grounded;

a sun gear in the first simple planetary gear set is rotationally coupled to a rotor shaft of the traction motor; and

a carrier in the second simple planetary gear set is rotationally coupled to the differential.

13 . The method of claim 12 , wherein:

the traction motor is arranged coaxial to the differential; and

the engine interface assembly is arranged perpendicular to the traction motor.

14 . A hybrid electric axle system, comprising:

an engine interface assembly comprising:

a sprag clutch rotationally coupled to an input shaft and a gear shaft in gear set that is rotationally coupled to a differential; and

a dog clutch configured to selectively rotationally couple the input shaft and the gear shaft in the gear set;

wherein the input shaft includes a mechanical interface that is configured to receive mechanical power from an internal combustion engine; and

an electric drive assembly including a traction motor that is rotationally coupled to a gear train;

wherein the gear train is rotationally coupled to the differential;

wherein the engine interface assembly and the electric drive assembly are packaged in an axle housing; and

wherein the input shaft is transversely arranged in relation to the traction motor.

15 . The hybrid electric axle system of claim 14 , wherein:

the dog clutch includes a lock ring with teeth that mate with teeth in the gear;

the teeth in the lock ring include leading faces that are chamfered; and

the dog clutch includes an indexing ball and spring that are arranged in a recess in the input shaft.

16 . The hybrid electric axle system of claim 14 , wherein:

a first ring gear in the first simple planetary gear set is grounded;

a second ring gear in the second simple planetary gear set is grounded.

17 . The hybrid electric axle system of claim 16 , wherein:

a first sun gear in the first simple planetary gear set is rotationally coupled to a rotor shaft of the traction motor; and

a first carrier is rotationally coupled to a second sun gear in the second simple planetary gear set; and

a second carrier in the second simple planetary gear set is rotationally coupled to the differential.

18 . The hybrid electric axle system of claim 17 , wherein:

the traction motor is arranged coaxial to the differential; and

the engine interface assembly is arranged perpendicular to the traction motor.

Assignments (1)

References Cited (12)