Disconnecting axle assembly

• US 10,487,889 B2
• Filed: 03/24/2017
• Issued: 11/26/2019
• Est. Priority Date: 03/25/2016
• Status: Active Grant

• Current Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: American AXLE & Manufacturing Incorporated (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Valente, Paul J., Downs, James P.
• Primary Examiner(s): Wright, Dirk
• Application Number:
  US16/077,202
• Publication Number:
  US 20190024731A1
• Time in Patent Office: 977 Days
• Field of Search: None
• CPC Class Codes: B60K 17/165 provided between independent half axles B60K17/18, B60K17/20 take precedence
• CPC Class Codes: B60K 17/35 including arrangements for suppressing or influencing the power transfer, e.g. viscous clutches differential gearing with locking devices F16H48/20
• CPC Class Codes: F16D 13/52 Clutches with multiple lamellae ; Clutches in which three or more axially moveable members are fixed alternately to the shafts to be coupled and are pressed from one side towards an axially-located member F16D13/385 takes precedence
• CPC Class Codes: F16D 13/74 Features relating to lubrication
• CPC Class Codes: F16D 2300/06 Lubrication details not provided for in group F16D13/74
• CPC Class Codes: F16D 25/082 the line of action of the fluid-actuated members co-inciding with the axis of rotation
• CPC Class Codes: F16D 25/123 in view of cooling and lubrication
• CPC Class Codes: F16D 43/28 actuated by fluid pressure
• CPC Class Codes: F16H 2057/02052 Axle units; Transfer casings for four wheel drive
• CPC Class Codes: F16H 2057/02086 Measures for reducing size of gearbox, e.g. for creating a more compact transmission casing
• CPC Class Codes: F16H 48/10 with orbital spur gears
• CPC Class Codes: F16H 48/22 using friction clutches or brakes
• CPC Class Codes: F16H 48/32 using fluid pressure actuators
• CPC Class Codes: F16H 57/031 characterised by covers or lids for gearboxes
• CPC Class Codes: F16H 57/037 Gearboxes for accommodating differential gearings rotating cases for differential gearings F16H48/40
• CPC Class Codes: F16H 57/0404 Lubricant filters
• CPC Class Codes: F16H 57/0424 Lubricant guiding means in the wall of or integrated with the casing, e.g. grooves, channels, holes means for guiding lubricant into an axial channel of a shaft F16H57/0426
• CPC Class Codes: F16H 57/043 within rotary parts, e.g. axial channels or radial openings in shafts
• CPC Class Codes: F16H 57/0431 Means for guiding lubricant directly onto a tooth surface or to foot areas of a gear, e.g. by holes or grooves in a tooth flank
• CPC Class Codes: F16H 57/0441 Arrangements of pumps
• CPC Class Codes: F16H 57/0446 : the supply forming part of the transmission control unit, e.g. for automatic transmissions
• CPC Class Codes: F16H 57/0452 : Oil pans
• CPC Class Codes: F16H 57/0471 : Bearing
• CPC Class Codes: F16H 57/0473 : Friction devices, e.g. clutches or brakes
• CPC Class Codes: F16H 57/0479 : Gears or bearings on planet carriers
• CPC Class Codes: F16H 57/0483 : Axle or inter-axle differentials

Abstract

A disconnecting axle includes a housing assembly including a first end cap coupled to a first side of a housing member to define a clutch cavity, and a second end cap coupled to a second side of the housing member to define a differential cavity. The housing member can define a central bore, a sump, and a plurality of passages. The central bore extends axially between the clutch and differential cavities. The sump can be spaced apart from the clutch and differential cavities, and the central bore. A clutch passage couples the clutch cavity to the sump. A differential passage couples the differential cavity to the sump. A first output member of the differential extends axially within the central bore. A piston is configured to compress friction plates to selectively transmit torque. A pump can pump fluid from the sump to the cylinder to move the piston.

Claims

1. A disconnecting axle assembly comprising:

a housing assembly including a first end cap, a second end cap, a sump cover, and a housing member, the housing member defining a central bore, a clutch return passage, and a differential return passage, the first end cap being fixedly coupled to a first side of the housing member such that the first end cap and the housing member define a clutch cavity, the second end cap being fixedly coupled to a second side of the housing member such that the second end cap and the housing member define a differential cavity spaced apart from the clutch cavity, the central bore being disposed about an output axis and extending axially between the clutch cavity and the differential cavity, the sump cover being fixedly coupled to a third side of the housing member such that the sump cover and the housing member define a sump that is spaced apart from the clutch cavity, the differential cavity, and the central bore, the clutch return passage coupling the clutch cavity to the sump in fluid communication, and the differential return passage coupling the differential cavity to the sump in fluid communication;

a differential disposed within the differential cavity, the differential including an input member, a first output member, and a second output member, the first output member being supported within the housing assembly for rotation about the output axis and extending axially within the central bore; and

a clutch including a plurality of friction plates disposed within the clutch cavity and an actuator, a first set of the friction plates being coupled to the first output member for common rotation about the output axis, a second set of the friction plates being interleaved with the first set and coupled to a third output member for common rotation about the output axis, the actuator including a pump and a piston slidably disposed in a cylinder, the piston being configured to axially compress the friction plates to selectively transmit torque between the first and third output members, the pump being coupled to the housing assembly and configured to pump fluid from the sump to the cylinder.

2. The disconnecting axle assembly of claim 1, wherein the clutch return passage has a first aperture open to the clutch cavity proximate to a bottom of the clutch cavity and the clutch return passage is open to the sump at a location below the first aperture, and wherein the differential return passage has a second aperture open to the differential cavity proximate to a bottom of the differential cavity and the differential return passage is open to the sump at a location that is below the second aperture.

3. The disconnecting axle assembly of claim 1, wherein the housing member further defines a bore return passage having an inlet open to the central bore and an outlet open to the sump, the inlet of the bore return passage being above the outlet of the bore return passage.

4. The disconnecting axle assembly of claim 1, wherein the clutch includes a first clutch portion and a second clutch portion, the first friction plates being axially slidable relative to the first clutch portion and coupled for common rotation about the output axis with the first clutch portion, the second friction plates being axially slidable relative to the second clutch portion and coupled for common rotation about the output axis with the second clutch portion, the first clutch portion being fixedly coupled to the first output member and including a projection that extends radially outward to inhibit movement of the first and second clutch plates in a first axial direction to retain the first and second clutch plates between the first and second clutch portions.

5. The disconnecting axle assembly of claim 1, wherein the housing member further defines an air balance passage, the air balance passage extending axially between the clutch cavity and the differential cavity and being spaced apart from the central bore and open to the clutch cavity and the differential cavity above the output axis.

6. The disconnecting axle assembly of claim 5, wherein the housing member defines a bleed port open to the cylinder and the air balance passage and configured to restrict flow of fluid from the cylinder to a flowrate that is less than a flowrate of fluid pumped from the sump to the cylinder.

7. The disconnecting axle assembly of claim 1, wherein the differential includes a differential gearset configured to receive input torque from the input member and output differential torque to the first and second output members.

8. The disconnecting axle assembly of claim 7, wherein the differential gearset is a planetary gearset including an internal gear, a planet carrier, a plurality of planet gears, and a sun gear, wherein the input member of the differential is fixedly coupled to the internal gear, the first output is fixedly coupled to the planet carrier, and the second output is fixedly coupled to the sun gear.

9. The disconnecting axle assembly of claim 8, wherein the first output member includes a tubular shaft and a flange member, wherein a first end of the flange member includes a plurality of splines that meshingly engage a plurality of mating splines on the tubular shaft within the central bore, and a second end of the flange member is disposed within the differential cavity and extends radially outward of the first end of the flange member and is fixedly coupled to the planet carrier.

10. The disconnecting axle assembly of claim 9, wherein the sun gear includes a hub member that is supported by the first output member by a bearing disposed radially between the first output member and the hub member.

11. The disconnecting axle assembly of claim 1, further comprising a hypoid gear and an input pinion, the input member of the differential being fixedly coupled to the hypoid gear, the input pinion being meshingly engaged with the hypoid gear and being rotatably supported by the housing member for rotation about a second axis that is transverse to the output axis.

12. The disconnecting axle assembly of claim 11, further comprising a head bearing disposed within a bearing recess defined by the housing member, the head bearing supporting the input pinion for rotation relative to the housing member, wherein the housing member further defines a pinion return passage that couples the bearing recess and the central bore in fluid communication.

13. A disconnecting axle assembly comprising:

a housing assembly including a first end cap, a second end cap, a sump cover, and a housing member, the housing member defining a central bore, a clutch supply passage, and a clutch return passage, the first end cap being fixedly coupled to a first side of the housing member such that the first end cap and a first annular wall of the housing member define a clutch cavity, the second end cap being fixedly coupled to a second side of the housing member such that the second end cap and a second annular wall of the housing member define a differential cavity spaced apart from the clutch cavity, the central bore being disposed about an output axis and extending axially between the first and second annular walls to couple the clutch cavity and the differential cavity for fluid communication, the sump cover being fixedly coupled to a third side of the housing member such that the sump cover and the housing member define a sump that is spaced apart from the clutch cavity, the differential cavity, and the central bore, the housing member including a third annular wall and a fourth annular wall that extend axially from the first annular wall to define an annular cylinder, the clutch supply passage being open through the first annular wall radially between the third and fourth annular walls to be in fluid communication with the annular cylinder, the clutch return passage being open through the first annular wall radially outward of the annular cylinder and coupling the clutch cavity to the sump for fluid communication;

a differential disposed within the differential cavity, the differential including an input member, a first output member, and a second output member, the first output member being supported within the housing assembly for rotation about the output axis and extending axially within the central bore; and

a clutch including a plurality of friction plates disposed within the clutch cavity and an actuator, a first set of the friction plates being coupled to the first output member for common rotation about the output axis, a second set of the friction plates being interleaved with the first set and coupled to a third output member for common rotation about the output axis, the actuator including a piston and a pump, the piston being slidably disposed in the annular cylinder, the piston being configured to axially compress the friction plates to selectively transmit torque between the first and third output members, the pump having an inlet in fluid communication with the sump and an outlet in fluid communication with the clutch supply passage.

14. The disconnecting axle assembly of claim 13, wherein the clutch return passage has a first aperture open to the clutch cavity proximate to a bottom of the clutch cavity and the clutch return passage is open to the sump at a location below the first aperture.

15. The disconnecting axle assembly of claim 13, wherein the housing member defines a differential return passage that has a first aperture open to the differential cavity proximate to a bottom of the differential cavity and the differential return passage is open to the sump at a location that is below the first aperture.

16. The disconnecting axle assembly of claim 13, wherein the housing member further defines a bore return passage having an inlet open to the central bore and an outlet open to the sump, the inlet of the bore return passage being above the outlet of the bore return passage.

17. The disconnecting axle assembly of claim 13, wherein the clutch includes a first clutch portion and a second clutch portion, the first friction plates being axially slidable relative to the first clutch portion and coupled for common rotation about the output axis with the first clutch portion, the second friction plates being axially slidable relative to the second clutch portion and coupled for common rotation about the output axis with the second clutch portion, the first clutch portion being fixedly coupled to the first output member and including a projection that extends radially outward to inhibit movement of the first and second clutch plates in a first axial direction to retain the first and second clutch plates between the first and second clutch portions.

18. The disconnecting axle assembly of claim 13, wherein the housing member further defines an air balance passage and a bleed port, the air balance passage being spaced apart from the central bore and open through the first and second annular walls to couple the clutch cavity and the differential cavity for fluid communication above the output axis, the bleed port being open through the first annular wall radially between the third and fourth annular walls to be open to the annular cylinder, the bleed port further being open to the air balance passage and configured to restrict flow of fluid from the cylinder to a flowrate that is less than a flowrate of fluid pumped from the sump to the cylinder.

19. The disconnecting axle assembly of claim 13, wherein the differential includes a planetary gearset including an internal gear, a planet carrier, a plurality of planet gears, and a sun gear, wherein the input member of the differential is fixedly coupled to the internal gear, the first output is fixedly coupled to the planet carrier, and the second output is fixedly coupled to the sun gear.

20. The disconnecting axle assembly of claim 19, wherein the first output member includes a tubular shaft and a flange member, wherein a first end of the flange member includes a plurality of splines that meshingly engage a plurality of mating splines on the tubular shaft within the central bore, and a second end of the flange member is disposed within the differential cavity and extends radially outward of the first end of the flange member and is fixedly coupled to the planet carrier.