Self-contained axle module

Abstract

A self-contained axle module for a vehicle having a support structure is provided. The self-contained axle includes a housing removably coupled to the support structure and an output shaft extending from the housing. An electric motor is coupled to the housing and drives the output shaft. Two wheel end assemblies coupled to the output shaft, and an independent suspension assembly is coupled between each wheel end assembly and the housing, so that the independent suspension assemblies and the wheel end assemblies and the electric motor and the housing are removable from the vehicle as a unit by detaching the housing from the support structure.

1 . A self-contained axle module with independent suspension for a vehicle, with the vehicle including a support structure, a source for electrical power, and a source of cooling medium, the self-contained axle module comprising:
 a housing configured to be coupled to the support structure;   an output shaft extending from opposite sides of the housing;   an electric motor coupled to the housing and the source for electric power, and operable to rotate the output shaft;   a motor drive controller unit coupled to the electric motor and configured to control at least one of a speed and a torque of the electric motor;   a first wheel end assembly coupled to the output shaft;   a second wheel end assembly coupled to the output shaft;   a first independent suspension assembly coupled to the housing and supporting the first wheel end assembly;   a second independent suspension assembly coupled to the housing and supporting the second wheel end assembly;   wherein, the first and second independent suspension assemblies and the first and second wheel end assemblies and the housing and the electric motor are configured to be removable from the support structure as a unit by removing the housing from the support structure.   
   
   
       2 . The self-contained axle module of  claim 1 , wherein the housing comprises a first side plate and a second side plate configured to be removably coupled to the support structure. 
   
   
       3 . The self-contained axle module of  claim 1 , wherein the electric motor is mounted on the housing at an angle, relative to the plane of the support structure, other than 90 degrees. 
   
   
       4 . The self-contained axle module of  claim 3 , wherein the angle is between 10 degrees and 40 degrees. 
   
   
       5 . The self-contained axle module of  claim 2 , including a skid plate coupled to the first and second side plates and configured to protect the underside portion of the housing. 
   
   
       6 . The self-contained axle module of  claim 1 , including a heat exchanger mounted on the housing and configured to provide cooling for an interior of the housing, with the heat exchanger configured to be coupled to the source of cooling medium. 
   
   
       7 . A vehicle comprising:
 a support structure;   an electric power bus;   at least one self-contained axle module coupled to the support structure; and   wherein each self-contained axle module comprises:   a housing removably coupled to the support structure;   a shaft extending from the housing;   an electric motor coupled to the housing and the electric power bus and operable to drive the shaft;   a first wheel end assembly coupled to the shaft;   a second wheel end assembly coupled to the shaft;   a first suspension assembly independently suspending the first wheel end assembly relative to the housing;   a second suspension assembly independently suspending the second wheel end assembly relative to the housing;   wherein the self-contained axle module is removable as a unit by removing the housing from the support structure.   
   
   
       8 . The vehicle of  claim 7 , further comprising a vehicle controller coupled to the self-contained axle module and the electric power bus. 
   
   
       9 . The vehicle of  claim 8  further comprising a data bus coupled to the self-contained axle module and the vehicle controller. 
   
   
       10 . The vehicle of  claim 8 , further comprising a motor drive controller unit coupled to the electric motor and to the vehicle controller to communicate signals to the vehicle controller so that at least one of a speed and a torque of the electric motor are controlled based upon the signals. 
   
   
       11 . The vehicle of  claim 8 , wherein the vehicle controller is configured to control the electric motor to brake the vehicle. 
   
   
       12 . The vehicle of  claim 7 , wherein the self-contained axle module is removably attachable to the vehicle support structure at any one of a plurality of locations along the support structure. 
   
   
       13 . The vehicle of  claim 7 , wherein the electric motor is configured to regenerate power back to a principal power unit or a power storage unit of the vehicle. 
   
   
       14 . A self-contained and interchangeable axle module for use with a vehicle, the vehicle having a support structure, the axle module comprising:
 a housing removably attachable to the support structure;   an output shaft extending from the housing;   at least one electric motor coupled to the housing and operable to drive the output shaft;   a wheel end assembly coupled to one end of the output shaft;   an independent suspension assembly coupled to the wheel end assembly and the housing;   wherein the independent suspension assembly and the wheel end assembly and the electric motor and the housing are removable from the vehicle as a unit by detaching the housing from the support structure.   
   
   
       15 . The self-contained and interchangeable axle module of  claim 14 , wherein the housing is removably attachable to the support structure at any one of a plurality of locations along the support structure. 
   
   
       16 . The self-contained and interchangeable axle module of  claim 14 , wherein the output shaft comprises a first segment extending outwardly from a first side of the housing and coupled to the first wheel end assembly, and a second segment extending outwardly from a second side of the housing and coupled to the second wheel end assembly. 
   
   
       17 . The self-contained and interchangeable axle module of  claim 14 , wherein the housing comprises a first side plate and a second side plate configured for attachment to the support structure. 
   
   
       18 . The self-contained and interchangeable axle module of  claim 14 , further comprising a power take-off apparatus mounted on the housing. 
   
   
       19 . The self-contained and interchangeable axle module of  claim 14 , further comprising a skid plate coupled to the housing. 
   
   
       20 . The self-contained and interchangeable axle module of  claim 14  further comprising another wheel end assembly coupled to another end of the output shaft, and another suspension assembly coupled to the another wheel end assembly and the housing, so that the independent suspension assemblies and the wheel end assemblies and the electric motor and the housing are removable from the vehicle as a unit by detaching the housing from the support structure.