Abstract: An oil pan is attached to a motor to form an oil sump. An oil sump can have one or more valves. Oil can buoy a rotatably mounted valve member into a closed position, and gravity can rotate the valve into an open position. A valve can have a stadium shape. Valves can be placed symmetrically or asymmetrically with regard to a forward-reverse travel direction axis or to a left-right lateral acceleration axis. A bulbous portion of a valve member can enclose an air cavity and can extend into a valve opening. A valve can be placed at an oil pickup, wherein oil can buoy the valve to an open position and otherwise the valve member can be rotated to a closed position.

Abstract: A multi-motor electric-vehicle drive unit system comprises: a first drive unit comprising: a first motor casing; a first oil reservoir mounted to a bottom of the first motor casing; and a first inverter mounted to the first motor casing, wherein the first drive unit is installed so that the first inverter has a first orientation; and a second drive unit comprising: a second motor casing, wherein the second motor casing is identical to the first motor casing; a second oil reservoir mounted to a bottom of the second motor casing, wherein the second oil reservoir has a different shape than the first oil reservoir; and a second inverter mounted to the second motor casing, wherein the second drive unit is installed so that the second inverter has a second orientation, the second orientation different from the first orientation.

Abstract: A dual axial cooling system for an electric motor includes a cover assembly provided at first and second axial ends of a stator of the electric motor. Each cover assembly includes a first side portion that is oriented so as to face an interior of the stator, with a plurality of holes formed in the first side portion. A second side portion is coupled to the first side portion, so that a passage is formed between the first and second side portions. A supply nozzle portion is in fluid communication with the plurality of openings via the passage defined between the first and second side portions. The plurality of openings receive cooling fluid from the supply nozzle portion, and discharge the cooling fluid in an axial direction, from each axial end portion of the stator, to provide axial cooling in two axial directions into the stator.

Abstract: A motor for a vehicle comprises: a motor housing; an oil sump mounted to the motor for oil to drain from the motor housing into the oil sump, a width of the oil sump being greater than a depth of the oil sump, the oil sump having an oil pickup for circulating the oil; and a valve member mounted at a pivot point inside the oil sump, the valve member enclosing an air cavity for buoyancy, wherein the valve member is configured to rotate about the pivot point due to being buoyed by the oil.

Abstract: A drive unit system for an axle of an electric vehicle comprises: a first drive unit comprising a first rotor inside a first stator; a first transmission for a first wheel of the axle, the first transmission having a first input shaft coupled to a first gear having a first helix angle; a second transmission for a second wheel of the axle, the second transmission having a second input shaft coupled to a second gear having a second helix angle opposite to the first helix angle; and a coupling connecting the first and second input shafts to each other.

Abstract: A motor for a vehicle comprises: a motor housing; an oil sump mounted to the motor for oil to drain from the motor housing into the oil sump, a width of the oil sump being greater than a depth of the oil sump, the oil sump having an oil pickup for circulating the oil; and a valve member mounted at a pivot point inside the oil sump, the valve member enclosing an air cavity for buoyancy, wherein the valve member is configured to rotate about the pivot point due to being buoyed by the oil.

Abstract: A constant velocity joint for use in a vehicle and a method of mounting a constant velocity joint including a splined shaft. The constant velocity joint also includes an O-ring gland, an inner race, an outer race, rolling elements, and a boot. The splined shaft of the constant velocity joint transmits torque from a splined hub of a second rotating element.

Abstract: Methods and systems are provided for cooling an electric motor. In embodiments, the cooling jacket includes a helical channel having a coolant inlet and a coolant outlet. The pitch of the helical channel decreases along an axial dimension of the helical channel, such that the pitch, and thus the cross-sectional area available for flow of the coolant, is greatest at or near the coolant inlet and smallest at or near the coolant outlet. The cooling jacket also includes flow-through loops associated with the first and final turns of the helical channel to allow coolant to circulate about entry and exit portions of the motor multiple times.

Abstract: A modular gearbox unit and drive system are provided. The modular gearbox unit and drive system may be part of a vehicle platform having multiple drivetrain mount areas including identical mount features disposed at each mount area. Each drivetrain mount area can receive a modular single-motor drive unit or a modular multiple-motor drive unit using the same mount or bolt pattern and features. These modular single-motor and multiple-motor drive units have a common bolt pattern and mating features that correspond to the mount features of the vehicle platform and/or vehicle frame. The modular gearbox unit and drive system allows a vehicle powertrain to be reconfigured, during or after assembly, quickly and easily using the same mount points.

Abstract: A system and method for automatic oil exchange service for electric vehicle gearboxes. The system and method includes a mechanism for monitoring and reporting status of the oil change in the gearbox. This ensures that each oil change is kept track of, that the oil is the correct grade, and that the vehicle ends up with oil that has maximum properties, avoiding contamination and improving the life of the gearbox. The present invention may be integrated directly at the same place as an electric vehicle charging station, supercharger station, or at any battery swap station.

Abstract: A compact side-by-side motor gearbox unit is provided. The motor gearbox unit includes two independent electric motors and gearboxes with motor drive shafts and gearbox power output shafts mounted in opposite directions, the motors are held in a shared housing. The drive shafts of each electric motor in the motor gearbox unit are offset from one another and not colinear with one another. The power output shafts of the gearboxes are aligned along a common power output axis providing a half-shaft connection to a drive wheel on one side of the motor gearbox unit and a different half-shaft connection to another drive wheel on the other side of the motor gearbox unit.

Abstract: Methods and systems for controlling noise in multiple motor gearbox drive units having a common housing are provided. The disclosure describes adjusting an angular position of a drive element of a first motor drive unit relative to the angular position of a drive element of a second motor drive unit in a multiple motor gearbox drive unit. This adjustment to the relative angular position of the drive elements shifts the phase angle of noise sound waves generated by the first and second motor drive units in the multiple motor gearbox drive unit. In some cases, the phase angle shift causes a noise sound wave generated by the first motor drive unit to cancel a noise sound wave generated by the second motor drive unit thereby reducing the overall noise emitted from the common housing of the multiple motor gearbox drive unit while operating.

Abstract: A constant velocity joint for use in a vehicle and a method of mounting a constant velocity joint including a splined shaft. The constant velocity joint also includes an O-ring gland, an inner race, an outer race, rolling elements, and a boot. The splined shaft of the constant velocity joint transmits torque from a splined hub of a second rotating element.

Abstract: Methods and systems for controlling noise in multiple motor gearbox drive units having a common housing are provided. The disclosure describes adjusting an angular position of a drive element of a first motor drive unit relative to the angular position of a drive element of a second motor drive unit in a multiple motor gearbox drive unit. This adjustment to the relative angular position of the drive elements shifts the phase angle of noise sound waves generated by the first and second motor drive units in the multiple motor gearbox drive unit. In some cases, the phase angle shift causes a noise sound wave generated by the first motor drive unit to cancel a noise sound wave generated by the second motor drive unit thereby reducing the overall noise emitted from the common housing of the multiple motor gearbox drive unit while operating.

Abstract: A modular gearbox unit and drive system are provided. The modular gearbox unit and drive system may be part of a vehicle platform having multiple drivetrain mount areas including identical mount features disposed at each mount area. Each drivetrain mount area can receive a modular single-motor drive unit or a modular multiple-motor drive unit using the same mount or bolt pattern and features. These modular single-motor and multiple-motor drive units have a common bolt pattern and mating features that correspond to the mount features of the vehicle platform and/or vehicle frame. The modular gearbox unit and drive system allows a vehicle powertrain to be reconfigured, during or after assembly, quickly and easily using the same mount points.

Abstract: Packaging for transmissions with an epicyclic gearbox speed reducer and oil pump is provided. Packaging comprises an epicyclic/planetary gearbox or single stage gear reducer with a sun gear, ring unit, and one or more planetary gears on the ring unit, and an oil pump located inside the packaging. The oil pump may be driven directly by a carrier, or driven by a carrier using a gear stage set. This configuration provides a tighter packaging of the full assembly of an epicyclic/planetary gearbox for transmissions with an internal oil pump, which reduces the weight of the unit, provides lubrication, and avoids splashing. The pump packaging may also be particularly valuable for electric vehicle (“EV”) independent motor applications.

Abstract: A compact side-by-side motor gearbox unit is provided. The motor gearbox unit includes two independent electric motors and gearboxes with motor drive shafts and gearbox power output shafts mounted in opposite directions, the motors are held in a shared housing. The drive shafts of each electric motor in the motor gearbox unit are offset from one another and not colinear with one another. The power output shafts of the gearboxes are aligned along a common power output axis providing a half-shaft connection to a drive wheel on one side of the motor gearbox unit and a different half-shaft connection to another drive wheel on the other side of the motor gearbox unit.

Abstract: Packaging for transmissions with an epicyclic gearbox speed reducer and oil pump is provided. Packaging comprises an epicyclic/planetary gearbox or single stage gear reducer with a sun gear, ring unit, and one or more planetary gears on the ring unit, and an oil pump located inside the packaging. The oil pump may be driven directly by a carrier, or driven by a carrier using a gear stage set. This configuration provides a tighter packaging of the full assembly of an epicyclic/planetary gearbox for transmissions with an internal oil pump, which reduces the weight of the unit, provides lubrication, and avoids splashing. The pump packaging may also be particularly valuable for electric vehicle (“EV”) independent motor applications.

Abstract: A system and method for automatic oil exchange service for electric vehicle gearboxes. The system and method includes a mechanism for monitoring and reporting status of the oil change in the gearbox. This ensures that each oil change is kept track of, that the oil is the correct grade, and that the vehicle ends up with oil that has maximum properties, avoiding contamination and improving the life of the gearbox. The present invention may be integrated directly at the same place as an electric vehicle charging station, supercharger station, or at any battery swap station.

Abstract: A gear assembly can include a biasing apparatus, which can include a hydraulic biasing member. The biasing apparatus can be activated to urge a scissor gear tooth of a scissor gear toward a second gear tooth of a second gear. The urging of the scissor gear tooth toward the second gear tooth can close a backlash gap between a first gear tooth of a first gear and the second gear tooth of the second gear.