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Stellantis Granted Patent for Three-Speed Gearbox For EVs

New Gearbox Design Can Be Used For EVs and Hybrids...

Stellantis (FCA US, LLC) continues to push the boundaries of electric vehicle (EV) technology. Following the February 2024 grant of a patent for a two-speed gearbox designed for electric off-road SUVs, the company has now secured another patent—this time for a three-speed gearbox for electric and hybrid vehicles. The new gearbox design, initially filed in August 2023, was officially granted on September 17th, 2024.

Addressing Gearbox Challenges in EVs –

2024 Jeep® Wagoneer S Launch Edition’s Electronic Shifter. (Jeep).

Most EVs today are equipped with single-speed gearboxes. While these systems excel in torque delivery, they can struggle to sustain high torque over long periods or provide a range of speeds, limiting performance, especially on highways. Stellantis’ new three-speed gearbox aims to overcome these challenges by delivering better torque control and a more flexible speed range.

Gearbox Assembly Details –

2024 Jeep® Wagoneer S Launch Edition. (Jeep).

The patent describes a three-speed gearbox assembly for EVs featuring several advanced components:

  • First Planetary Gear Set: This is directly connected to the electric motor output. A first clutch can couple the motor to a second portion of the gear set, while a second clutch can ground this portion to the housing.
  • Second Planetary Gear Set: Connected to the output of the first gear set and linked to the vehicle’s first axle shaft, it transmits power through a carrier, further improving the system’s flexibility.
  • Third Planetary Gear Set: This set connects the output of the second gear set to the vehicle’s second axle shaft. A third clutch grounds this gear set to the housing as necessary, while the fourth clutch provides a locked differential function by connecting the two axle shafts for additional traction control.

The system’s clutches operate in various combinations to enable different gears:

  • First Gear: This gear engages the second and third clutches, providing maximum torque for low-speed operations such as off-road driving.
  • Second Gear: Engages the first and third clutches for balanced power and efficiency in on-road driving.
  • Third Gear: Engages the second and fourth clutches for high-speed efficiency.

Additionally, the fourth clutch allows for locking the first and second axle shafts, which is essential for scenarios requiring enhanced traction, such as off-road driving.

Detailed Gear System Breakdown – 

2024 Dodge Charger Daytona Scat Pack. (Dodge).

The planetary gear sets in the assembly consist of a central “sun” gear, planet gears, and a ring gear. These components work together to manage power transmission efficiently:

  • First Planetary Gear Set: This set comprises a sun gear that can be selectively coupled to the electric motor or grounded via clutches, with a ring gear transferring power to the second planetary gear set.
  • Second Planetary Gear Set: The sun gear connects to the first set’s output, with its carrier linked to the first axle, distributing power to the wheels.
  • Third Planetary Gear Set: This set features a sun gear connected to the output of the second set and a carrier that can be grounded via a clutch. The ring gear is linked to the second axle shaft, completing the power flow to both wheels.

The assembly also includes limited-slip clutches on both axle shafts, which ensure improved traction and handling in diverse driving conditions.

Advantages of the Three-Speed Gearbox –

2024 Dodge Charger Daytona Scat Pack. (Dodge).

This advanced gearbox offers several advantages over traditional single-speed EV gearboxes:

  • Improved Torque Control: The multi-speed design allows for better torque management at low speeds while maintaining efficiency at higher speeds.
  • Enhanced Performance: The gearbox’s locked differential function and flexible gear operation support both off-road and highway driving.
  • Scalability: This design can be adapted to a wide range of electric and hybrid vehicles, providing Stellantis with flexibility in its future EV lineup.

Looking Ahead – 

As the electrified market expands, innovations like Stellantis’ three-speed gearbox will be instrumental in advancing vehicle performance. This patent aims to address the limitations of current EV technology, positioning Stellantis as a leader in developing more versatile and capable electric drivetrains. The automaker can enhance efficiency and power across its evolving lineup by integrating this technology into its future electric and hybrid models.

Source: USPTO

Robert S. Miller

Robert S. Miller is a diehard Mopar enthusiast who lives and breathes all that is Mopar. The Michigander is not only the Editor for MoparInsiders.com, 5thGenRams.com, and HDRams.com but an automotive photographer. He is an avid fan of offshore powerboat racing, which he travels the country to take part in.

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Okay, that's pretty decent news actually. Of course, me being the Dodge fanatic that I am, my first thoughts are of the Charger Daytona Scat Pack and the previous article about the launch control system and a few other things. While I'm not really an EV person for my own personal reasons, this definitely piques my interest a little bit. I already have a feeling this new Charger is going to be the most customizable & performance oriented EV on the road in the next few years and despite what some may think, this car is going to sell and it's going to sell pretty well, in my opinion. It may not be purchased by alot of traditionalists but yeah, it's going to move numbers. A three-speed gearbox will ultimately not only improve performance but also range, which is a big thing for EVs since they're slower to charge that an ICE vehicle and Charging stations aren't as abundant as gas stations. The biggest thing is bringing a more natural feel to EVs by having an actual mechanical gearbox. As it stands, Dodge has the Daytona Charger R/T and Scat Pack, and an upcoming Daytona SRT Charger Banshee. The Banshee is the trim package that is supposed to get a multi-speed transmission but this article and the previous article about Dodge getting the rolling launch control system makes me wonder what is really in store for the electric Mopar muscle cars coming down the line in an actually positive way. The Scat Pack can already out perform the standard Hellcat cars so with that being said, taking this same platform, adding an 800v system which not only produces more power but has an advantage when it comes to charging speeds, then adding a three-speed gearbox that not only boosts performance but also boosts range while adding that feeling back into the driving experience which can be enhanced by drive modes (i.e. SLAM mode), giving it a roll race option along with the other drive modes that it has, more power (potentially having a tri-motor setup), building upon the Daytona's electro-mechanical differential, along with building upon what the Daytona Scat pack already offers and then adding alot SRT baked into this vehicle, where does that actually leave us? I mean let's really think about it for a moment, right on the Dodge website, it explains the car has a lighter, stiffer chassis (even though we all know the EV is a genuine heavyweight car), with a low center of gravity thanks to the battery back and the motors. The car has a nearly balanced weight distribution front to back and brakes bigger than a dinner plate. Let's add to that some of the suspension and chassis technology and wisdoms learned from the Demon and the Demon 170 and maybe even a little bit from the Viper and now you start to see a bit of what this car could truly be. While many consider the Fratzonic chamber to be gimmicky and wrong, having an instrument that gives you the audible feedback that is familiar with a gasoline powered performance car makes a bit of sense when your barreling down the 1320, or flying around Laguna Seca, or just up and down your favorite backroad or stretch of highway, especially if it's tuned to blip or over rev with that V8-reminsicent soundtrack it produces. plus the system also gives a bit of resonance in the car along with a bit of vibration to simulate the feeling of an actual engine under the hood. Now I get it, this isn't everyone's cup of tea or shot of whiskey, but for an EV, this is pretty dang awesome. The other thing is, what is direct connection going to offer for these cars, outside of the Stage kits? These cars are all about style and performance so again that opens up the door for anything from hoods, spoilers, wheels, graphics, front lips, side splitters, under body pannels, diffusers, interior upgrades, suspension upgrades, brake caliper upgrades, etc. And as always, but wait, there's more. Dodge has the rumored Stealth SUV coming out on this platform which is geared to be a performance oriented SUV replacing the Durango. How much of this will trickle into that. Then there is the Wagoneer S which is constantly compared to the Grand Cherokee Trackhawk. Will there be an SRT-E Wagoneer S coming down the pipeline with this 800V system and all kinds of goodies? Time will Tell. This article also specifically mentions about this gearbox being versatile enough for off road performance. Jeep had the upcoming Recon on the STLA: Large platform, which could receive this 3-speed gearbox as well. You figure, anything on the STLA Large platform can receive some level of SRT treatment or Direct Connection treatment or some kind of Jeep performance off road treatment and anything on this platform can get the 800V system so there is major potential for these vehicles to stand out and be engaging and organic, which would set them apart from any mainstream EV out there. Not to mention, what does this do for the Ram 1500 REV or even the Ramcharger pickup trucks? How might this positively effect range and towing, especially on the Ramcharger. You already have the 3.6L range extender on board and then add this to the equation and now you have an EV pickup that checks off alot more boxes when it comes to performance like a Ram pickup truck should. Also, since EVs are being mandated to have sound, what happens when pretty much all Mopar vehicles have a variation of the Fratzonic chamber on them and 3-speed gearboxes? We now have EVs that look like a Dodge, SOUND like a Dodge and drive like a Dodge. Will this take the place of ICE vehicles, not at all. But it does open up the market for a wider range of buyers that should enhance the Mopar brands and make them more profitable. I think with this, plus the Hurricane-6 cars and hopefully soon Hurricane-6 hybrid & some real performance Hurricane-4 hybrid Mopars, we're truly going to see a world of performance we couldn't have imagined before.

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