Powertrain configurations for two-motor, two-clutch hybrid electric vehicles

• US 10,369,878 B2
• Filed: 07/14/2016
• Issued: 08/06/2019
• Est. Priority Date: 02/08/2013
• Status: Active Grant

• Current Assignee: Cummins Electrified Power NA Inc. (Cummins Incorporated)
• Original Assignee: Cummins Electrified Power NA Inc. (Cummins Incorporated)
• Inventors: Frank, Andrew, Ferchau, Joerg, Fahreddin, Leonhard, Razo, Julio, Kumar, Krishna, Serra, Anthony
• Primary Examiner(s): Young, Edwin A
• Application Number:
  US15/210,002
• Publication Number:
  US 20160347164A1
• Time in Patent Office: 1,118 Days
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/405 Housings
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 20/20 Control strategies involving selection of hybrid configuration, e.g. selection between series or parallel configuration
• CPC Class Codes: B60Y 2200/92 Hybrid vehicles
• CPC Class Codes: B60Y 2300/182 Selecting between different operative modes, e.g. comfort and performance modes
• CPC Class Codes: B60Y 2400/60 Electric Machines, e.g. motors or generators
• CPC Class Codes: B60Y 2400/82 Four wheel drive systems
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 90/14 Plug-in electric vehicles
• CPC Class Codes: Y10S 903/906 Motor or generator
• CPC Class Codes: Y10S 903/916 with plurality of drive axles
• CPC Class Codes: Y10S 903/93 Conjoint control of different elements
• CPC Class Codes: Y10S 903/952 Housing details

Abstract

Powertrain configurations for hybrid electric vehicles (HEV) and plug-in hybrid electric vehicles (PHEV) are disclosed herein. One powertrain comprises: a prime mover; an electric motor-generator, said electric motor-generator mechanically coupled to said prime mover via a first clutch; an electric motor, said electric motor mechanically coupled to said electric motor-generator via a second clutch; a battery, said battery electrically coupled to said electric motor-generator and said electric motor, said battery capable of supplying electrical energy to said electric motor-generator and said electric motor; and a controller, said controller capable of supplying control signals to said prime mover, said first clutch, said electric motor-generator, said second clutch and said electric motor such that said controller is capable of dynamically affecting a plurality of operating modes; wherein further said plurality of operating modes comprises one of a group, said group comprising: all electric mode, series mode, series-parallel mode and parallel mode.

Claims

1. A powertrain for a Hybrid Electric Vehicle (HEV), said powertrain comprising:

a prime mover;

a first electric motor-generator, said first electric motor-generator mechanically coupled to said prime mover via a first clutch;

a second electric motor-generator, said second electric motor-generator mechanically coupled to said first electric motor-generator via a second clutch;

said first clutch and said second clutch configured to affect dynamic open/closed/slip operation;

a battery, said battery electrically coupled to said first electric motor-generator and said second electric motor-generator, said battery configured to supply electrical energy to said first electric motor-generator and said second electric motor-generator; and

a controller, said controller configured to supply control signals to said prime mover, said first clutch, said first electric motor-generator, said second clutch and said second electric motor-generator such that said controller is configured to dynamically transition between a plurality of operating modes;

wherein further said plurality of operating modes comprises one of a group, said group comprising;

all electric mode, high-torque electric mode, series mode, high regeneration mode, series-parallel mode and parallel mode.

2. The powertrain of claim 1 wherein said HEV is one of a group, said group comprising:

a hybrid electric vehicle and a plug-in hybrid electric vehicle.

3. The powertrain of claim 2 wherein said REV is one of a group, said group comprising:

a rear-wheel drive powertrain, a front-wheel drive powertrain and an all-wheel drive powertrain.

4. The powertrain of claim 2 wherein said HEV further comprises a wall charger.

5. The powertrain of claim 4 wherein said HEV further comprises a battery management system.

6. The powertrain of claim 2 wherein said powertrain further comprises a housing, said housing mechanically coupled to said HEV and further wherein said housing is sized to contain at least one or more components of said powertrain, said components comprising one of a group, said group comprising:

said prime mover, said first clutch, said first electric motor-generator, said second clutch and said second electric motor-generator.

7. The powertrain of claim 6 wherein said housing further comprises a cooling conduit, said cooling conduit configured to guide a flow of cooling fluid past one or more of said components.

8. The powertrain of claim 6 wherein said housing further comprises a material configured to provide electro-magnetic compatibility.

9. The powertrain of claim 8 wherein said material comprises one of a group, said group comprising:

aluminum, copper, nickel and chrome.

10. The powertrain of claim 1 wherein said vehicle comprises a gross vehicle weight substantially in the range of 6000 lbs to 10,000 lbs, said prime mover is an engine of substantially 2.7 L displacement, said second electric motor-generator comprises substantially at least 80 kW peak power and substantially at least 900 Nm peak torque, said first electric motor-generator comprises substantially at least 50 kW peak power and substantially at least 300 Nm peak torque and said battery comprises a capacity of substantially in the range of 5 to 21 kWh.

11. The powertrain of claim 1 wherein said vehicle comprises a gross vehicle weight substantially in the range of 14,000 lbs to 26,000 lbs, said prime mover is an engine of substantially 4.5 L displacement, said second electric motor-generator comprises substantially at least 110 kW peak power and substantially at least 1400 Nm peak torque, said first electric motor-generator comprises substantially at least 50 kW peak power and substantially at least 600 Nm peak torque and said battery comprises a capacity of substantially in the range of 5 to 27 kWh.

12. The powertrain of claim 1 wherein said vehicle comprises a gross vehicle weight substantially in the range of 10,000 lbs to 14,000 lbs, said prime mover is an engine of substantially 2.7 L displacement, said second electric motor-generator comprises substantially at least 90 kW peak power and substantially at least 1200 Nm peak torque, said first electric motor-generator comprises substantially at least 50 kW peak power and substantially at least 400 Nm peak torque and said battery comprises a capacity of substantially in the range of 5 to 24 kWh.

13. The powertrain of claim 1 wherein said vehicle comprises a gross vehicle weight less than 6000 lbs, said prime mover is an engine of substantially 2.0 L displacement, said second electric motor-generator comprises substantially at least 50 kW peak power and substantially at least 500 Nm peak torque, said first electric motor-generator comprises substantially at least 50 kW peak power and substantially at least 200 Nm peak torque and said battery comprises a capacity of substantially in the range of 5 to 16 kWh.

14. The powertrain of claim 1 wherein said vehicle comprises a gross vehicle weight less than 4000 lbs, said prime mover is an engine of substantially in the range of 0.5 L to 2.0 L displacement, said second electric motor-generator comprises substantially at least 75 kW peak power and substantially at least 300 Nm peak torque, said first electric motor-generator comprises substantially at least 35 kW peak power and substantially at least 200 Nm peak torque and said battery comprises a capacity of substantially in the range of 3 to 16 kWh.