HYBRID ELECTRIC VEHICLE POWERTRAIN WITH TORQUE TRANSFER CASE

• US 20070034428A1
• Filed: 03/06/2006
• Published: 02/15/2007
• Est. Priority Date: 08/15/2005
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Janson, David
• Granted Patent: US 7,424,924 B2
• Time in Patent Office: Days
• US Class Current: 180/65.235
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/507 Operating parameters
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 7/18 Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y10S 903/906 Motor or generator
• CPC Class Codes: Y10S 903/909 Gearing

Abstract

A torque transfer case for a hybrid electric vehicle powertrain with engine and electric power sources is described, the electric power source comprising an electric motor and a battery. It distributes driving power to front and rear traction wheel and axle assemblies to effect all-wheel drive or four-wheel drive as well as regenerative power recovery. The electric power source can be used for engine cranking and the engine can be used for battery charging.

Claims

1. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine, a first traction wheel and axle assembly, a second traction wheel and axle assembly, a power transmission drivably connected to the engine and a torque transfer case with a transfer case torque input shaft connected drivably to a transmission torque output shaft, the powertrain comprising:

an electric motor-generator;

a first transfer case torque output shaft connected drivably to the first traction wheel and axle assembly;

the electric motor-generator and the first transfer case torque output shaft being assembled on a common first axis;

a second transfer case torque output shaft disposed on a second axis that is offset from the first axis;

the second traction wheel and axle assembly being drivably connected to the second transfer case torque output shaft;

a torque cross-drive mechanism drivably connecting the motor-generator to the second transfer case torque output shaft;

the torque cross-drive mechanism comprising a torque output gear drivably connected to the second transfer case torque output shaft, at least one torque input gear drivably connected to the motor-generator and at least one idler gear drivably connecting the one torque input and torque output gears;

the one torque input gear of the cross-drive mechanism being journalled on the first axis;

the torque output gear of the cross-drive mechanism being journalled on the second axis; and

at least one idler gear being journalled on a third axis that is offset from the first and second axes.

2. The hybrid electric vehicle powertrain set forth in claim 1 wherein the torque cross-drive mechanism comprises a second torque input gear of different pitch diameter than the one torque input gear;

a second idler gear drivably engaging the second torque input gear of the cross-drive mechanism; and

a range coupler mechanism including a first range coupler clutch selectively connecting the transfer case torque input shaft to the one torque input gear and a second range coupler clutch selectively connecting the transfer case torque input shaft to the second torque input gear.

3. The hybrid electric vehicle powertrain set forth in claim 2 including a four-wheel drive clutch selectively connecting the first and second idler gears to establish a four-wheel drive mode.

4. The hybrid electric vehicle powertrain set forth in claim 2 wherein the first and second range coupler clutches are located on the first axis intermediate the one and the second torque input gears.

5. The hybrid electric vehicle powertrain set forth in claim 3 wherein the four-wheel drive clutch is located on the third axis adjacent the second idler gear.

6. The hybrid electric vehicle powertrain set forth in claim 4 wherein the four-wheel drive clutch is located on the third axis adjacent the second idler gear.

7. The hybrid electric vehicle powertrain set forth in claim 2 wherein the second torque input gear is drivably connected to the first traction wheel and axle assembly and the second transfer case torque output shaft is drivably connected to the second traction wheel and axle assembly.

12. The hybrid electric vehicle powertrain set forth in claim 1 wherein the driving connection between the second transfer case torque output shaft and the torque output gear of the cross-drive mechanism includes a disconnect clutch for interrupting power delivery selectively to the second traction wheel and axle assembly.

13. The hybrid electric vehicle powertrain set forth in claim 2 wherein the driving connection between the second transfer case torque output shaft and the torque output gear of the cross-drive mechanism includes a disconnect clutch for interrupting power delivery selectively to the second traction wheel and axle assembly.

8. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine, a first traction wheel and axle assembly, a second traction wheel and axle assembly, a power transmission drivably connected to the engine and a torque transfer case with a transfer case torque input shaft connected to a transmission torque output shaft, the powertrain comprising:

an electric motor-generator;

a first transfer case torque output shaft drivably connected to the first traction wheel and axle assembly;

a second transfer case torque output shaft connected drivably to the second traction wheel and axle assembly;

the electric motor-generator and the first transfer case torque output shaft being on a common first axis;

at least one torque transfer case torque input gear on the first axis;

the second torque transfer case torque output shaft being on a second axis;

a range coupler clutch assembly connecting the motor-generator to the torque transfer case torque input shaft;

at least one idler gear defining in part a driving connection between the one torque transfer case torque input gear and the second torque output shaft;

a torque splitter gear unit on the first axis comprising a first gear element connected to the first torque transfer case torque output shaft;

the range coupler clutch assembly selectively connecting a second gear element of the torque splitter gear unit to the transfer case torque input shaft; and

a geared driving connection between a third gear element of the torque splitter gear unit and the second transfer case torque output shaft whereby an all-wheel drive mode is established.

9. The hybrid electric vehicle powertrain set forth in claim 8 including a four-wheel coupler clutch for locking-up gear elements of the torque splitter gear unit whereby a four-wheel drive mode is established.

10. The hybrid electric vehicle powertrain set forth in claim 8 wherein the geared connection between the third gear element of the torque splitter gear unit and the second transfer case torque output shaft comprises a second torque transfer case torque input gear;

and

a second idler gear drivably connecting the second torque transfer case torque input gear to the one idler gear, the idler gears being located on a third axis.

11. The hybrid electric vehicle powertrain set forth in claim 10 wherein the pitch-diameters of the one and the second torque transfer case torque input gears are different whereby either of two drive ranges are available.

14. The hybrid electric vehicle powertrain set forth in claim 8 including a disconnect clutch for interrupting power delivery selectively to the second traction wheel and axle assembly.

15. The hybrid electric vehicle powertrain set forth in claim 9 including a disconnect clutch for interrupting power delivery selectively to the second traction wheel and axle assembly.