VEHICULAR SWITCHING, INCLUDING SWITCHING TRACTION MODES AND SHIFTING GEARS WHILE IN ELECTRIC TRACTION MODE

• US 20080243324A1
• Filed: 04/01/2008
• Published: 10/02/2008
• Est. Priority Date: 02/21/2006
• Status: Active Grant

• Current Assignee: Clean Emissions Technologies, Inc.
• Original Assignee: ZERO Tension Systems LLC
• Inventors: Harris, Warner Olan
• Granted Patent: US 7,921,945 B2
• Time in Patent Office: Days
• US Class Current: 701/22
• CPC Class Codes: B60K 17/28 characterised by arrangement, location, or type of power take-off
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• 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 10/11 Stepped gearings
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 30/19 Improvement of gear change, e.g. by synchronisation or smoothing gear shift
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• CPC Class Codes: F16H 59/46 dependent on a comparison between speeds
• CPC Class Codes: F16H 63/42 Ratio indicator devices
• CPC Class Codes: Y02T 10/62 Hybrid vehicles

Abstract

A vehicle has an internal combustion engine (ICE) and a electric traction motor (ETM) coupled by a standard transmission through a differential to drive traction wheels. A control system receives sensor signals including speed sensors, a load sensor, and an incline sensors. The control system processes the speed signals to generate indicator signals corresponding to speed of the ETM, the vehicle speed, the shifting gears and the speed of the transmission output shaft. One or more displays present indications of when the speed of a shifting gear corresponding to the speed of the ETM matches the speed of the vehicle thus the speed of the transmission output shaft. An operator may shift, without clutching, from neutral and to a next shifting gear when there is an indication that the speed of the next shifting gear matches the speed of a shifting collar coupled to the transmission output shaft

Claims

1. A vehicle having a standard transmission for driving a differential coupled to traction wheels comprising:

an internal combustion engine (ICE) coupled through a clutch to a transmission input shaft of the standard transmission, wherein the ICE is engaged to rotate the transmission input shaft when a clutch pedal operating the clutch is not depressed and the ICE is disengaged from the transmission input shaft when the clutch pedal is depressed;

a power take-off (PTO) having a transfer gear coupled the transmission input shaft;

an electric traction motor (ETM) having an output shaft coupled to an output shaft of the transfer gear, wherein the ETM rotates the transmission input shaft in response to power applied to the ETM when the ICE is disengaged from the input shaft and the ETM is rotated in response to rotation of the transmission input shaft when the clutch engages the ICE to the transmission input shaft;

a control system receiving signals from an electrical system of the vehicle and sensors monitoring operations of the vehicle and generating output control signals;

an auxiliary electrical power system coupled to power the ETM and sub-systems of the vehicle when in an ETM operating mode;

one or more actuators receiving power from the auxiliary power system in response to the output control signals when in the ETM operational mode, wherein one of the actuators is a clutch actuator that holds the clutch pedal depressed, when in the ETM operational mode; and

releases the clutch pedal for normal operation when in an ICE operational mode; and

one or more indicators configured to present to a user, in the ETM operating mode, a signal indicating when to shift from neutral to cause a shifting collar rotating at a speed determined by the vehicle speed to engage a next shifting gear rotating at a speed determined by the ETM rotational speed.

2. The vehicle of claim 1, wherein the one or more indicators indicate the ETM rotational speed and thus a speed of the shifting gears.

3. The vehicle of claim 2, wherein the one or more indicators indicate the vehicle speed and thus a speed of the shifting collars coupled to the transmission output shaft.

4. The vehicle of claim 2, wherein the one or more indicators present an indication of a difference in rotational speed between a particular shifting gear and the shifting collars coupled to the transmission output shaft.

5. The vehicle of claim 4, wherein the one or mote indicators present a light that is ON when a particular shifting gear may be engaged by a shifting collar.

6. The vehicle of claim 4, wherein the one or more indicators present a light that has a particular color when a particular shifting gear may be engaged by a shifting collar.

7. The vehicle of claim 1, wherein the control system includes control logic that receives a plurality of sensor signals and generates speed indication signals coupled to the one or more indicators and gear matching signals.

8. The vehicle of claim 7, wherein the control logic receives a sensor signal indicating a speed proportional to a speed of the ETM, a sensor signal indicating a speed proportional to a speed of the vehicle, a sensor signal indicating vehicle loading, a sensor signal indicating an incline of the vehicle relative to a road surface, and switch signals indicating a present position of a gear shifter and generates the speed indication signals and gear matching signals for the one or more displays.

9. The vehicle of claim 8, wherein the control logic processes the sensor signals and generates an indication of which shifting gear to engage to optimize operations of the vehicle.

10. The vehicle of claim 1, wherein the sensor monitoring operations of the vehicle include a variable signal indicating a position of an accelerator pedal and a brake signal indicating when the vehicle is braking.

11. The vehicle of claim 10, wherein the ETM is switched into a generator mode in response to the brake signal.

12. A method of operating a vehicle having a standard transmission with a transmission input shaft coupled by a clutch to an internal combustion engine (ICE) and coupled by a power take-off transfer gear to a drive shaft of an electric traction motor (ETM) comprising:

enabling a control system receiving signals from an electrical system of the vehicle and sensors monitoring operations of the vehicle and generating output control signals;

enabling an ETM operational mode of the control system in response to an ETM mode signal and a signal indicating the ICE is powered OFF;

signaling a clutch actuator to hold a clutch pedal in a depressed position in response to the ETM mode signal, wherein the clutch disengages the ICE from the transmission input shaft when the clutch pedal is depressed and engages the ICE to the transmission input shaft when the clutch pedal is not depressed;

determining a rotational speed of each of a plurality of shifting gears driven by the ETM in response to a first speed signal;

determining a rotational speed of shifting collars coupled to the output shaft of the transmission in response to a second speed signal;

generating a shift indication when a particular shifting gear matches the rotational speed of a particular shifting collar; and

shifting from neutral to engage the particular shifting collar with the particular shifting gear without disengaging the ETM from the PTO transfer gear in response observing on one or more displays the shift indication.

13. The method of claim 12, further comprising turning OFF the ICE with the ignition switch and turning ON the ETM operation mode when the ignition switch is in the accessory position.

14. The method of claim 13 further comprising:

operating an accelerator pedal of the ICE thereby sending a variable signal to the control system; and

supplying variable power to the ETM from an auxiliary power system in response to the variable signal to thereby control a speed of the vehicle.

15. The method of claim 14 further comprising adjusting the speed of the ETM and/or the vehicle speed until the one or more display has a shift indication that a particular shifting gear matches the rotational speed of a particular shifting collar.

16. The method of claim 13 further comprising:

holding the clutch pedal in the depressed position;

switching the ignition switch from the accessory position thereby signaling the control system to disconnect power from the ETM thereby releasing the clutch actuator;

starting the ICE using the ignition switch;

operating the accelerator pedal to set a desired rotational speed for the ICE;

engaging a desired shifting gear corresponding to the vehicle speed and the ICE rotational speed; and

releasing the clutch pedal to engage the ICE with the transmission input shaft.

17. The method of claim 16 further comprising switching the ETM to a generator mode to provide battery charging current.

18. The method of claim 13 further comprising:

removing power from the ETM when in the ETM operational mode in response to a brake signal indicating the brake pedal is depressed thereby activating braking; and

shifting to a lower shifting gear from neutral in response to a shift indication that a speed of the next lower shifting gear matches a speed of a shifting collar coupled to the transmission output shaft.

19. The method of claim 18 further comprising switching the ETM to a generator mode in response to the brake signal.

20. The method of claim 14, further comprising providing power to auxiliary drivers for necessary vehicle sub-systems using the auxiliary power source.

21. The method of claim 20, wherein the auxiliary drivers comprise drivers for comfort sub-systems.

23. The apparatus of claim 12, wherein the first indicator is associated with the selected shifting gear and the apparatus further comprises:

speed logic operable for receiving a speed signal dependent upon rotation of the electric motor, adjusting the speed signal responsive to a predetermined gear ratio associated with the selected shifting gear, and sending the adjusted speed signal to the first indicator, wherein the speed presented by the first indicator is responsive to the adjusted speed signal and is also dependent upon the gear ratio associated with the selected shifting gear.

24. The apparatus of claim 12, wherein the second indicator is associated with the selected shifting gear and the apparatus further comprises:

speed logic operable for receiving a spaced signal dependent upon rotation of the road wheels, adjusting the speed signal responsive to a predetermined gear ratio associated with the selected shifting gear, and sending the adjusted speed signal to the second indicator, wherein the speed presented by the second indicator is responsive to the adjusted speed signal and is also dependent upon the gear ratio associated with the selected shifting gear independently of whether the selected shifting gear is engaged in fixed rotational relationship to the transmission output, so that the second indicator presents a rotation speed for the selected shifting gear as if the selected shifting gear has the fixed rotational relationship to the transmission output regardless of whether the selected shifting gear actually does have the fixed rotational relationship.

25. The apparatus of claim 12, wherein one of the first and second indicators is associated with the selected shifting gear and the apparatus further comprises:

additional indicators associated with additional respective ones of the shifting gears.

26. The apparatus of claim 15, further comprising:

logic operable to generate shifting gear select signals for the current road wheel rotation speed responsive to comparing a speed dependent upon the road wheel speed and a speed dependent upon the electric motor speed, wherein generating the select signals logic includes adjust either the road wheel dependent speed or the electric motor dependent speed responsive to the respective shifting gears, wherein the indicators associated with the respective shifting gears include signaling devices operable to present the shifting gear select signals responsive to receiving the select signals from the logic.

27. The apparatus of claim 12, wherein the speed indications presented by the indicators include visually presented speed indications.

28. The apparatus of claim 12, wherein the speed indications presented by the indicators include audibly presented speed indications.

22. An apparatus in a vehicle having an internal combustion engine (“

ICE”

) mechanically coupled via a manual clutch to an input of a transmission, the clutch being operable, responsive to actuation by a driver, for disengaging the ICE from the transmission, the apparatus including;

an electric motor coupled to the transmission input via a transfer gear such that operation of the clutch to disengage the ICE from the transmission does not disengage the electric motor from the transmission, wherein the transmission includes an output coupled to road wheels of the vehicle;

an actuator coupled to the clutch;

controls operable to position the actuator to hold the clutch with the ICE disengaged from the transmission so the road wheels are powered by the electric motor instead of the ICE, wherein the transmission includes shifting gears and a shifting mechanism having a neutral position, wherein in the neutral position the shifting gears are disengaged from the transmission input and output, and having engaged positions for the respective shifting gears, wherein with the shifting mechanism in the respective engaged positions the shifting gears engage the transmission output and have fixed rotational relationships with respect to rotation of the road wheels;

a first speed indicator operable to present to the driver a speed dependent upon rotation of the electric motor; and

a second speed indicator operable to present to the driver a speed dependent upon rotation of the road wheels, so that with the road wheels rotating and the ICE disengaged from the transmission via the clutch, the driver may select and engage one of the shifting gears by i) shifting the shifting mechanism to the neutral position, ii) adjusting rotation of the electric motor by reference to the first and second speed indicators to match rotation of the selected shifting gear for current rotation of the road wheels, and iii) shifting the shifting mechanism to the position engaging the selected gear to the transmission output.

29. A method in a vehicle having an internal combustion engine (“

ICE”

) mechanically coupled via a manual clutch to an input of a manual transmission, the clutch being operable, responsive to actuation by a driver, for disengaging the ICE from the transmission, the method including;

coupling an electric motor to the transmission input via a transfer gear, such that operation of the clutch to disengage the ICE from the transmission does not disengage the electric motor from the transmission, wherein the transmission includes an output coupled to road wheels of the vehicle;

coupling an actuator to the clutch;

positioning the actuator to hold the clutch with the ICE disengaged from the transmission for powering the road wheels by the electric motor and not the ICE, wherein the transmission includes shifting gears and a shifting mechanism having a neutral position in which the shifting gears are disengaged from the transmission input and output and having engaged positions for the respective shifting gears, wherein with the shifting mechanism in the respective engaged positions the shifting gears engage the transmission output and have fixed rotational relationships with respect to rotation of the road wheels; and

presenting to the driver a first speed indication dependent upon rotation of the electric motor and a second speed indication dependent upon rotation of the road wheels, so that with the road wheels rotating and the ICE disengaged from the transmission via the clutch, the driver may select and engage one of the shifting gears by i) shifting the shifting mechanism to the neutral position, ii) adjusting rotation of the electric motor by reference to the speed indicators to match rotation of the selected gear for current rotation of the road wheels, and iii) shifting the shifting mechanism to the position engaging the selected gear to the transmission output.