Drivetrain with hybrid transfer case

• US 6,719,656 B2
• Filed: 01/22/2003
• Issued: 04/13/2004
• Est. Priority Date: 10/19/2001
• Status: Expired due to Fees

• Current Assignee: New Venture Gear, Incorporated (Magna International Incorporated)
• Original Assignee: New Venture Gear, Incorporated (Magna International Incorporated)
• Inventors: Bowen, Thomas C.
• Primary Examiner(s): PANG, ROGER L
• Application Number:
  US10/349,472
• Publication Number:
  US 20030148843A1
• Time in Patent Office: 447 Days
• Field of Search: 475/5, 475/6, 180/65.2, 180/65.6, 180/65.7, 180/247, 180/248, 477/5
• US Class Current: 475/5
• CPC Class Codes: B60K 17/34 for driving both front and rear wheels, e.g. four wheel drive vehicles arrangement or mounting of control devices for changing number of driven wheels B60K23/08
• CPC Class Codes: B60K 23/08 for changing number of driven wheels , for switching from driving one axle to driving two or more axles B60K17/3515 takes precedence
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/387 Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
• CPC Class Codes: B60K 6/405 Housings
• 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: B60K 6/54 Transmission for changing ratio
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/443 Torque
• CPC Class Codes: B60L 2240/461 Speed
• CPC Class Codes: B60L 2240/545 Temperature
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/24 : by lever actuation
• CPC Class Codes: B60L 2250/26 : by pedal actuation
• CPC Class Codes: B60L 50/16 : with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 7/14 : for vehicles propelled by ac motors
• CPC Class Codes: B60W 10/02 : including control of driveline clutches
• CPC Class Codes: B60W 10/08 : including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/10 : including control of change-speed 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 20/40 : Controlling the engagement or disengagement of prime movers, e.g. for transition between prime movers power-up or power-down of the driveline B60W30/192
• CPC Class Codes: F16H 3/725 : with means to change ratio in the mechanical gearing
• CPC Class Codes: H02K 7/006 : Structural association of a motor or generator with the drive train of a motor vehicle
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• 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: Y10S 903/906 : Motor or generator
• CPC Class Codes: Y10S 903/91 : Orbital, e.g. planetary gears
• CPC Class Codes: Y10S 903/914 : Actuated, e.g. engaged or disengaged by electrical, hydraulic or mechanical means
• CPC Class Codes: Y10S 903/916 : with plurality of drive axles
• CPC Class Codes: Y10S 903/917 : with transmission for changing gear ratio
• CPC Class Codes: Y10S 903/945 : Characterized by control of gearing, e.g. control of transmission ratio
• CPC Class Codes: Y10S 903/946 : Characterized by control of driveline clutch
• CPC Class Codes: Y10S 903/952 : Housing details

Abstract

A hybrid transfer case includes a mainshaft, front and rear output shafts, an electric motor/generator connected to the mainshaft, and an input clutch for selectively coupling the transmission to the mainshaft. The transfer case further includes a planetary gearset having a sun gear driven by the mainshaft, a ring gear, and planet gears supported from a carrier. The carrier drives the rear output shaft and a transfer assembly couple to the front output shaft. A direct clutch is operable to selectively coupled the carrier for rotation with the mainshaft. A low brake is operable to selectively brake rotation of the ring gear. A transfer clutch controls the amount of drive torque delivered through the transfer assembly to the front output shaft. A hybrid control system is provided for controlling actuation of the various clutch and brake assemblies and the electric motor/generator to establish various drive modes.

Claims

1. A transfer case for use in a hybrid motor vehicle having an engine and first and second drivelines, comprising:

an input shaft adapted to be driven by the engine;

a mainshaft;

a first clutch for selectively coupling said input shaft to said mainshaft;

a first output shaft adapted for connection to the first driveline;

a second output shaft adapted for connection to the second driveline;

a planetary gearset having a sun gear driven by said mainshaft, a ring gear, and planet gears rotatably supported from a carrier and which are meshed with said sun gear and said ring gear, said carrier operably connected to said first and second output shafts;

a second clutch for selectively coupling said mainshaft to said carrier;

a third clutch for selectively coupling said ring gear to a stationary member; and

an electric motor for selectively driving said mainshaft.

2. The transfer case of claim 1 wherein said first clutch is operable in a released state to release said mainshaft from driven engagement with said input shaft and is further operable in an applied state to couple said mainshaft for rotation with said input shaft, wherein said second clutch is operable in a released state to permit relative rotation between said carrier and said mainshaft and is further operable in an applied state to couple said carrier for rotation with said mainshaft, and wherein said third clutch is operable in a released state to permit rotation of said ring gear and is further operable in an applied state to couple said ring gear to said stationary member.

3. The transfer case of claim 2 wherein a high-range drive connection is established between said mainshaft and said carrier when said second clutch is operating in its applied state and said third clutch is in its released state, and wherein a low-range drive connection is established between said mainshaft and said carrier when said second clutch is in its released state and said third clutch is in its applied state.

4. The transfer case of claim 2 wherein a hybrid four-wheel high-range drive mode is established when said first and second clutches are applied, said third clutch is released, and said electric motor is actuated such that drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

5. The transfer case of claim 2 wherein an engine four-wheel high-range drive mode is established when said first and second clutches are applied, said third clutch is released and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

6. The transfer case of claim 2 wherein an electric four-wheel high-range drive mode is established when said first and third clutches are released, said second clutch is applied and said electric motor is activated to drive said mainshaft.

7. The transfer case of claim 2 further comprising a fourth clutch for selectively coupling said carrier to said second output shaft, said fourth clutch is operable in a released state to define a two-wheel drive mode, said fourth clutch is further operable in an applied state to define a four-wheel drive mode.

8. The transfer case of claim 7 wherein an electric two-wheel high-range drive mode is established when said first, third and fourth clutches are released, said second clutch is applied, and said electric motor is actuated to drive said mainshaft.

9. The transfer case of claim 7 wherein a hybrid two-wheel high-range drive mode is established when said first and second clutches are applied, said third and fourth clutches are released, and said electric motor is actuated such that drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

10. The transfer case of claim 7 wherein an engine two-wheel high-range drive mode is established when said first and second clutches are applied, said third and fourth clutches are released, and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

11. The transfer case of claim 7 wherein an electric two-wheel low-range drive mode is established when said first, second and fourth clutches are released, said third clutch is applied, and said electric motor is activated to drive said mainshaft.

12. The transfer case of claim 7 wherein a hybrid two wheel low-range drive mode is established when said first clutch is applied, said second clutch is released, said third clutch is applied, said fourth clutch is released, and said electric motor is actuated such that drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

13. The transfer case of claim 7 wherein an engine two-wheel low-range drive mode is established when said first clutch is applied, said second clutch is released, said third clutch is applied, said fourth clutch is released, and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

14. The transfer case of claim 7 wherein said fourth clutch can be fully engaged to define a locked four-wheel drive mode or actuation of said fourth clutch can be varied to define an on-demand four-wheel drive mode.

15. The transfer case of claim 1 wherein said first clutch is a spring-apply multi-plate clutch assembly operable disposed between said input shaft and said mainshaft, said first clutch is normally operable in its applied state and can be selectively shifted into its released state via actuation of a first power-operated actuator, wherein said second clutch is a spring-apply multi-plate clutch assembly operably disposed between said mainshaft and said carrier, said second clutch is normally operable in its applied state and can be selectively shifted into its released state via actuation of a second power-operated actuator, and wherein said third clutch is a spring-release multi-plate brake assembly operably disposed between said ring gear and a stationary member, said third clutch is normally operable in its released state and can be selectively shifted into its applied state via actuation of said second power-operated actuator.

16. The transfer case of claim 15 further comprising a control system having a controller and sensors for detecting operating characteristics of the vehicle and sending sensor signals to said controller, said controller operable to send control signals to said electric motor and said first and second actuators for controlling coordinated actuation thereof.

17. The transfer case of claim 1 further comprising a control system for controlling coordinate actuation of said first, second and third clutches and activation of said electric motor.

18. The transfer case of claim 1 wherein said electric motor includes a stator secured to a housing and a rotor secured to said mainshaft.

19. The transfer case of claim 1 further comprising:

a valvebody supporting a first electrohydraulic control valve controlling actuation of said first clutch, a second electrohydraulic control valve controlling actuation of said second clutch, and a third electrohydraulic control valve controlling actuation of said third clutch; and

a hydraulic circuit providing high pressure fluid to said first, second and third control valves.

20. A transfer case for use in a four-wheel drive motor vehicle having an engine and front and rear drivelines, comprising:

an input shaft adapted to be driven by the engine;

a mainshaft driving a reduction unit having an output member;

a first clutch for selectively coupling said input shaft to said mainshaft;

a rear output shaft driven by said output member and adapted for connection to the rear driveline;

a front output shaft driven by said output member and adapted for connection to the front driveline;

a second clutch operable in a first mode to establish a high-range drive connection between said mainshaft and said output member and in a second mode to establish a low-range drive connection therebetween; and

an electric motor for selectively driving said mainshaft.

21. The transfer case of claim 20 wherein a hybrid four-wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is activated such that said mainshaft is driven by said electric motor and the engine.

22. The transfer case of claim 20 wherein an electric four wheel high-range drive mode is established when said first clutch uncouples said mainshaft from said input shaft, said second clutch is operating in its first mode, and said electric motor is activated so as to drive said mainshaft.

23. The transfer case of claim 20 wherein an engine four-wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is off such that the engine drives said mainshaft.

24. The transfer case of claim 20 wherein a hybrid four-wheel low-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is activated such that said mainshaft is driven by said electric motor and the engine.

26. The transfer case of claim 20 wherein an engine four wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is off such that the engine drives said mainshaft.

27. The transfer case of claim 20 wherein said reduction unit further includes a reaction member driven by said output member, and wherein said second clutch includes a direct clutch assembly that is operable for selectively coupling said output member for rotation with said mainshaft and a low brake assembly that is operable for selectively braking rotation of said reduction member, whereby said first mode of said second clutch is established when said direct clutch assembly is engaged and said low brake assembly is released, and said second mode of said second clutch is established when said direct clutch assembly is released and said low brake assembly is engaged.

28. The transfer case of claim 27 when said reduction unit is a planetary gearset with a sun gear driven by said mainshaft, a ring gear as its reaction member, and planet gears meshed with said sun gear and ring gear that are supported from a carrier as its output member.

29. The transfer case of claim 28 wherein said first clutch is operable in a released state to release said mainshaft from driven engagement with said input shaft and is further operable in an applied state to couple said mainshaft for rotation with said input shaft, wherein said direct clutch assembly is operable in a released state to permit relative rotation between said carrier and said mainshaft and is further operable in an applied state to couple said carrier for rotation with said mainshaft, and wherein said low brake assembly is operable in a released state to permit rotation of said ring gear and is further operable in an applied state to brake said ring gear against rotation.

30. The transfer case of claim 20 further comprising a third clutch for selectively coupling said output member of said reduction unit to said front output shaft, said third clutch is operable in a first mode to establish a two-wheel drive mode wherein all drive torque is transferred to the rear driveline through said rear output shaft, said third clutch is further operable in a second mode to establish a four-wheel drive mode wherein at least a portion of the drive torque is transferred to the front driveline through said front output shaft.

25. The transfer case of 20 wherein an electric four-wheel low-range drive mode is established when said first clutch uncouples said mainshaft from said input shaft, said second clutch is operating in its first mode, and said electric motor is activated so as to drive said mainshaft.

31. A hybrid motor vehicle, comprising:

a powertrain including an internal combustion engine and a transmission;

a first driveline including a first axle driving a pair of first wheels;

a second driveline including a second axle driving a pair of second wheels;

a transfer case including an input shaft driven by said powertrain, a mainshaft driven by said input shaft, a first output shaft operably connected to said first driveline, a second output shaft operably connected to said second driveline, a planetary reduction unit having a sun gear driven by said mainshaft, a ring gear and planet gears meshed with said sun and ring gears, said planet gears rotatably supported from a carrier which operably drives said first and second output shafts, a direct clutch for selectively coupling said mainshaft to said carrier, a low brake for selectively braking rotation of said ring gear, and an electric motor for driving said mainshaft; and

a control system for controlling actuation of said direct clutch, said low brake and said electric motor for defining a hybrid drive mode and an engine drive mode.

32. The hybrid motor vehicle of claim 31 wherein a hybrid four-wheel high-range drive mode is established when said direct clutch is applied, said low brake is released, and drive torque generated by said electric motor is combined with drive torque from the powertrain to drive said mainshaft.

33. The hybrid motor vehicle of claim 31 wherein an engine four-wheel high-range drive mode is established when said direct clutch is applied, said low brake is released, and said electric motor is off such that drive torque generated by the powertrain drives said mainshaft.

34. The hybrid motor vehicle of claim 31 wherein a hybrid four-wheel low-range drive mode is established when said direct clutch is released, said low brake is applied, and drive torque generated by said electric motor is combined with drive torque from the powertrain to drive said mainshaft.

35. The hybrid motor vehicle of claim 31 wherein an engine four-wheel low-range drive mode is established when said direct clutch is released, said low brake is applied, and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

36. The transfer case of claim 31 further comprising:

an input clutch for selectively coupling said input shaft to said mainshaft; and

a transfer clutch for selectively coupling said carrier to said second output shaft;

wherein said control system is operable for controlling actuation of said input clutch and transfer clutch.

37. The hybrid motor vehicle of claim 36 wherein an electric four-wheel high-range drive mode is established when said input clutch is released, said direct clutch is applied, said low brake is released, and said electric motor is activated to drive said mainshaft.

38. The hybrid motor vehicle of claim 36 wherein said input clutch is operable in a released state to release said mainshaft from driven engagement with said input shaft and is further operable in an applied state to couple said mainshaft for rotation with said input shaft, wherein said direct clutch is operable in a released state to permit relative rotation between said carrier and said mainshaft and is further operable in an applied state to couple said carrier for rotation with said mainshaft, and wherein said low brake is operable in a released state to permit rotation of said ring gear and is further operable in an applied state to brake said ring gear against rotation.

39. The hybrid motor vehicle of claim 38 wherein a high-range drive connection is established between said mainshaft and said carrier when said direct clutch is operating in its applied state and said low brake is in its released state, and wherein a low-range drive connection is established between said mainshaft and said carrier when said direct clutch is in its released state and said low brake is in its applied state.

40. The hybrid motor vehicle of claim 39 wherein said transfer clutch is operable in a released state such that all drive torque is transferred from said carrier to said first output shaft to define a two-wheel drive mode, said transfer clutch is further operable in an applied state such that drive torque is transferred from said carrier to both of said first and second output shafts to define a four-wheel drive mode.

41. The hybrid motor vehicle of claim 40 wherein an electric two-wheel high-range drive mode is established when said input clutch is released, said direct clutch is applied, said low brake is released, said transfer clutch is released and said electric motor is actuated to drive said mainshaft.

42. The hybrid motor vehicle of claim 40 wherein a hybrid two-wheel high-range drive mode is established when said input clutch is applied, said direct clutch is applied, said low brake is released, said transfer clutch is released and drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

43. The hybrid motor vehicle of claim 40 wherein an engine two-wheel high-range drive mode is established when said input clutch is applied, said direct clutch is applied, said low brake is released, said transfer clutch is released and said electric motor is off such that drive torque generated by the engine drives said mains haft.

44. The hybrid motor vehicle of claim 40 wherein an electric two-wheel low-range drive mode is established when said input clutch is released, said direct clutch is released, said low brake is applied, said transfer clutch is released and said electric motor is activated to drive said mainshaft.

45. The hybrid motor vehicle of claim 40 wherein a hybrid two-wheel low-range drive mode is established when said input clutch is applied, said direct clutch is released, said low brake is applied, said transfer clutch is released and drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

46. The hybrid motor vehicle of claim 40 wherein an engine two-wheel low-range drive mode is established when said input clutch is applied, said direct clutch is released, said low brake is applied, said transfer clutch is released and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

47. The hybrid motor vehicle of claim 40 wherein an electric four-wheel high-range drive mode is established when said input clutch is released, said direct clutch is applied, said low brake is released, said transfer clutch is applied and said electric motor is activated to drive said mainshaft.

48. The hybrid motor vehicle of claim 47 wherein said transfer clutch can be fully engaged to define a locked four-wheel high-range drive mode or actuation of said transfer clutch can be varied to define an on-demand four-wheel high-range drive mode.

49. The hybrid motor vehicle of claim 40 wherein a hybrid four-wheel high-range drive mode is established when said input clutch is applied, said direct clutch is applied, said low brake is released, said transfer clutch is applied and drive torque generated by said electric motor is combined with drive torque from the engine to drive said mainshaft.

50. The hybrid motor vehicle of claim 49 wherein said transfer clutch can be fully engaged to define a locked four-wheel high-range drive mode or actuation of said transfer clutch can be varied to define an on-demand four-wheel high-range drive mode.

51. The hybrid motor vehicle of claim 40 wherein an engine four-wheel high-range drive mode is established when said input clutch is applied, said direct clutch is applied, said low brake is released, said transfer clutch is applied and said electric motor is off such that drive torque generated by the engine drives said mainshaft.

52. The hybrid motor vehicle of claim 51 wherein said transfer clutch can be fully engaged to define a locked four-wheel high-range drive mode or actuation of said transfer clutch can be varied to define an on-demand four-wheel high-range drive mode.

53. A hybrid motor vehicle, comprising:

a powertrain;

a first driveline including a first axle driving a pair of first wheels;

a second driveline including a second axle driving a pair of second wheels;

a transfer case including an input shaft driven by said powerirain, a mainshaft driving a reduction unit having an output member, a first clutch for selectively coupling said input shaft to said mainshaft, a first output shaft driven by said output member and operably connected to said first driveline, a second output shaft driven by said output member and operably connected to said second driveline, a second clutch operable in a first mode to establish a high-range drive connection between said mainshaft and said output member and in a second mode to establish a low-range drive connection therebetween, and an electric motor for selectively driving said mainshaft; and

a control system for controlling coordinated actuation of said first and second clutches and said electric motor.

54. The hybrid motor vehicle claim 53 of wherein a hybrid four-wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is activated such that said mainshaft is driven by said electric motor and said powertrain.

55. The hybrid motor vehicle of claim 53 wherein an electric four-wheel high-range drive mode is established when said first clutch uncouples said mainshaft from said input shaft, said second clutch is operating in its first mode, and said electric motor is activated to drive said mainshaft.

56. The hybrid motor vehicle of claim 53 wherein an engine four-wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is off such that said powertrain drives said mainshaft.

57. The hybrid motor vehicle of claim 53 wherein a hybrid four-wheel low-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is activated such that said mainshaft is driven by said electric motor and said powertrain.

58. The hybrid motor vehicle of claim 53 wherein an electric four-wheel low-range drive mode is established when said first clutch uncouples said mainshaft from said input shaft, said second clutch is operating in its first mode, and said electric motor is activated to drive said mainshaft.

59. The hybrid motor vehicle of claim 53 wherein an engine four-wheel high-range drive mode is established when said first clutch couples said input shaft to said mainshaft, said second clutch is operating in its first mode, and said electric motor is off such that said powertrain drives said mainshaft.

60. The hybrid motor vehicle of claim 53 wherein said reduction unit further includes a reaction member driven by said output member, and wherein said second clutch includes a direct clutch that is operable for selectively coupling said output member for rotation with said mainshaft and a low brake assembly that is operable for selectively braking rotation of said reduction member, whereby said first mode of said second clutch is established when said direct clutch assembly is engaged and said low brake assembly is released, and said second mode of said second clutch is established when said direct clutch assembly is released and said low brake assembly is engaged.

61. The hybrid motor vehicle of claim 60 when said reduction unit is a planetary gearset with a sun gear driven by said mainshaft, a ring gear as its reaction member, and planet gears meshed with said sun gear and ring gear that are supported from a carrier as its output member.

62. The hybrid motor vehicle of claim 53 further comprising a third clutch for selectively coupling said output member of said reduction unit to said front output shaft, said third clutch is operable in a first mode to establish a two-wheel drive mode wherein all drive torque is transferred to the rear driveline through said rear output shaft, said third clutch is operable in a second mode to establish a four-wheel drive mode wherein at least a portion of the drive torque is transferred to the front driveline through said front output shaft.