Hybrid vehicle system

• US 6,857,985 B2
• Filed: 10/22/2003
• Issued: 02/22/2005
• Est. Priority Date: 02/27/2002
• Status: Expired due to Fees

• Current Assignee: Magna Drivertrain of America Incorporated
• Original Assignee: Magna Drivertrain of America Incorporated
• Inventors: Williams, Cameron P
• Primary Examiner(s): PANG, ROGER L
• Application Number:
  US10/691,293
• Publication Number:
  US 20040082433A1
• Time in Patent Office: 489 Days
• Field of Search: 475/5, 477/3, 477/5, 477/6, 180 652- 654
• US Class Current: 477/5
• CPC Class Codes: B60K 17/356 having fluid or electric motor, for driving one or more wheels disposition of motor in, or adjacent to, traction wheel B60K7/00
• 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 23/0808 for varying torque distribution between driven axles, e.g. by transfer clutch
• CPC Class Codes: B60K 6/38 characterised by the driveline clutches shift clutches within the gearing or transmission B60K6/36 , B60K6/54
• CPC Class Codes: B60K 6/383 One-way clutches or freewheel devices
• 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 6/48 Parallel type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60K 6/547 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 10/10 including control of change-speed gearings
• CPC Class Codes: B60W 10/119 including control of all-wheel-driveline means, e.g. transfer gears or clutches for dividing torque between front and rear axle B60W10/14 takes precedence
• 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: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10S 903/912 Drive line clutch
• CPC Class Codes: Y10S 903/913 One way
• 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 903/919 : Stepped shift
• 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

Abstract

A hybrid vehicle system is provided with an internal combustion engine driving one set of wheels and an electric motor connected to the other wheels via an active clutch system. A power take-off unit is provided for selectively providing driving torque from the internal combustion engine to the electric motor to operate the motor in a regenerative operating mode. The active clutch system is selectively engaged and disengaged based upon whether the vehicle is operating in an internal combustion engine operating mode, an electric motor operating mode, a combined electric motor and internal combustion engine operating mode, or a regenerative operating mode.

Claims

1. A hybrid motor vehicle, comprising:

an engine having a rotary output;

transmission having a rotary input and a rotary output connected to a first axle assembly having a first pair of wheels;

a first clutch for selectively coupling said engine output to said transmission input for providing driving torque to said first pair of wheels;

an electric motor having a rotary member connected to a second axle assembly having a second pair of wheels;

a transfer unit driven by said engine output;

a second clutch for selectively coupling said transfer unit to said rotary member of said electric motor;

a third clutch for selectively coupling said rotary member of said electric motor to said second axle assembly; and

a hybrid control unit for controlling selective actuation of said electric motor and said first, second and third clutches, such that an electric drive mode is established when said first and second clutches are released, said third clutch is engaged and said electric motor provides drive torque to said second axle assembly for driving said second pair of wheels.

2. The hybrid motor vehicle of claim 1 further comprising:

an engine control unit for controlling operation of said engine; and

a transmission control unit for controlling shifting of said transmission so as to establish various speed ratio drive connections between said transmission input and said transmission output, said hybrid control unit communicating with said engine control unit and said transmission control unit to establish said electric drive mode and an engine drive mode.

3. The hybrid motor vehicle of claim 2 wherein said first clutch is engaged and said second clutch is released during said engine drive mode such that said engine delivers drive torque through said transmission to said first pair of wheels.

4. The hybrid motor vehicle of claim 3 wherein said third clutch can be engaged such that said rotary member of said electric motor is driven by said second axle assembly during said engine drive mode for driving said electric motor as a generator.

5. The hybrid motor vehicle of claim 1 wherein said first clutch is engaged and said second and third clutches are released during an engine drive mode for providing drive torque to said first pair of wheels.

6. The hybrid motor vehicle of claim 5 wherein said second clutch can be selectively engaged during said engine drive mode for driving said rotary member of said electric motor such that said electric motor functions as a generator for charging a battery.

7. The hybrid motor vehicle of claim 1 wherein said first and third clutches are engaged and said second clutch is released during a hybrid engine and electric motor drive mode such that said engine provides drive torque to said first pair of wheels and said electric motor provides drive torque to said second pair of wheels.

8. The hybrid motor vehicle of claim 1 wherein said second axle assembly includes a differential connected to said rotary member of said electric motor for driving a pair of drive axles, and wherein said third clutch includes a pair of clutches for selectively connecting each of said drive axles to a corresponding one of said second pair of wheels.

9. The hybrid motor vehicle of claim 1 wherein said second axle assembly includes a differential and a pair of drive axles connecting said second pair of wheels to said differential, and wherein said third clutch is operable for selectively coupling said rotary member of said electric motor to said differential.

10. A four-wheel drive hybrid vehicle, comprising:

a first pair of wheels;

a second pair of wheels;

an engine;

a power transfer unit driven by said engine;

a first clutch for selectively connecting said engine to said first pair of wheels;

an electric motor;

a second clutch for selectively connecting said power transfer unit to said electric motor; and

a third clutch for selectively connecting said electric motor to said second pair of wheels, and wherein an electric drive mode is established when said first and second clutches are released and said third clutch is engaged such that said electric motor drives said second pair of wheels.

11. The four-wheel drive hybrid vehicle of claim 10 wherein said first clutch is engaged and said third clutch is released during an engine drive mode.

12. The four-wheel drive hybrid vehicle of claim 11 wherein said second clutch may be engaged during said engine drive mode for driving said electric motor as a generator to charge a battery.

13. The four-wheel drive hybrid vehicle of claim 10 wherein said first and third clutches are engaged and said second clutch is released during a hybrid combined engine and motor drive mode such that said engine provides drive torque to said first pair of wheels and said electric motor provides drive torque to said second pair of wheels.

14. The four-wheel drive hybrid vehicle of claim 10 further comprising a control unit for controlling operation of said engine, said electric motor and said first, second and third clutches.

15. The four-wheel drive hybrid vehicle of claim 10 further comprising a transmission that is drivingly connected to said first pair of wheels, and wherein said first clutch is operable for selectively connecting said engine to said transmission.

16. The four-wheel drive hybrid vehicle of claim 10 further comprising a differential driven by said motor and a pair of driveshafts driven by said differential, and wherein said third clutch includes a pair of clutches operable for selectively coupling each of said driveshafts to a corresponding one of said second pair of wheels.

17. The four-wheel drive hybrid vehicle of claim 10 further comprising an axle assembly interconnecting said second pair of wheels, and wherein said third clutch is operable for selectively connecting said electric motor to said axle assembly.

18. A hybrid drive system, comprising

an engine;

a power transfer unit directly driven by said engine;

a first axle assembly having a first pair of wheels;

an electric motor;

a first clutch for selectively transmitting drive torque from said engine to said first axle assembly;

a second clutch for selectively connecting said power transfer unit to said electric motor;

a second axle assembly having a second pair of wheels;

a third clutch for transferring drive torque from said electric motor to said second axle assembly; and

a control unit for controlling operation of said engine and said electric motor and selective actuation of said first, second and third clutches, and wherein an electric drive mode is established when said first and second clutches are released and said third clutch is engaged such that said electric motor drives said second pair of wheels.

19. The hybrid drive system of claim 18 wherein said electric motor has a rotary motor shaft, wherein said second clutch is operable for selectively coupling said power transfer unit to said motor shaft, and wherein said third clutch is operable for transferring drive torque from said motor shaft to said second axle assembly.

20. A hybrid motor vehicle, comprising:

an engine having a rotary output;

a transmission having a rotary input and a rotary output connected to a first axle assembly having a first pair of wheels;

a first clutch for selectively coupling said engine output to said transmission input for providing driving torque to said firs pair of wheels;

an electric motor having a rotary member connected to a second axle assembly having a second pair of wheels;

a transfer unit driven by said engine output;

a second clutch for selectively couplings said transfer unit to said rotary member of said electric motor;

a third clutch for selectively coupling said rotary member of said electric motor to said second axle assembly; and

a hybrid control unit for controlling selective actuation of said electric motor and said first, second and third clutches, whereby a hybrid drive mode is established when said first and third clutches are engaged and said second clutch is released such that said engine transmits drive torque to said first pair of wheels while said electric motor transmits drive torque to said second pair of wheels.

21. A four-wheel drive hybrid vehicle, comprising:

a first pair of wheels;

a second pair of wheels;

an engine;

a power transfer unit driven by said engine;

a first clutch for selectively connecting said engine to said first pair of wheels;

an electric motor;

a second clutch for selectively connecting said power transfer unit to said electric motor; and

a third clutch for selectively connecting said electric motor to said second pair of wheels, and wherein a hybrid drive mode is established when said first and third clutches are engaged and said second clutch is released such that said engine drives said first pair of wheels and said motor drives said second pair of wheels.

22. The four-wheel drive hybrid vehicle of claim 21 wherein said first clutch is engaged and said third clutch is released during an engine drive mode.

23. The four-wheel drive hybrid vehicle of claim 22 wherein said second clutch may be engaged during said engine drive mode for driving said electric motor as a generator to charge a battery.

24. The four-wheel drive hybrid vehicle of claim 21 wherein said first and second clutches are released and said third clutch is engaged during an electric drive mode such that said electric motor drives said second pair of wheels.

25. The four-wheel drive hybrid vehicle of claim 21 further comprising an axle assembly interconnecting said second pair of wheels, and wherein said third clutch is operable for selectively connecting said electric motor to said axle assembly.

26. A hybrid motor vehicle, comprising:

a front axle assembly having a pair of front wheels;

a rear axle assembly having a pair of rear wheels;

an engine;

a transmission driving said rear axle assembly;

a power transfer unit operably disposed between said engine and said transmission and having an input member driven by said engine for rotatively driving an output member;

an electric motor having a rotary motor shaft;

a first clutch operable for selectively coupling said transmission to said engine for transmitting engine drive torque to said rear axle assembly;

a second clutch operable for selectively coupling said motor shaft to said output member of said power transfer unit;

a third clutch operable for selectively coupling said motor shaft to said front axle assembly for transmitting motor drive torque to said front axle assembly; and

a hybrid control system for controlling actuation of said clutches and said electric motor so as to establish one of an electric drive mode and an engine drive mode.

27. The hybrid motor vehicle of claim 26 wherein said electric drive mode is established when said first and second clutches are released and said third clutch is engaged such that said motor drive torque generated by said motor is transmitted to said front wheels.

28. The hybrid motor vehicle of claim 26 wherein said engine drive mode is established when said first clutch is engaged and said second and third clutches are released such that engine drive torque is transmitted through said transmission to said rear wheels.

29. The hybrid motor vehicle of claim 26 wherein a hybrid drive mode is established when said first and third clutches are engaged and said second clutch is released such that said engine transmits engine drive torque to said rear wheels while said motor transmits motor drive torque to said front wheels.