Transmission arrangements for hybrid electric vehicles

• US 7,086,977 B2
• Filed: 12/29/2003
• Issued: 08/08/2006
• Est. Priority Date: 05/03/2001
• Status: Expired due to Term

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Kozarekar, Shailesh, Supina, Joseph
• Primary Examiner(s): ESTREMSKY, SHERRY LYNN
• Application Number:
  US10/747,427
• Publication Number:
  US 20040166980A1
• Time in Patent Office: 953 Days
• Field of Search: 475/1, 475/5, 475/151, 475/207, 475/198, 475/201, 475/203, 475/223, 475/225, 475/302, 180/65.2, 180/65.4, 180/65.6
• US Class Current: 475/5
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60K 6/448 Electrical distribution type
• CPC Class Codes: B60K 6/54 Transmission for changing ratio
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2240/44 related to combustion engines
• CPC Class Codes: B60L 2240/486 Operating parameters
• CPC Class Codes: B60L 2240/507 Operating parameters
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• 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 20/30 Control strategies involving selection of transmission gear ratio control of change speed gearings, together with other vehicle sub-units B60W10/10; HEV transmission gearing B60K6/36; gearings and control thereof F16H
• 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: B60W 30/18027 Drive off, accelerating from standstill
• CPC Class Codes: F16H 2037/0866 Power split variators with distributing differentials, with the output of the CVT connected or connectable to the output shaft
• CPC Class Codes: F16H 2200/0034 : the gear ratios comprising two forward speeds
• CPC Class Codes: F16H 2200/2005 : with one sets of orbital gears
• CPC Class Codes: F16H 2200/2007 : with two sets of orbital gears
• CPC Class Codes: F16H 3/725 : with means to change ratio in the mechanical gearing
• CPC Class Codes: F16H 3/727 : with at least two dynamo electric machines for creating an electric power path inside the gearing, e.g. using generator and motor for a variable power torque path special adapted for a hybrid electric vehicle B60K6/20
• CPC Class Codes: F16H 3/728 : with means to change ratio in the mechanical gearing
• CPC Class Codes: F16H 37/046 : with an additional planetary gear train, e.g. creep gear, overdrive
• CPC Class Codes: F16H 57/0439 : using multiple pumps with different power sources or a single pump with different power sources, e.g. one and the same pump may selectively be driven by either the engine or an electric motor
• 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

Abstract

A geared, power transmission mechanism for a hybrid electric vehicle wherein multiple power flow paths are established between an engine and vehicle traction wheels and between an electric motor and the vehicle traction wheels. At least one of the power flow paths is characterized by at least two ratios.

Claims

1. A powertrain for a hybrid electric vehicle having an engine, an electric generator and an electric motor acting as a pair of drive power sources for driving vehicle traction wheels, the powertrain comprising:

gear elements drivably connecting the pair of power sources to the traction wheels through first and second geared power flow paths, gear elements defining at least one geared power flow path having at least two gear ratios;

one of the pair of drive power sources being connected by the gear elements to the traction wheels through the first geared power flow path independently of the second geared power flow; and

a clutch in the one geared power flow path connecting together two gear elements of the one geared power flow path to establish a first of the two gear ratios when it is engaged, a second gear ratio in the one geared power flow path being established when the clutch is disengaged.

2. The powertrain set forth in claim 1 wherein the first geared power flow path comprises a first planetary gear unit, the first planetary gear unit having a sun gear connected to the generator, a carrier connected to the engine and a ring gear connected drivably to a second planetary gear unit;

the engine defining one power source on an engine axis and the motor defining in part another power source on a motor axis; and

a clutch and brake friction element sub-assembly for the second planetary gear unit establishing selectively each of the gear ratios;

the motor being connected drivably to the traction wheels through fixed ratio gear elements and the second planetary gear unit being connected drivably to the traction wheels to complement motor driving power.

3. The powertrain set forth in claim 2 wherein the first planetary gear unit is disposed on the engine axis and the second planetary gear unit is disposed on an axis that is offset from and parallel to the engine axis.

4. The powertrain set forth in claim 1 wherein the first planetary gear unit and the second planetary gear unit are disposed on a common axis coinciding with the engine axis.

5. The powertrain set forth in claim 1 wherein the vehicle traction wheels are rear traction wheels, the first and second geared power flow paths sharing common gear elements, the gear elements defining a rear wheel drive powertrain configuration.

6. The powertrain set forth in claim 1 including an electric generator brake for braking the generator thereby providing a torque reaction for the gear elements to establish a fully mechanical power flow path from the engine.

7. The powertrain set forth in claim 1 including a second clutch in the one geared power flow path, the second clutch being engaged during operation in the second gear ratio and disengaged during operation in the first gear ratio.

8. The powertrain set forth in claim 1 wherein one geared power flow path comprises a planetary gear unit with a sun gear, a ring gear and a planetary carrier;

the generator being connected to the sun gear, the engine being connected to the carrier and the ring gear being drivably connected to the traction wheels.

9. A powertrain for a hybrid electric vehicle having an engine, an electric generator and an electric motor defining a pair of power sources, the powertrain comprising:

a planetary gear unit with a first planetary element connected drivably to the generator and a second planetary element connected drivably to the engine whereby a first power flow path to vehicle traction wheels is established;

a geared connection between the motor and the vehicle traction wheels, the geared connection defining a second power flow path that is independent of the first power flow path while sharing with the first power flow path at least one gear element; and

a clutch friction element sub-assembly for establishing, when it is selectively engaged and disengaged, each of two gear ratios in the planetary gear unit.

10. The powertrain set forth in claim 9 wherein the planetary gear unit comprises a high ratio power output gear element and a low ratio power output gear element, the geared connection comprising countershaft gearing on a countershaft axis spaced from and parallel to an axis for the engine and an axis for the motor;

and

a selectively engageable clutch on the countershaft axis to connect the high ratio power output gear element, when it is engaged and the clutch friction element sub-assembly is disengaged, to the vehicle traction wheels, the low ratio power output gear element being connected to the vehicle traction wheels when the clutch on the countershaft axis is disengaged and the clutch friction element sub-assembly is engaged.

11. The powertrain set forthin claim 10 wherein:

the countershaft gearing comprises two gear elements of different pitch diameter, the selectively engageable clutch on the countershaft axis connecting drivably the smaller of the two countershaft gear elements to the vehicle traction wheels to establish a first countershaft gear ratio;

the larger of the two countershaft gear elements being connected drivably to the vehicle traction wheels to establish a second countershaft gear ratio when the selectively engageable clutch on the countershaft axis is open.

12. The powertrain set forth in claim 11 wherein the planetary gear unit comprises a brake for anchoring the second planetary gear element whereby the planetary gear unit is conditioned for reverse drive as the engine is braked;

the planetary gear unit being conditioned for forward drive in each gear ratio when the brake is released;

the brake, when it is applied, accommodating generator torque reaction thereby enabling the generator to enhance motor torque when the motor operates in reverse drive.

13. The powertrain set forth in claim 12 wherein the ring gear is drivably connected to the traction wheels through another planetary gear unit defining the at least two gear ratios.

14. The powertrain set forth in claim 13 wherein the other planetary gear unit is disposed on a countershaft axis that is parallel to an axis for the engine.

15. The powertrain set forth in claim 13 wherein both planetary gear units are disposed on axes that are common to an engine axis.

16. The powertrain set forth in claim 10 wherein the planetary gear unit comprises a brake for anchoring the second planetary gear element whereby the planetary gear unit is conditioned for reverse drive as the engine is braked;

the planetary gear unit being conditioned for forward drive in each gear ratio when the brake is released;

the brake, when it is applied, accommodating generator torque reaction thereby enabling the generator to enhance motor torque when the motor operates in reverse drive.

17. The powertrain set forth in claim 9 wherein the planetary gear unit comprises a brake for anchoring the second planetary gear element whereby the planetary gear unit is conditioned for reverse drive as the engine is braked;

the planetary gear unit being conditioned for forward drive in each gear ratio when the brake is released;

the brake, when it is applied, accommodating generator torque reaction thereby enabling the generator to enhance motor torque when the motor operates in reverse drive.

18. The powertrain set forth in claim 17 wherein the enhancement of motor torque effects power distribution to the traction wheels at the same power level for both forward drive and reverse drive.

19. The powertrain set forth in claim 9 including an electric generator brake for braking the generator thereby providing a torque reaction for the planetary gear unit to establish a fully mechanical power flow path from the engine.

20. The powertrain set forth in claim 9 including a second clutch in the first power flow path, the second clutch being disengaged when the clutch friction element sub-assembly is engaged during operation in one of the two gear ratios and engaged during operation in a second of the two gear ratios.