Hybrid-vehicle drive system and operation method with a transmission

• US 7,223,200 B2
• Filed: 10/02/2002
• Issued: 05/29/2007
• Est. Priority Date: 10/22/2001
• Status: Expired due to Term

• Current Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Original Assignee: Toyota Jidosha Kabushiki Kaisha (Toyota Motor Corporation)
• Inventors: Taga, Yutaka, Takaoka, Toshifumi, Kojima, Masakiyo
• Primary Examiner(s): LEWIS, TISHA D
• Application Number:
  US10/261,411
• Publication Number:
  US 20030078134A1
• Time in Patent Office: 1,700 Days
• Field of Search: 477/3, 477/15, 477/17, 477/20, 475/2, 475/4, 475/5, 475208-219, 475/302, 475/343, 180/652, 180/65.6, 180/65.7
• US Class Current: 477/3
• 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 6/48 Parallel type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/486 Operating parameters
• 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 10/115 with planetary gears
• 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 2710/0666 Engine torque
• CPC Class Codes: B60W 2710/083 Torque
• CPC Class Codes: B60W 2710/105 Output torque
• CPC Class Codes: B60W 30/18036 Reversing
• 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 2059/085 Power mode
• 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: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility

Abstract

A hybrid-vehicle drive method and system includes an internal combustion engine that includes an output shaft, a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism, a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism, a second electric motor/generator connected to the wheel drive shaft, and a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft.

Claims

1. A hybrid-vehicle drive system, comprising:

an internal combustion engine that includes an output shaft;

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft;

a transmission located on a connecting portion of the second electric motor/generator with the wheel drive shaft, wherein the transmission has a plurality of forward-drive gear positions and a reverse-drive gear position; and

a controller that selects a reverse driving mode from a first mode in which the transmission is placed in the reverse-drive gear position and a second mode in which the power distribution mechanism is adjusted to drive the vehicle in a reverse direction.

2. A method of operating a hybrid-vehicle drive system comprising:

(a) an internal combustion engine that includes an output shaft;

(b) a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

(c) a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

(d) a second electric motor/generator connected to the wheel drive shaft; and

(e) a transmission located on the wheel drive shaft, the method comprising the steps of;

setting a gear position of the transmission to a first gear position having a predetermined high-speed gear ratio as a first gear ratio; and

maintaining the transmission in the first gear position irrespective of changes in a vehicle speed, as long as the hybrid-vehicle drive system is able to provide a required value of a torque at vehicle axles while the internal combustion engine is operated at a high fuel efficiency.

3. The method according to claim 2, wherein the transmission is set and maintained in a second gear position having a second gear ratio that is larger by one level than the first gear ratio, irrespective of changes in the vehicle speed, as long as the hybrid-vehicle drive system is able to provide the required value of the torque at the vehicle axles but not if the transmission is placed in the first gear position.

4. The method according to claim 3, wherein the transmission is set and maintained in a third gear position having a third gear ratio that is larger by one level than the second gear ratio, irrespective of changes in the vehicle speed, as long as the hybrid-vehicle drive system is able to provide the required value of the torque at the vehicle axles but not if the transmission is placed in the second gear position.

5. The method according to claim 2, wherein shifting of the transmission from one gear position to another gear position is inhibited for a predetermined period of time after the transmission is shifted to said one gear position.

6. The method according to claim 2, wherein the hybrid-vehicle drive system provides a required value of torque at vehicle axles by changing a power of at least one of the first and second electric motor/generators, instead of changing a gear position of the transmission, for a predetermined period of time.

7. The method according to claim 2, wherein:

the hybrid-vehicle drive system is selectively placed in one of a normal operating mode and a sporty operating mode; and

when the hybrid-vehicle drive system is placed in the sporty operating mode, a control operation to keep the transmission in a predetermined high-speed gear position is cancelled irrespective of changes in vehicle speed.

8. A method of operating a hybrid-vehicle drive system including:

(a) an internal combustion engine that includes an output shaft;

(b) a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

(c) a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

(d) a second electric motor/generator connected to the wheel drive shaft; and

(e) a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft, the method comprising;

changing a ratio of a first torque produced at vehicle axles by the internal combustion engine to a second torque produced at the vehicle axles by the second electric motor/generator at each gear position of the transmission to a fault ratio of the first torque to the second torque when one of the internal combustion engine and the second electric motor/generator is faulty, from a normal ratio of the first torque to the second torque when both of the internal combustion engine and the second electric motor/generator operate normally.

9. The method according to claim 8, wherein the ratio of the torque produced by the internal combustion engine to the torque produced by the second electric motor/generator, when viewed in a coordinate system representing a relationship between a vehicle speed and the torque, is changed in accordance with gear-position regions into which an operable region defined by the vehicle speed and the torque is divided by boundary lines that extend in parallel with a vehicle-speed axis of the coordinate system.

10. The method according to claim 9, wherein the ratio of the torque produced by the internal combustion engine to the torque produced by the second electric motor/generator, when viewed in the vehicle-speed versus torque coordinate system, is changed by moving the boundary lines in a direction parallel with a torque axis of the coordinate system, when one of the internal combustion engine and the second electric motor/generator is faulty.

11. A hybrid-vehicle drive system, comprising:

an internal combustion engine that includes an output shaft;

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft;

a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft, the transmission having a plurality of forward-drive gear positions and a reverse-drive gear position, the reverse-drive gear position being established through engagement or disengagement of an engaging device provided in the transmission, the transmission including a planetary gear mechanism having a sun gear, a ring gear, planetary pinions and a carrier; and

a controller that selects a reverse driving mode from a first mode in which the transmission is placed in the reverse-drive gear position and a second mode in which the power distribution mechanism is adjusted to drive the vehicle in a reverse direction.

12. The hybrid-vehicle drive system according to claim 11, wherein the transmission is located at the wheel drive shaft on one side of the connecting portion of the second electric motor/generator which is closer to the internal combustion engine.

13. The hybrid-vehicle drive system according to claim 11, wherein the transmission is located at the wheel drive shaft on one side of the connecting portion of the second electric motor/generator which is remote from the internal combustion engine.

14. A hybrid-vehicle drive system, comprising:

an internal combustion engine that includes an output shaft;

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft;

a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft, the transmission having a plurality of forward-drive gear positions and a reverse-drive gear position; and

a controller that selects a reverse driving mode from a first mode in which the transmission is placed in the reverse-drive gear position and a second mode in which the power distribution mechanism is adjusted to drive the vehicle in a reverse direction.

15. The hybrid-vehicle drive system according to claim 14, wherein the transmission is located at the wheel drive shaft on one side of the connecting portion of the second electric motor/generator which is closer to the internal combustion engine.

16. The hybrid-vehicle drive system according to claim 14, wherein the transmission is located at the wheel drive shaft on one side of the connecting portion of the second electric motor/generator which is remote from the internal combustion engine.

17. A hybrid-vehicle drive system, comprising:

an internal combustion engine that includes an output shaft;

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft;

a transmission located on a connecting line or path between the second electric motor/generator and the wheel drive shaft, wherein the transmission has a plurality of forward-drive gear positions and a reverse-drive gear position; and

a controller that selects a reverse driving mode from a first mode in which the transmission is placed in the reverse-drive gear position and a second mode in which the power distribution mechanism is adjusted to drive the vehicle in a reverse direction.

18. A method of operating a hybrid-vehicle drive system including:

(a) an internal combustion engine that includes an output shaft;

(b) a first electric motor/generator connected to the output shaft of the internal combustion engine via a single power distribution mechanism;

(c) a wheel drive shaft connected to the output shaft of the internal combustion engine via the single power distribution mechanism;

(d) a second electric motor/generator connected to the wheel drive shaft; and

(e) a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft, the method comprising;

mutually compensating by the transmission an engine torque by the internal combustion engine and a motor torque by the second electric motor/generator, the engine and motor torques produced at vehicle axles at each gear position of the transmission when one of the internal combustion engine and the second electric motor/generator is faulty.

19. A hybrid-vehicle drive system comprising:

an internal combustion engine that includes an output shaft;

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft; and

a transmission located on the wheel drive shaft, wherein

a gear position of the transmission is set to a first gear position having a predetermined high-speed gear ratio as a first gear ratio; and

the transmission is maintained in the first gear position irrespective of changes in a vehicle speed, as long as the hybrid-vehicle drive system is able to provide a required value of a torque at vehicle axles while the internal combustion engine is operated at a high fuel efficiency.

20. The hybrid-vehicle drive system according to claim 19, wherein

the transmission is set and maintained in a second gear position having a second gear ratio that is larger by one level than the first gear ratio, irrespective of changes in the vehicle speed, as long as the hybrid-vehicle drive system is able to provide the required value of the torque at the vehicle axles but not if the transmission is placed in the first gear position.

21. The hybrid-vehicle drive system according to claim 20, wherein

the transmission is set and maintained in a third gear position having a third gear ratio that is larger by one level than the second gear ratio, irrespective of changes in the vehicle speed, as long as the hybrid-vehicle drive system is able to provide the required value of the torque at the vehicle axles but not if the transmission is placed in the second gear position.

22. The hybrid-vehicle drive system according to claim 19, wherein

shifting of the transmission from one gear position to another gear position is inhibited for a predetermined period of time after the transmission is shifted to said one gear position.

23. The hybrid-vehicle drive system according to claim 19, wherein

the hybrid-vehicle drive system provides a required value of torque at the vehicle axles by changing a power of at least one of the first and second electric motor/generators, instead of changing a gear position of the transmission, for a predetermined period of time.

24. The hybrid-vehicle drive system according to claim 19, wherein

the hybrid-vehicle drive system is selectively placed in one of a normal operating mode and a sporty operating mode, and when the hybrid-vehicle drive system is placed in the sporty operating mode, a control operation to maintain the transmission in the predetermined high-speed gear position is cancelled irrespective of changes in vehicle speed.

25. A hybrid-vehicle drive system comprising:

an internal combustion engine that includes an output shaft

a first electric motor/generator connected to the output shaft of the internal combustion engine via a power distribution mechanism;

a wheel drive shaft connected to the output shaft of the internal combustion engine via the power distribution mechanism;

a second electric motor/generator connected to the wheel drive shaft; and

a transmission located on at least one of the wheel drive shaft and a connecting portion of the second electric motor/generator with the wheel drive shaft, wherein

a ratio of a first torque produced at vehicle axles by the internal combustion engine to a second torque produced at the vehicle axles by the second electric motor/generator at each gear position of the transmission is changed when one of the internal combustion engine and the second electric motor/generator is faulty, from the ratio of the first torque to the second torque when both of the internal combustion engine and the second electric motor/generator operates normally.

26. The hybrid-vehicle drive system according to claim 25, wherein

the ratio of the first torque produced by the internal combustion engine to the second torque produced by the second electric motor/generator, when viewed in a coordinate system representing a relationship between a vehicle speed and the torque, is changed in accordance with gear-position regions into which an operable region defined by the vehicle speed and the torque is divided by boundary lines that extend in parallel with a vehicle-speed axis of the coordinate system.

27. The hybrid-vehicle drive system according to claim 26, wherein

the ratio of the first torque produced by the internal combustion engine to the second torque produced by the second electric motor/generator, when viewed in the vehicle-speed versus torque coordinate system, is changed by moving the boundary lines in a direction parallel with a torque axis of the coordinate system, when one of the internal combustion engine and the second electric motor/generator is faulty.