Torque transfer case for a hybrid electric vehicle

• US 7,455,135 B2
• Filed: 08/15/2005
• Issued: 11/25/2008
• Est. Priority Date: 08/15/2005
• Status: Active Grant

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Janson, David, Baldwin, Reid
• Primary Examiner(s): PHAN, HAU VAN
• Application Number:
  US11/161,734
• Publication Number:
  US 20070034427A1
• Time in Patent Office: 1,198 Days
• Field of Search: 180/65.1, 180/65.2, 180/65.4, 180/65.8, 180/247, 180/248, 180/249, 180/197, 180/65.3, 180/65.6, 903/903, 903/916, 903/917, 903/921, 903/940, 290/40.C, 701/22, 701/88
• US Class Current: 180/65.31
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• 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: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y10S 903/916 with plurality of drive axles

Abstract

A torque transfer case for a hybrid electric vehicle powertrain is disclosed. The transfer case receives torque from a power transmission mechanism and distributes driving torque to a primary traction wheel and axle assembly and to a secondary traction wheel and axle assembly wherein an electric motor power boost for each traction wheel and axle assembly is available as well as a regenerative braking power recover from either or both.

Claims

1. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine, a first traction wheel and axle assembly, a second traction wheel and axle assembly, a power transmission mechanism driveably connected to the engine and a torque transfer case with a transfer case torque input shaft connected to a transmission mechanism torque output shaft, the powertrain comprising:

an electric motor;

a first transfer case torque output shaft connected driveably to the first traction wheel and axle assembly;

a second transfer case torque output shaft connected driveably to the second traction wheel and axle assembly;

the electric motor and the first transfer case torque output shaft being assembled on a common first axis;

a torque multiplier gearset;

a torque input element of the torque multiplier gearset being connected driveably to the motor;

the second transfer case torque output shaft being disposed on a second axis that is offset from the first axis;

a torque cross-drive mechanism driveably connecting a torque output element of the torque multiplier gearset to the second transfer case torque output shaft, and a 4×

4 coupler clutch establishing a driving connection between the first transfer case torque output shaft and a torque input element of the torque cross-drive mechanism, the electric motor being connected to the second transfer case torque output shaft only when the 4×

4 coupler clutch is open.

2. The hybrid electric vehicle powertrain set forth in claim 1 wherein the torque cross-drive mechanism includes a cross-drive torque input element located on the first axis intermediate the electric motor and the torque multiplier gearset.

3. The hybrid electric vehicle powertrain set forth in claim 2 wherein the 4×

4 coupler clutch selectively connects a torque output element of the torque multiplier gearset to the first transfer case torque output shaft.

4. The hybrid electric vehicle powertrain set forth in claim 1 wherein the torque multiplier gearset is a planetary gearset with a ring gear, a sun gear and a pinion carrier, the sun gear being driveably connected to the electric motor and the pinion carrier being the torque output element of the torque multiplier gearset.

5. The hybrid electric vehicle powertrain set forth in claim 4 including a torque splitter differential gearset comprising a compound planetary gearset having a sun gear connected driveably to the pinion carrier of the torque multiplier gearset and a pinion carrier connected to the first transfer case torque output shaft.

6. The hybrid electric vehicle powertrain set forth in claim 5 wherein the 4×

4 coupler clutch selectively locks together the sun gear and the pinion carrier of the torque splitter differential gearset to effect a high locked-up ratio and a low locked-up ratio as driving torque is delivered simultaneously to both the first and second traction wheel and axle assemblies.

7. The hybrid electric vehicle powertrain set forth in claim 4 wherein the transfer case includes a torque-splitter differential gearset comprising a simple planetary gearset having a sun gear driveably connected to the pinion carrier of the torque multiplier gearset and a ring gear connected to the first transfer case torque output shaft.

8. The hybrid electric vehicle powertrain set forth in claim 7 wherein the transfer case includes a 4×

4 coupler clutch means for selectively locking together the sun gear and the ring gear of the torque-splitter differential gearset to effect a high locked-up ratio and a low locked-up ratio as driving torque is delivered simultaneously to both the first and second traction wheel and axle assemblies.

9. The hybrid electric vehicle powertrain set forth in claim 4 wherein the 4×

4 coupler clutch selectively connects the pinion carrier to the first transfer case torque output shaft.

10. The hybrid electric vehicle powertrain set forth in claim 1 wherein the transfer case includes a range coupler clutch for selectively connecting driveably the transmission mechanism torque output shaft to the first transfer case torque output shaft and to the torque input element of the torque multiplier gearset.

11. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine, a front traction wheel and axle assembly, a rear traction wheel and axle assembly, a power transmission driveably connected to the engine and a torque transfer case with a transfer case torque input shaft connected to a transmission mechanism torque output shaft, the torque transfer case comprising:

an electric motor;

a first transfer case torque output shaft connected driveably to the rear traction wheel and axle assembly;

a second transfer case torque output shaft being connected driveably to the front traction wheel and axle assembly;

the electric motor and the first transfer case torque input member being assembled on a common first axis;

a torque multiplier gearset drivably connected to the motor;

a torque splitter differential gearset having a first torque output element connected to a torque output element of the torque multiplier gearset;

a range coupler clutch means for selectively connecting the transfer case torque input shaft to a torque splitter differential gearset torque input element and to a torque input element of the torque multiplier gearset;

a second torque output element of the torque splitter differential gearset being driveably connected to the first transfer case torque output shaft; and

a 4×

4 coupler clutch selectively locking together two torque transmitting elements of the torque splitter differential gearset during simultaneous power delivery to the front and rear traction wheel and axle assemblies.

12. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine, a front traction wheel and axle assembly, a rear traction wheel and axle assembly, a power transmission mechanism driveably connected to the engine, and a torque transfer case with a transfer case torque input shaft connected to a transmission mechanism torque output shaft, the powertrain comprising:

an electric motor;

first and second transfer case torque output shafts connected driveably, respectively, to the rear and the front traction wheel and axle assemblies;

a torque multiplier gearset;

a torque splitter differential gearset, the torque multiplier gearset, the motor and the torque splitter differential gearset being mechanically coupled to define torque flow paths for electric and mechanical power delivery to the traction wheel and axle assemblies; and

a range coupler selectively connecting the transmission torque output shaft through the torque-splitter differential gearset to the first torque transfer case torque output shaft for power delivery to the first traction wheel and axle assembly and to the torque input element of the torque multiplier gearset for power delivery to the second traction wheel and axle assembly.

13. The hybrid electric vehicle powertrain set forth in claim 12 wherein the motor is connected driveably to the torque input element of the torque multiplier gear set.

14. The hybrid electric vehicle powertrain set forth in claim 12 wherein the electric motor, the torque multiplier gearset and the torque splitter differential gearset are disposed on a common axis;

and

a cross-drive defining a power flow path to the second transfer case torque output shaft, the cross-drive comprising a driving member disposed on the common axis and a driven member disposed on an axis offset from the common axis, the second transfer case torque output shaft being connected to the cross-drive driven member.

15. A hybrid electric vehicle powertrain for an automotive vehicle comprising an engine and a torque transfer case with a transfer case torque input shaft connected drivably to the engine, the powertrain comprising:

an electric motor;

a first transfer case torque output shaft;

a second transfer case torque output shaft;

the electric motor and the first transfer case torque output shaft being assembled on a common axis;

a torque multiplier gearset;

a torque input element of the torque multiplier gearset being connected driveably to the motor;

a range coupler selectively connecting a transmission mechanism torque output shaft to the first transfer case torque output shaft and to the torque input element of the torque multiplier gearset; and

a torque cross-drive mechanism driveably connecting a torque output element of the torque multiplier gearset to the second transfer case torque output shaft.

16. The hybrid electric vehicle powertrain set forth in claim 15 wherein the second transfer case torque output shaft is disposed on an axis that is offset from and parallel to the common axis.

17. The hybrid electric vehicle powertrain set forth in claim 15 wherein the torque output shaft axis is offset in a lateral direction from the common axis.