Electric hybrid powertrain system

• US 7,572,201 B2
• Filed: 09/06/2006
• Issued: 08/11/2009
• Est. Priority Date: 10/20/2005
• Status: Active Grant

• 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): Lewis; Tisha D
• Application Number:
  US11/470,361
• Publication Number:
  US 20070093341A1
• Time in Patent Office: 1,070 Days
• Field of Search: 475/4, 475/5, 180/65.6, 180/65.7, 903/903, 903/909, 903/911, 903/915, 903/917
• US Class Current: 475/5
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 17/344 having a transfer gear
• 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 6/46 Series type
• 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: 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: F16H 2037/0873 with switching, e.g. to change ranges
• CPC Class Codes: F16H 2200/0034 the gear ratios comprising two forward speeds
• CPC Class Codes: F16H 2200/2007 with two sets of orbital gears
• CPC Class Codes: F16H 2200/2023 using a Ravigneaux set with 4 connections
• CPC Class Codes: F16H 2200/2041 with four engaging means
• CPC Class Codes: F16H 2200/2064 using at least one positive clutch, e.g. dog clutch
• CPC Class Codes: F16H 3/728 with means to change ratio in the mechanical gearing
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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: Y10S 903/911 : with two or more gear sets
• CPC Class Codes: Y10S 903/917 : with transmission for changing gear ratio

Abstract

A hybrid electric vehicle powertrain having an engine and an electric motor and generator sub-system, which establish mechanical and electric power flow paths. Multiple-ratio gearing in a power flow path for forward drive enhances vehicle traction torque for heavy-duty vehicle applications. Reverse drive performance is enhanced by torque multiplying gearing in a reverse drive power delivery path.

Claims

1. A hybrid electric vehicle powertrain comprising an engine, an electric motor, an electric generator, a battery and gearing defining power flow paths between the motor and vehicle traction wheels and between the engine and the vehicle traction wheels;

the gearing including a gear unit having at least one power input gear element, a power output gear element and a reaction gear element, the power input gear element being in the power flow path between the engine and first vehicle traction wheels, the power output gear element being connected drivably to the first vehicle traction wheels; and

a clutch and brake assembly for establishing forward drive gearing ratios and one reverse drive gearing ratio in the gear unit;

the motor being mechanically connected to second vehicle traction wheels;

the generator, the motor and the battery being electrically coupled in the power flow path between the motor and the traction wheels;

the gearing further including a powersplit planetary gearset having one gearset element connected to the engine, a second gearset element connected to the generator and a third gearset element connected by the clutch and brake assembly to the at least one power input element of the gear unit.

2. The hybrid electric vehicle powertrain set forth in claim 1 wherein the gear unit is a compound planetary gear unit with two compound planetary gear unit power input elements;

the clutch and brake assembly having selectively engageable clutches for connecting separately and third gearset element to the two compound planetary gear unit power input element.

3. The hybrid electric vehicle powertrain set forth in claim 2 wherein the selectively engageable clutches are wet clutches with lubricated friction material on friction torque members of the wet clutches.

4. The hybrid electric vehicle powertrain set forth in claim 2 wherein the selectively engageable clutches are synchronizer clutches under the control of a transmission control module.

5. The hybrid electric vehicle powertrain set forth in claim 1 wherein the powersplit planetary gearset has a simple planetary gear arrangement with a sun gear, a ring gear, a carrier and planet pinions mounted on the carrier;

the second gearset element being the sun gear connected drivably to the generator;

the one gearset element being the carrier connected to at least the engine; and

the third gearset element being the ring gear connected to the at least one power input gear element of the gear unit by the clutch and brake assembly.

6. The hybrid electric vehicle powertrain set forth in claim 2 wherein the powersplit planetary gearset has a simple planetary gear arrangement with a sun gear, a ring gear, a carrier and planet pinions mounted on the carrier;

the sun gear being connected drivably to the generator;

the engine being connected drivably to the carrier; and

the ring gear being connected separately by the clutch and brake assembly to the two compound planetary gear unit power input elements.

7. The hybrid electric vehicle powertrain set forth in claim 1 wherein the third gearset element is adapted to be braked by the clutch and brake assembly whereby the engine drives the generator to charge the battery as the motor drives the vehicle traction wheels in a hybrid-series operating mode.

8. A hybrid electric powertrain for a vehicle having front and rear traction wheels comprising an engine, an electric motor, an electric generator, a battery and gearing defining power flow paths between the engine and a first power output shaft and between the motor and a second power output shaft

the gearing including a gear unit and a powersplit planetary gearset, the gear unit comprising a power input gear element and a reaction gear element, the power input gear element being in a power flow path between the engine and the vehicle rear traction wheels, a power output element of the gear unit being connected drivably to the rear traction wheels through the first power output shaft;

and

a clutch and brake assembly for establishing two forward drive gearing ratios and one reverse drive gearing ratio in the power flow path for the engine;

the generator, the motor and the battery being electrically coupled by the planetary gearset in the power flow path between the motor and the front traction wheels through the second power output shaft

the power flow path between the motor and the front traction wheels including a front wheel driveshaft extending in a direction offset from and parallel to an axis for the gearing;

the gear unit being a compound planetary gear unit with two compound planetary gear unit power input elements;

the clutch and brake assembly having selectively engageable clutches for connecting separately a gearset element to of the powersplit gearest to the two compound planetary gear unit power input elements.

9. The hybrid electric powertrain set forth in claim 8 wherein the selectively engageable clutches are wet clutches with lubricated friction material on friction torque members of the wet clutches.

10. The hybrid electric vehicle powertrain set forth in claim 8 wherein the selectively engageable clutches are synchronizer clutches under the control of a transmission control module.

11. The hybrid electric powertrain set forth in claim 8 wherein the powersplit planetary gearset has a simple planetary gear arrangement with a sun gear, a ring gear, a carrier and planet pinion mounted on the carrier;

the sun gear being connected drivably to the generator;

the engine being connected drivably to the carrier;

the ring gear being connected drivably to the power input gear element of the gear unit by the clutch and brake assembly.

12. The hybrid electric powertrain set forth in claim 8 wherein the powersplit planetary gearset has a simple planetary gear arrangement with a sun gear, a ring gear, a carriers and planet pinions mounted on the carrier;

the sun gear being connected drivably to the generator;

the engine being connected drivably to the carrier;

the ring gear being connected separately by the clutch and brake assembly to the two compound planetary gear unit power input elements.

13. The hybrid electric powertrain set forth in claim 11 wherein the gearset element is adapted to be braked by the clutch and brake assembly whereby the engine drives the generator to charge the battery as the motor drives the vehicle traction wheels in a hybrid-series operating mode.

16. The hybrid electric vehicle powertrain set forth in claim 8 wherein the generator is mounted on a generator axis that is transversely offset from and parallel to a motor axis.

17. The hybrid electric vehicle powertrain set forth in claim 8 wherein the motor is mounted on a motor axis that is transversely offset from and parallel to the second power output shaft.

14. A hybrid electric powertrain for a vehicle having front and rear traction wheels comprising an engine, an electric motor, an electric generator, a battery and gearing defining power flow paths between the engine and a first power output shaft and between the motor and a second power output shaft;

the gearing having at least one power input gear element and a reaction gear element, the power input element being in the power flow path between the engine and vehicle rear traction wheels, a power output element of the gearing being connected drivably to the rear traction wheels through the first power output shaft; and

a clutch and brake assembly for establishing two forward drive gearing ratios and one reverse drive gearing ratio;

the motor being connected drivably to front traction wheels through the second power output shaft;

the generator, the motor and the battery being electrically coupled in the power flow path between the motor and front traction wheels;

the power flow paths between the engine and the rear traction wheels and between the motor and the front traction wheels are braking power delivery paths from the traction wheel whereby the motor acts as a generator and stores electrical energy in the battery; and

a disconnect clutch in the braking power delivery path from the front traction wheels for disconnecting the rear traction wheels from the front traction wheels if braking power from the front traction wheels exceeds braking power from the rear traction wheels whereby skidding of the rear traction wheels is avoided during vehicle braking.

15. The hybrid electric vehicle powertrain set forth in claim 14 wherein the power flow path between the motor and the second power flow path includes a motor speed sensitive clutch between the motor and the front traction wheels whereby the speed sensitive clutch is disengaged to interrupt the power flow path between the motor and the first power output shaft if motor speed exceeds a pre-determined value.