Powertrain with input shaft and engine speed synchronization and method for shifting gears in a powertrain

• US 8,292,780 B2
• Filed: 04/28/2008
• Issued: 10/23/2012
• Est. Priority Date: 04/28/2008
• Status: Active Grant

• Current Assignee: AB Volvo
• Original Assignee: MACK Trucks Incorporated (AB Volvo)
• Inventors: Jerwick, John
• Primary Examiner(s): Wright, Dirk
• Application Number:
  US12/935,196
• Publication Number:
  US 20110034297A1
• Time in Patent Office: 1,639 Days
• Field of Search: 477/5
• US Class Current: 477/5
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 2240/486 Operating parameters
• 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 10/11 Stepped gearings
• 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 2510/1015 Input shaft speed, e.g. turbine speed
• CPC Class Codes: B60W 2710/1011 Input shaft speed, e.g. turbine speed
• CPC Class Codes: B60W 30/19 Improvement of gear change, e.g. by synchronisation or smoothing gear shift
• CPC Class Codes: F16H 2061/0422 by an electric machine, e.g. by accelerating or braking the input shaft
• CPC Class Codes: F16H 2306/54 Synchronizing engine speed to transmission input speed
• CPC Class Codes: F16H 61/0403 Synchronisation before shifting
• CPC Class Codes: Y02T 10/62 Hybrid vehicles

Abstract

A powertrain includes a prime mover, a transmission, an input shaft adapted to transmit torque between the prime mover and the transmission, an output shaft adapted to transmit torque between the transmission and a driveline, and a master clutch between the prime mover and the input shaft, the clutch being movable between a disengaged position and an engaged position in which the clutch is not and is adapted to transmit torque between the prime mover and the input shaft, respectively. An electric motor is arranged for torque transmission with at least one of the input shaft and the output shaft, and a controller is provided for controlling the electric motor to rotate the input shaft at a rotational speed within an operating range of the prime mover when the clutch is moved from the disengaged to the engaged position.

Claims

1. A powertain, comprising:

a prime mover;

a transmission;

an input shaft adapted to transmit torque between the prime mover and the transmission;

an output shaft adapted to transmit torque between the transmission and a driveline;

a master clutch between the prime mover and the input shaft, the clutch being movable between a disengaged position and an engaged position in which the clutch is not and is adapted to transmit torque between the prime mover and the input shaft, respectively;

an electric motor arranged for torque transmission with at least one of the input shaft and the output shaft; and

a controller for controlling the electric motor to rotate the input shaft at a rotational speed within a non-zero operating range of the prime mover when the clutch is moved from the disengaged to the engaged position.

2. The powertrain as set forth in claim 1, wherein the electric motor is adapted to operate as a generator to limit the rotational speed of the input shaft.

3. The powertrain as set forth in claim 2, wherein the electric motor it adapted to operate as a motor to increase the rotational speed of the input shaft.

4. The powertrain as set forth in claim 1, wherein the electric motor is adapted to operate as a motor to increase the rotational speed of the input shaft.

5. The powertrain as set forth in claim 1, wherein the controller is arranged to control the electric motor to rotate the input shaft at a rotational speed substantially equal to a rotational speed of a crankshaft of the prime mover.

6. The powertrain as set forth in claim 1, wherein the transmission is an automated manual transmission.

7. The powertrain as set forth in claim 1, wherein the controller is arranged to prevent engagement of the clutch when the rotational speed of the input shaft is below an operating range of the prime mover.

8. The powertrain as set forth in claim 1, wherein the controller is arranged to prevent engagement of the clutch when the rotational speed of the input shaft is above an operating range of the prime mover.

9. The powertrain as set forth in claim 1, wherein the controller is arranged to initiate operation of the electric motor to drive the input shaft in conjunction with the prime mover when the clutch is engaged and rotational speed of the input shaft approaches a lower operating range of the prime mover.

10. The powertrain as set forth in claim 9, wherein the controller is arranged to initiate operation of the electric motor as a generator to limit rotational speed of the input shaft when the clutch is engaged and the input shaft is driven the prime mover and rotational speed of the input shaft approaches upper operating range of the prime mover.

11. The powertrain as set forth in claim 1, wherein the controller is arranged to initiate operation of the electric motor as a generator to limit rotational speed of the input shaft when the clutch is engaged and the input shaft is driven by the prime mover and rotational speed of the input shaft approaches an upper operating range of the prime mover.

12. The powertrain as set forth in claim 1, wherein the electric motor comprises a first electric motor arranged for torque transmission with the input shaft and a second electric motor arranged for torque transmission with the output shaft.

13. The powertrain as set forth in claim 1, wherein the electric motor comprises a first electric motor arranged for torque transmission with the input shaft between the master clutch and the transmission.

14. The powertrain as set forth in claim 1, wherein the powertrain comprises a vocational vehicle.

15. A method for shifting gears in a powertrain, comprising:

disengaging a master clutch between a prime mover and an input shaft to a transmission;

shifting gears in the transmission while the master clutch is disengaged;

engaging the master clutch between the prime mover and the input shaft after shifting gears in the manual transmission;

controlling a rotational speed of the input shaft after shifting gears and prior to engaging the master clutch while the prime mover rotates so that the rotational speed of the input shaft is within an operating range of the prime mover.

16. The method as set forth in claim 15, comprising operating the electric motor as a generator to limit the rotational speed of the input shaft.

17. The method as set forth in claim 16, comprising operating the electric motor as a motor to increase the rotational speed of the input shaft.

18. The method as set forth in claim 15, comprising operating the electric motor as a motor to increase the rotational speed of the input shaft.

19. The method as set forth in claim 15, comprising controlling the electric motor to rotate the input shaft at a rotational speed substantially equal to a rotational speed of a crankshaft of the prime mover.

20. The method as set forth in claim 15, comprising controlling the clutch to prevent engagement of the clutch when the rotational speed of the input shaft is below an operating range of the prime mover.

21. The method as set forth in claim 15, comprising controlling the clutch to prevent engagement of the clutch when the rotational speed of the input shaft is above an operating range of the prime mover.

22. The method as set forth in claim 15, comprising initiating operation of the electric motor to drive the input shaft in conjunction with the prime mover when the clutch is engaged and rotational speed of the input shaft approaches a lower operating range of the prime mover.

23. The method as set forth in claim 22, comprising initiating operation of the electric motor as a generator to limit rotational speed of the input shaft when the clutch is engaged and the input shaft is driven by the prime mover and rotational speed of the input shaft approaches an upper operating range of the prime mover.

24. The method as set forth in claim 15, comprising initiating operation of the electric motor as a generator to limit rotational speed of the input shaft when the clutch is engaged and the input shaft is driven by the prime mover and rotational speed of the input shaft approaches an upper operating range of the prime mover.