Vehicle propulsion system having a continuously variable transmission and method of making same

• US 8,535,200 B2
• Filed: 03/17/2009
• Issued: 09/17/2013
• Est. Priority Date: 03/17/2009
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Vyas, Parag, Hernandez, Yaru Mendez, Fiseni, Alexander Felix
• Primary Examiner(s): Restifo, Jeffrey J
• Application Number:
  US12/405,874
• Publication Number:
  US 20100240492A1
• Time in Patent Office: 1,645 Days
• Field of Search: 180/65.265, 180/65.285, 180/65.28, 477/3, 475/5
• US Class Current: 477/3
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/543 the transmission being a continuously variable transmission
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• 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 10/10 including control of change-speed gearings
• CPC Class Codes: B60W 10/107 with endless flexible members
• CPC Class Codes: B60W 10/11 Stepped 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 30/18027 Drive off, accelerating from standstill
• CPC Class Codes: F16H 37/021 toothed gearing combined with continuous variable friction gearing
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A vehicle propulsion system includes an electric machine (EM) configured to generate an unconditioned output. The vehicle propulsion system also includes a continuously variable transmission (CVT) having an input side and an output side, the input side mechanically coupled to the EM and configured to receive the unconditioned output from the EM and produce a conditioned output on the output side. A fixed-ratio transmission is mechanically coupled to the output side of the CVT and configured to receive the conditioned output from the CVT and produce a reconditioned output.

Claims

1. A vehicle propulsion system comprising:

an electric machine (EM) configured to generate an unconditioned output;

a continuously variable transmission (CVT) having an input shaft and an output shaft, the input shaft mechanically coupled to the EM and configured to receive the unconditioned output from the EM and output a conditioned output on the output shaft; and

a fixed-ratio transmission mechanically coupled to the output shaft of the CVT and configured to;

receive the conditioned output from the CVT; and

produce a reconditioned output; and

wherein the fixed-ratio transmission is coupled to the CVT absent a geared connection between the CVT and the fixed-ratio transmission that bypasses the output shaft of the CVT.

2. The vehicle propulsion system of claim 1 wherein the fixed-ratio transmission is configured to deliver the reconditioned output to a vehicle traction system.

3. The vehicle propulsion system of claim 2 wherein the vehicle traction system comprises a differential coupled to an output of the fixed-ratio transmission.

4. The vehicle propulsion system of claim 2 wherein the vehicle traction system comprises a drive shaft and a plurality of wheels.

5. The vehicle propulsion system of claim 1 further comprising a battery storage unit electrically connected to the EM.

6. The vehicle propulsion system of claim 1 further comprising a bidirectional controller electrically connected to the EM and configured to determine a desired propulsion system output.

7. The vehicle propulsion system of claim 6 wherein the bidirectional controller is further configured to selectively operate at least one of the EM and the CVT based on the desired propulsion system output.

8. The vehicle propulsion system of claim 6 further comprising an internal combustion engine (ICE) mechanically connected between the EM and the input shaft of the CVT and configured to deliver an ICE output to the CVT.

9. The vehicle propulsion system of claim 8 wherein the bidirectional controller is further configured to selectively operate the CVT to condition the ICE output based on the desired propulsion system output.

10. The vehicle propulsion system of claim 8 further comprising a clutch positioned between the ICE and the input shaft of the CVT.

11. A vehicle having a vehicle propulsion system, the vehicle comprising:

a vehicle traction system;

an electro-mechanical device configured to produce an unconditioned output;

a continuously variable transmission (CVT) having an input shaft and an output shaft, the input shaft directly coupled to an output of the electro-mechanical device and configured to receive the unconditioned output, condition the unconditioned output by transmitting the unconditioned output from a first pair of sheaves of the CVT to a second pair of sheaves of the CVT, and output a conditioned output on the output shaft; and

a fixed-ratio transmission directly coupled to the output shaft of the CVT and configured to;

receive the conditioned output from the CVT; and

deliver a desired vehicle propulsion system output to the vehicle traction system; and

wherein a distance between respective sheaves of the first and second pair of sheaves defines a gear ratio of the CVT.

12. The vehicle of claim 11 further comprising a controller configured to:

operate the electro-mechanical device to produce the unconditioned output;

monitor vehicle operating conditions to determine the desired propulsion system output;

control the CVT to selectively condition the output from the electro-mechanical device; and

control the fixed-ratio transmission to recondition the conditioned output from the CVT and generate the desired propulsion system output.

13. The vehicle of claim 12 wherein the controller is further configured to operate the fixed-ratio transmission to deliver the reconditioned output to a differential.

14. The vehicle of claim 12 wherein the controller is further configured to:

operate the CVT at a fixed gear ratio for a first time period; and

operate the CVT at a variable gear ratio for a second time period.

15. The vehicle of claim 14 wherein the controller is further configured to selectively adjust the variable gear ratio to achieve a desired output torque.

16. The vehicle of claim 14 wherein the controller is further configured operate the CVT at the fixed gear ratio until a rotational speed of the electro-mechanical device reaches a threshold speed.

17. The vehicle of claim 12 wherein the controller is further configured to selectively operate the electro-mechanical device to charge a battery storage unit.

18. The vehicle of claim 12 wherein the controller is further configured to selectively operate the CVT within a desired region of operation to maximize an operating efficiency of the vehicle propulsion system.

19. The vehicle of claim 12 wherein the controller is further configured to selectively operate an internal combustion engine (ICE) to produce an ICE output, the ICE positioned between the output of the electro-mechanical device and the input shaft of the CVT.

20. The vehicle of claim 19 wherein the controller is further configured to operate the ICE within an optimal speed range to maximize an operating efficiency of the ICE.

21. The vehicle of claim 19 wherein the controller is further configured to selectively disengage a mechanical bypass between the ICE and the CVT and operate the electro-mechanical device and the CVT to produce the desired propulsion system output.

22. The vehicle of claim 21 wherein the controller is further configured to operate the ICE to charge a battery storage unit.

23. A method of fabricating a vehicle power system comprising:

coupling an output of an electric motor (EM) to a continuously variable transmission (CVT) having an input shaft and an output shaft;

coupling a fixed transmission to the output shaft of the CVT and absent a geared connection between the fixed transmission and the input shaft of the CVT that bypasses the output shaft of the CVT; and

coupling the fixed transmission to a vehicle traction system, the fixed transmission configured to modify an output of the CVT and deliver the modified CVT output to the vehicle traction system.

24. The method of claim 23 further comprising:

coupling an input of an internal combustion engine (ICE) to the output of the EM; and

coupling an output of the ICE to the input shaft of the CVT.

25. The method of claim 24 further comprising:

coupling a battery storage unit to the ICE; and

configuring the ICE to deliver an auxiliary power to the battery storage unit.

26. The method of claim 23 wherein coupling the fixed transmission to the vehicle traction system comprises coupling the fixed transmission to a differential.