System, architecture, and method for minimizing power consumption and increasing performance in electric vehicles

• US 9,676,295 B2
• Filed: 12/11/2013
• Issued: 06/13/2017
• Est. Priority Date: 07/21/2010
• Status: Active Grant

• Current Assignee: Superior Electron LLC
• Original Assignee: Superior Electron LLC
• Inventors: Zing, Christopher P., Wiest, Joachim H., Fung, Henry T.
• Primary Examiner(s): Ip, Paul
• Application Number:
  US14/103,308
• Publication Number:
  US 20140100732A1
• Time in Patent Office: 1,280 Days
• Field of Search: 318 8, 318 13, 318 34, 318139, 475 5, 475 6, 475275, 701 22, 180 6525, 180 65265
• CPC Class Codes: B60L 15/2045 for optimising the use of energy
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2220/42 with use of more than one motor
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: H05K 999/99 dummy group
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An electric vehicle accomplishes speed changes through the use of electronically controlled, multiple electric motor configurations that are coupled to an output drive shaft instead of a speed change transmission. A parallel-coupled motor configuration includes at least two motors that are each coupled to the output drive shaft through respective gear arrangements, each gear arrangement having a respective gear ratio. In a serially-coupled motor configuration, the stator of the second motor is coupled to the rotor of the first motor, where the rotor of the second motor is coupled to the output drive shaft. The required torque to reach or maintain a desired vehicle speed can be obtained by selective energization of either one or both of the motors (in both multi-motor configurations). Two motors are also coupled to a differential gear so that the rotational speed contributed by both motors are additive at the output shaft.

Claims

1. An electrical drive system for a vehicle, the drive system comprising:

a drive arrangement configured for connection with a vehicle wheel;

a parallel gear set connected to the drive arrangement wherein said parallel gear set includes first and second inputs;

a differential gear set including an output connected to said second input of the parallel gear set;

a plurality of electric motors including a first motor, a second motor, and a third motor, the second motor connected to said first input of the parallel gear seat, and the third motor selectively connected to a first input of the differential gear set wherein said first input of said differential gear set comprises a differential port of said differential gear set; and

an electronic control unit (ECU) configured to execute control logic stored in a memory associated with said ECU to control the operation of the plurality of electric motors.

2. The drive system of claim 1, wherein the ECU is configured to operate the plurality of electric motors in a plurality of modes.

3. The drive system of claim 2, wherein a first mode of the plurality of modes includes the first motor and the second motor arranged in a serially-coupled configuration, the second motor connected to the first input of the parallel gear set, and the third motor connected to the first input of the differential gear set.

4. The drive system of claim 3, wherein the serially-coupled configuration includes a stator portion of the second motor mechanically coupled with a rotor portion of the first motor.

5. The drive system of claim 3, wherein a stator portion of the first motor is mechanically grounded in the first mode.

6. The drive system of claim 3, wherein a second input of the differential gear set is mechanically grounded in the first mode.

7. The drive system of claim 3, wherein, in the first mode, the ECU is configured to energize the first motor and the second motor, and to allow the third motor to spin freely.

8. The drive system of claim 7, wherein the third motor acts as a flywheel in the first mode.

9. The drive system of claim 3, wherein a second mode of the plurality of modes includes the first motor connected to a second input of the differential gear set.

10. The drive system of claim 9, wherein the second mode includes the second motor connected to the first input of the parallel gear set.

11. The drive system of claim 9, wherein a stator portion of the second motor is mechanically grounded in the second mode.

12. The drive system of claim 9, wherein the third motor is disconnected from the differential gear set in the second mode.

13. The drive system of claim 9, wherein the first input of the differential gear set is mechanically grounded in the second mode.

14. The drive system of claim 9, wherein the third motor is disconnected from the differential gear set in the second mode.

15. The drive system of claim 9, wherein a stator portion of the first motor is mechanically grounded in the second mode.

16. The drive system of claim 9, comprising a coupling member configured to selectively couple the first motor with (i) the second motor or (ii) the second input of the differential gear set.

17. An electrical drive system for a vehicle, the system comprising:

a drive arrangement configured for connection with a vehicle wheel;

a parallel gear set connected to the drive arrangement;

a first differential gear set including an output connected to a first input of the parallel gear set;

a second differential gear set including an output connected to a second input of the parallel gear set;

a plurality of electric motors including a first motor, a second motor connected to a first input of the first differential gear set wherein said first input comprises a differential port of the first differential gear set, and a third motor connected to a first input of the second differential gear set; and

an electronic control unit (ECU) configured to execute control logic stored in a memory associated with said ECU to control the operation of the plurality of electric motors.

18. The drive system of claim 17, wherein the ECU is configured to operate the plurality of electric motors in a plurality of modes.

19. The drive system of claim 18, wherein a first mode of the plurality of modes includes the first motor connected to a second input of the first differential gear set.

20. The drive system of claim 19, wherein the second input of the first differential gear set comprises a main port of the first differential gear set.

21. The drive system of claim 19, wherein a second input of the second differential gear set comprises a main port of the second differential gear set, and the second input of the second differential gear set is mechanically grounded in the first mode.

22. The drive system of claim 19, wherein the first motor is connected to the second input of the first differential gear set via a coupling member.

23. The drive system of claim 22, wherein the coupling member comprises an electromagnetically-controlled clutch controlled via the ECU.

24. The drive system of claim 22, wherein the coupling member is configured to selectively couple the first motor with (i) the second input of the first differential gear set, (ii) a mechanical ground, or (iii) the second input of the second differential gear set.

25. The drive system of claim 24, wherein the ECU is configured to control operation of the coupling member.

26. The drive system of claim 24, wherein the coupling member includes a plurality of clutches.

27. The drive system of claim 19, wherein, in the first mode, the ECU is configured to energize the first motor and the second motor, and configured to allow the third motor to spin freely.

28. The drive system of claim 27, wherein the third motor acts as a flywheel in the first mode.

29. The drive system of claim 19, wherein, in a second mode of the plurality of modes, the first motor is connected to a second input of the second differential gear set.

30. The drive system of claim 29, wherein the second input of the first differential gear set is mechanically grounded in the second mode.

31. The drive system of claim 29, wherein a third mode of the plurality of modes includes simultaneously energizing the first motor, the second motor, and the third motor.