Front end motor-generator system and hybrid electric vehicle operating method

• US 10,479,180 B2
• Filed: 12/14/2016
• Issued: 11/19/2019
• Est. Priority Date: 12/14/2016
• Status: Active Grant

• Current Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Original Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Inventors: Colavincenzo, David, Venegas Diaz, Fernando
• Primary Examiner(s): Scott, Jacob S.
• Application Number:
  US15/378,853
• Publication Number:
  US 20180162213A1
• Time in Patent Office: 1,070 Days
• Field of Search: None
• CPC Class Codes: B60K 2025/022 by a mechanical transmission
• CPC Class Codes: B60K 25/02 directly from an engine shaft
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/387 Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/485 Motor-assist type
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/42 Voltage source inverters
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/443 Torque
• CPC Class Codes: B60L 2240/507 Operating parameters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/22 : Balancing the charge of battery modules
• CPC Class Codes: B60L 7/22 : Dynamic electric resistor braking, combined with dynamic electric regenerative braking
• CPC Class Codes: B60W 10/02 : including control of driveline clutches
• CPC Class Codes: B60W 20/40 : Controlling the engagement or disengagement of prime movers, e.g. for transition between prime movers power-up or power-down of the driveline B60W30/192
• CPC Class Codes: B60Y 2200/92 : Hybrid vehicles
• CPC Class Codes: B60Y 2300/91 : Battery charging
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: B60Y 2400/405 : Electric motors actuators
• CPC Class Codes: B60Y 2400/406 : Hydraulic actuators
• CPC Class Codes: B60Y 2400/408 : Pneumatic actuators
• CPC Class Codes: B60Y 2400/421 : Dog type clutches or brakes
• CPC Class Codes: B60Y 2400/4244 : of wet type, e.g. using multiple lamellae
• CPC Class Codes: F16D 11/14 : with clutching members movable only axially F16D11/02, F16D11/08 take precedence
• CPC Class Codes: F16D 25/0638 : with more than two discs, e.g. multiple lamellae
• CPC Class Codes: F16D 25/082 : the line of action of the fluid-actuated members co-inciding with the axis of rotation
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• 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 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10S 903/905 : Combustion engine
• CPC Class Codes: Y10S 903/914 : Actuated, e.g. engaged or disengaged by electrical, hydraulic or mechanical means
• CPC Class Codes: Y10S 903/951 : Assembly or relative location of components

Abstract

A system and method are provided for hybrid electric internal combustion engine applications in which a motor-generator, a switchable coupling and a torque transfer unit are arranged co-axially-arranged with the front end of the engine crankshaft in the constrained environment in front of an engine in applications such as commercial vehicles, off-road vehicles and stationary engine installations. The motor-generator is preferably laterally offset from the switchable coupling. The switchable coupling is an integrated unit in which a crankshaft vibration damper, an engine accessory drive pulley and a clutch overlap with an axial depth nearly the same as a conventional belt drive pulley and engine damper. The system includes an electrical energy store that receives energy generated by the motor-generator when the coupling is engaged. When the coupling is disengaged, the motor-generator may drive the pulley portion of the clutch-pulley-damper to drive engine accessories using energy returned from the energy store.

Claims

1. An integrated switchable coupling of a hybrid electric arrangement for an internal combustion engine, comprising:

an engine-side portion configured to be coupled for co-axial rotation to a rotatable shaft of the engine;

a drive-side portion configured to drive an engine accessory drive, to be selectively engaged with the engine-side portion, and to be driven by an electric motor at a front side of the drive-side portion opposite a rear side of the drive side portion facing the rotatable engine shaft; and

an engagement actuator configured to selectively engage the drive side portion with the engine-side portion,

wherein

the drive-side portion concentrically surrounds at least a portion of the engagement actuator along a coupling rotation axis,

the rotatable engine shaft is an engine crankshaft,

the engine-side portion includes a crankshaft damper portion,

the drive-side portion includes a pulley portion having on an outer circumference at least one accessory drive surface configured to engage an accessory drive,

the engagement actuator is a clutch, the clutch including an engine-side engagement portion, and a drive-side engagement portion at least one of coupled to and integrally formed with the drive-side portion of the integrated switchable coupling, and

the at least one accessory drive surface is configured to drive an accessory drive belt.

2. The integrated switchable coupling of claim 1, wherein

an outer circumference of the engine-side portion includes a further accessory drive surface.

3. The integrated switchable coupling of claim 1, wherein

the clutch is a dog clutch.

4. The integrated switchable coupling of claim 1, wherein

the clutch is a plate clutch.

5. The integrated switchable coupling of claim 4, wherein

the plate clutch is a multi-plate clutch.

6. The integrated switchable coupling of claim 1, further comprising:

a clutch actuator configured to axially displace at least one of the clutch engine-side portion and the clutch drive-side portion into and out of engagement with the other of the at least one of the clutch engine-side portion and the clutch drive-side portion.

7. The integrated switchable coupling of claim 6, wherein

the clutch actuator is a hydraulic actuator.

8. The integrated switchable coupling of claim 7, wherein

the hydraulic actuator includes a hydraulic pressure supply arranged to apply hydraulic pressure to the at least one of the clutch engine-side portion and the clutch drive-side portion, and at least one solenoid-controlled valve arranged to control at least one of application and release of the hydraulic pressure to engage or disengage the clutch.

9. The integrated switchable coupling of claim 6, wherein

the clutch actuator is an electric actuator.

10. The integrated switchable coupling of claim 9, wherein

the electric actuator is an electric solenoid configured to be co-axially facing the front side of the drive-side portion and aligned to actuate a clutch actuation shaft to axially displace the at least one of the clutch engine-side portion and the clutch drive-side portion.

11. The integrated switchable coupling of claim 1, wherein

the clutch is biased into an engaged position by a biasing element.

12. An integrated switchable coupling of a hybrid electric arrangement for an internal combustion engine, comprising:

an engine-side portion configured to be coupled for co-axial rotation to a rotatable shaft of the engine;

a drive-side portion configured to drive an engine accessory drive, to be selectively engaged with the engine-side portion, and to be driven by an electric motor at a front side of the drive-side portion opposite a rear side of the drive side portion facing the rotatable engine shaft;

an engagement actuator configured to selectively engage the drive side portion with the engine-side portion; and

a clutch actuator configured to axially displace at least one of the clutch engine-side portion and the clutch drive-side portion into and out of engagement with the other of the at least one of the clutch engine-side portion and the clutch drive-side portion,

wherein

the drive-side portion concentrically surrounds at least a portion of the engagement actuator along a coupling rotation axis, and

the clutch actuator is a pneumatic actuator.

13. The integrated switchable coupling of claim 12, wherein

the pneumatic actuator is configured to be co-axially facing the front side of the drive-side portion and aligned to actuate a clutch actuation shaft to axially displace the at least one of the clutch engine-side portion and the clutch drive-side portion.

14. An integrated switchable coupling of a hybrid electric arrangement for an internal combustion engine, comprising:

an engine-side portion configured to be coupled for co-axial rotation to a rotatable shaft of the engine,

a drive-side portion configured to drive an engine accessory drive, to be selectively engaged with the engine-side portion, and to be driven by an electric motor at a front side of the drive-side portion opposite a rear side of the drive side portion facing the rotatable engine shaft, and

an engagement actuator configured to selectively engage the drive side portion with the engine-side portion,

wherein

the drive-side portion concentrically surrounds at least a portion of the engagement actuator along a coupling rotation axis,

the rotatable engine shaft is an engine crankshaft,

the engine-side portion includes a crankshaft damper portion,

the drive-side portion includes a pulley portion having on an outer circumference at least one accessory drive surface configured to engage an accessory drive,

the engagement actuator is a clutch, the clutch including an engine-side engagement portion, and a drive-side engagement portion at least one of coupled to and integrally formed with the drive-side portion of the integrated switchable coupling, and

the pulley portion of the drive-side portion of the integrated switchable coupling extends axially around the clutch.

15. The integrated switchable coupling of claim 14, wherein

the pulley portion of the drive-side portion of the integrated switchable coupling extends axially around the damper portion of the engine-side portion of the integrated switchable coupling.