Front end motor-generator system and modular generator drive apparatus

• US 10,630,137 B2
• Filed: 12/14/2017
• Issued: 04/21/2020
• 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, Young, Dennis
• Primary Examiner(s): Odeh, Nadeem
• Application Number:
  US15/842,495
• Publication Number:
  US 20180166945A1
• Time in Patent Office: 859 Days
• Field of Search: 701 22
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• 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 6/442 Series-parallel switching type
• CPC Class Codes: F02B 67/06 driven by means of chains, belts, or like endless members
• CPC Class Codes: F16H 1/20 involving more than two intermeshing members
• CPC Class Codes: F16H 37/02 comprising essentially only toothed or friction gearings
• CPC Class Codes: F16H 55/36 Pulleys with features essential for adjustment F16H55/52
• CPC Class Codes: F16H 57/02 Gearboxes; Mounting gearing therein
• CPC Class Codes: H02K 7/00 Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
• CPC Class Codes: H02K 7/006 Structural association of a motor or generator with the drive train of a motor vehicle
• CPC Class Codes: H02K 7/116 with gears
• CPC Class Codes: H02K 7/18 Structural association of electric generators with mechanical driving motors, e.g. with turbines
• CPC Class Codes: H02K 7/1815 structurally associated with reciprocating piston engines general aspects of generating sets, e.g. housing, F02B63/04
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• CPC Class Codes: Y10S 903/906 Motor or generator
• CPC Class Codes: Y10S 903/96 having chargeable mechanical accumulator

Abstract

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

Claims

1. A torque transfer segment, comprising:

a gearbox housing having a first housing portion and a second housing portion configured to be coupled to the first housing portion at corresponding first housing sections;

a drive gear at a second section of the first housing portion, the drive gear being configured to be co-axially coupled for rotation with a switchable coupling;

a motor-generator gear at a second section of the second housing portion, the motor-generator gear being configured to be co-axially coupled with a motor-generator;

an idler gear arrangement including at least one idler gear, the idler gear arrangement configured to transfer torque between the drive gear and the motor-generator gear,

wherein

at least a portion of the idler gear arrangement is located at the first housing sections of the housing portions when the first housing portion is coupled to the second housing portion,

the first housing portion and the second housing portion are configured to be coupled together in a plurality of orientations relative to one another about a rotation axis of the at least one idler gear,

the at least one idler gear having at least two gearwheels axially separate from one another along the rotation axis of the at least one idler gear, and

when the first housing portion and the second housing portion are coupled together, a plane perpendicular to a rotation axis of the drive gear is axially offset from a plane perpendicular to a rotation axis of the motor-generator gear.

2. The torque transfer segment of claim 1, wherein

the idler gear arrangement includes at least one additional gearwheel in addition to the at least two axially-separate gearwheels, and

the gearwheels of the idler gear arrangement are arranged to transfer torque between the drive gear and the motor-generator gear.

3. The torque transfer segment of claim 1, wherein

the first housing sections of the first housing portion and the second housing portion include corresponding fastener mounting features in a predetermined pattern, the mounting features being arranged such that the first housing portion and the second housing portion are coupleable at a plurality of orientations about the idler gear rotation axis at fixed angular offsets.

4. The torque transfer segment of claim 3, wherein

the fixed angular offset is in a range from 45°

to 120°

.

5. The torque transfer segment of claim 3, wherein

the fixed angular offset is 120°

.

6. The torque transfer segment of claim 1, wherein

the first housing portion includes gearbox housing mounting features configured such that the first housing portion is mountable at a plurality of orientations relative to a torque source coupled to the switchable coupling about a rotation axis of the switchable coupling.

7. The torque transfer segment of claim 6, wherein

at least one of the first and second housing portions includes separate support mounting features configured to be coupled to a support separate from the torque source.

8. The torque transfer segment of claim 7, wherein

the separate support mounting features are configured to be coupled to a tie-rod.

9. The torque transfer segment of claim 6, wherein

the torque source is an internal combustion engine.

10. A front end motor-generator system, comprising:

a torque source configured to supply torque to a torque consumer;

a motor-generator;

a torque transfer segment having a motor-generator end configured to receive the motor-generator and to transfer torque between the motor-generator end and a coupling end of the torque transfer segment; and

an integrated switchable coupling having a coupling rotation axis arranged co-axially with a rotation axis of the torque source, the integrated switchable coupling being located between the coupling end of the torque transfer segment and the torque source, the integrated switchable coupling including

an torque source-side portion coupled to the torque source,

a drive-side portion coupled to the torque transfer segment coupling end, and

an engagement actuator configured to selectively engage the torque source-side portion with the drive-side portion, at least a portion of the engagement actuator being concentrically surrounded by the drive-side portion along the coupling rotation axis;

an accessory drive arranged to be driven by the drive-side portion of the integrated switchable coupling and to drive at least one accessory;

an energy storage system, the energy storage system including

an energy store configured to store electrical energy generated by the motor-generator and to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the integrated switchable coupling, and

an electrical energy conversion and distribution network configured to convert a current type of the electrical energy transferred between the motor-generator and the energy store between alternating current and direct current when the electrical energy is transferred from the motor-generator to the energy store and between direct current and alternating current when the electrical energy is transferred from the energy store to the motor-generator; and

a front end motor-generator system controller configured to switch the engagement actuator between engaged and disengaged states and control operation of the electrical energy conversion and distribution network during transfer of the electrical energy between the motor-generator and the energy store,

wherein the torque transfer segment includes

a gearbox housing having a first housing portion at the coupling end of the torque transfer segment and a second housing portion at the motor-generator end of the torque transfer segment, the second housing portion being configured to be coupled to the first housing portion at corresponding first housing sections;

a drive gear at a second section of the first housing portion, the drive gear being configured to be co-axially coupled for rotation with a switchable coupling;

a motor-generator gear at a second section of the second housing portion, the motor-generator gear being configured to be co-axially coupled with the motor-generator;

an idler gear arrangement including an idler gear, the idler gear arrangement being configured to transfer torque between the drive gear and the motor-generator gear,

the idler gear is located at the first housing sections of the housing portions when the first housing portion is coupled to the second housing portion,

the first housing portion and the second housing portion are configured to be coupled together in a plurality of orientations relative to one another about a rotation axis of the idler gear,

the idler gear includes at least two gearwheels axially separate from one another along the rotation axis of the idler gear, and

when the first housing portion and the second housing portion are coupled together, a plane perpendicular to a rotation axis of the drive gear is axially offset from a plane perpendicular to a rotation axis of the motor-generator gear.

11. The front end motor generator system of claim 10, wherein

the idler gear arrangement includes at least one additional gearwheel in addition to the at least two axially-separate gearwheels, and

the gearwheels of the idler gear arrangement are arranged to transfer torque between the drive gear and the motor-generator gear.

12. The front end motor generator system of claim 10, wherein

the first housing sections of the first housing portion and the second housing portion include corresponding fastener mounting features in a predetermined pattern, the mounting features being arranged such that the first housing portion and the second housing portion are coupleable at a plurality of orientations about the idler gear rotation axis at fixed angular offsets.

13. The front end motor generator system of claim 12, wherein

the fixed angular offset is in a range from 45°

to 120°

.

14. The front end motor generator system of claim 12, wherein

the fixed angular offset is 120°

.

15. The front end motor generator system of claim 10, wherein

the first housing portion includes gearbox housing mounting features configured such that the first housing portion is mountable at a plurality of orientations relative to the torque source coupled to the integrated switchable coupling about the rotation axis of the integrated switchable coupling.

16. The front end motor generator system of claim 15, wherein

at least one of the first and second housing portions includes separate support mounting features configured to be coupled to a support separate from the torque source.

17. The front end motor generator system of claim 16, wherein

the separate support mounting features are configured to be coupled to a tie-rod.

18. The front end motor generator system of claim 15, wherein

the torque source is an internal combustion engine,

the torque consumer is a driveline arranged to propel a vehicle,

the internal combustion engine is configured to deliver torque to the vehicle driveline from an end of an engine crankshaft having an engine flywheel, and

the integrated switchable coupling is located between the coupling end of the torque transfer segment and an end of the engine crankshaft opposite the flywheel end.

19. A torque transfer segment, comprising:

a gearbox housing having a first housing portion and a second housing portion configured to be coupled to the first housing portion at corresponding first housing sections;

a drive gear at a second section of the first housing portion, the drive gear being configured to transfer torque to an accessory drive;

a motor-generator gear at a second section of the second housing portion, the motor-generator gear being configured to be co-axially coupled with a motor-generator;

an idler gear arrangement including an idler gear, the idler gear arrangement being configured to transfer torque between the drive gear and the motor-generator gear,

wherein

the idler gear is located at the first housing sections of the housing portions when the first housing portion is coupled to the second housing portion,

the first housing portion and the second housing portion are configured to be coupled together in a plurality of orientations relative to one another about a rotation axis of the idler gear,

the idler gear includes at least two gearwheels axially separate from one another along the rotation axis of the idler gear, and

when the first housing portion and the second housing portion are coupled together, a plane perpendicular to a rotation axis of the drive gear is axially offset from a plane perpendicular to a rotation axis of the motor-generator gear.

20. The torque transfer segment of claim 19, wherein

the accessory drive includes an accessory belt drive pulley coupled for co-axial rotation with the drive gear.