Motor integration assembly

• US 10,688,859 B2
• Filed: 03/21/2018
• Issued: 06/23/2020
• Est. Priority Date: 10/06/2011
• Status: Active Grant

• Current Assignee: XL Hybrids, Inc. (The Shyft Group, Inc.)
• Original Assignee: XL Hybrids
• Inventors: Leach, Brian Joseph, Brenner, Neal Ennis, Hafer, Jason Paul, McCabe, Joseph D.
• Primary Examiner(s): Phan, Hau V
• Application Number:
  US15/927,317
• Publication Number:
  US 20180208046A1
• Time in Patent Office: 825 Days
• CPC Class Codes: B60K 2006/4808 Electric machine connected or connectable to gearbox output shaft
• CPC Class Codes: B60K 6/20 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
• CPC Class Codes: B60K 6/405 Housings
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60Y 2200/10 Road Vehicles
• CPC Class Codes: B60Y 2200/92 Hybrid vehicles
• CPC Class Codes: B60Y 2400/82 Four wheel drive systems
• CPC Class Codes: F16H 2057/02034 Gearboxes combined or connected with electric machines structural association with electric machines H02K7/116
• CPC Class Codes: F16H 57/02 Gearboxes; Mounting gearing therein
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10S 903/902 Prime movers comprising electrical and internal combustion motors
• CPC Class Codes: Y10S 903/916 with plurality of drive axles

Abstract

A motor integration assembly includes a supporting structure for connecting a transmission of a vehicle to a drivetrain of the vehicle, wherein the support structure includes a housing to receive a portion of the drivetrain of the vehicle. The motor integration assembly also includes a torque transfer unit for transferring torque from an electric machine to the portion of the drivetrain of the vehicle.

Claims

1. A motor integration assembly, comprising:

a supporting structure configured to receive (i) a first portion of a drivetrain of a four-wheel vehicle having an internal combustion engine, the first portion configured to deliver torque from a transmission of the four-wheel vehicle, and (ii) a second portion of the drivetrain of the four-wheel vehicle, the second portion configured to transfer torque to at least one wheel of the four-wheel vehicle;

an electric machine for providing torque to the second portion of the drivetrain and for converting the four-wheel vehicle into a hybrid-electric four-wheel vehicle;

a torque transfer unit for transferring torque from the electric machine to the second portion of the drivetrain of the four-wheel vehicle;

a housing mounted to the four-wheel vehicle, the housing comprising;

an electrical storage system electrically connectable to the electric machine, the electrical storage system located externally from the electric machine and the torque transfer unit, the electrical storage system mounted aft of the electric machine; and

a control unit, located near the electrical storage system, that controls the torque transferred from the torque transfer unit to the second portion of the drivetrain; and

electrical connections that connect and permit communication between the electric machine and the control unit, the control unit configured to control and condition electric power flow between the electric machine and the electrical storage system,

wherein the torque transferred from the electric machine complements torque delivered from the internal combustion engine to the at least one wheel of the four-wheel vehicle having the motor integration assembly installed.

2. The motor integration assembly of claim 1, wherein the supporting structure includes a bracket.

3. The motor integration assembly of claim 1, wherein the electric machine is substantially aligned with the first portion of the drivetrain and the second portion of the drivetrain of the four-wheel vehicle along an axis of rotation.

4. The motor integration assembly of claim 1, wherein the torque transfer unit includes gearing for transferring torque from the electric machine to the second portion of the drivetrain of the four-wheel vehicle.

5. The motor integration assembly of claim 1, wherein the electric machine converts electrical power to mechanical power.

6. A hybrid-electric four-wheel vehicle system, comprising:

a transmission for providing torque to a first portion of a drivetrain of a hybrid-electric four-wheel vehicle having an internal combustion engine;

an electric machine for providing torque to a second portion of the drivetrain of the hybrid-electric four-wheel vehicle and for converting a four-wheel vehicle into the hybrid-electric four-wheel vehicle, the second portion configured to transfer torque to at least one wheel of the hybrid-electric four-wheel vehicle; and

a motor integration assembly, comprising,

a supporting structure configured to receive (i) the first portion of the drivetrain of the hybrid-electric four-wheel vehicle and (ii) the second portion of the drivetrain of the hybrid-electric four-wheel vehicle;

a torque transfer unit for transferring torque from the electric machine to the second portion of the drivetrain of the hybrid-electric four-wheel vehicle;

a housing mounted to the hybrid-electric four-wheel vehicle, the housing comprising;

an electrical storage system electrically connectable to the electric machine, the electrical storage system located externally from the electric machine and the torque transfer unit, the electrical storage system mounted aft of the electric machine; and

a control unit, located near the electrical storage system, that controls the torque transferred from the torque transfer unit to the second portion of the drivetrain; and

electrical connections that connect and permit communication between the electric machine and the control unit, the control unit configured to control and condition electric power flow between the electric machine and the electrical storage system,

wherein the torque transferred from the electric machine complements torque delivered from the internal combustion engine to the at least one wheel of the four-wheel vehicle having the motor integration assembly installed.

7. The hybrid-electric four-wheel vehicle system of claim 6, wherein the supporting structure includes a bracket.

8. The hybrid-electric four-wheel vehicle system of claim 6, wherein the electric machine is substantially aligned with the first portion of the drivetrain and the second portion of the drivetrain of the four-wheel vehicle along an axis of rotation.

9. The hybrid-electric four-wheel vehicle system of claim 6, wherein the torque transfer unit includes gearing for transferring torque from the electric machine to the second portion of the drivetrain of the four-wheel vehicle.

10. The hybrid-electric four-wheel vehicle system of claim 6, wherein the electric machine converts electrical power to mechanical power.

11. A method of installing a hybrid-electric conversion system, comprising:

installing a conversion system that connects to a drivetrain of a four-wheel vehicle having an internal combustion engine, the conversion system comprising;

a supporting structure configured to receive (i) a first portion of the drivetrain of the four-wheel vehicle, the first portion configured to deliver torque from a transmission of the four-wheel vehicle, and (ii) a second portion of the drivetrain of the four-wheel vehicle, the second portion configured to transfer torque to at least one wheel of the four-wheel vehicle; and

an electric machine for providing torque to the second portion of the drivetrain and for converting the four-wheel vehicle into a hybrid-electric four-wheel vehicle; and

a torque transfer unit for transferring torque from the electric machine to the second portion of the drivetrain; and

a housing mounted to the hybrid-electric four-wheel vehicle, the housing comprising;

an electrical storage system electrically connectable to the electric machine, the electrical storage system located externally from the electric machine and the torque transfer unit, the electrical storage system mounted aft of the electric machine, and

a control unit, located near the electrical storage system, that controls the torque transferred from the torque transfer unit to the second portion of the drivetrain, and

electrical connections that connect and permit communication between the electric machine and the control unit, the control unit configured to control and condition electric power flow between the electric machine and the electrical storage system,

wherein the torque transferred from the electric machine complements torque delivered from the internal combustion engine to the at least one wheel of the four-wheel vehicle having the conversion system installed.

12. The method of claim 11, wherein the supporting structure includes a bracket.

13. The method of claim 11, wherein the electric machine is substantially aligned with a first portion of the drivetrain and the second portion of the drivetrain of the four-wheel vehicle along an axis of rotation.

14. The method of claim 11, wherein the torque transfer unit includes gearing for transferring torque from the electric machine to the second portion of the drivetrain of the four-wheel vehicle.

15. The method of claim 11, wherein the electric machine converts electrical power to mechanical power.