Electric drive module and method for operating an electric drive module

• US 9,637,022 B2
• Filed: 04/30/2015
• Issued: 05/02/2017
• Est. Priority Date: 04/30/2015
• Status: Active Grant

• Current Assignee: E-aam Driveline Systems Ab (American AXLE & Manufacturing Holdings Incorporated)
• Original Assignee: E-aam Driveline Systems Ab (American AXLE & Manufacturing Holdings Incorporated)
• Inventors: Trnnberg, Gabriel, Gavling, Emil K., Gebel, Phillip A., Gieryluk, Henric J.
• Primary Examiner(s): Scott, Jacob S
• Assistant Examiner(s): Dang, Tinh
• Application Number:
  US14/700,210
• Publication Number:
  US 20160318419A1
• Time in Patent Office: 733 Days
• CPC Class Codes: B60L 15/025 using field orientation; Vector control; Direct Torque Control [DTC]
• CPC Class Codes: B60L 15/2036 Electric differentials, e.g. for supporting steering vehicles
• CPC Class Codes: B60L 2220/50 Structural details of electrical machines
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/662 Temperature
• CPC Class Codes: B60L 2240/667 Precipitation
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: F16H 48/08 comprising bevel gears
• CPC Class Codes: F16H 48/36 characterised by intentionally generating speed difference between outputs
• 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: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

An electric drive module and a method for switching a drive module between a torque vectoring and at least one propulsion mode are provided. A controller can switch the drive module to the torque vectoring mode when a first set of conditions is met and can switch to one of the propulsion modes when either a second or a third set of conditions is met. The first set can include: torque requested by an operator is less than or equal to a first demand threshold; and a vehicle velocity is greater than or equal to a first velocity threshold. The second set can include: the vehicle velocity is less than a second velocity threshold; and a vehicle lateral instability is less than or equal to an instability threshold. The third set can include: the torque requested by the operator of the vehicle is greater than a second demand threshold.

Claims

1. A method for controlling transmission of power to a set of vehicle wheels, the method comprising:

providing a drive module for powering the set of vehicle wheels, the drive module being operable in a torque vectoring mode and at least one propulsion mode;

switching the drive module to the torque vectoring mode when a first set of conditions is met; and

switching the drive module to a propulsion mode of the at least one propulsion mode when either a second set of conditions is met or a third set of conditions is met; and

wherein the first set of conditions includes;

a torque requested by an operator of the vehicle is less than or equal to a first predetermined demand threshold; and

a velocity of the vehicle is greater than or equal to a first predetermined velocity threshold;

wherein the second set of conditions includes;

the velocity of the vehicle is less than a second predetermined velocity threshold; and

a lateral instability of the vehicle is less than or equal to a predetermined instability threshold; and

wherein the third set of conditions includes;

the torque requested by the operator of the vehicle is greater than a second predetermined demand threshold.

2. The method of claim 1, wherein the first set of conditions further includes:

a torque output of the drive module is less than or equal to a predetermined torque threshold.

3. The method of claim 1, wherein the second set of conditions further includes:

an energy level of a power storage device is greater than or equal to a predetermined energy level.

4. The method of claim 1, wherein the second predetermined demand threshold is greater than or equal to the first predetermined demand threshold.

5. The method of claim 1, wherein the second predetermined velocity threshold is less than or equal to the first predetermined velocity threshold.

6. The method of claim 1, wherein the at least one propulsion mode includes a first propulsion mode and a second propulsion mode, and wherein the method includes switching the drive module to the first propulsion mode when the second set of conditions is met and switching the drive module to the second propulsion mode when the third set of conditions is met.

7. The method of claim 6, wherein the first propulsion mode is a low speed propulsion mode and the second propulsion mode is a high speed propulsion mode.

8. A controller for a drive module that is operable in a plurality of modes to drive a pair of vehicle wheels, the controller being configured to:

determine a torque requested by an operator of the vehicle, a velocity of the vehicle, and a level of instability of the vehicle;

switch the drive module to a torque vectoring mode when a first set of conditions is met; and

switch the drive module to a propulsion mode when either a second set of conditions is met or a third set of conditions is met;

wherein the first set of conditions includes;

the torque requested by the operator is less than or equal to a first predetermined demand threshold; and

the velocity of the vehicle is greater than or equal to a first predetermined velocity threshold;

wherein the second set of conditions includes;

the velocity of the vehicle is less than a second predetermined velocity threshold; and

a lateral instability of the vehicle is less than or equal to a predetermined instability threshold; and

wherein the third set of conditions includes;

the torque requested by the operator of the vehicle is greater than a second predetermined demand threshold.

9. The controller of claim 8, wherein the first set of conditions further includes:

a torque output of the drive module is less than or equal to a predetermined torque threshold.

10. The controller of claim 8, wherein the second set of conditions further includes:

an energy level of a power storage device is greater than or equal to a predetermined energy level.

11. The controller of claim 8, wherein the second predetermined demand threshold is greater than or equal to the first predetermined demand threshold.

12. The controller of claim 8, wherein the second predetermined velocity threshold is less than or equal to the first predetermined velocity threshold.

13. The controller of claim 8, wherein the controller is configured to switch the drive module to a low speed propulsion mode when the second set of conditions is met, and to switch the drive module to a high speed propulsion mode when the third set of conditions is met.

14. A drive module comprising:

a motor;

an input member driven by the motor;

a differential assembly having a differential carrier and first and second differential outputs received in the differential carrier;

a transmission receiving rotary power from the input member;

a shiftable element that is axially movable between a first position and a second position, wherein positioning of the shiftable element in the first position couples the transmission to the differential assembly to establish a torque vectoring mode in which the transmission applies an equal but oppositely directed torque to the first and second differential outputs, and wherein positioning of the shiftable element in the second position couples the transmission to the differential assembly to directly drive the differential carrier;

an actuator coupled to the shiftable element and configured to axially move the shiftable element between the first and second positions; and

a control module configured to control the actuator to move the shiftable element to the first position when a first set of conditions is met, and to move the shiftable element to the second position when one of a second set of conditions is met or a third set of conditions is met;

wherein the first set of conditions includes;

a torque requested by the operator is less than or equal to a first predetermined demand threshold; and

a velocity of the vehicle is greater than or equal to a first predetermined velocity threshold;

wherein the second set of conditions includes;

the velocity of the vehicle is less than a second predetermined velocity threshold; and

a lateral instability of the vehicle is less than or equal to a predetermined instability threshold; and

wherein the third set of conditions includes;

the torque requested by the operator of the vehicle is greater than a second predetermined demand threshold.

15. The drive module of claim 14, wherein the first set of conditions further includes:

a torque output of the drive module is less than or equal to a predetermined torque threshold.

16. The drive module of claim 14, wherein the second set of conditions further includes:

an energy level of a power storage device is greater than or equal to a predetermined energy level.

17. The drive module of claim 14, wherein the second predetermined demand threshold is greater than or equal to the first predetermined demand threshold.

18. The drive module of claim 14, wherein the second predetermined velocity threshold is less than or equal to the first predetermined velocity threshold.

19. The drive module of claim 14, wherein the transmission includes a first planetary stage and a second planetary stage, the first planetary stage having a first sun gear that is coupled to a second sun gear of the second planetary stage for rotation therewith.

20. The drive module of claim 19, wherein the shiftable element is axially movable to a third position, wherein positioning of the shiftable element in the third position couples the transmission to the first and second sun gears to directly drive the first and second sun gears, wherein the control module is configured to control the actuator to move the shiftable element to the third position when the second set of conditions is met, and to move the shiftable element to the second position when the third set of conditions is met.