U.S. patent application number 16/088289 was filed with the patent office on 2020-10-22 for electric drivetrain axles with multi-speed gearboxes.
This patent application is currently assigned to DANA HEAVY VEHICLE SYSTEMS GROUP, LLC. The applicant listed for this patent is DANA HEAVY VEHICLE SYSTEMS GROUP, LLC. Invention is credited to RAYMOND J. HAKA, KRISHNA KUMAR, STEVEN J. WESOLOWSKI.
Application Number | 20200331342 16/088289 |
Document ID | / |
Family ID | 1000005132191 |
Filed Date | 2020-10-22 |
View All Diagrams
United States Patent
Application |
20200331342 |
Kind Code |
A1 |
HAKA; RAYMOND J. ; et
al. |
October 22, 2020 |
ELECTRIC DRIVETRAIN AXLES WITH MULTI-SPEED GEARBOXES
Abstract
An electric drivetrain having a primary motor-generator
assembly, an electric axle drive unit and a power source. The
primary motor-generator assembly includes a primary mover, a first
gearbox in driving engagement with the primary mover and a first
clutch. The first gearbox is in driving engagement with the primary
mover. The electric axle drive unit includes a differential
assembly, a second motor-generator assembly in driving engagement
with a wheel assembly and a third motor-generator assembly in
driving engagement with another wheel assembly. The differential
assembly is in selective engagement with the first clutch, the
second motor-generator assembly via a first axle clutch, and the
third motor-generator assembly via a second axle clutch. The
electric axle drive unit is selectively engaged with the primary
motor-generator assembly via the first clutch. The second and third
motor-generator assemblies include a motor-generator and a reducing
gearbox portion.
Inventors: |
HAKA; RAYMOND J.; (BRIGHTON,
MI) ; KUMAR; KRISHNA; (HOLLAND, OH) ;
WESOLOWSKI; STEVEN J.; (WATERVILLE, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DANA HEAVY VEHICLE SYSTEMS GROUP, LLC |
MAUMEE |
OH |
US |
|
|
Assignee: |
DANA HEAVY VEHICLE SYSTEMS GROUP,
LLC
MAUMEE
OH
|
Family ID: |
1000005132191 |
Appl. No.: |
16/088289 |
Filed: |
March 28, 2017 |
PCT Filed: |
March 28, 2017 |
PCT NO: |
PCT/US2017/024480 |
371 Date: |
September 25, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62314349 |
Mar 28, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F16H 2200/0021 20130101;
B60K 17/02 20130101; F16H 2200/2043 20130101; F16H 2200/2007
20130101; F16H 37/082 20130101; B60K 17/22 20130101; B60K 1/04
20130101; B60K 17/046 20130101; F16H 2200/2041 20130101; F16H
2200/0039 20130101; B60Y 2200/91 20130101; F16H 2200/2035 20130101;
B60K 1/02 20130101; F16H 3/666 20130101; F16H 2200/2038 20130101;
B60K 17/16 20130101; F16H 2200/0034 20130101 |
International
Class: |
B60K 17/04 20060101
B60K017/04; F16H 3/66 20060101 F16H003/66; F16H 37/08 20060101
F16H037/08; B60K 1/02 20060101 B60K001/02; B60K 17/02 20060101
B60K017/02; B60K 17/22 20060101 B60K017/22; B60K 17/16 20060101
B60K017/16; B60K 1/04 20060101 B60K001/04 |
Claims
1. An electric drivetrain for a motor vehicle, comprising: a
primary motor-generator assembly including a primary mover, a first
gearbox, and a first clutch, wherein the first gearbox is in
driving engagement with the primary mover and the first clutch and
the first clutch is in selective driving engagement with a drive
shaft and the primary mover; an electric axle drive unit including
a differential assembly, a second motor-generator assembly in
driving engagement with a first wheel assembly, a third
motor-generator assembly in driving engagement with a second wheel
assembly, a first axle clutch and a second axle clutch; and a power
source in communication with the second motor-generator assembly
and the third motor-generator assembly, wherein the differential
assembly is in selective driving engagement with the first clutch,
in selective driving engagement with the second motor-generator
assembly via the first axle clutch, and in selective driving
engagement the third motor-generator assembly via the second axle
clutch, wherein the electric axle drive unit is selectively
drivingly engaged with the primary motor-generator assembly via the
first clutch, wherein the second motor-generator assembly includes
a second motor-generator and a second gearbox portion, wherein the
third motor-generator assembly includes a third motor-generator and
a third gearbox portion, and wherein the third gearbox and second
gearbox portions are reduction gearboxes.
2. The electric drivetrain of claim 1, wherein the primary mover is
a first motor generator and wherein the power source is in
communication with the primary motor-generator assembly.
3. The electric drivetrain of claim 1, wherein the reduction
gearboxes are two-speed gearboxes.
4. The electric drivetrain of claim 1, wherein the reduction
gearboxes are three-speed gearboxes.
5. The electric drivetrain of claim 1, wherein the reduction
gearboxes include a planetary gear set.
6. A motor vehicle comprising the electric drivetrain of claim 1 as
a tag axle multi-axle driveline.
7. A motor vehicle comprising the electric drivetrain of claim 1 as
a pusher axle in a multi-axle driveline.
8. The electric drivetrain of claim 3, wherein the two-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier and a second sun gear, wherein the first
sun gear is coupled to the motor-generator, the first planet
carrier and the second sun gear, wherein the first planet carrier
is coupled to the first ring gear and the second planet carrier,
and wherein the second ring gear is coupled to the planet carrier;
a brake configured to selectively ground the first ring gear; a
first clutch operably coupled to the second ring gear; a second
clutch operably coupled to the second planet carrier; and an output
shaft drivingly engaged with the wheel assembly, wherein the first
and second clutches are selectively coupled to the output
shaft.
9. The electric drivetrain of claim 3, wherein the two-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier and a second sun gear, wherein the first
sun gear is coupled to the motor-generator, the first planet
carrier and the second sun gear, wherein the first planet carrier
is coupled to the first ring gear, and wherein the second ring gear
is coupled to the first ring gear and the second planet carrier; a
first clutch coupled to the first ring gear and configured to
selectively ground the first ring gear; a second clutch coupled to
the first planet carrier and configured to selectively ground the
first planet carrier; and an output shaft drivingly connected to
the second planet carrier and the wheel assembly.
10. The electric drivetrain of claim 4, wherein the three-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier and a second sun gear, wherein the first
sun gear is coupled to the motor-generator, the first planet
carrier and the second sun gear, wherein the first planet carrier
is coupled to the first ring gear and the second planet carrier,
and wherein the second ring gear is coupled to the second planet
carrier; an output shaft drivingly engaged with the wheel assembly;
a first clutch configured to selectively couple the motor-generator
to the first planet carrier; a second clutch coupled to the second
planet carrier and configured to selectively couple the second
planet carrier to the output shaft; a third clutch coupled to the
second ring gear and configured to selectively couple the second
ring gear to the output shaft; and a brake configured to
selectively ground the first ring gear.
11. The electric drivetrain of claim 10, wherein the three-speed
gearbox further comprises a fourth clutch configured to selectively
couple the first ring gear and the second ring gear.
12. The electric drivetrain of claim 4, wherein the three-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier and a second sun gear, wherein the first
sun gear is coupled to the motor-generator, the first planet
carrier, wherein the first planet carrier is coupled to the first
ring gear, and wherein the second ring gear is coupled to the first
ring gear and the second planet carrier; an output shaft drivingly
engaged with the second planet carrier and the wheel assembly; a
first clutch configured to selectively couple the first sun gear
and the second sun gear; a second clutch configured to selectively
couple the second ring gear and the second sun gear; a third clutch
configured to selectively ground the first planet carrier; and a
fourth clutch configured to selectively ground the first ring
gear.
13. The electric drivetrain of claim 4, wherein the three-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier and a second sun gear, wherein the first
sun gear is coupled to the motor-generator, the first planet
carrier and the second sun gear, wherein the first planet carrier
is coupled to the first ring gear, and wherein the second ring gear
is coupled to the first ring gear and the second planet carrier; an
output shaft drivingly engaged with the second planet carrier and
the wheel assembly; a first clutch configured to selectively couple
the second sun gear and the output shaft; a second clutch
configured to selectively ground the first planet carrier; and a
third clutch configured to selectively ground the first ring
gear.
14. The electric drivetrain of claim 3, wherein the two-speed
gearbox comprises: a planetary gear set including a first ring
gear, a first planet carrier, a first sun gear, a second ring gear,
a second planet carrier, a second sun gear, a third ring gear, a
third planet carrier, and a third sun gear, wherein the first sun
gear is coupled to the motor-generator and the first planet
carrier, wherein the first planet carrier is coupled to the first
ring gear and the second sun gear, wherein the second ring gear is
coupled to the first ring gear and the second planet carrier,
wherein the second planet carrier is coupled to the second sun gear
and third sun gear, and wherein the third planet carrier is coupled
to the third ring gear, an output shaft, and the third ring gear;
and a first clutch configured to selectively ground the first ring
gear and third ring gear, wherein the output shaft is drivingly
engaged with the wheel assembly.
15. The electric drivetrain of claim 1, wherein the power source
includes a battery.
16. The electric drive train of claim 8, wherein the planetary gear
set further includes a first pinion gear coupled to a second pinion
gear and the first ring gear, wherein the first pinion gear and
second pinion gear form a stepped pinion gear.
Description
RELATED APPLICATION
[0001] The present application claims priority to and the benefit
from Provisional U.S. Patent Application Ser. No. 62/314,349 filed
on Mar. 28, 2016. The content of the above-noted patent application
is hereby expressly incorporated by reference into the detailed
description of the present application
BACKGROUND
[0002] Hybrid and electric vehicles are enjoying increased
popularity and acceptance due in large part to the cost of fuel and
greenhouse carbon emission government regulations for internal
combustion engine vehicles. Hybrid vehicles include both an
internal combustion engine as well as an electric motor to propel
the vehicle. There is increasing interest in replacing conventional
drivetrain architecture with battery electric drivetrain
architectures due to pollution concerns, particularly in urban
areas, and increasing regulations regarding vehicle emissions. To
date, electric drivetrain architectures have shown to be heavy,
costly, and complex. Such known architectures have a tendency to
increase an unsprung weight of and poorly utilize a space available
for a battery electric drivetrain.
[0003] It would be advantageous to develop an electric drivetrain
architecture that reduces an unsprung weight, increases cost
efficiency, and improves drivetrain packaging incorporating the
electric drivetrain architecture.
SUMMARY
[0004] Provided herein is an electric drivetrain for a motor
vehicle having a primary motor-generator assembly, an electric axle
drive unit and a power source. The primary motor-generator assembly
includes a primary mover, a first gearbox and a first clutch. The
first gearbox is in driving engagement with the primary mover and
the first clutch and the first clutch is in selective driving
engagement with a drive shaft and the primary mover. The electric
axle drive unit includes a differential assembly, a second
motor-generator assembly in driving engagement with a first wheel
assembly, a third motor-generator assembly in driving engagement
with a second wheel assembly, a first axle clutch and a second axle
clutch. The power source is in communication with the second
motor-generator assembly and the third motor-generator assembly.
The differential assembly is in selective driving engagement with
the first clutch, in selective driving engagement with the second
motor-generator assembly via the first axle clutch, and in
selective driving engagement the third motor-generator assembly via
the second axle clutch. The electric axle drive unit is selectively
drivingly engaged with the primary motor-generator assembly via the
first clutch. The second motor-generator assembly includes a second
motor-generator and a second gearbox portion and the third
motor-generator assembly includes a third motor-generator and a
third gearbox portion. The third gearbox and second gearbox
portions are reduction gearboxes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The above, as well as other advantages of the present
embodiments, will become readily apparent to those skilled in the
art from the following detailed description when considered in the
light of the accompanying drawings in which:
[0006] FIGS. 1a-1c are schematic style views of an electric
drivetrain according to a preferred embodiment;
[0007] FIG. 2 is a schematic style view of an electric drivetrain
according to another preferred embodiment;
[0008] FIG. 3 is a schematic style view of an electric drivetrain
according to another preferred embodiment;
[0009] FIG. 4 is a schematic style view of an electric drivetrain
according to another preferred embodiment;
[0010] FIG. 5 is a schematic style view of an electric drivetrain
according to another preferred embodiment;
[0011] FIG. 6 is a schematic style view of a gearbox according to a
preferred embodiment;
[0012] FIG. 7 is a schematic style view of a gearbox according to
another preferred embodiment;
[0013] FIG. 8 is a schematic style view of a gearbox according to
another preferred embodiment;
[0014] FIG. 9a is a schematic style view of a gearbox according to
another preferred embodiment;
[0015] FIG. 9b is a lever diagram depicting the gearbox according
to FIG. 9a;
[0016] FIG. 10 is a schematic style view of a gearbox according to
another preferred embodiment;
[0017] FIGS. 11a-11b are schematic style views of a gearbox
according to another preferred embodiment;
[0018] FIG. 12 is a schematic style view of a gearbox according to
another preferred embodiment; and
[0019] FIG. 13 is a schematic style view of a gearbox according to
another preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] It is to be understood that the preferred embodiments may
assume various alternative orientations and step sequences, except
where expressly specified to the contrary. It is also to be
understood that the specific devices and processes illustrated in
the attached drawings, and described in the following specification
are simply exemplary embodiments of the inventive concepts of the
present disclosure. Hence, specific dimensions, directions,
orientations or other physical characteristics relating to the
embodiments disclosed are not to be considered as limiting, unless
expressly stated otherwise.
[0021] This electric drivetrain relates to electric powertrain
configurations and architectures that will be used in hybrid
vehicles and electric vehicles. The powertrains disclosed herein
are applicable to HEV, EV and Fuel Cell electric & Hybrid
electric systems. It should be understood that electric or hybrid
electric vehicles incorporating embodiments of the hybrid
architectures disclosed herein are capable of including a number of
other powertrain components, such as, but not limited to,
high-voltage battery pack with a battery management system or
ultracapacitor, on-board charger, DC-DC converters, a variety of
sensors, actuators, and controllers, among others.
[0022] For purposes of description, schematics referred to as lever
diagrams are used herein. A lever diagram, also known as a lever
analogy diagram, is a translational-system representation of
rotating parts for a planetary gear system. In certain embodiments,
a lever diagram is provided as a visual aid in describing the
functions of the transmission. In a lever diagram, a compound
planetary gear set is often represented, by a single vertical line
("lever"). The input, output, and reaction torques are represented
by horizontal forces on the lever. The lever motion, relative to
the reaction point, represents direction of rotational velocities.
For example, a typical planetary gear set having a ring gear, a
planet carrier, and a sun gear is represented by a vertical line
having nodes "R" representing the ring gear, node "S" representing
the sun gear, and node "C" representing the planet carrier. It
should be appreciated that any mechanical coupling is depicted on a
lever diagram as a node or a solid dot. For example, a node
represents two components in a drivetrain that are rigidly
connected.
[0023] FIG. 1a is a schematic style view of an electric drivetrain
100 according to a preferred embodiment. The electric drivetrain
100 includes a primary motor-generator assembly 102 and an electric
axle drive unit 104. The electric axle drive unit 104 is drivingly
engaged with the primary motor-generator assembly 102 through a
drive shaft 106, for example. The electric axle drive unit 104 is
also drivingly engaged with a pair of wheel assemblies 108. The
primary motor-generator assembly 102 and the electric axle drive
unit 104 are in electrical communication with a battery and control
assembly 110. The electric drivetrain 100 as shown is a battery
electric vehicle drivetrain, and may be operated in a plurality of
operating modes.
[0024] As depicted in FIG. 1, the drivetrain 100 includes a battery
120 as an energy storage device. However, it is understood that
other embodiments may include other power sources including energy
storage devices or electrochemical energy conversion devices or
combinations thereof including, but not limited to, an
ultracapicitor or a fuel cell particularly in a fuel cell electric
vehicle drivetrains (FCEV).
[0025] The primary motor-generator assembly 102 includes a first
motor-generator 112, a gearbox 114, and a primary clutch 116. The
gearbox 114 is in driving engagement with the first motor-generator
112 and a portion of the primary clutch 116. A remaining portion of
the primary clutch 116 is in driving engagement with the drive
shaft 106. The gearbox 114 and the primary clutch 116 are in
communication with the battery and the control assembly 110 or
another controller. In some embodiments, the drivetrain 100
includes a separate battery controller (not shown) as part of a
battery management system (not shown).
[0026] In some embodiments, all components of the drivetrain 100
are under the supervisory control of a vehicle system controller
(VSC) not shown. Each drivetrain component can have a separate
controller under the supervisory control of the VSC.
[0027] In some embodiments, the controller 118 and/or VSC is
configured to receive a number of electronic signals from sensors
provided on the vehicle and/or gearboxes. The sensors optionally
include temperature sensors, speed sensors, position sensors, among
others. In some embodiments, the controller 118 and the VSC is
configured to perform routines such as signal acquisition, signal
arbitration, or other known methods for signal processing and is
configured to electronically communicate to a variety of actuators
and sensors.
[0028] The first motor-generator 112 is in driving engagement with
the gearbox 114. The first motor-generator 112 is in electrical
communication with the battery and control assembly 110. Depending
on the electrical control of the first motor-generator 112 using
the battery 120 and control assembly 110, the first motor-generator
112 may apply force to or retard the gearbox 114 and any other
drivetrain components drivingly engaged therewith. Force is applied
by the first motor-generator 112 by converting electrical energy
stored in a battery 120 into kinetic energy by rotating an input of
the gearbox 114 and any components drivingly engaged therewith.
When the input of the gearbox 114 is retarded in response to the
electrical control by a controller 118, the first motor-generator
112 generates electrical energy, which may be stored in the battery
120.
[0029] The gearbox 114 is a drive ratio-adjusting device including
an assembly of gears, clutches, actuators and other components
typically used in transmissions. In some embodiments, the gearbox
114 can be, but is not limited to, a dual clutch transmission, an
automatic mechanical transmission, a manual gearbox or an automatic
gearbox. As a non-limiting example, the gearbox 114 may be a fixed
ratio gearbox and may provide a plurality of drive ratios to
facilitate an operation of the first motor-generator 112 across a
greater number of speed and torque requirements of the electric
axle drive unit 104. The gearbox 114 is drivingly engaged with the
first motor-generator 112 and a portion of the primary clutch 116.
The gearbox 114 is in communication with the controller 118.
Additionally, the gearbox 114 may have its own controller (not
shown) that is communication with the controller 118 and the VSC.
In some embodiments, the gearbox controller coordinates engagement
of the clutch 116 and/or the VSC controls the engagement of the
clutch 116. In response to communication from one of the
controllers or VSC, a drive ratio of the gearbox 114 is adjusted
and/or selected.
[0030] The primary clutch 116 is a clutch which can be variably
engaged, such as a plate or cone style clutch. The primary clutch
116 allows the first motor-generator 112 to drivingly engage the
electric axle drive unit 104 when the primary clutch 116 is at
least partially engaged. In some embodiments, the primary clutch
116 is also in communication with the controller 118. In response
to communication from the controller 118 to the primary clutch 116,
the primary clutch 116 is placed in a disengaged, partially
engaged, or engaged position. If the primary clutch 116 is
disengaged, the first motor-generator 112 is not drivingly engaged
to drive unit 104.
[0031] The electric axle drive unit 104 includes a differential
assembly 122, a second motor-generator assembly 124, and a third
motor-generator assembly 126. In some embodiments, as depicted in
FIGS. 1a-1c, the electric drive axle unit 104 further includes a
first axle clutch 128 and a second axle clutch 130. The
differential assembly 122 is in driving engagement with the primary
clutch 116 (through the drive shaft 106), the second
motor-generator assembly 124 through the first axle clutch 128, and
the third motor-generator assembly 126 through the second axle
clutch 130. The second motor-generator assembly 124 is in driving
engagement with the differential assembly 122 through the first
axle clutch 128 and one of the wheel assemblies 108. The third
motor-generator assembly 126 is in driving engagement with the
differential assembly 122 through the second axle clutch 130 and a
remaining one of the wheel assemblies 108. In some embodiments, the
second motor-generator assembly 124 is in electrical communication
with the controller 118 and the battery 120. In some embodiments,
the third motor-generator assembly 126 is in electrical
communication with the controller 118 and the battery 120. In some
embodiments, the differential assembly 122 is a common differential
gear set implemented to transmit rotational power.
[0032] The first axle clutch 128 is a clutch which can be placed in
at least an engaged and a disengaged position, such as a dog
clutch. Further, it is understood that the first axle clutch 128
may be a clutch that can be variably engaged, such as a plate or
cone style clutch. The first axle clutch 128 allows the
differential assembly 128 to drivingly engage the second
motor-generator assembly 124 when the first axle clutch 128 is at
least partially engaged. The first axle clutch 128 is also in
communication with the controller 118. In response to communication
from the controller 118 to the first axle clutch 128, the first
axle clutch 128 is placed in at least an engaged and a disengaged
position.
[0033] The second axle clutch 130 is a clutch which can placed in
at least an engaged and a disengaged position, such as a dog
clutch. Further, it is understood that the second axle clutch 130
may be a clutch that can be variably engaged, such as, but not
limited to, a plate or cone style clutch. The second axle clutch
130 allows the differential assembly 122 to drivingly engage the
third motor-generator assembly 126 when the second axle clutch 130
is at least partially engaged. In some embodiments, the second axle
clutch 130 is in communication with the controller 118. In response
to communication from the controller 118 to the second axle clutch
130, the second axle clutch 130 is placed in at least an engaged
and a disengaged position.
[0034] The differential assembly 122 is disposed within an axle
housing (not shown). The differential assembly 122 is in driving
engagement with an axle drive pinion 132 and the motor-generator
assemblies 124, 126. At least one bearing (not shown), which may be
a thrust roller bearing, is in contact with a portion of the
differential assembly 122 to enable it to rotate within the axle
housing. The differential assembly 122 is a conventional
differential assembly including a ring gear, differential housing,
drive pinions, and side gears as known in the art. The side gears
of the differential assembly 122 are respectively drivingly engaged
with axle output shafts respectively drivingly engaged with the
axle clutches 128, 130. The ring gear of the differential assembly
122 is drivingly engaged with the axle drive pinion 132 to
facilitate driving engagement between the first motor-generator 112
and the differential assembly 122 through the gearbox 114, the
primary clutch 116, and the drive shaft 106.
[0035] The second motor-generator assembly 124 is in driving
engagement with a portion of the first axle clutch 128 and one of
the wheel assemblies 108. The second motor-generator assembly 124
includes a gearbox portion 134 and a motor-generator portion 136.
The gearbox portion 134 is a ratio-adjusting device, such as, but
not limited to an epicyclic gearset, a gear train, or a dual speed
gearbox used to increase or decrease a drive ratio between the
first axle clutch 128 and the wheel assembly 108. More
particularly, the gearbox portion 134 is a two-speed or three-speed
gearbox.
[0036] In some embodiments, the motor-generator portion 136 is in
electrical communication with the controller 118 and the battery
120. Depending on an electrical control of the motor-generator
portion 136 using the controller 118, the motor-generator portion
136 may apply force to or retard a portion of the first axle clutch
128 and the associated wheel assembly 108. Force is applied by the
motor-generator portion 136 by converting electrical energy stored
in the battery 120 into kinetic energy by rotating the wheel
assembly 108 and any components drivingly engaged therewith. When
the portion of the first axle clutch 128 and the associated wheel
assembly 108 is retarded in response to electrical control by the
controller 118, the motor-generator portion 136 generates
electrical energy, which may be stored in the battery 120.
[0037] The third motor-generator assembly 126 is in driving
engagement with portion of the second axle clutch 130 and a
remaining one of the wheel assemblies 108. The third
motor-generator assembly 126 includes a gearbox portion 138 and a
motor-generator portion 140. The gearbox portion 138 is a
ratio-adjusting device, such as but not limited to an epicyclic
gearset, a gear train, or a dual speed gearbox used to increase or
decrease a drive ratio between the portion of the second axle
clutch 130 and the wheel assembly 108. More particularly, the
gearbox portion 138 is a two-speed or three-speed gearbox.
[0038] In some embodiments, the motor-generator portion 140 is in
electrical communication with the controller 118 and the battery
120. Depending on an electrical control of the motor-generator
portion 140 using the controller 118, the motor-generator portion
140 may apply force to or retard the portion of the second axle
clutch 130 and the associated wheel assembly 108. Force is applied
by the motor-generator portion 140 by converting electrical energy
stored in the battery 120 into kinetic energy by rotating the wheel
assembly 108 and any components drivingly engaged therewith. When
the portion of the second axle clutch 130 and the associated wheel
assembly 108 is retarded in response to electrical control by the
controller 118, the motor-generator portion 140 generates
electrical energy, which may be stored in the battery 120.
[0039] The battery and control assembly 110 includes the controller
118 and the battery 120. The controller 118 is in electrical
communication with the battery 120.
[0040] In some embodiments, the controller 118 is in electrical
communication with at least the first motor-generator 112, the
primary clutch 116, the second motor-generator assembly 124, the
third motor-generator assembly 126, and the axle clutches 128, 130.
It is understood that the controller 118 may also be in
communication with other components of the electric drivetrain 100
or the vehicle (not shown). In some embodiments, the controller 118
and/or the VSC controls an operating mode of the electric
drivetrain 100 of the vehicle by placing the primary clutch 116 and
the axle clutches 128, 130 in an engaged or disengaged position and
by controlling the first motor-generator 112, the second
motor-generator assembly 124, and the third motor-generator
assembly 126 to apply force to or retard portions of the electric
drivetrain 100 that each are respectively drivingly engaged
with.
[0041] Additionally, in some embodiments, the gearbox portions 134,
138 and clutches 128, 130 may have separate controllers (not shown)
in communication with the controller 118 and the VSC. In some
embodiments, the separate controllers coordinate engagement of the
clutches 128, 130 and/or the VSC controls the engagement of the
clutches 128, 130.
[0042] In some embodiments, the VSC is configured to manage torque
and power of the motor-generators 112, 136, 140 along with
controlling the ratio selections of the gearbox portions 134,
138.
[0043] In one embodiment, the battery 120 is a rechargeable,
electrochemical energy storage device in electrical communication
with the controller 118, the first motor-generator 112, the second
motor-generator assembly 124, and the third motor-generator
assembly 126. It is understood that the battery 120 may also be in
electrical communication with other components of the electric
drivetrain 100 or the vehicle to supply power thereto. In response
to the controller 118 or the VSC adjusting an operating mode of the
electric drivetrain 100, the battery 120 may be charged or
discharged.
[0044] In use, the electric drivetrain 100 may be operated in a
plurality of operating modes. The electric drivetrain 100 may be
operated in a drive mode, a regeneration/braking mode, and a
disconnect mode. Further, it is understood that the operating modes
described hereinbelow with respect to the electric drivetrain 100
may be adapted for use with the other electric drivetrains
described herein, utilizing the architecture of each to operate in
the drive mode, the regeneration/braking mode, and the disconnect
mode.
[0045] In the drive mode, the primary motor-generator assembly 102,
the electric axle drive unit 104, or both the primary
motor-generator assembly 102 and the electric axle drive unit 104
apply force to cause rotation of at least one of the wheel
assemblies 108 to propel the vehicle incorporating the electric
drivetrain 100. When only the primary motor-generator assembly 102
is used in the drive mode, the primary clutch 116 and the axle
clutches 128, 130 are placed in an engaged position, and the first
motor-generator 112, in response to communication from the
controller 118 or VSC, applies force to the electric drivetrain 100
to propel the vehicle. When only the electric axle drive unit 104
is used in the drive mode, the primary clutch 116 is placed in the
disengaged position and the axle clutches 128, 130 are placed in an
engaged position, and the second motor-generator assembly 124 and
the third motor-generator assembly 126, in response to
communication from the controller 118 or VSC, apply force to the
electric drivetrain 100 to propel the vehicle. When both the
primary motor-generator assembly 102 and the electric axle drive
unit 104 are used in the drive mode, the primary clutch 116 and the
axle clutches 128, 130 are placed in an engaged position, and the
first motor-generator 112, the second motor-generator assembly 124,
and the third motor-generator assembly 126, in response to
communication from the controller 118 or VSC, apply force to the
electric drivetrain 100 to propel the vehicle.
[0046] In the regeneration/braking mode, the primary
motor-generator assembly 102, the electric axle drive unit 104, or
both the primary motor-generator assembly 102 and the electric axle
drive unit 104 are used to retard the electric drivetrain 100 for
the vehicle to facilitate capturing kinetic energy of the vehicle
as electrical power to be stored in the battery 120. The
regeneration/braking mode may be used to assist a conventional
braking system or may be used to regulate a speed of the vehicle
when descending an incline. When the primary motor-generator
assembly 102 is used in the regeneration/braking mode, the primary
clutch 116 and the axle clutches 128, 130 are placed in an engaged
position and, and the first motor-generator 112 retards the
electric drivetrain 100 to capture kinetic energy as electrical
power.
[0047] When the electric axle drive unit 104 is used in the
regeneration/braking mode, the primary clutch 116 may be placed in
a disengaged position and the axle clutches 128, 130 are placed in
a disengaged condition, and the electric axle drive unit 104
retards the electric drivetrain 100 to capture kinetic energy as
electrical power. When axle clutches 128, 130 are disengaged, the
motor-generators 136, 140 are able to supply power to the wheel
assemblies 108 or capture kinetic energy from the wheel assemblies
108.
[0048] When both the primary motor-generator assembly 102 and the
electric axle drive unit 104 are used in the regeneration/braking
mode, the primary clutch 116 and the axle clutches 128, 130 are
placed in a engaged position, and both the electric axle drive unit
104 and the first motor-generator 112 retard the electric
drivetrain 100 to capture kinetic energy as electrical power.
[0049] In the disconnect mode, through the use of the axle clutches
128, 130, the electric drivetrain 100 benefits from decreased
parasitic losses by being able to disconnect the differential
assembly 122 and the drive shaft 106 from the motor-generator
assemblies 124, 126. This benefit may occur when the electric
drivetrain 100 incorporates two or more electrically driven axles,
and only one of the electrically driven axles is used to propel the
vehicle such as in tandem axle assemblies.
[0050] Further, the electric drivetrain 100 benefits from the
ability to disconnect unneeded portions of the electric drivetrain
100, such as when a cruise speed of the vehicle is reached. As a
non-limiting example, the primary clutch 116 and the axle clutches
128, 130 may be disengaged to improve efficiency of the electric
drivetrain 100 due to the elimination of axle torque losses.
[0051] Further, the electric drivetrain 100 provides the benefits
of reducing a size of the motor-generators 112, 136, 140 to reduce
cost and packaging requirements. The distributed motor-generators
112, 136, 140 provided by the electric drivetrain 100 improve
vehicle dynamics and provide for fail-safe operation in the event
that one of the motor-generators 112, 136, 140 becomes impaired or
non-operational. The electric drivetrain 100 provides the benefits
of reducing an amount of unsprung weight due to a reduced weight of
the motor-generators 112, 136, 140 when compared to a single
mounted on an axle. Lastly, the electric drivetrain 100 provides
enhanced versatility, as the electric drivetrain 100 may be used in
multiple applications, such as, but not limited to, bus or tractor
applications.
[0052] An inverter (not shown) is electrically connected to the
motor-generators 112, 136, 140 for the purpose of supplying the
motor-generators 112, 136, 140 with energy. The battery 120 is
electrically connected to the inverter in order to convert a direct
current of the battery 120 by means of the inverter into an
alternating current for the motor-generator 112, 136, 140.
[0053] In another preferred embodiment, as depicted in FIG. 1b, the
motor-generator 112 is replaced with an internal combustion engine
112a or other prime mover for use with a hybrid vehicle. In some
embodiments, the controller 118 is in electrical communication with
at least the primary clutch 116, the second motor-generator
assembly 124, the third motor-generator assembly 126, and the axle
clutches 128, 130. The battery 120 is a rechargeable,
electrochemical energy storage device in electrical communication
with the controller 118, the second motor-generator assembly 124,
and the third motor-generator assembly 126.
[0054] For description purposes, the terms "prime mover", "engine,"
and like terms, are used herein to indicate a power source. Said
power source could be fueled by energy sources including
hydrocarbon, electrical, biomass, nuclear, solar, geothermal,
hydraulic, pneumatic, and/or wind to name but a few. Although
typically described in a vehicle or automotive application, one
skilled in the art will recognize the broader applications for this
technology and the use of alternative power sources for driving
chicle having this technology.
[0055] As depicted in FIG. 1c, the electric drive axle unit 104 may
be include as an unpowered tag or pusher axle to form a multi-axle
driveline for a motor vehicle. In one embodiment, as shown in FIG.
1c, the electric drive axle unit 104 is positioned as a secondary
electric axle of a 6.times.4 tandem axle vehicle. However, in some
embodiments, the electric drive axle unit 104 may be positioned as
the primary electric axle to form a 6.times.2 tandem axle
vehicle.
[0056] FIG. 2 illustrates an electric drivetrain 200 according to
another embodiment. The electric drivetrain 200 is a variation of
the electric drivetrain 100, and has similar features thereto. The
embodiment shown in FIG. 2 includes similar components to the
electric drivetrain 100. Similar features of the embodiment shown
in FIG. 2 are numbered similarly in series. Different and
additional features of the variation shown in FIG. 2 are described
hereinbelow and can be appreciated by one skilled in the art in
view of FIG. 1 and the other embodiments illustrated and described
in this disclosure.
[0057] FIG. 2 is a schematic style view of the electric drivetrain
200 for a vehicle (not shown) according to another embodiment. The
electric drivetrain 200 includes an electric axle drive unit 242.
The electric axle drive unit 242 is drivingly engaged with a pair
of wheel assemblies 208. The electric axle drive unit 242 is in
electrical communication with a battery and control assembly 210.
The electric drivetrain 200 as shown is a battery electric vehicle
drivetrain, and may be operated in a plurality of operating modes,
as described hereinabove. While not shown, it is understood that
the electric drivetrain 200 may be operated with an unpowered tag
or pusher axle to form a multi-axle driveline.
[0058] The electric axle drive unit 242 includes a first
motor-generator 244, a differential assembly 222, a second
motor-generator assembly 224, a third motor-generator assembly 226,
a first axle clutch 228, and a second axle clutch 230. The
differential assembly 222 is in driving engagement with the first
motor-generator 244, the second motor-generator assembly 224
through the first axle clutch 228, and the third motor-generator
assembly 226 through the second axle clutch 230. The second
motor-generator assembly 224 is in driving engagement with the
differential assembly 222 through the first axle clutch 228 and one
of the wheel assemblies 208. The third motor-generator assembly 226
is in driving engagement with the differential assembly 222 through
the second axle clutch 230 and a remaining one of the wheel
assemblies 208. In some embodiments, the second motor-generator
assembly 224 is in electrical communication with the controller 218
and the battery 220. The third motor-generator assembly 226 is in
electrical communication with the controller 218 and the battery
220.
[0059] The first motor-generator 244 is in driving engagement with
the differential assembly 222. The first motor-generator 244 may be
coupled to an axle housing (not shown). In some embodiments, the
first motor-generator 244 is in electrical communication with the
battery and control assembly 210. Depending on an electrical
control of the first motor-generator 244 using the battery and
control assembly 210, the first motor-generator 244 may apply force
to or retard the differential assembly 222 and any other drivetrain
components drivingly engaged therewith. Force is applied by the
first motor-generator 244 by converting electrical energy stored in
a battery 220 into kinetic energy by driving the differential
assembly 222 and any components drivingly engaged therewith. When
the differential assembly 222 is retarded in response to electrical
control by a controller 218 or VSC, the first motor-generator 244
generates electrical energy, which may be stored in the battery
220.
[0060] FIG. 3 illustrates an electric drivetrain 300 according to
another embodiment. The electric drivetrain 300 is a variation of
the electric drivetrain 100, and has similar features thereto. The
embodiment shown in FIG. 3 includes similar components to the
electric drivetrain 100. Similar features of the variation shown in
FIG. 3 are numbered similarly in series. Different and additional
features of the variation shown in FIG. 3 are described hereinbelow
and can be appreciated by one skilled in the art in view of FIG. 1
and the other embodiments illustrated and described in this
disclosure.
[0061] FIG. 3 is a schematic style view of the electric drivetrain
300 for a vehicle (not shown) according to another embodiment. The
electric drivetrain 300 includes an electric axle drive unit 346.
The electric axle drive unit 346 is drivingly engaged with a pair
of wheel assemblies 308. The electric axle drive unit 346 is in
electrical communication with a battery and control assembly 310.
The electric drivetrain 300 as shown is a battery electric vehicle
drivetrain, and may be operated in a plurality of operating modes,
as described hereinabove. While not shown, it is understood that
the electric drivetrain 300 may be operated with an unpowered tag
or pusher axle to form a multi-axle driveline.
[0062] The electric axle drive unit 346 includes a first
motor-generator 348, a gearbox 350, a primary clutch 352, a
differential assembly 322, a second motor-generator assembly 324, a
third motor-generator assembly 326, a first axle clutch 328, and a
second axle clutch 330. The gearbox 350 is drivingly engaged with
the first motor-generator 348 and the primary clutch 352. The
differential assembly 322 is in driving engagement with the primary
clutch 352, the second motor-generator assembly 324 through the
first axle clutch 328, and the third motor-generator assembly 326
through the second axle clutch 330. The second motor-generator
assembly 324 is in driving engagement with the differential
assembly 322 through the first axle clutch 328 and one of the wheel
assemblies 308. The third motor-generator assembly 326 is in
driving engagement with the differential assembly 322 through the
second axle clutch 330 and a remaining one of the wheel assemblies
308. In some embodiments, the second motor-generator assembly 324
is in electrical communication with the controller 318 and the
battery 320. The third motor-generator assembly 326 is in
electrical communication with the controller 318 and the battery
320.
[0063] The first motor-generator 348 is in driving engagement with
the gearbox 350. The first motor-generator 348 may be coupled to an
axle housing (not shown). In some embodiments, the first
motor-generator 348 is in electrical communication with the battery
and control assembly 310. Depending on an electrical control of the
first motor-generator 348 using the battery and control assembly
310, the first motor-generator 348 may apply force to or retard the
gearbox 350 and any other drivetrain components drivingly engaged
therewith. Force is applied by the first motor-generator 348 by
converting electrical energy stored in a battery 320 into kinetic
energy by driving the gearbox 350 and any components drivingly
engaged therewith. When the gearbox 350 is retarded in response to
electrical control by a controller 318 or VSC, the first
motor-generator 348 generates electrical energy, which may be
stored in the battery 320.
[0064] The gearbox 350 is a drive ratio-adjusting device including
an assembly of gears, clutches, actuators and other components
typically used in transmissions. As a non-limiting example, the
gearbox 350 may be a fixed ratio gearbox and may provide a
plurality of drive ratios to facilitate an operation of the first
motor-generator 348 across a greater number of speed and torque
requirements of the electric axle drive unit 346. The gearbox 350
is drivingly engaged with the first motor-generator 348 and a
portion of the primary clutch 352. The gearbox 350 is in
communication with the controller 318 and/or VSC. In response to
communication from the controller 318 or VSC, a drive ratio of the
gearbox 350 is adjusted.
[0065] The primary clutch 352 is a clutch which can be variably
engaged, such as a plate or cone style clutch. The primary clutch
352 allows the first motor-generator 348 to drivingly engage the
electric axle drive unit 346 through the gearbox 350 when the
primary clutch 352 is at least partially engaged. The primary
clutch 352 is also in communication with the controller 318 and/or
VSC. In response to communication from the controller 318 or VSC to
the primary clutch 352, the primary clutch 352 is placed in a
disengaged, partially engaged, or engaged position.
[0066] FIG. 4 illustrates an electric drivetrain 400 according to
another embodiment. The electric drivetrain 400 is a variation of
the electric drivetrain 100, and has similar features thereto. The
embodiment shown in FIG. 4 includes similar components to the
electric drivetrain 100. Similar features of the variation shown in
FIG. 4 are numbered similarly in series. Different and additional
features of the variation shown in FIG. 4 are described hereinbelow
and can be appreciated by one skilled in the art in view of FIG. 1
and the other embodiments illustrated and described in this
disclosure.
[0067] FIG. 4 is a schematic style view of the electric drivetrain
400 for a vehicle (not shown) according to another embodiment. The
electric drivetrain 400 includes a first motor-generator 454 and an
electric axle drive unit 456.
[0068] The electric axle drive unit 456 is drivingly engaged with a
pair of wheel assemblies 408. In some embodiments, the electric
axle drive unit 456 is in electrical communication with a battery
and control assembly 410. The electric drivetrain 400 as shown is a
battery electric vehicle drivetrain, and may be operated in a
plurality of operating modes, as described hereinabove. While not
shown, it is understood that the electric drivetrain 400 may be
operated with an unpowered tag or pusher axle to form a multi-axle
driveline.
[0069] The first motor-generator 454 is in driving engagement with
the electric axle drive unit 456 through the drive shaft 406, and
is remotely mounted from the electric axle drive unit 456. The
first motor-generator 454 is in electrical communication with the
battery and control assembly 410. Depending on an electrical
control of the first motor-generator 454 using the battery and
control assembly 410, the first motor-generator 454 may apply force
to or retard the electric axle drive unit 456 and any other
drivetrain components drivingly engaged therewith. Force is applied
by the first motor-generator 454 by converting electrical energy
stored in a battery 420 into kinetic energy by rotating an input of
the electric axle drive unit 456 and any components drivingly
engaged therewith. When the input of the electric axle drive unit
456 is retarded in response to electrical control by a controller
418 or VSC, the first motor-generator 454 generates electrical
energy, which may be stored in the battery 420.
[0070] The electric axle drive unit 456 includes a gearbox 458, a
primary clutch 460, a differential assembly 422, a second
motor-generator assembly 424, a third motor-generator assembly 426,
a first axle clutch 428, and a second axle clutch 430. The gearbox
458 is drivingly engaged with the first motor-generator 454 through
the drive shaft 406 and the primary clutch 460. The differential
assembly 422 is in driving engagement with the primary clutch 460,
the second motor-generator assembly 424 through the first axle
clutch 428, and the third motor-generator assembly 426 through the
second axle clutch 430. The second motor-generator assembly 424 is
in driving engagement with the differential assembly 422 through
the first axle clutch 428 and one of the wheel assemblies 408. The
third motor-generator assembly 426 is in driving engagement with
the differential assembly 422 through the second axle clutch 430
and a remaining one of the wheel assemblies 408. In some
embodiments, the second motor-generator assembly 424 is in
electrical communication with the controller 418 and the battery
420. The third motor-generator assembly 426 is in electrical
communication with the controller 418 and the battery 420.
[0071] The gearbox 458 is a drive ratio adjusting device disposed
in a housing (not shown) of the electric axle drive unit 456
including an assembly of gears, clutches, actuators and other
components typically used in transmissions. As a non-limiting
example, the gearbox 458 may be a fixed ratio (gearbox and may
provide a plurality of drive ratios to facilitate an operation of
the first motor-generator 454 across a greater number of speed and
torque requirements of the electric axle drive unit 456. The
gearbox 458 is drivingly engaged with the first motor-generator 454
and a portion of the primary clutch 460. The gearbox 458 is in
communication with the controller 418 and/or VSC. In response to
communication from the controller 418 or VSC, a drive ratio of the
gearbox 458 is adjusted.
[0072] The primary clutch 460 is a clutch disposed in a housing
(not shown) of the electric axle drive unit 456 which can be
variably engaged, such as a plate or cone style clutch. The primary
clutch 460 allows the gearbox 458 to drivingly engage the
differential assembly 422 when the primary clutch 460 is at least
partially engaged. The primary clutch 460 is also in communication
with the controller 418 and/or VSC. In response to communication
from the controller 418 or VSC to the primary clutch 460, the
primary clutch 460 is placed in a disengaged, partially engaged, or
engaged position.
[0073] FIG. 5 illustrates an electric drivetrain 500 according to
another preferred embodiment. The electric drivetrain 500 is a
variation of the electric drivetrain 100, and has similar features
thereto. The embodiment shown in FIG. 5 includes similar components
to the electric drivetrain 100. Similar features of the variation
shown in FIG. 5 are numbered similarly in series. Different and
additional features of the variation shown in FIG. 5 are described
hereinbelow and can be appreciated by one skilled in the art in
view of FIG. 1 and the other embodiments illustrated and described
in this disclosure.
[0074] FIG. 5 is a schematic style view of the electric drivetrain
500 for a vehicle (not shown) according to another preferred
embodiment. The electric drivetrain 500 includes a first
motor-generator 562 and an electric axle drive unit 564. The
electric axle drive unit 564 is drivingly engaged with a pair of
wheel assemblies 508. The electric axle drive unit 564 is in
electrical communication with a battery and control assembly 510.
The electric drivetrain 500 as shown is a battery electric vehicle
drivetrain, and may be operated in a plurality of operating modes,
as described hereinabove. While not shown, it is understood that
the electric drivetrain 500 may be operated with an unpowered tag
or pusher axle to form a multi-axle driveline.
[0075] The first motor-generator 562 is in driving engagement with
the electric axle drive unit 564 through the drive shaft 506, and
is remotely mounted from the electric axle drive unit 564. The
first motor-generator 562 is in electrical communication with the
battery and control assembly 510. Depending on an electrical
control of the first motor-generator 562 using the battery and
control assembly 510, the first motor-generator 562 may apply force
to or retard the electric axle drive unit 564 and any other
drivetrain components drivingly engaged therewith. Force is applied
by the first motor-generator 562 by converting electrical energy
stored in a battery 520 into kinetic energy by rotating an input of
the electric axle drive unit 564 and any components drivingly
engaged therewith. When the input of the electric axle drive unit
564 is retarded in response to electrical control by a controller
518 or VSC, the first motor-generator 562 generates electrical
energy, which may be stored in the battery 520.
[0076] The electric axle drive unit 564 includes a kinetic energy
recovery system 566, a gearbox 568, a primary clutch 570, a
differential assembly 522, a second motor-generator assembly 524, a
third motor-generator assembly 526, a first axle clutch 528, and a
second axle clutch 530. The kinetic energy recovery system 566 is
drivingly engaged with the first motor-generator through the drive
shaft 506 and the gearbox 568. The gearbox 568 is drivingly engaged
with the primary clutch 570. The differential assembly 522 is in
driving engagement with the primary clutch 570, the second
motor-generator assembly 524 through the first axle clutch 528, and
the third motor-generator assembly 526 through the second axle
clutch 530. The second motor-generator assembly 524 is in driving
engagement with the differential assembly 522 through the first
axle clutch 528 and one of the wheel assemblies 508. The third
motor-generator assembly 526 is in driving engagement with the
differential assembly 522 through the second axle clutch 530 and a
remaining one of the wheel assemblies 508. The second
motor-generator assembly 524 is in electrical communication with
the controller 518 and/or VSC and the battery 520. The third
motor-generator assembly 526 is in electrical communication with
the controller 518 and/or VSC and the battery 520.
[0077] The kinetic energy recovery system 566 is disposed in a
housing (not shown) of the electric axle drive unit 564 and stores
and applies energy present in the electric drivetrain 500. The
kinetic energy recovery system 566 may be a flywheel type kinetic
energy recovery system, wherein kinetic energy is captured during a
braking operation, for example, and stored in a flywheel. Further,
when the electric driveline 500 requires additional output, such as
for an acceleration or launching event, energy stored in the
flywheel is applied to the electric driveline 500. As shown in FIG.
5, the kinetic energy recovery system 566 is drivingly engaged with
the gearbox 568 and the first motor-generator 562 through the drive
shaft 506. The kinetic energy recovery system 566 is in
communication with the controller 518 and/or VSC, which commands
the kinetic energy recovery system 566 to store and releases energy
into the electric driveline 500 based on, for example, a state of
charge of the battery 520 or a mode of operation of the electric
driveline 500.
[0078] The gearbox 568 is a drive ratio adjusting device disposed
in a housing (not shown) of the electric axle drive unit 564
including an assembly of gears, clutches, actuators and other
components typically used in transmissions. As a non-limiting
example, the gearbox 568 may be a fixed ratio gearbox and may
provide a plurality of drive ratios to facilitate an operation of
the first motor-generator 562 across a greater number of speed and
torque requirements of the electric axle drive unit 564. The
gearbox 568 is drivingly engaged with the kinetic energy recovery
system 566 and a portion of the primary clutch 570. The gearbox 568
is in communication with the controller 518 and/or VSC. In response
to communication from the controller 518 or VSC, a drive ratio of
the gearbox 568 is adjusted. The primary clutch 570 is a clutch
disposed in a housing (not shown) of the electric axle drive unit
564 which can be variably engaged, such as a plate or cone style
clutch. The primary clutch 570 allows the gearbox 568 to drivingly
engage the differential assembly 522 when the primary clutch 570 is
at least partially engaged. The primary clutch 570 is also in
communication with the controller 518 and/or VSC. In response to
communication from the controller 518 or VSC to the primary clutch
570, the primary clutch 570 is placed in a disengaged, partially
engaged, or engaged position.
[0079] In some embodiments, as depicted in FIG. 6, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
two-speed planetary gearboxes 600. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 602. The planetary gear set 602 is provided with
a first ring gear 604, a first planet carrier 606, a first sun gear
608, a second ring gear 610, a second planet carrier 612 and a
second sun gear 614. In some embodiments, the first sun gear 608 is
coupled to the motor-generator 136, 140, 236, 240, 336, 340, 436,
440, 536, 540, the first planet carrier 606 and the second sun gear
614. The first planet carrier 606 is coupled to the first ring gear
604 and the second planet carrier 612. The first ring gear 604 is
grounded through a brake 616. The second ring gear 610 is operably
coupled to a first clutch 620 and the second planet carrier 612 is
operably coupled to a second clutch 622. The first and second
clutches 620, 622 are selectively engaged to couple the second ring
gear 610 and the second planet carrier 613 to an output that is
drivingly engaged with a wheel assembly 108, 208, 308, 408,
508.
[0080] During operation of the gearbox 600, the brake 616 is
engaged at all times. The gearbox 600 provides two modes of
operation. When the first clutch 620 is engaged and the second
clutch 622 is disengaged, the gearbox 606 operates in a first mode
providing a low speed gear ratio. When the first clutch 620 is
disengaged and the second clutch 622 is engaged, the gearbox 600
operates in a second mode providing a high speed gear ratio. The
first and second clutches 620, 622 are activated using an actuation
device including, but not limited to, an electromagnetic or
pneumatic actuator.
[0081] In some embodiments, as depicted in FIG. 7, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
two-speed planetary gearboxes 700. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 702. The planetary gear set 702 is provided with
a first ring gear 704, a first planet carrier 706, a first sun gear
708, a second ring gear 710, a second planet carrier 712 and a
second sun gear 714. In some embodiments, the first sun gear 708 is
coupled to the motor-generator 136, 140, 236, 240, 336, 340, 436,
440, 536, 540, the first planet carrier 706 and the second sun gear
714. The first planet carrier 706 is coupled to the first ring gear
704 and a first clutch 720. The first clutch 720 selectively
grounds the first planet carrier 706. The first ring gear 704 is
coupled to a second clutch 722 and the second ring gear 710. The
second clutch 722 selectively grounds the first ring gear 704. The
second ring gear 710 is coupled to the second planet carrier 712.
The second planet carrier 712 is coupled to an output that is
drivingly engaged with a wheel assembly 108, 208, 308, 408,
508.
[0082] During operation, the gearbox 700 provides two modes of
operation. When the first clutch 720 is engaged and the second
clutch 722 is disengaged, the gearbox 700 operates in a first mode
providing a low speed gear ratio. When the first clutch 720 is
disengaged and the second clutch 722 is engaged, the gearbox
operates in a second mode providing a high speed gear ratio. The
first and second clutches 720, 722 are activated using an actuation
device including, but not limited to, an electromagnetic or
pneumatic actuator.
[0083] In some embodiments, as depicted in FIG. 8, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
two-speed stepped pinion planetary gearbox 800. The motor-generator
136, 140, 236, 240, 336, 340, 436, 440, 536, 540 is drivingly
connected to a planetary gear set 802. The planetary gear set 802
is provided with a first ring gear 804, a first planet carrier 806,
a first sun gear 808, a second ring gear 810, a second planet
carrier 812, a second sun gear 814, a first pinion gear 815 and a
second pinion gear 817. The first pinion gear 815 and second pinion
gear from a stepped pinion gear. In some embodiments, the first sun
gear 808 is coupled to the motor-generator 136, 140, 236, 240, 336,
340, 436, 440, 536, 540 and the first planet carrier 806. The first
planet carrier 806 is coupled to the first ring gear 804 and the
second planet carrier 812. The first ring gear 804 is coupled to a
first clutch 822 and the first pinion gear 815. The first pinion
gear 815 is coupled to the second pinion gear 817 which is coupled
to the second ring gear 810. The second ring gear 810 is coupled to
the second planet carrier 812 and selectively coupled to an output
through a second clutch 822. The second planet carrier 812 is
selectively coupled to the output through a third clutch 824. The
first clutch 820 selectively grounds the first ring gear 804. The
output is drivingly engaged to a wheel assembly 108, 208, 308, 408,
508.
[0084] During operation of the gearbox 800 provides two modes of
operation. When the second clutch 822 is engaged and the third
clutch 824 is disengaged, the gearbox 800 operates in a first mode
providing a low speed gear ratio. When the second clutch 822 is
disengaged and the third clutch 824 is engaged, the gearbox 800
operates in a second mode providing a high speed gear ratio. The
clutches 820, 822, 824 are activated by using an actuation device
including, but not limited to, an electromagnetic or pneumatic
actuator.
[0085] In some embodiments, as depicted in FIGS. 9a-9b, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
three-speed planetary gearbox 900. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 902. The planetary gear set 902 is provided with
a first ring gear 904, a first planet carrier 906, a first sun gear
908, a second ring gear 910, a second planet carrier 912, a second
sun gear 914, a third sun gear 915, a third ring gear 917, and a
third planet carrier 919. In some embodiments, the first sun gear
908 is coupled to the motor-generator 136, 140, 236, 240, 336, 340,
436, 440, 536, 540 and the first planet carrier 906. The first
planet carrier 906 is coupled to the first ring gear 904 and the
second sun gear 914. The first ring gear 904 is coupled to a first
clutch 920 and the second ring gear 910 which is coupled to the
second planet carrier 912. The second planet carrier 912 is coupled
to the third sun gear 915 which is coupled to the third planet
carrier 919. The third planet carrier 919 is coupled to the third
ring gear 917 and an output of the gearbox 900. The third ring gear
is selectively grounded by a brake 921. The first clutch 920
selectively grounds the first ring gear 904. In further
embodiments, the first clutch 920 is a selector clutch configured
to select three modes of operation. The output is drivingly engaged
to a wheel assembly 108, 208, 308, 408, 508.
[0086] During operation of the gearbox 900 provides three modes of
operation depending on the position of the first clutch 920. When
the first clutch 920 is engaged with the planetary gear set 902 the
gearbox 906 operates in a high speed gear ratio. When the first
clutch 920 is in a neutral or disengaged mode, gearbox 900 operates
in a neutral or direct drive mode. When the first clutch 920
selectively grounds the first ring gear 904 it provides a low-speed
gear ratio operational mode. The clutch 920 is activated by using
an actuation device including, but not limited to, an
electromagnetic or pneumatic actuator.
[0087] In some embodiments, as depicted in FIG. 10, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 includes
a gearbox having a two-speed layshaft gear arrangement 1002. The
motor-generator 136, 140, 236, 240, 336, 340, 436, 440, 536, 540 is
drivingly connected to an output shaft 1002. The two-speed layshaft
gear arrangement 1002 includes a set of gear passes 1004, 1006,
1008 rotatably connected to the output shaft 1002 and a rotatable
layshaft 1010. A portion of the first gear pass 1004 is rotatably
connected to the output shaft 1002 and a portion is rotatably
connected to the layshaft 1010. A selector clutch 1012 is
positioned on the output shaft 1002 between the first gear pass
1004 and a second gear pass 1006. The second gear pass 1002 has a
portion drivingly connected to the output shaft 1002 and a portion
rotatably connected to the layshaft 1010. Further, a third gear
pass 1006 has a portion rotatably connected to the output shaft
1002 and a portion rotatably connected to the layshaft 1010. In
some embodiments, the layshaft 1010 is a hollow rotatable shaft
that is parallel to the output shaft 1002.
[0088] During operation of the gearbox 1000, the selector clutch
1012 selectively connects the first gear pass 1004 and second gear
pass 1006 to the layshaft 1010. When the selector clutch 1012
drivingly connects the first gear pass 1004 with the layshaft 1010,
the gearbox 1000 operates in a low speed gear ratio. When the
selector clutch 1012 drivingly connects the second gear pass 1006
with the layshaft 1010, the gearbox 1000 operates in a high speed
gear ratio. The clutch 1012 can be activated by using an actuation
device including, but not limited to, an electromagnetic or
pneumatic actuator. The layshaft 1010 is drivingly connected to the
wheel assemblies 108, 208, 308, 408, 508. In further embodiments,
the gearbox 1000 can include additional layshafts with additional
gear passes and additional selector clutches to increase the number
of gear ratio which the gearbox 1000 can provide.
[0089] In some embodiments, as depicted in FIG. 11a, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
three-speed planetary gearbox 1100. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 1102. The planetary gear set 1102 is provided
with a first ring gear 1104, a first planet carrier 1106, a first
sun gear 1108, a second ring gear 1110, a second planet carrier
1112, and a second sun gear 1114. In some embodiments, the first
sun gear 1108 is coupled to the motor-generator 136, 140, 236, 240,
336, 340, 436, 440, 536, 540, the first planet carrier 1106 and the
second sun gear 1114. The first planet carrier 1106 is coupled to
the first ring gear 1104, the second planet carrier 1112 and a
first clutch 1120. The first clutch 1120 selectively couples the
output of the motor-generator 136, 140, 236, 240, 336, 340, 436,
440, 536, 540 to the first planet carrier 1106. The first ring gear
1104 is coupled to a brake 1121 that selectively grounds the first
ring gear 1104. The second planet carrier 1112 is coupled to the
second sun gear 1114, the second ring gear 1110 and is selectively
coupled to an output through a second clutch 1122. The second ring
gear 1110 is selectively coupled to the output through a third
clutch 1124. The output is drivingly engaged to a wheel assembly
108, 208, 308, 408, 508.
[0090] During operation of the gearbox 1100 provides three modes of
operation depending on the position of the engagement of the
clutches 1120, 1122, 1124. When the first clutch 1120 is engaged
and the motor-generator 136, 140, 236, 240, 336, 340, 436, 440,
536, 540 is drivingly connected to the first planet carrier 1106
and the first sun gear 1108 operates in a neutral mode. If the
brake 1121, second clutch 1122 and third clutch 1124 are disengaged
then the gearbox 1100 operates in a direct drive mode. When the
first clutch 1120 and the second clutch 1122 are disengaged and the
brake 1121 and third clutch 1124 are engaged, the gearbox 1100
operates in a high-speed gear ratio operational mode. When the
first clutch 1120 and the third clutch 1124 are disengaged and the
brake 1121 and second clutch 1122 are engaged, the gearbox 1100
operates in a low-speed gear ratio operational mode. The clutches
1120, 1122, 1124 are activated using an actuation device including,
but not limited to, an electromagnetic or pneumatic actuator.
[0091] In further embodiments, the gearbox 1100 includes a fourth
clutch 1126 that selectively couples the first ring gear 1104 and
the second ring gear 1110 as depicted in FIG. 11 b. When the first
clutch 1120, third clutch 1124, fourth clutch 1126 are engaged and
the brake 1121 and second clutch 1122 are disengaged, then the
gearbox 1100 operates in a direct drive mode. When the first clutch
1120, second clutch 1122 and fourth clutch 1126 are disengaged and
the brake 1121 and third clutch 1124 are engaged, the gearbox 1100
operates in a high-speed gear ratio operational mode. When the
first clutch 1120, the third clutch 1124 and fourth clutch 1126 are
disengaged and the brake 1121 and second clutch 1122 are engaged,
the gearbox 1100 operates in a low-speed gear ratio operational
mode. The clutches 1120, 1122, 1124, 1126 are activated using an
actuation device including, but not limited to, an electromagnetic
or pneumatic actuator.
[0092] In some embodiments, as depicted in FIG. 12, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
three-speed planetary gearboxes 1200. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 1202. The planetary gear set 1202 is provided
with a first ring gear 1204, a first planet carrier 1206, a first
sun gear 1208, a second ring gear 1210, a second planet carrier
1212 and a second sun gear 1214. In some embodiments, the first sun
gear 1208 is coupled to the motor-generator 136, 140, 236, 240,
336, 340, 436, 440, 536, 540, the first planet carrier 1206 and
selectively coupled to the second sun gear 1214 through a first
clutch 1220. The first planet carrier 1206 is coupled to the first
ring gear 1204 and a second clutch 1222. The second clutch 1222
selectively grounds the first planet carrier 1206. The first ring
gear 1204 is coupled to a third clutch 1224 and the second ring
gear 1210. The third clutch 1224 selectively grounds the first ring
gear 1204. The second ring gear 1218 is coupled to the second
planet carrier 1212 and is selectively coupled to the second sun
gear 1214 through a fourth clutch 1226. The second planet carrier
1212 is coupled to an output that is drivingly engaged with a wheel
assembly 108, 208, 308, 408, 508.
[0093] During operation of the gearbox 1200 provides three modes of
operation. When the first clutch 1220 and fourth clutch 1226 are
engaged and the second clutch 1222 and third clutch 1224 are
disengaged, the gearbox 1206 operates in a first direct drive mode.
When the first clutch 1220, second clutch 1222 and fourth clutch
1226 are disengaged and the third clutch 1224 is engaged, the
gearbox operates in a second mode providing a high speed gear
ratio. When the first clutch 1220, second clutch 1222 and third
clutch 1224 are disengaged and the fourth clutch 1226 is engaged,
the gearbox operates in a second mode providing a low speed gear
ratio. The clutches 1220, 1222, 1224, 1226 are activated using an
actuation device including, but not limited to, an electromagnetic
or pneumatic actuator.
[0094] In some embodiments, as depicted in FIG. 13, the gearbox
portions 134, 138, 234, 238, 334, 338, 434, 438, 534, 538 are
three-speed planetary gearboxes 1300. The motor-generator 136, 140,
236, 240, 336, 340, 436, 440, 536, 540 is drivingly connected to a
planetary gear set 1302. The planetary gear set 1302 is provided
with a first ring gear 1304, a first planet carrier 1306, a first
sun gear 1308, a second ring gear 1310, a second planet carrier
1312 and a second sun gear 1314. In some embodiments, the first sun
gear 1308 is coupled to the motor-generator 136, 140, 236, 240,
336, 340, 436, 440, 536, 540, the first planet carrier 1306 and the
second sun gear 1314. The first planet carrier 1306 is coupled to
the first ring gear 1304 and a first clutch 1320. The first clutch
1320 selectively grounds the first planet carrier 1306. The first
ring gear 1304 is coupled to a second clutch 1322 and the second
ring gear 1310. The second clutch 1322 selectively grounds the
first ring gear 1304. The second ring gear 1318 is coupled to the
second planet carrier 1312. The second planet carrier 1312 is
coupled to an output that is drivingly engaged with a wheel
assembly 108, 208, 308, 408, 508. The second sun gear 1314 is
selectively coupled to the output through a third clutch 1324.
[0095] During operation of the gearbox 1300 provides three modes of
operation. When the first clutch 1320 and second clutch 1322 are
disengaged and the third clutch 1324 is engaged, the gearbox 1306
operates in a direct drive mode. When the first clutch 1320 is
engaged and the second clutch 1322 and third clutch are disengaged,
the gearbox 1306 operates in a first mode providing a low speed
gear ratio. When the first clutch 1320 and third clutch 1324 are
disengaged and the second clutch 1322 is engaged, the gearbox
operates in a second mode providing a high speed gear ratio. The
first and second clutches 1320, 1322 are activated by using an
actuation device including, but not limited to, an electromagnetic
or pneumatic actuator.
[0096] In accordance with the provisions of the patent statutes,
the present embodiments have been described in what is considered
to represent its preferred embodiments, however, it should be noted
that the embodiments can be practiced otherwise than as
specifically illustrated and described without departing from its
scope or spirit.
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