Vehicle comprising transfer case and method for operating said vehicle
11273707 · 2022-03-15
Assignee
Inventors
- Sven Gasparovic (Graz, AT)
- Andreas Rudolf Hafner (Lieboch, AT)
- Simon Kaimer (Fernitz, AT)
- Daniel Lindvai-Soos (Graz, AT)
- Daniel PRIX (Graz, AT)
- Gerhard Hofer (Pinggau, DE)
- Dominik Schober (Graz, AT)
- Franz Wallner (Ilz, AT)
- Alexander Hehenberger (Premstaetten, AT)
- Martin Bloder (Sinabelkirchen, AT)
Cpc classification
B60K6/387
PERFORMING OPERATIONS; TRANSPORTING
B60K17/3467
PERFORMING OPERATIONS; TRANSPORTING
B60K17/3462
PERFORMING OPERATIONS; TRANSPORTING
B60K2006/4808
PERFORMING OPERATIONS; TRANSPORTING
B60K17/356
PERFORMING OPERATIONS; TRANSPORTING
B60K6/52
PERFORMING OPERATIONS; TRANSPORTING
B60K2006/4833
PERFORMING OPERATIONS; TRANSPORTING
B60K6/365
PERFORMING OPERATIONS; TRANSPORTING
B60K5/02
PERFORMING OPERATIONS; TRANSPORTING
B60K6/40
PERFORMING OPERATIONS; TRANSPORTING
B60K17/342
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A vehicle having a longitudinal engine and permanent rear axle drive is proposed, which vehicle has an internal combustion engine and an electric machine, a transfer gearbox distributing drive torques as required to two drive axles, the transfer gearbox having three shafts, a main shaft serving as a drive shaft of the rear axle, a secondary shaft serving as a drive shaft for the front axle, and an intermediate shaft applying a torque, a shifting unit being installed between the reduction gear-box and the power summation gearbox.
Claims
1. A vehicle having a longitudinally arranged engine combustion and permanent rear axle drive, which vehicle has an internal combustion engine and an electric machine, a transfer gearbox distributing drive torques as required to two drive axles, the front and rear axles, the transfer gearbox being connected to three shafts, a main shaft serving as a drive shaft of the rear axle, a secondary shaft serving as a drive shaft for the front axle, and an intermediate shaft applying a torque from the electric machine to the transfer gearbox, the transfer gearbox having a reduction gearbox and a power summation gearbox, and the summed output power of the power summation gearbox prevailing at the secondary shaft by way of a chain of a chain drive or a gearwheel set, wherein a shifting unit is installed between the reduction gearbox and the power summation gearbox, and wherein the shifting unit shifts between three operating modes.
2. The vehicle as claimed in claim 1, wherein the reduction gearbox is a planetary gear mechanism or a step-down means.
3. The vehicle as claimed in claim 1, wherein the power summation gearbox is a planetary gear mechanism.
4. The vehicle as claimed in claim 3, characterized in that the electric machine engages via the reduction gearbox and the intermediate shaft into the sun gear of the power summation gearbox, the internal combustion engine engaging into the internal gear of the power summation gearbox.
5. The vehicle as claimed in claim 3, wherein the power is transmitted at the front axle via a planetary carrier of the power summation gearbox.
6. The vehicle as claimed in claim 1, wherein the reduction gearbox and the power summation gearbox are arranged on the same axle.
7. The vehicle as claimed in claim 1, wherein the power summation gearbox is arranged on the main shaft, and the reduction gearbox is arranged on the intermediate shaft.
8. The vehicle as claimed in claim 1, wherein the electric machine is attached coaxially with respect to the main shaft, and the intermediate shaft engages around the main shaft as a hollow shaft.
9. The vehicle as claimed in claim 1, wherein the shifting unit consists of a frictionally locking connection and a positively locking connection with an actuator which is arranged or engages in between.
10. The vehicle as claimed in claim 9, wherein the shifting unit utilizes the frictionally locking connection in the first shifting position, which frictionally locking connection serves to transmit and limit a torque.
11. The vehicle as claimed in claim 9, wherein in a second shifting position, the shifting unit serves by way of the positively locking connection for the transmission of a smaller torque than in the first shifting position and is disconnected by way of an active load change of the electric machine.
12. The vehicle as claimed in claim 1, wherein the shifting unit has a zero position as third shifting position.
13. A method for operating a vehicle having a transfer gearbox as claimed in claim 1, wherein a shifting logic circuit of a three-gear shifting mechanism bringing about torque limiting by way of a frictionally locking connection.
14. The method for operating a vehicle as claimed in claim 13, wherein the shifting logic circuit brings about a rotational speed safeguard for the electric machine by way of the frictionally locking connection.
15. The method for operating a vehicle as claimed in claim 13, wherein after an existing shifting request, the shifting logic circuit examines parameters which serve both for the rotational speed safeguard and the torque limiting.
16. The method for operating a vehicle as claimed in claim 13, wherein in a second shifting position, the shifting unit serves by way of the positively locking connection for the transmission of a smaller torque than in the first shifting position, and is disconnected by way of an active load change of the electric machine.
17. A vehicle having a longitudinally arranged engine combustion and permanent rear axle, which vehicle has an internal combustion engine and an electric machine, a transfer gearbox distributing drive torque as required between two drive axles, the front and rear axles, the transfer gearbox being connected to three shafts, a main shaft serving as a drive shaft of the rear axle, a secondary shaft serving as a drive shaft for the front axle, and an intermediate shaft applying a torque from the electric motor to the transfer gearbox, the transfer gearbox having a reduction gearbox and a power summation gearbox, and the summed output power of the power summation gearbox prevailing at the secondary shaft by way of a chain drive or a gearwheel set, wherein a shifting unit is installed between the reduction gearbox and the power summation gearbox, and wherein the shifting unit includes a frictionally locking connection and a positively locking connection with an actuator which is arranged or engages in between.
Description
DRAWINGS
(1) The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
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DESCRIPTION OF THE INVENTION
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(13) An internal combustion engine 6 for the vehicle with longitudinal engine architecture and permanent rear axle drive is connected to a first shaft, the main shaft 3. The connection is made via a main clutch 10 and a main gearbox 7.
(14) The main shaft 3 permanently drives the rear axle 8. In addition to the internal combustion engine 6, an electric machine 2 is provided which is coupled to a power summation gearbox 11 via an intermediate shaft 5. The input of the power summation gearbox 11 is connected to the main shaft 3; at the output end the power summation gearbox 11 is adjacent to a secondary shaft 4. The secondary shaft 4 is connected to the front axle 9.
(15) A preferred embodiment is designed for vehicles which, in addition to the customary 12V on-board electrical system, also have a 48V on-board electrical system. A powerful electric machine operated at 48V can therefore be used. The distributor gearbox obtains part, e.g. 10%, of the total power from the electric ma-chine 2.
(16) By means of the power summation gearbox 11, part of the total output of the internal combustion engine 6 is channeled off by a support moment of the electric machine 2 and boosted by the output of the electric machine 2. This allows variable torque distribution between the front axle 9 and the rear axle 8 with a high degree of precision, even in unfavorable driving conditions.
(17) The distribution gearbox 1 is essentially made up of the power summation gear-box 11 and the reduction gearbox 12 of the electric machine 2. The electric machine 2 provides the support moment which defines the torque of the secondary shaft 4. In this case, most of the drive power, e.g. 90%, is supplied by the internal combustion engine 6 via the drive shaft, the main shaft 3, and a small part, e.g. 10%, by the electric machine 2. In addition, the electric machine 2 controls the total torque transmitted to the secondary shaft 4 by means of the torque provided. When rotational speed differences occur between the front axle 9 and the rear axle 8, the torque can, nevertheless, be variably distributed between the front and rear axle 9, 8.
(18) Apart from the main shaft 3 which transmits torque to the rear axle 8, and the secondary shaft 4 which transmits torque to the front axle 9, a third shaft—the intermediate shaft 5—is used, on which the electric machine 2 and the planetary gear mechanism, the reduction gearbox 12, the electric machine 2 are located. In a first arrangement according to
(19) A first embodiment of the inventive solution is depicted in
(20) The torque from the electric machine 2 is transmitted by the reduction gearbox 12 in such a manner that a required support moment for the power summation gear-box 11 is available.
(21) The intermediate shaft 5 of the electric machine 2 drives a sun gear 21 of the first planetary gear mechanism 20. A planetary carrier 23 in which the planetary gears 22 rotate is fixedly connected to a housing of the distributor gearbox 1 and the torque of the electric machine 2 is tapped and transmitted via a shaft 40 at an internal gear 24 of the first planetary gear mechanism 20.
(22) The torque supplied by the electric machine 2 is then applied via the shaft 40 to the sun gear 31 of the second planetary gear mechanism 30, in order to tap a desired torque at the front axle 9, e.g.: 1300 Nm.
(23) In the power summation gearbox 11, the second planetary gear mechanism 30, the electric machine 2 contributes via its torque a part, e.g. 10%, which corre-sponds to roughly 130 Nm in the example, and the remainder e.g.: 90% corre-sponding to 1170 Nm is tapped from the main shaft 3.
(24) The torque of the electric machine 2 which is reduced by the reduction gearbox 12 drives the sun gear 31 of the second planetary gear mechanism 30 in the power summation gearbox 11.
(25) An internal gear 34 of the second planetary gear mechanism 30 is connected in a driving manner via a driving wheel set 35 to the main shaft 3.
(26) The summed torque of the sun gear 31 and internal gear 34 at a planetary carrier 33 of the second planetary gear mechanism 30 is transmitted via a chain drive 13 to the secondary shaft 4.
(27) The torque distribution, in other words the contribution made by the two drive elements, the internal combustion engine 6 and the electric machine 2, defines the transmission of the power summation gearbox 11. The correlation between the torque of the front axle 9 and the torque of the electric machine 2 gives rise to the possibility of selecting pure two-wheel drive when the torque of the electric machine 2 is turned back to zero.
(28) The electric machine 2 may also be operated in generator mode and convert corresponding mechanical energy into electrical energy and store this in a battery. In recuperation mode, the electric machine 2 is driven by the entrained front axle 9.
(29) In an alternative embodiment, the driving wheel set 35 is not realized by a pair of gearwheels, but by a chain drive 13.
(30) The second embodiment according to
(31) In all embodiments, the chain drive 13 for driving the secondary shaft 4 may be replaced by a pair of gearwheels.
(32) In applications of electric machines 2 in the drivetrain for the active four-wheel setting, for example, the high-transmission mass inertia moment of the electric machine 2 may lead to unwanted coupling moments between the front and rear axles 9, 8 or disturbance torques at one of the front and rear axles 9, 8. A slippage between the front and rear axles 9, 8 may, moreover, lead to rotational speeds at the electric machine 2 which damage the electric machine 2. Apart from these safety-critical requirements, it should likewise be possible for transmission between the electric machine 2 and an axle, either the front or rear axle 9, 8, to be switched, so that effective electric driving or recuperation is possible.
(33) In a further embodiment, as is shown in
(34) In this third embodiment, the electric machine 2 is arranged concentrically about the main shaft 3. The third shaft, the intermediate shaft 5, is configured as a hollow shaft in this case and transmits the torque via a front drive set 36 to a reduction gearbox 12. The reduction gearbox 12 in this embodiment is designed as a pure reduction gear in this case.
(35) A reduction gearwheel 27 is connected to the sun gear 31 of the power summation gearbox 11 with a fixed drive. As in the preceding embodiments, a drive wheel set 35 drives the internal gear 34 of the power summation gearbox 11.
(36) The planetary gear carrier 33 is in turn connected in terms of drive to a front drive set 36 which drives the secondary shaft 4. Between the front drive set 36 and the reduction gearwheel 27, a shifting unit is indicated as a U-shaped connection. In the shifting state in
(37) In
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(39) When the frictionally locking connection 51 is in the first shifting position, four-wheel drive should be represented depending on the selected torque of the electric machine 2. In this case, an actuator 53 moves the shifting unit 50 into a position in which the frictionally locking connection 51 is closed. The position is marked in
(40) By actively reversing the actuator 53, unwanted disturbance torques, e.g. coupling moments based on the mass inertia of the electric machine 2, can also be neutralized. A differential speed may likewise be received through slippage of the frictionally locking connection 51.
(41) When the positively locking connection 52 is in a second shifting position, the electric machine 2 should convert mechanical energy into electrical energy and vice versa. Since a differential speed customarily prevails prior to shifting, the electric machine 2 can be used to adjust the rotational speeds and by way of an active load change of the electric machine 2, the positively locking connection 52 can be disconnected at any time. The actuator 53 need therefore only apply a small amount of force for this shifting position which is characterized in
(42) A third shifting position, a zero position N, is used for the general protection of the electric machine 2. In this shifting position, the shifting unit 50 has a small drag torque.
(43) This 3-gear shifting unit is configured as a combination of frictionally locking and positively locking connections for realizing different electrical machine functions and protective functions.
(44) In
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(46) In
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(48) Alternative embodiments are depicted in
(49) If the rotor of the electric machine 2 is configured as a hollow shaft, the electric machine 2 may also be positioned coaxially to the main shaft 3. In this case, the reduction gearbox 12 and the power summation gearbox 11 are arranged on the intermediate shaft 5, as shown in
(50) The positions of the electric machine 2, the reduction gearbox 12, and the power summation gearbox 11 can be interchanged arbitrarily between the main shaft 3, the secondary shaft 4, and the intermediate shaft 5. For example, the electric machine 2 in
(51) The intermediate shaft 5 can be dispensed with by arranging the electric machine 2 with the two gearboxes, the power summation gearbox 11, and the reduction gearbox 12 on the primary axle, the main shaft 3 or the secondary shaft 4. In this case, the electric machine 2 or the two gearboxes, the power summation gearbox 11 and the reduction gearbox 12, may lie on a shaft, as depicted in
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(53) Apart from the main shaft 3 which transmits torque to the rear axle 8, and the secondary shaft 4 which transmits torque to the front axle 9, a third shaft, the intermediate shaft 5, is used, on which the shifting unit 50 is located. The electric machine 2 and the reduction gearbox 12 are mounted coaxially on the main shaft 3, which means that the rotor diameter of the electric machine 2 and the reduction gearbox internal diameter must be greater than the main axle shaft diameter. The torque is supplied to the intermediate shaft 5 from the electric machine 2 by way of a differential gearbox 14. In this arrangement, the power summation gearbox 11 is likewise located on the intermediate shaft 5.
(54) The torque of the electric machine 2 is transmitted by the reduction gearbox 12 and the differential gearbox 14 in such a manner that a required supporting moment is adjacent to the sun gear 31 of the power summation gearbox 11, in order to divert a desired torque to the front axle 9. The electric machine 2 normally en-gages into the sun gear 21 of the planetary gear mechanism from the reduction gearbox 12; the internal gear 24 is fixedly connected to the housing and the torque is tapped at the planetary carrier 23 and transmitted through the differential gearbox 14.
(55) In the power summation gearbox 11, the electric machine 2 contributes part and the remainder is diverted from the main shaft 3. The torque of the electric machine 2, which is transmitted by the planetary gear mechanism, the reduction gearbox 12, and the differential gearbox 14, engages into the sun gear 31 in the power summation gearbox 11. The internal gear 34 of the power summation gearbox 11 is connected to the main shaft 3 in a driving manner. The summed torque of the sun gear 31 and the internal gear 34 is transmitted at the planetary gear mechanism 33 via a gearwheel stage to the secondary shaft 4.
(56) The shifting unit 50 allows shifting between two operating modes. In four-wheel drive, a frictionally locking connection 51 is closed, wherein the sun gear 31 of the power summation gearbox 11 and the electric machine 2 are connected. In this case, the electric machine 2 delivers additional torque in four-wheel drive, wherein improved driving dynamics can be produced. In recuperation mode, a positively locking connection, an actuator 53, is closed, wherein the internal gear of the power summation gearbox 11 and the electric machine 2 are connected. In this case, braking energy can be recovered from the rear axle 8 and converted into electrical energy and stored in a battery. With a small amount of expenditure, it is possible for the brake energy to be recovered from the front axle 9, as the planetary carrier 33 of the power summation gearbox 11 is then connected to the electric machine 2. When both frictionally locking and positively locking connections are uncoupled, the electric machine 2 is uncoupled from the power summation gearbox 11, in order to minimize losses by the power summation gearbox 11 and to guarantee pure rear-wheel drive.
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(58) In the neutral operating mode according to
(59) In the 2WD/recuperation operating mode according to
(60) For the embodiment as claimed in
(61) Apart from the main shaft 3 which transmits torque to the rear axle 8 and the secondary shaft 4 which transmits torque to the front axle 9, the intermediate shaft 5 is used on which the electric machine and the reduction gearbox 12 of the electric machine 2 are located. In this arrangement, the power summation gearbox 11 is likewise located on the intermediate shaft 5.
(62) The torque of the electric machine 2 is transmitted by the reduction gearbox 12 in such a manner that a required support moment is applied to the sun gear 21 of the power summation gearbox 11, in order to divert a desired torque at the front axle 9, e.g. 1300 Nm. The electric machine 2 usually engages into the first stage of a spur gear set which then drives the second stage.
(63) In the power summation gearbox 11 the electric machine 2 contributes a part, e.g. 10%=130 Nm, after the reduction gearbox 12 and the remainder, e.g. 90%=1170 Nm is diverted from the main shaft 3. The torque of the electric machine 2 which is transmitted by the reduction gearbox 12 engages into the sun gear 21 in the power summation gearbox 11. The internal gear 24 of the power summation gearbox 11 is connected to the main shaft 3 in a driving manner. The summed torque of the sun gear 21 and internal gear 24 is transmitted to the secondary shaft 4.
(64) The relationship of the torque distribution e.g. 10%: 90% defines the transmis-sion ratio of the power summation gearbox 11. The correlation between the torque of the front axle 9 and the torque of the electric machine 2 gives rise to the possibility of selecting pure two-wheel drive when the torque of the electric machine 2 is equal to 0 Nm.
(65) Conversely, the electric machine 2 may also be operated in generator mode and convert corresponding mechanical energy into electrical energy and store this in a battery (recuperation).
(66) The system has a shifting unit 50 which is arranged on the intermediate shaft 5. The shifting unit 50 is activated via an actuator 53 and has 3 shifting positions, wherein these are produced by positively locking connections 52 such as claw couplings.
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LIST OF REFERENCE DESIGNATIONS
(70) 1 Transfer gearbox
(71) 2 Electric machine
(72) 3 Main shaft
(73) 4 Secondary shaft
(74) 5 Intermediate shaft
(75) 6 Internal combustion engine
(76) 7 Main gearbox
(77) 8 Rear axle
(78) 9 Front axle
(79) 10 Main clutch
(80) 11 Power summation gearbox
(81) 12 Reduction gearbox
(82) 13 Chain drive
(83) 14 Differential gearbox
(84) 20 First planetary gear mechanism
(85) 21 Sun gear of the first planetary gear mechanism
(86) 22 Planetary gears of the first planetary gear mechanism
(87) 23 Planetary carrier of the first planetary gear mechanism
(88) 24 Internal gear of the first planetary gear mechanism
(89) 25 Drive gear
(90) 26 Input drive set
(91) 27 Reduction gearwheel
(92) 30 Second planetary gear mechanism
(93) 31 Sun gear of the second planetary gear mechanism
(94) 32 Planetary gears of the second planetary gear mechanism
(95) 33 Planetary carrier of the second planetary gear mechanism
(96) 34 Internal gear of the second planetary gear mechanism
(97) 35 Drive wheel set
(98) 36 Front drive set
(99) 40 Shaft
(100) 50 Shifting unit
(101) 51 Frictionally locking connection
(102) 52 Positively locking connection
(103) 53 Actuator
(104) 60 Protective element