Power split all-wheel drive system
11554656 · 2023-01-17
Assignee
Inventors
Cpc classification
B60K17/3467
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The present disclosure refers to an all-wheel drive system (10) for a vehicle (12), including: an electrical motor (24) being connected to a first axle (26) of a planetary gear set (28) arranged at an output side (30) of a vehicle gearbox (32), and a second axle (34) of the planetary gear set (28) being connected or connectable to the gearbox output shaft (36) or to ground (G) by a coupling (I).
Claims
1. All-wheel drive system (10) for a vehicle (12), comprising: an electrical motor (24) being connected to a first axle (26) of a planetary gear set (28) arranged at an output side (30) of a vehicle gearbox (32), and a second axle (34) of the planetary gear set (28) being connected or connectable to the gearbox output shaft (36) or to ground (G) by a coupling (I), while a third axle (38) of the planetary gear set (28) is connected or connectable to the front axle (14) of the associated vehicle (12), and wherein the coupling (I) is switchable and in a disconnected state, the coupling (I) is disconnected from the gearbox output shaft (36) and connecting the second axle (34) of the planetary gear set (28) to ground (G).
2. All-wheel drive system (10) according to claim 1 wherein the first (26), second (34), and third axles (34) of the planetary gear set (28) are comprised by either one of a sun gear wheel (40), a planet carrier (42), and a ring gear wheel (44).
3. All-wheel drive system (10) according to claim 1, wherein said coupling (I) is a non-friction clutch.
4. All-wheel drive system (10) for a vehicle (12), comprising: a differential (56) arranged between a vehicle gearbox (32) and a front (14) and rear axle (16) of an associated vehicle (12), a first planetary gear set (28) having a planetary gear set output (58) being connected to one of the differential outputs (60), and a second planetary gear set (62) having a planetary gear set output (64) being connected to the other one of the differential outputs (68), wherein said first (28) and second planetary gear set (62) are sharing a common ring wheel (44), and an electrical motor (24) is selectively connectable to one of the planetary gear sets (28) or to a gearbox output shaft (36) by means of a coupling (I).
5. All-wheel drive system (10) according to claim 4, wherein in a disconnected state, the coupling (I) is connecting the electrical motor (24) to the gearbox output shaft (36).
6. All-wheel drive system (10) according to claim 4, wherein said coupling (I) is a non-friction clutch.
7. All-wheel drive system (10) according to claim 6, wherein the non-friction clutch is a dog clutch (48) or a coupling sleeve (76).
8. Vehicle (12), comprising an all-wheel drive system (10) comprising: an electrical motor (24) being connected to a first axle (26) of a planetary gear set (28) arranged at an output side (30) of a vehicle gearbox (32), and a second axle (34) of the planetary gear set (28) being connected or connectable to the gearbox output shaft (36) or to ground (G) by a coupling (I), while a third axle (38) of the planetary gear set (28) is connected or connectable to the front axle (14) of the associated vehicle (12)), and wherein the coupling (I) is switchable and in a disconnected state, the coupling (I) is disconnected from the gearbox output shaft (36) and connecting the second axle (34) of the planetary gear set (28) to ground (G).
9. Vehicle (12), comprising an all-wheel drive system (10) comprising: a differential (56) arranged between a vehicle gearbox (32) and a front (14) and rear axle (16) of an associated vehicle (12), a first planetary gear set (28) having a planetary gear set output (58) being connected to one of the differential outputs (60), and a second planetary gear set (62) having a planetary gear set output (64) being connected to the other one of the differential outputs (68), wherein said first (28) and second planetary gear set (62) are sharing a common ring wheel (44), and an electrical motor (24) is selectively connectable to one of the planetary gear sets (28) or to a gearbox output shaft (36) by means of a coupling (I).
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) In the following, reference will be made to the appended Figures, in which:
(2)
(3)
(4)
(5)
(6) Further, reference will be made to the appended Additional Illustrations, in which Additional Illustrations 1-18 are showing further technical subject-matter that forms part of the present disclosure.
DETAILED DESCRIPTION
(7) A schematic view of an all-wheel drive system 10 for a vehicle 12 according to the inventive Concept 1 is shown in
(8) Further, the vehicle comprises an internal engine 18. The internal engine 18 may comprise an internal combustion engine 20, an internal electrical engine 22 or a combination thereof.
(9) The all-wheel drive system 10 of the inventive Concept 1 essentially comprises an electrical motor 24 being connected to a first axle 26 of a planetary gear set 28. The planetary gear set 28 is arranged at an output side 30 of a gearbox 32 of the associated vehicle 12. There is a coupling I permanently or selectively connecting a second axle 34 of the planetary gear set 28 to a gearbox output shaft 36 or to ground G, while a third axle 38 of the planetary gear set 28 is connected or connectable to the front axle 14 of the associated vehicle 12.
(10) Optionally, the first 26, second 34, and third axle 38 of the planetary gear set 28 may be comprised by either one of a sun gear wheel 40, a planet carrier 42 or a ring gear wheel 44. In the embodiment shown in
(11) If the second axle 34 of the planetary gear set 28 is permanently connected to the gearbox output shaft 36 via a non-switchable coupling I, a torque from the internal engine 18 of the vehicle 12 is delivered via the vehicle gearbox 32 and split up in a pre-defined ratio among the front 14 and rear axles 16. The electrical motor 24 is then capable of operating at a level appropriate to compensate for any wheel slip that may occur between the front 14 and rear axles 16 during operation of the vehicle 12 in a very fast and accurate manner. This operating level may be around zero rotations per minute and is proportional to the wheel slip to be compensated for. This mode is referred to as a longitudinal torque vectoring all-wheel drive (AWD) mode of Concept 1 herein.
(12) If the second axle 34 of the planetary gear set 28 is permanently connected to ground G via a non-switchable coupling I, the rear axle 16 is driven by the internal engine 18 of the vehicle 12 and the front axle 14 is driven by the electrical motor 24. Again, the electrical motor 24 is capable of adapting the front wheel drive (FWD) with respect to any wheel slip occurring between the wheels of the front 14 and rear axle 16. This mode is referred to as a hybrid all-wheel drive (AWD) mode of Concept 1 herein.
(13) In the preferred embodiment shown in
(14) The all-wheel drive system 10 as in the preferred embodiment shown in
(15) Based on that, the all-wheel drive system 10 shown in
(16) In a first drive mode, also referred to as an electric vehicle drive mode of Concept 1, the coupling I is connected to ground G, the second coupling II is open and the third coupling III is closed. As the second coupling II is open, the internal engine 18 of the vehicle 12 is not providing any torque to any of the front 14 or rear axles 16. As the coupling I is connected to ground G, the second axle 34, which is the planet carrier 42 in this example, of the planetary gear set 28 stands still. Thus, a torque delivered by the electrical motor 24 is transmitted via the first axle 26, which is the sun gear wheel 40 in this example, via a planet gear wheel 43 of the planetary gear set 28 to the third axle 38, which is the ring gear wheel 44 in this example. The torque is then further transmitted via the front drive shaft 15 and the closed third coupling III to the front axle 14. Thus, the first drive mode is an electric front wheel drive mode (FWD). The drive voltage applied to the electrical motor 24 may be 48 V, for example, but could be any other suitable drive voltage.
(17) In a second drive mode, also referred to as a hybrid drive mode of Concept 1, which preferably is an all-wheel drive mode (AWD), the coupling I is connected to ground G, the second coupling II is closed and the third coupling III is closed. As the coupling I is connected to ground G, the planet carrier 42 is standing still. As the second coupling II is also closed, the internal engine 18 of the vehicle 12 is providing a torque to the rear axle 16 via the gearbox output shaft 36 and the rear drive shaft 17. At the same time, as the third coupling III is also closed, the torque from the electrical motor 24 is transmitted to the front axle 14 in the above stated manner. Thus, the second drive mode is an internal engine 18 rear wheel drive mode (RWD) and electric front wheel drive mode (FWD). For example, this can be a low speed all-wheel drive mode (AWD).
(18) In a third drive mode, also referred to as a longitudinal torque vectoring drive mode (TVD) of Concept 1, which preferably is an all-wheel drive mode (AWD), the coupling I is connected to the gearbox output shaft 36, the second coupling II is closed and the third coupling III is closed. As the second coupling II is closed, the internal engine 18 of the vehicle 12 is providing a torque to the rear axle 16 via the gearbox output shaft 36 and the rear drive shaft 17 and at the same time to the planet carrier 42, which passes on the torque to the front axle 14 via the ring gear wheel 44 and the third coupling III. The torque controlled to be supplied by the electrical motor 24 is proportional to the desired transfer of torque between the rear axle 16 and the front axle 14. As long as no wheel slip occurs, the torque is controlled to be at a pre-defined level, which leads to a split of the torque supplied by the internal engine 18 among the rear drive shaft 17 and the front drive shaft 15 in a pre-defined ratio, according to the desired dynamic vehicle 12 properties for different driving situations. If a wheel slip occurs, the electrical motor 24 is controlled to operate at a rotational speed and torque proportional to the wheel slip between the rear axle 16 and the front axle 14.
(19) In a fourth drive mode, also referred to as a low drag mode, sailing mode or disconnected mode of Concept 1, the coupling I is connected to ground G and the second coupling II and third coupling III are open. This means, the planetary gear set 28 is standing still and none of the front 14 or rear axles 16 are connected to any torque source of the vehicle 12. Thus, the vehicle 12 is rolling freely, depending on its current kinetic energy.
(20) In a fifth drive mode, also referred to as an internal engine 18 drive mode of Concept 1, the coupling I is connected to ground G, the second coupling II is closed and the third coupling III is open. In this mode, the front axle 14 is disconnected from the drive system and the rear axle 16 is driven by the internal engine 18. Accordingly, this is a rear wheel drive mode (RWD).
(21)
(22) Preferably, the number of teeth may have the following configurations:
(23) Z.sub.EM=25;
(24) Z.sub.EM2=50 or 94;
(25) Z.sub.a=43;
(26) Z.sub.b=43;
(27) Z.sub.c=129;
(28) Z.sub.f1=43; and
(29) Z.sub.f2=57.
(30) Based on that, the following gear ratios may apply:
(31) electrical motor 24 to rear drive shaft 17=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a+1)=94/25*(129/43+1)=+15;
(32) electrical motor 24 to front drive shaft 15=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a)*(Z.sub.f2/Z.sub.f1)=94/25*(−129/43)*(−57/43)=15; and
(33) internal engine 18 (not shown) to rear drive shaft 17=1.
(34) The above ratios are for example relevant for the longitudinal torque vectoring drive (TVD) mode, the third drive mode of Concept 1 respectively, wherein torque vectoring between the front 14 and rear axles 16 is done via the electrical motor 24.
(35) Further, the following gear ratios may apply:
(36) electrical motor 24 to rear drive shaft 17=disconnected; and
(37) electrical motor 24 to front drive shaft 15=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a)*(Z.sub.f2/Z.sub.f1)=94/25*(−129/43)*(−57/43)=15.
(38) The above ratios are for example relevant for the hybrid drive mode of Concept 1, the second drive mode respectively, wherein coupling I is connected to ground G.
(39) Also the following gear ratios may apply, for example to the longitudinal torque vectoring drive (TVD) mode of Concept 1:
(40) electrical motor 24 to rear drive shaft 17=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a+1)=50/25*(129/43+1)=8; and
(41) electrical motor 24 to front drive shaft 15=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a)*(Z.sub.f2/Z.sub.f1)=50/25*(−129/43)*(57/43)=−8.
(42) Also the following gear ratios may apply, for example to the hybrid drive mode of Concept 1:
(43) electrical motor 24 to rear drive shaft 17=disconnected, and
(44) electrical motor 24 to front drive shaft 15=Z.sub.EM2/Z.sub.EM*(Z.sub.c/Z.sub.a)*(Z.sub.f2/Z.sub.f1)=50/25*(−129/43)*(−57/43)=8.
(45) In
(46) As can be seen in
(47)
(48) The Figures show the all-wheel drive system 10, that essentially comprises a differential 56 arranged between a vehicle gearbox 32 and a front 14 and rear axle 16 of the associated vehicle 12. Further, there is a first planetary gear set 28 having a planetary gear set output 58 being connected to one of the differential outputs 60. Further there is a second planetary gear set 62 having a planetary gear set output 64 being connected to the other one of the differential outputs 68. The first 28 and second planetary gear set 62 are sharing a common ring wheel 44, and an electrical motor 24 is selectively connectable to one of the planetary gear sets 28 or to a gearbox output shaft 36 by means of a coupling I.
(49) The focus of the description of Concept 2 will be put on the differences to Concept 1 and in particular to the part of the system 10 starting from the gearbox output shaft 36 in the direction of its front 14 and rear axles 16. Apart from that, if not different statement is made herein, reference can be fully made to the foregoing description.
(50) The system 10 of
(51) Illustrated couplings II and III in this Concept 2 are optional if not stated otherwise, but are preferred and therefore illustrated in
(52) The coupling I in the inventive Concept 2 is a switchable coupling 46. Preferably, the coupling I is a switchable non-friction clutch 46. Particularly preferred and illustrated in
(53) As can be seen in
(54) Based on this, for example three drive modes can be configured:
(55) In a first drive mode shown in
(56) In a second drive mode shown in
(57) In a third drive mode shown in
(58) The following table provides an overview of the complexity of Concept 1 and Concept 2 with regard to a friction-clutch based AWD in P3 configuration as known from the prior art.
(59) TABLE-US-00001 State of the Feature comprised art Concept 1 Concept 2 Dog clutch NO (low YES (medium YES (medium complexity) complexity) complexity) Conventional YES (high NO (low NO (low (friction) clutch complexity) complexity) complexity) incl. additional actuator Transmission 2-stage 1 + 1-stage 2 + 1-stage gearbox or gearbox + gearboxes + 2x 3-stage planetary planetary gear gear box gear set set + differential
(60) From the table it can be gained that the inventive Concepts 1 and 2 do not increase the technical complexity, but at the same time achieve improved wheel slip avoidance and torque split, respectively, better response times and increased overall system performance, as stated herein. Thus, the utility value of Concepts 1 and 2 is increased at a maintained level of system complexity compared to the prior art.
(61) The following table provides an overview of pros and cons of Concept 1 and Concept 2 with regard to a friction-clutch based AWD in P3 configuration as known from the prior art.
(62) TABLE-US-00002 Feature State of the comprised art Concept 1 Concept 2 Response time 100-200 ms 30-50 ms 30-50 ms (improved) (improved) AWD Torque 10-15% 3-5% 3-5% tolerance (improved) (improved) AWD energy Slip energy Slip energy Slip energy consumption converted to convertible to convertible to heat by electric energy in electric energy in friction one of the slip one of the slip clutch directions. Battery directions. Battery drainage in opposite drainage in opposite direction possible direction possible (improved) (improved) Complexity Reference maintained maintained complexity stick-slip- high low (improved) low (improved) effects AWD Reference e.g. 48 V AWD e.g. 50/50 AWD Performance performance in normal mode; in normal mode; longitudinal torque longitudinal torque vectoring AWD in vectoring AWD in performance mode performance mode (improved) (improved)
(63) Below, further subject-matter is disclosed that features a relation to the invention disclosed herein.
(64) A power split all wheel drive and P3 system:
(65) The present invention relates to an improved system for all wheel drive (AWD) of a vehicle.
(66) Existing solutions to provide all wheel drive have been on the market for many years. However, as the technology develops there is a need to further improvements, especially with regards to fuel consumption and driving characteristics.
(67) The present invention seeks to overcome the drawbacks of existing systems by providing an improved system as defined by the independent numbered embodiment. Preferred embodiments are defined by the dependent embodiments.
(68) In the following, reference will be given by the appended Additional Illustrations in which:
(69) Additional Illustrations 1-2 are schematic views of an all wheel drive system according to an embodiment;
(70) Additional Illustration 3 is a schematic view of an all wheel drive system according to an embodiment; and
(71) Additional Illustrations 4-18 are schematic views of all wheel drive system according to further embodiments.
(72) An AWD system is shown in Additional Illustration 1, in the below denoted “Concept 1”. The system allows for four different operational modes: Electric vehicle mode (48V FWD) Low speed AWD (ICE RWD and 48V FWD) Longitudinal Torque Vectoring AWD (Power split AWD) Low drag mode (planetary gear set standing still)
These modes are further explained by the following table.
(73) TABLE-US-00003 Clutch Clutch Clutch Electric 1 2 3 Motor RearAxle FrontAxle Mode To Open Closed Vehicle Disconnected 48 V FWD FWD EV-mode GND speed dependent motor RPM To Closed Closed Vehicle ICE RWD 48 V FWD Hybrid mode GND speed (Low speed dependent AWD) motor RPM To Closed Closed Motor PowerSplit PowerSplit Longitudinal Gbox RPM AWD AWD Torque working Vectoring around 0 AWD RPM RPM proportional to front to rear slip To Open Open 0 RPM Sailing Sailing Low drag GND disconnect (planetary gear set standing still)
(74) In Additional Illustration 2, some further detail of the embodiment shown in Additional Illustration 1 are given. The following applies for torque vectoring (TV) mode and hybrid mode, respectfully.
(75) TVMode:
(76) EMToRearDiff=Z.sub.EM2/Z.sub.EM2*(Z.sub.c/Z.sub.a+1)=50/25*(129/43+1)=8 EMToFrontDiff==Z.sub.EM2/Z.sub.EM2*(Z.sub.c/Z.sub.a)*((Z.sub.f2/Z.sub.f1)=50/25*(−129/43)*(57/43)=−8
Hybrid Mode: EMToRearDiff=− EMToFrontDiff==Z.sub.EM2/Z.sub.EM2*(Z.sub.c/Z.sub.a)*(Z.sub.f2/Z.sub.f1)=50/25*(−129/43)*(−57/43)=8
(77) In Additional Illustration 3 another embodiment is shown, in the below denoted “Concept 2”. The possible modes available by this embodiment are: Electric vehicle mode (48V 50/50 AWD) Low speed AWD (ICE and EM 50/50 AWD) Longitudinal Torque Vectoring AWD (Power split AWD)
(78) As compared to the embodiment of Additional Illustrations 1-2, these modes are further explained by the following table.
(79) TABLE-US-00004 Clutch Clutch Clutch Electric 1 2 3 Motor RearAxle FrontAxle Mode To Open N/A Vehicle 48 V RWD 48 V FWD EV-mode- GBOX speed 50/50 AWD dependent motor RPM To Closed N/A Vehicle ICE/EM ICE/EM Hybrid GBOX speed RWD FWD mode - dependent 50/50 AWD motor RPM To Closed N/A Motor RPM PowerSplit PowerSplit Longitudinal Planetary working ICE AWD ICE AWD Torque GBOX around 0 Vectoring RPM RPM AWD proportional to front to rear slip N/A N/A N/A N/A N/A N/A N/A
(80) The following table provides an overview of the complexity of Concept 1 and Concept 2, as well as a prior art solution (friction AWD+P3).
(81) TABLE-US-00005 Friction Plate AWD + P3 Concept 1 Concept 2 Dog clutch YES (red YES (red YES (red category) category) category) Conventional YES (red NO (green NO (green clutch incl. category) category) category) additional actuator Transmission 2-stage gearbox 1 + 1-stage 2 + 1-stage (green category) gearbox + gearboxes + 2x planetary gearset planetary (orange category) gearsets + differential (red category)
(82) The following table provides an overview of pros and cons of Concept 1 and Concept 2, as well as a prior art solution (conventional AWD clutch with P3).
(83) TABLE-US-00006 Conventional AWD Clutch with P3 Concept 1 Concept 2 Response time 100-200 ms (red 30-50 ms (green 30-50 ms (green category) category) category) AWD Torque 0 (red category) + (green + (green accuracy category) category) AWD energy Slip energy Slip energy Slip energy consumption converted to heat converted to converted to (red category) electric energy electric energy in (battery charge) one of the slip (green directions. category) Battery drainage in opposite direction (orange category) Complexity 0 (green 0 or −? (green −− (red category) category) category) Torque Independent of High front to rear High front to rear Capacity front to rear slip slip will cause slip will cause (discarding heat loss of torque loss of torque development) capacity. Control capacity. Control (green category) must inhibit too must inhibit too high slip (orange high slip (orange category) category) NVH 0 (red category) +? (green +? (green category) category) AWD Conventional 48 V AWD in 50/50 AWD in Performance AWD only (red normal mode normal mode category) longitudinal longitudinal torque vectoring torque vectoring AWD in AWD in performance performance mode (orange mode (green category) category)
(84) Additional Illustrations 4-18 show other embodiments of an all wheel drive system.
NUMBERED EMBODIMENTS
(85) 1. An all wheel drive system comprising a differential arranged between a vehicle gearbox and a front and rear axle of an associated vehicle, a first planetary gear set having a planetary gear set output being connected to one of the differential outputs, and a second planetary gear set having a planetary gear set output being connected to the other one of the differential outputs, said first and second planetary gear set sharing a common ring wheel, and an electrical motor being connected to one of the planetary gear sets by means of a coupling.
(86) 2. The all wheel drive system according to embodiment 1, wherein in a disconnected state, the coupling is connecting the electrical motor to the gearbox output shaft.
(87) 3. An all wheel drive system comprising an electrical motor being connected to a first axle of a planetary gear set arranged at an output side of a vehicle gearbox, and a coupling connecting a second axle of the planetary gear set to the gearbox output shaft while a third axle of the planetary gear set is connected to the front axle of the associated vehicle.
(88) 4. The all wheel drive system according to embodiment 3, wherein in a disconnected state, the coupling is connecting the second axle of the planetary gear set to ground.
(89) 5. The all wheel drive system according to any one of embodiments 1-4, wherein said coupling being a non-friction clutch.
(90) 6. The all wheel drive system according to embodiment 5, wherein the non-friction clutch is a dog clutch or a coupling sleeve.
(91) 7. The all wheel drive system according to embodiment 3, wherein the first, second, and third axles of the planetary gear set is either one of a sun gear, a planet carrier, and a ring wheel, in any configuration.
(92) An all wheel drive system is provided.