DRIVE AXLE OF AN ELECTRIC VEHICLE AND POWERSHIFTING METHOD

Abstract

A drive axle of an electric vehicle has first and a second drive wheels (R1, R2) with wheel axles (a1, a2), a first electric machine (EM1) and a second electric machine (EM2) with a common rotation axis (m), a transmission (G3) with a transmission input shaft (EW) and a transmission output shaft (AW), and an axle differential (DI) with a differential input (DIK) and two differential output shafts (3a, 3b). The first electric machine (EM1) is connected to the transmission input shaft (EW) and the transmission output shaft (AW) is connected to the differential input (DIK). The second electric machine (EM2) can be connected as an additional drive when necessary.

Claims

1. A drive axle of an electric vehicle, the drive axle comprising: a first drive wheel (R1) and a second drive wheel (R2); a first wheel axle (a1) and a second wheel axle (a2); a first electric machine (EM1) and a second electric machine (EM2) with a common rotation axis (m); a change-speed transmission (G3, G2) with a transmission input shaft (EW) and a transmission output shaft (AW); and an axle differential (DI) with a differential input (DIK) and two differential output shafts (3a, 3b); wherein the first electric machine (EM1) is connected to the transmission input shaft (EW) and the transmission output shaft (AW) is connected to the differential input (DIK); and wherein the second electric machine (EM2) can be connected as an additional drive when necessary.

2. The drive axle according to claim 1: wherein the transmission is in the form of a three-gear transmission (G3) with a first shifting element (A), a second shifting element (B), a third shifting element (C), and two planetary gearsets (PS1, PS2) coupled with one another; wherein the first planetary gearset (PS1) comprises a first sun shaft (S01), a first ring gear shaft (HR1) and a first web shaft (ST1) and the second planetary gearset (PS2) comprises a second sun shaft (SO2), a second ring gear shaft (HR2) and a second web shaft (ST2); wherein the first web shaft (ST1) is connected fast to the second ring gear shaft (HR2); wherein the first sun shaft (S01) forms the transmission input shaft (EW); wherein the first ring gear shaft (HR1) is held fixed; wherein the second web shaft (ST2) forms the transmission output shaft (AW), and wherein, to engage the first, gear, the first shifting element (A) can be actuated, to engage the second gear the second shifting element (B) can be actuated, and to engage the third gear the third shifting element (C) can be actuated.

3. The drive axle according to claim 2, wherein by means of the first shifting element (A) the second sun shaft (SO2) can be coupled to the housing, and wherein by means of the third shifting element (C) the second sun shaft (SO2) can be coupled to the first sun shaft (SO1).

4. The drive axle according to claim 2, wherein by means of the second shifting element (B) the second planetary gearset (PS2) is blocked, since respectively two of the three shafts (SO2, HR2, ST2) are connected to one another.

5. (canceled)

6. The drive axle according to claim 1, wherein the change-speed transmission is in the form of a two-gear transmission (G2) with a first shifting element (A), a third shifting element (C) and two planetary gearsets (PS1, PS2) coupled to one another; wherein the first planetary gearset (PS1) comprises a first sun shaft (S01), a first ring gear shaft (HR1), and a first web shaft (ST1); wherein the second planetary gearset (PS2) comprises a second sun shaft S02), a second ring gear shaft (HR2) and a second web shaft (ST2); wherein the first web shaft (ST1) is connected fast to the second ring gear shaft (HR2); wherein the first sun shaft (SO1) forms the transmission input shaft (EW); wherein the first ring gear shaft (HR1) is held fixed; wherein the second web shaft (ST2) forms the transmission output shaft (AW); and wherein, to engage the first gear, the first shifting element (A) can be actuated and, to engage the second gear, the third shifting element (C) can be actuated.

7. The drive axle according to claim 6, wherein by means of the first shifting element (A) the second sun shaft (SO2) can be coupled to the housing.

8. The drive axle according to claim 7, wherein by means of the third shifting element (C) the second sun shaft (SO2) can be coupled to the first sun shaft (S01).

9. The drive axle according to claim 8, wherein the shifting elements (A, B, C) are in the form of unsynchronized claw-type shifting elements.

10. The drive axle according to claim 9, wherein the transmission (G3, G2) has neutral positions in which the first electric machine (EM1) can be decoupled.

11. The drive axle according to claim 2, further comprising a sliding sleeve, wherein the shifting elements (A, B, C) are integrated in the sliding sleeve (SM) and the sliding sleeve (SM) is arranged and can be displaced on the second sun shaft (SO2).

12. The drive axle according to claim 11, further comprising an actuator (AK1), wherein the sliding sleeve (SM) can be actuated by the actuator (AK1).

13. The drive axle according to claim 12, further comprising a coupling mechanism (KE) having two coupling positions (D, E), wherein the second electric machine (EM2) can be connected by means of the coupling mechanism (KE).

14. The drive axle according to claim 13, wherein in a first coupling position (E) the second electric machine (EM2) can be coupled with the transmission input shaft (EW), and wherein in a second coupling position (D) the second electric machine (EM2) can be coupled to the second sun shaft (SO2).

15. (canceled)

16. The drive axle according to claim 14, wherein the coupling mechanism (KE) has a neutral position in which the second electric machine (EM2) can be decoupled.

17. The drive axle according to claim 13, wherein the sliding sleeve (SM) has an access point (DU) through which a connection to the coupling mechanism (KE) can be made.

18. The drive axle according to claim 1, wherein the first wheel axle (a1) of the first drive wheel (R1) and the second wheel axle (a2) of the second drive wheel (R2) are arranged coaxially or axis-parallel with the common rotation axis (m) of the first electric machine (EM1) and the second electric machine (EM2).

19. The drive axle according to claim 1, further comprising fixed gear ratio steps (PS3a, PS3b, PS4a, PS4b, STa, STb) arranged between the two differential output shafts (3a, 3b) and the first and second drive wheels (R1, R2).

20. The drive axle according to claim 19, wherein the fixed gear ratio steps are in the form of a third planetary gearset (PS3a, PS3b) with the ring gear shaft (H R3) held fixed, or the fixed gear ratio steps are in the form of a spur gear stationary transmission (STa, STb) with a drive input gearwheel (Z1), a drive output gearwheel (Z2) and two intermediate wheels (Z3, Z4).

21. The drive axle according to claim 20, wherein the drive axle (3, 4) is in the form of a portal axle, such that the two differential output shafts (3a, 3b) have an axle offset (u, v), respectively, relative to the first wheel axle (a1) and to the second wheel axle (a2).

22. The drive axle according to claim 19, wherein the fixed gear ratio step is in the form of a fourth planetary gearset (PS4a, PS4b) with the web held fixed.

23-29. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Example embodiments of the invention are illustrated in the drawing and will be described in greater detail below, so that from the description and/or the drawing further features and/or advantages can emerge. The drawings show:

[0025] FIG. 1: A drive axle of an electric vehicle according to the invention, with two electric machines and a three-gear change-speed transmission,

[0026] FIG. 2: The drive axle of FIG. 1 with a shifting variant,

[0027] FIG. 3: The drive axle of FIG. 1, but in the form of a portal axle, in a first embodiment,

[0028] FIG. 4: The drive axle of FIG. 1, but in the form of a portal axle, in a second embodiment.

[0029] FIG. 5: A drive axle with a two-gear transmission, and

[0030] FIG. 6: A chive arrangement for an electric vehicle, with central drive.

DETAILED DESCRIPTION

[0031] FIG. 1 shows, as a first example embodiment of the invention, a drive axle 1 which comprises two drive wheels R1, R2 with wheel axles a1 a2, a first electric machine EM1 with a first rotor RO1, a second electric machine EM2 with a second rotor RO2, and a three-gear change-speed transmission G3, Associated with the transmission G3 is a shifting mechanism SE3 with a first shifting element A, a second shifting element B and a third shifting element C. Between the two drive wheels R1, R2 there is arranged a differential DI with a differential input in the form of a differential cage DIK and two differential output shafts 3a, 3b.

[0032] The three-gear change-speed transmission G3, called just the transmission G3 for short in what follows, comprises two planetary gearsets coupled to one another, namely a first planetary gearset PS1 with a first sun shaft SO1, a first web shaft ST1 and a first ring gear shaft HR1 fixed to the housing, and a second planetary gearset PS2 with a second sun shaft SO2, a second web shaft ST2 and a second ring gear shaft HR2, which is connected fixed to the first web shaft ST1 and forms a coupling shaft between the two planetary gearsets PS1 and PS2. The first sun shaft SO1 is connected fast to the first rotor RO1 and thus forms the transmission input shaft EW of the transmission G3. The second web shaft ST2 forms the transmission output shaft AW, which drives the differential DI, i.e. it is connected fast to the differential cage DIK. The two planetary gearsets PS1, PS2 form a gearset that corresponds with the gearset disclosed in the previous application. Between the differential DI and the drive wheels R1, R2 fixed gear ratios are arranged in each case, here depicted as a third planetary gearset PS3a arranged on the right and a third planetary gearset PS3b arranged on the left, which are configured mirror-symmetrically. The differential DI has two differential output shafts 3a, 3b which drive the sun shafts SO3 of the planetary gearsets PS3a, PS3b. The ring gear shafts HR3 are in each case held fixed; the drive output takes place in each case by way of the web shaft ST3, which as drive output shafts 2a, 2b, drive the drive wheels R1, R2.

[0033] With the shifting mechanism SE3 three gears can be engaged. To engage the first gear, the second sun shaft SO2 is coupled, i.e. held fast by means of the first shifting element A, to the housing, represented by hatching. Thus, the two planetary gearsets PS1, PS2 run with fixed gear ratios in each case, which when multiplied with one another, determine the gear ratio of the first gear.

[0034] The second shifting element B, by means of which the second gear is engaged, blocks the second planetary gearset PS2 in that basically two of the three shafts SO2, ST2, HR2 can be coupled to one another. In the example embodiment illustrated, the second sun shaft SO2 is coupled to the second ring gear shaft HR2. Owing to the blocking, the second planetary gearset PS2 rotates as a block, i.e, with a gear ratio of 1:1 so that the gear ratio of the second gear is determined by the fixed gear ratio of the first planetary gearset PS1.

[0035] The third shifting element C, by means of which the third gear is engaged, connects the second sun shaft SO2 to the first sun shaft SO1. This produces a dual coupling of the first and second planetary gearsets PS1, PS2, whereby a superimposed operation of the first and second planetary gearsets PS1, PS2 with a lower gear ratio for the third gear is obtained.

[0036] The shifting elements A, B and C are preferably in the form of unsynchronized claws, although basically frictional, synchronized shifting elements can also be used for the shifting functions described. Between the three shift positions in which either the shifting element A, or the shifting element B or the shifting element C is closed, the transmission G3 also has two neutral positions in which the first electric machine EM1 can be decoupled from the transmission G3. This makes possible a so-termed coasting operation, i.e. free rolling of the electric vehicle without losses due to the co-rotation of the first electric machine EM1. As can also be seen from the figure, the rotor RO1 of the first electric machine EM1 has a cylindrical hollow space in which the two planetary gearsets PS1, PS2 and partially also the differential DI can be accommodated in a space-saving manner; in particular, in that way structural space in the axial direction is saved.

[0037] As stated above, the second sun shaft SO2 of the second planetary gearset PS2 participates in all the shift positions—and accordingly all the shifting elements, i.e. the first, second and third shifting elements A, B, C, can be integrated in a single sliding sleeve SM which, in all the shift positions, is connected to the second sun shaft SO2 in a rotationally fixed manner. The sliding sleeve SM is actuated by a single actuator AK1. Since the gears one to three can be engaged one after another by displacing the sliding sleeve SM in one direction, respectively across the neutral positions, the possibility exists of synchronizing the shifting elements.

[0038] The second electric machine EM2 can be connected or decoupled by means of a coupling mechanism KE. The said coupling mechanism KE comprises a first coupling element D and a second coupling element E. By means of the second coupling element E, the second electric machine EM2 is connected via its rotor RO2 to the transmission input shaft EW of the transmission. By virtue of this coupling of the two rotors RO1, RO2, the two electric machines EM1, EM2 rotate at the same rotation speed. Thus, the second electric machine EM2 boosts the drive power which, if the electric machines EM1 and EM2 are identical, can be doubled.

[0039] By means of the first coupling element D the second electric machine EM2 is connected to the second sun shaft SO2, this coupling connection being enabled by an access point DU in the sliding sleeve SM of the shifting mechanism SE3. The first coupling element D can thus access the sun shaft SO2 of the second planetary gearset PS2 through the sliding sleeve SM. In that way the power of the second electric machine EM2 flows along another path in the transmission G3 so that the power flows of the two electric machines EM1, EM2 are superimposed.

[0040] According to the invention, with the first coupling position D of the coupling mechanism KE support of the traction force is achieved, whereby powershifts by the transmission G3 are made possible. For example, if during a gearshift, i.e. the engagement of a new gear, the power flow from the first electric machine EM1 is interrupted, then a torque is supplied to the sun shaft SO2 of the second planetary gearset PS2 by the second electric machine EM2, which torque causes the traction force in the drive output shaft AW or the second web shaft ST2 to be maintained. This shifting without interruption of the traction force is also known as a powershifting process, which is described in greater detail in what follows.

[0041] In the powershifting process according to the invention the first electric machine EM1 acts as the main drive machine, since it is connected fixed to the transmission G3 by way of the transmission input shaft EW. To support the gearshifts, the second electric machine EM2 is connected for preparatory purposes to the second sun shaft SO2.

[0042] Below, the gearshift process from the first to the second gear is described, for which the first shifting element A of the shifting mechanism SE3 is first opened and the second shifting element B is then closed. Starting from the situation that the second electric machine EM2 was previously connected to the transmission input shaft EW, i.e. the two electric machines EM1, EM2 are both operating in driving mode, first of all the load on the second electric machine EM2 is reduced, i.e, the second coupling element E of the coupling mechanism KE is opened and the first coupling element D is synchronized with the second electric machine EM2, i.e. in this case braked down to zero rotation speed. Then the first coupling element D is closed. The second electric machine EM2 is thereby connected to the second sun shaft SO2. Thereafter a torque is built up by the second electric machine EM2, so that the first shifting element A, which acts as a brake, is relieved of load. If the second electric machine EM2 cannot supply enough torque, the torque of the first electric machine EM1 is correspondingly reduced. Then the first shifting element A is opened. The torques of the first and second electric machines EM1, EM2 are controlled or regulated in such manner that the rotation speed of the second electric machine EM2 is increased and the rotation speed of the first electric machine EM1 is reduced. For that purpose, preferably the torque of the second electric machine EM2—if possible—is increased somewhat and at the same time the torque of the first electric machine EM1 is somewhat reduced. The target rotation speed of the second sun shaft SO2, which corresponds to the rotation speed of the second electric machine EM2, is the rotation speed of the second ring gear shaft HR2 so that the second shifting element B becomes synchronous. As soon as the second shifting element B is synchronous, it can be closed. The torques of the first and second electric machines EM1, EM2 can now be divided in any desired way since a fixed gear, namely the second gear, is engaged. If needs be the second electric machine EM2 can be decoupled from the second sun shaft SO2. If the full drive power is required, the second electric machine EM2 can also be connected to the transmission input shaft EW or the first sun shaft SO1.

[0043] The shifting mechanism SE3 or its sliding sleeve SM is actuated by a first actuator. AKE while the coupling mechanism KE is actuated by a second actuator AK2. The common rotation axis m of the two electric machines EM1, EM2 coincides with the two wheel axles a1, a2. The planetary gearsets PS1, PS2, PS3a, PS3b, of which in each case only the top half is shown, are arranged rotationally symmetrically relative to the rotation axis in.

[0044] The powershifting process when shifting from the second to the third gear, wherein the second shifting element B is opened and the third shifting element C is closed, takes place analogously to the shifting process from the first to the second gear as described above. Downshifts take place analogously but in the reverse direction of the rotation speeds in the first and second electric machines.

[0045] FIG. 2 shows, as a further example embodiment of the invention, a drive axle 2 which essentially corresponds particularly in its functional components to the drive axle 1 in FIG. 1; for the same components, the same indexes are used as in FIG. 1. The coupling of the shafts of the second planetary gearset in the shift position B is different from that in FIG. 1. FIG. 2 shows a blocking variant in which the sun shaft SO2 and the web shaft ST2, which is at the same time the transmission output shaft AW of the transmission G3, are connected with one another. Thus, the second planetary gearset PS2 rotates as a block, i.e. with a gear ratio of 1:1. To that extent this blocking variant corresponds functionally to the blocking shown in FIG. 1. Basically, for the second planetary gearset PS2 there is a further blocking variant in which the web shaft ST2 is connected to the ring gear shaft HR2. This blocking variant, in which the sun shaft SO2 plays no part, is in this case less preferable since it cannot be produced with a single sliding sleeve. SM connected to the sun shaft SO2.

[0046] FIG. 3, as a further example embodiment of the invention, shows a drive axle 3 which corresponds essentially to the drive axle 1 according to FIG. 1, but with the difference that the drive axle 3 is in the form of a portal axle, i.e. the wheel axles a1, a2 are offset by a distance u relative to the rotation axis m. This results in greater ground clearance. The axle offset u is produced by virtue of two mirror-symmetrically formed gear ratio steps PS4a, PS4b arranged in the area of the drive wheels R1, R2, which steps are in the form of planetary gearsets in which, in each case, the web is held fixed. Drive input takes place from the differential output shafts 3a, 3b via a planetary gearwheel, whereas the drive output takes place via the sun shaft to the drive output shafts 2a, 2b, coaxially with the wheel axles a1, a2. The planetary gearsets PS4a, PS4b correspond to the planetary gearset 30 according to FIG. 3 of the previous application and the associated description on page 11, continued on page 12, first paragraph thereof, to which reference should be made as a supplement.

[0047] FIG. 4 shows, as a further example embodiment of the invention, a drive axle 4, which is again in the form of a portal axle but with modified, wheel-adjacent constant gear ratio steps which are in this case in the form of spur gear stationary transmissions STa, STb, with an axle offset v between the differential output shafts 3a, 3b and the drive output shafts 2a, 2b. The stationary transmission STa comprises a drive input gearwheel Z1 arranged rotationally fixed on the drive input shaft 3a, a drive output gearwheel Z2 arranged on the drive output shaft 2a and two intermediate wheels Z3. Z4 each of which meshes with the drive input gearwheel Z1 and the drive output gearwheel Z2. A wheel diagram for the arrangement of the gearwheels Z1, Z2, Z3 and Z4 in a radial plane is shown in the figure at the top, on the right. By virtue of the intermediate wheels Z3 and Z4, on the one hand a power split and on the other hand a relatively larger axial offset v, which is larger than the axial offset u of the fourth planetary gearset PS4a, PS4b in FIG. 3, is obtained.

[0048] FIG. 5 shows, as a further example embodiment of the invention, a drive axle 5 in which the transmission is in the form of a two-gear transmission G2, and which comprises a shifting mechanism SE2 with only two shifting elements, the first shifting element A and the third shifting element C. Thus, compared with the three-gear transmission G3 according to FIG. 1, in the two-gear transmission G2 the second shifting element B has been omitted. The first and second gears are engaged by means of the two shifting elements A and C. When the shifting element A is closed the second sun shaft SO2 is connected to the housing, so that both planetary gearsets PS1 and PS2 rotate with a fixed gear ratio. The fixed gear ratios connected one behind the other determine the gear ratio of the first gear. The second gear is formed by closing the shifting element C, whereby the two sun shafts SO1, SO2 are coupled to one another—giving superimposed operation of the two planetary gearsets PS1, PS2, from which the gear ratio for the second gear results. The gear interval or gear spread between the first and second gears in the two-gear transmission is thus the same as between the first and third gears in the three-gear transmission G3 (FIG. 1). The two-gear transmission G2 has a shorter shifting path for the sliding sleeve SM, since there are only three shift positions, namely “A”, Neutral and “C”. The transmission output shaft AW of the two-gear transmission G2, i.e. the second web shaft ST2, is connected directly to the differential cage DIK of the differential DI. The variant for a two-gear transmission G2 shown here is basically compatible with the three-gear transmission G3 for all the above example embodiments, i.e. if necessary, the three-gear transmission G3 can be replaced by the two-gear transmission G2 since the second shifting element B is omitted.

[0049] FIG. 6 shows as a further example embodiment of the invention a drive arrangement 6, which is in the form of a so-termed central drive. The difference compared with the previous example embodiments is that the electric machines EM1, EM2 and the transmission G3 are not arranged in the area of the wheel axles a3, a4 but in a “central” position in the electric vehicle. The first electric machine EM1 with the transmission G3 and the shifting mechanism SE3 and the second electric machine EM2 with the coupling mechanism KE, form a drive unit with a rotation and symmetry axis m, which is arranged perpendicularly to the wheels axles a3, a4 of the drive wheels R3, R4. Between the drive wheels R3 and R4 is arranged a differential DI with differential output shafts 6a, 6b which drive the drive wheels R3 and R4. The differential DI is driven by the transmission output shaft AW of the transmission G3 by way of a bevel drive KT. For that purpose, a bevel gear pinion KT1 which is fixed on the transmission output shaft AW meshes with a crown wheel KT2, which is connected fixed to the differential cage of the differential DI.

[0050] The three-gear transmission G3 shown in FIG. 6 can be replaced by the two-gear transmission G2 shown in FIG. 5.

INDEXES

[0051] 1 Drive axle [0052] 2 Drive axle [0053] 2a Drive output shaft on the right [0054] 2b Drive output shaft on the left [0055] 3 Drive input shaft [0056] 3a Differential output shaft on the right [0057] 3b Differential output shaft on the left [0058] 4 Drive axle [0059] 5 Drive axle [0060] 6 Drive arrangement [0061] 6a Differential output shaft [0062] 6b Differential output shaft [0063] A First shifting element [0064] AK1 Actuator [0065] AK2 Actuator [0066] AW Transmission output shaft [0067] a1 Wheel axle, left [0068] a2 Wheel axle, right [0069] a3 Wheel axle [0070] a4 Wheel axle [0071] B Second shifting element [0072] C Third shifting element [0073] D First coupling element. [0074] DI Axle differential [0075] DIK Differential cage [0076] DU Access point [0077] E Second coupling element [0078] EM1 First electric machine [0079] EM2 Second electric machine [0080] EW Transmission input shaft [0081] G2 Two-gear transmission [0082] G3 Three-gear transmission [0083] HR1 First ring gear shaft [0084] HR2 Second ring gear shaft [0085] HR3 Third ring gear shaft [0086] KE Coupling mechanism [0087] KT1 Bevel gear drive [0088] KT2 Crown wheel [0089] m Rotation axis (EM1, EM2) [0090] PS1 First planetary gearset [0091] PS2 Second planetary gearset [0092] PS3a Third planetary gearset, right [0093] PS3b Third planetary gearset, left [0094] PS4a Fourth planetary gearset, right [0095] PS4b Fourth planetary gearset, left [0096] R1 Drive wheel, left [0097] R2 Drive wheel, right [0098] R3 Drive wheel [0099] R4 Drive wheel [0100] RO1 Rotor (EM) [0101] RO2 Rotor (EM2) [0102] SE2 Shifting mechanism (G2) [0103] S3 Shifting mechanism (G3) [0104] SM Sliding sleeve [0105] SO1 First sun shaft (PS1) [0106] SO2 Second sun shaft (PS2) [0107] SO3 Third sun shaft (PS3) [0108] ST1 First web shaft (PS1) [0109] ST2 Second web shaft (PS2) [0110] ST3 Third web shaft (PS3) [0111] STa Spur gear stationary transmission, left [0112] ST6 Spur gear stationary transmission, right [0113] u Axle offset [0114] v Axle offset [0115] Z1 Drive input gearwheel [0116] Z2 Drive output gearwheel [0117] Z3 Intermediate wheel [0118] Z4 Intermediate wheel