Powertrain for a hybrid vehicle and a method for control of the powertrain
09789757 · 2017-10-17
Assignee
Inventors
Cpc classification
Y10T74/19014
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60K6/387
PERFORMING OPERATIONS; TRANSPORTING
B60K2006/4825
PERFORMING OPERATIONS; TRANSPORTING
F16H3/006
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60K6/547
PERFORMING OPERATIONS; TRANSPORTING
Y10S903/946
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B60K6/36
PERFORMING OPERATIONS; TRANSPORTING
F16H3/0915
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60W30/19
PERFORMING OPERATIONS; TRANSPORTING
B60W10/113
PERFORMING OPERATIONS; TRANSPORTING
Y10S903/914
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F16H2200/0052
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
B60K2006/4816
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60K6/387
PERFORMING OPERATIONS; TRANSPORTING
B60K6/547
PERFORMING OPERATIONS; TRANSPORTING
B60W10/113
PERFORMING OPERATIONS; TRANSPORTING
B60W30/19
PERFORMING OPERATIONS; TRANSPORTING
B60K6/36
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A powertrain for a hybrid vehicle includes a first propulsion unit for powering the vehicle, a second propulsion unit for powering the vehicle, a Dual Clutch Transmission (DCT), and the second propulsion unit the ECU is programmed to control the gear shift such that when a gear shift of the first propulsion unit is made in order to change the overall gear ratio from the first input shaft to the output shaft by changing the double clutch engagement from the second clutch, engaging the second power path, to the first clutch, engaging the first power path, the power connection between the second propulsion unit and the second power path is maintained.
Claims
1. A powertrain for a hybrid vehicle, the powertrain comprising: a first propulsion unit for powering the vehicle a second propulsion unit for powering the vehicle a Dual Clutch Transmission (DCT) comprising a first input shaft and an output shaft, the first input shaft being mechanically connected to a double clutch arrangement wherein a first power path is defined by engaging a first clutch of the double clutch arrangement and a second power path is defined by engaging a second clutch of the double clutch arrangement wherein power is transferred from the first input shaft to the output shaft, each power path comprising a main gear box wherein the main gear box comprises at least two gears having different gear ratios, the first propulsion unit being mechanically connected to the first input shaft such that a torque provided by the first propulsion unit is transferred to the output shaft via either of the first and second power path, and each of the power paths having gear ratios defined by gearwheels in the power path such that an overall gear ratio from the first input shaft to the output shaft is defined and at least some of the gear ratios of the first and second power path being designed such that a one-step upshift or downshift of the overall gear ratio from the first input shaft to the output shaft involves a shift of the power path, and the second propulsion unit being mechanically connected to a second input shaft of the DCT which connection does not include the double clutch arrangement and is connected to the second power path downstream the double clutch arrangement but upstream the associated main gear box the DCT is connected to an Electronic Control Unit (ECU) which is configured to control the engagement and disengagement of the first and second clutch of the double clutch arrangement and the gear positions of the gears of the main gear box associated with each one of the first and second power path, wherein the ECU is programmed to control the gear shift such that when a gear shift of the first propulsion unit is made in order to change the overall gear ratio from the first input shaft to the output shaft by changing the double clutch engagement from the second clutch, engaging the second power path, to the first clutch, engaging the first power path, the power connection between the second propulsion unit and the second power path is maintained, the second input shaft of the second propulsion unit is connected to a countershaft of the DCT, the countershaft being mechanically connected via gear wheels to a main shaft, the countershaft being a different shaft than output shafts from the first clutch respectively the second clutch of the double clutch arrangement, and the second propulsion unit is connected to the countershaft via a clutch.
2. A power train according to claim 1, wherein the ECU is programmed to control the gear shifts such that when a gear shift of the overall gear ratio from the first input shaft to the output shaft is made by changing the double clutch engagement from the first clutch, engaging the first power path, to the second clutch, engaging the second power path, the power connection between the second propulsion unit and the second power path is maintained provided that the desired gear of the main gear box associated with the second power path is already selected in order to shift to the desired overall gear ratio from the first input shaft to the output shaft.
3. A power train according to claim 1, wherein the ECU is programmed to control the power train such that when a gear shift of the overall gear ratio from the first input shaft to the output shaft is desired, and there is a need to change the double clutch engagement from the first clutch to the second clutch and to shift the gear of the main gear box of the second power path in order to get the desired overall gear ratio, the power connection between the second propulsion unit and the second power path is interrupted while the shift of the main gear in the second power path is performed, the shift of the main gear in the second power path is performed before the change of the double clutch engagement from the first clutch to the second clutch is performed.
4. A power train according to claim 1, wherein the first power path and the second power path comprises the same gear box.
5. A power train according to claim 4 wherein the first clutch, which forms part of the first power path, can be rotationally connected to a main shaft in the main gear box and the second clutch, which forms part of the second power path, is connected drivingly, with or without a gear ratio, to a countershaft (16) in the main gear box.
6. A power train according to claim 1, wherein there are separate main gear boxes for the first and second power path.
7. A powertrain according to claim 1, wherein the powertrain is designed such that there may be shifts performed between the three first overall gears from the first input shaft to the output shaft without the need for shifting the gear of the second propulsion unit being connected by the second input shaft to the output shaft via the main gear box.
8. A power train according to claim 1, wherein the first and second clutch of the double clutch arrangement are designed to provide different gear ratios.
9. A power train according to claim 8, wherein the gear ratios of the main gears in the main gear box for the first and second power path are the same.
10. A power train according to claim 1, wherein the first propulsion unit is an internal combustion engine and the second propulsion unit is an electric motor.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
DETAILED DESCRIPTION
(4) In
(5) The system described herein may be modified in several ways. For example, the specific kind of gear box is not crucial as long as there may be two different input connections from the dual clutch to the gearbox.
(6) Likewise, the kind of engines/motors used may also be different than the exemplified ICE and EM. In addition, the optional single clutch 13 between the second propulsion unit 4 and the main gear box 11 is located outside the DCT 5 but could also be a part of the DCT.
(7) In
(8) Hence, above is described two embodiments of the invention which enables certain positive benefits when changing a gear such that the power interruption during gear changes is decreased.
(9) In
(10) The selection of the desired gear is made by using different main gear clutches 17-21 for engagement or locking of gear wheels 22-31 so as to provide different power paths through the DCT 5. The power path from the first input shaft 6 to the output shaft 7 is also dependent on the output from the double clutch 8 which either may be via an inner intermediate shaft 32 connected to the first clutch 9 or via an outer intermediate shaft 33 connected to the second clutch 10.
(11) A first main gear clutch 17 is slidably attached on the main shaft 15 in between a first main shaft gearwheel 22 used for the reverse gear R and a second main shaft gear wheel 24 used for the first gear M1. The first and second main shaft gear wheels 22,24 are rotatably arranged on the main shaft 15 such that the clutch 17 may be used to lock either the first main shaft gear wheel 22 or the second main shaft gear wheel 24 to the main shaft 15. The first main shaft gear wheel 22 intermeshes with a not shown reverse idler gearwheel that, in turn, intermeshes with first countershaft gear wheel 23 fixedly connected to the countershaft 16 and the second main shaft gear wheel 24 intermeshes with a second countershaft gear wheel 25 which also is fixedly connected to the countershaft 16.
(12) A second main gear clutch 18 is slidably attached on the main gear shaft 15 in between the second main shaft gear wheel 24 and a third main shaft gear wheel 26 used for the second gear M2. Also the third main shaft gear wheel 26 is rotatably arranged on the main shaft 15 and the second main gear clutch 18 may be used to lock the third main shall gear wheel 26 to the main shaft 15. The third main shaft gear wheel 26 intermeshes with a third countershaft gear wheel 27 rotatably arranged on the countershaft 16.
(13) A third main gear clutch 19 is slidably attached on the main gear shaft 15 in between the third main shaft gearwheel 26 and an intermediate inner shaft gear wheel 28 used for the third gear M3 such that the clutch 19 may be used to lock the intermediate inner shaft gear wheel 28 to the main shaft 15 thus forming a direct connection between the intermediate inner shaft 32 and the main shaft 15. To be noted, the intermediate inner shaft gear wheel 28 is fixedly attached to the intermediate inner shaft 32 which is mechanically connected to the first clutch 9 of the double clutch arrangement 8. The intermediate inner shaft gear wheel 28 intermeshes with a fourth countershaft gear wheel 29 which is rotatably arranged on the countershaft 16.
(14) There is also an intermediate outer shaft gear wheel 30 which is fixedly attached to the intermediate outer shaft 33 which in turn is mechanically connected to the second clutch 10 of the double clutch arrangement 8. The intermediate outer shaft gear wheel 30 intermeshes with a fifth countershaft gear wheel 31 which is fixedly attached to the countershaft 16.
(15) A fourth main gear clutch 20 is slidably attached on the countershaft 16 in between the second countershaft gearwheel 25 and the third countershaft gear wheel 27 such that the clutch 17 may be used to lock the third countershaft gear wheel 27 to the countershaft 16.
(16) A fifth main gear clutch 21 is slidably attached to the fourth countershaft gear wheel 29 in between the third countershaft gear wheel 27 and the fourth countershaft gear wheel 29 such that the fifth main gear clutch 21 may be used to lock the fourth countershaft gear wheel 29 to the third countershaft gear wheel 27.
(17) There is further disclosed a second input shaft 12 connected to a second propulsion unit 4, e.g. an Electric Machine (EM), via a single clutch 13. The second input shaft 12 thus does not use the double clutch arrangement 8 and is directly connected to the countershaft 16. Hence, the second propulsion unit 4 will only have three different gear ratios (EMI, EM2, EM3) from its input shaft 12 to the output shaft 7 which are selected by the engaged gear (M1, M2, M3) between the countershaft 16 and the main shaft 15 in the main gear box 11. A suitable gear ratio for the torque from the electric machine 4 to the countershaft 15 via the second input shaft 12 may be included on any side of the single clutch 13. To be noted, the single clutch 13 is not necessary, the countershaft 16 may be disconnected by the control of the main gear clutches 17-21 so as to allow a gear shift of the torque from the second input shaft 12 connected to the electric machine 4. Neither is there a need for a gear in order to change the gear ratio of the torque from the EM 4. Hence, the EM 4 may be connected directly to the countershaft 16 without any clutch or gear. However, it is in many cases desired to be able to disconnect the electric machine at certain occasions or driving conditions and a clutch 13 between the countershaft 16 and the EM 4 is therefore often desired for practical reasons.
(18) In
(19) Hence, the gear ratios of the double clutch 8 and main gear box 11 are designed such that the lowest ICE gear (II) corresponds to the engagement of the first clutch 9, which has a low (L) gear ratio, and the engagement of the first main gear (M1) and is denoted (LM1). This configuration is shown in
(20) The second propulsion unit 4 (an Electric Machine (EM)) is connected to the countershaft 16 via a clutch arrangement 13 which is engaged such that the power from the EM 4 reaches the output shaft 7 from the countershaft 16 via the same path as the ICE, i.e. by the intermeshing second countershaft gear wheel 25 and second main shaft gear wheel 24 as indicated by the dashed lines from the second input shaft 12 to the output shaft 7. For the EM 4 the gear ratio to the output shaft 7 will be the product of the possible fixed ratio close to the single clutch 13 between the second input shaft 12 and EM 4 and the ratio provided by the gearwheels 24, 25.
(21) The second ICE gear (12) corresponds to engagement of the second clutch 10, which has a high (H) gear ratio, and the first main gear, i.e. M1, denoted HM1. This configuration is shown in
(22) In
(23) Hence, the above described configuration enables the second propulsion unit 4, the EM, to be connected when performing shifts between the first (II), second (12) and third (13) gear from the first input shaft 6 to the output shaft 7. This will make it possible to perform a two-step gear shift from the first gear (II) to the third gear (13), or vice versa, while still having a propulsion unit, i.e. the EM 4, connected such that it may provide motive power to the vehicle 1 when performing such a gear shift. Hence, by avoiding to disconnect the electric machine 4 when performing the shifts between the first three over all gears (II, 12, 13) will it be possible to provide motive force to the vehicle as well as using the electric machine 4 as a generator if braking is desired at any instance including at gear shifts. Hence, this configuration will make it possible to perform low speed driving with frequent stop and go, i.e. a city bus used in heavy traffic, without any need to disengage the EM 4 when only using the lower gears such that motive power may be supplied and regenerative braking used at every instant from the EM 4.
(24) In case there is a desire to perform further upshifts from the third gear (13) from the first input shaft 6 to the output shaft 7 to the fourth all over gear (14), there will first be a power interruption of the EM 4 by disengaging the first main gear clutch 17 engaging the first main gear M1 in the second power path, as shown in
(25) In order to change to the fourth overall gear 14, there will be a shift in the double clutch arrangement 8 from engaging the first clutch 9 as shown in
(26) In
(27) In order to perform still another upshift to the sixth ICE gear 16, the second main gear clutch 18 is disengaged from locking the third main shaft gear wheel 26 to the main shaft 15. Hence, the second main gear M2 for the second power path is disengaged and the second power path disengaged as shown in
(28) In the next sequence, which is shown in
(29) A shift to the sixth gear 16 is now easily made by disengaging the first clutch 9 of the double clutch arrangement 8 and engaging the second clutch 10. This configuration is shown in
(30) In order to make a down shift from the sixth gear 16 to II, the shift operations of the double clutch arrangement 8 and main gear box 11 are made in the reverse order.
(31) Further to be noted, there is no need to disconnect the second propulsion unit when shifting between the first three gears 11-13. Likewise, there is no need to disconnect the second propulsion unit when there is a desire to use the gears 13-15 if the main gears are in the correct positions, i.e. the main gear for the second power path has the second gear M2 engaged. Since the second propulsion unit is connected it may be possible to use the second propulsion unit 4 for an additional power torque such that a down shift from the third gear 13 to the third gear 12 may be avoided or postponed thus avoiding power interruptions and allowing these gears to be used for broader speed range for the vehicle. Hence, if the third gear 13 may be used at lower speeds there may be a rather wide speed range for which vehicle may travel without the need for gear shifts causing power interruptions for the second propulsion unit 4. The present power train system thus provides for an efficient control of the propulsion of the vehicle including smooth driving and energy efficient driving with energy recovery when braking. In the above example, any desired values of gear ratios may be used. The gear ratios may of course be different depending on the vehicle and its intended use as well as the power and kind of propulsion units used. The gear ratios of the main gear and the clutches for a DCT with a single gear box are generally selected such that the consecutive gears are located in different power paths, i.e. a one-step gear change implies a change of the engaged clutch in the double clutch arrangement. These gear ratios may change, in particular if there are fewer or further main gears for the same kind of vehicle or for different kinds of vehicles.
(32) For reverse gear (R) for the ICE, there are two different gear ratios depending on the selection of the first or second clutch having a low (L) or high (H) gear ratio and these gears are denoted LR for the low (first) reverse gear and HR for the high (second) reverse gear. The EM 4 will only have one reverse gear having a gear ratio corresponding to the gearwheels 22, 23.
(33) The above described shifting strategy has the benefit of reducing the power interruptions for the EM, in particular if control strategies are used which strive to shift between 11-13 and 13-15, i.e. to allow a rather high speed of the vehicle when there is an upshift to the fourth gear and allow a rather low speed of the vehicle when there is a downshift to the second gear. The uninterrupted power connection between the EM 4 and the output shaft 7 may be used for either providing a torque to the wheels if necessary or using the EM 4 as a generator if braking action is needed.
(34) The advantage is better understood if the arrangement is compared with alternative configurations of a hybrid drivetrain. For example, if an ICE is connected to the gear box via a single clutch and an EM is positioned between the clutch and the gear box, which is a known arrangement today, there will be a power interruption for the EM at each single gear shift. Hence, there will be a reduced possibility to provide a driving torque or regenerate braking energy with such an arrangement.
(35) In case an ICE is connected to a gearbox provided with a double clutch arrangement, i.e. a Dual Clutch Transmission (DCT), and an EM is connected to the drivetrain between the ICE and DCT, may there be less power interruptions. However, when using the EM as a generator when performing a braking operation, a downshift may be desired and the braking operation must be reduced in order to allow the rather heavy EM to accelerate to have a speed which matches the higher speed desired at the lower gear. In addition, it is many times difficult to adapt the speed of the EM to provide a smooth ride. Hence, the braking energy may thus not be as efficiently used as desired and the comfort may be reduced.
(36) Hence, the present arrangement with a DCT having an ICE connected to the double clutch arrangement and an EM connected, directly or via a single clutch, to either of the mechanical power lines of the double clutch, will provide for the possibility for an arrangement which efficiently may make use of braking energy and provide smooth driving properties.
(37) Above has been described a drive train having 3 gears in the main gear box. The number of gears is not essential to the invention but could also be fewer, even though it is not likely, or more, e.g. 4 or 5 gears. It could also be possible to have further gears, e.g. a range gear having high and low gear positions, in addition to the double clutch arrangement and main gear box.