The present disclosure relates to a multi-speed electric axle with a space efficient architecture.
Segments of the vehicle market are moving towards electrification. Certain vehicle platforms demand off-road and on-road capabilities. Certain off-road capable vehicles demand comparatively large gear reductions to achieve high torque while achieving high system efficiency. Further, some electric vehicles (EVs) have exhibited issues in achieving target gear ratios for off-road vehicle travel in a compact package while maintaining desired system stiffness for on-road noise, vibration, and harshness (NVH) and robust clutch arrangements.
The inventors have recognized the abovementioned challenges and developed a multi-speed electric axle assembly to at least partially overcome the challenges. The electric axle assembly includes, in one example, a multi-speed electric axle assembly. The multi-speed electric axle, in one example, includes an electric machine rotationally coupled an input shaft and a planetary gear set. In such an example, the planetary gear set includes a ring gear rotationally coupled to the input shaft or an output shaft. The planetary gear set further includes a carrier or the ring gear rotationally coupled to the input shaft or the output shaft. The electric axle assembly even further includes one or more clutches configured to selectively ground a sun gear or a carrier in the planetary gear set and rotationally couple the sun gear and the carrier. In this way, the electric axle achieves operating gear ratios for operating the EV in both off-road and on-road environments while maintaining axle stiffness goals which allow the vehicle to be operated in on-road environments with comparatively low NVH and in a comparatively compact package.
In one example, the ring gear may be rotationally coupled to the input shaft, the carrier may be rotationally coupled to the output shaft and the one or more clutches are configured to ground the sun gear. In such an example, the planetary gear set may be a simple planetary gear set. In this way, the electric axle assembly is able to achieve a comparatively lower gear ratio spread (e.g., a gear ratio spread of less than 1.6, in one use-case example) between the operating gears that are achieved via engagement of the two clutches. Consequently, the electric axle's shifting performance is tuned for certain vehicle platforms.
In an alternate example, the ring gear may be rotationally coupled to the output shaft, the sun gear may be rotationally coupled to the input shaft, and the one or more clutches are configured to selectively grounds the carrier. In such an example, the planetary gear set may be a meshed planet compound planetary gear set. In this way, the electric axle assembly is able to achieve a comparatively higher gear ratio spread (e.g., a gear ratio spread of greater than 1.8, in one use-case example) between the operating gears that are achieved via engagement of the two clutches. Consequently, the electric axle assembly shifting performance is tuned for alternate vehicle platforms, thereby increasing customer appeal.
It should be understood that the summary above is provided to introduce in simplified form a selection of concepts that are further described in the detailed description. It is not meant to identify key or essential features of the claimed subject matter, the scope of which is defined uniquely by the claims that follow the detailed description. Furthermore, the claimed subject matter is not limited to implementations that solve any disadvantages noted above or in any part of this disclosure.
Electric axles are described herein that achieve increased efficiency and on-road and off-road powertrain performance targets. To elaborate, in one example, a multi-speed (e.g., two-speed) electric axle with a highly efficient parallel axis geartrain, is provided, that can shift either on stop, shift on the fly with power off, or with added hardware, powershift a planetary gear set from a lower ratio stage with reduced meshing and bearing losses (e.g., a 1:1 gear ratio stage, in one use-case example) to a stage with a higher ratio (e.g., a planetary ratio less than 1.6, in one example or greater than 1.8, in another example). In this way, the system achieves a desired gear ratio range between the higher and lower speed modes in an axle package that has a desired amount of stiffness for on-road acceptable noise, vibration, and harshness (NVH), for instance while maintaining robust clutch arrangements.
As described herein an electric axle is an electric drive incorporated into an axle. The electric axle may be an electric beam axle, in one example. A beam axle is an axle with mechanical components structurally supporting one another and extending between drive wheels. For instance, the beam axle may be a structurally continuous structure that spans the drive wheels on a lateral axis, in one embodiment. Thus, wheels coupled to the beam axle substantially move in unison when articulating, during, for example, vehicle travel on uneven road surfaces. To elaborate, the camber angle of the wheels may remain substantially constant as the suspension moves through its travel. The beam axle may be coupled to a dependent suspension system 107, in one example. Therefore, the electric axle may be an unsprung mass.
The electric axle 104 includes an electric machine 106 (e.g., a traction motor). The electric machine 106 may be an electric motor-generator, for example. For instance, the electric machine 106 may be designed as a multi-phase alternating current (AC) motor-generator. However, in other examples, the electric machine may be a motor without generator capabilities.
As illustrated in
The electric axle 104 further includes an input shaft 114 and an intermediate shaft 116. A gear 118 fixedly coupled or incorporated in the input shaft 114 meshes with a gear 120, in the illustrated example. The gear 120 is fixedly coupled or incorporated into the intermediate shaft 116, in the illustrated example. Further, the intermediate shaft 116 is rotationally coupled to a planetary gear set 122 via a component 124. To expound, a ring gear 126 in the planetary gear set 122 is coupled to the intermediate shaft 116 via the component 124. The planetary gear set 122 is a simple planetary gear set in the illustrated example. However, other types of planetary gear sets may be used in the electric axle in other examples. For instance, as expanded upon herein, the electric axle may include a planetary gear set with multiple sets of planet gears such as a meshed planet compound planetary gear set. The planetary gear set 122 is arranged coaxial to the intermediate shaft 116, in the illustrated example, to increase axle compactness.
The planetary gear set 122 further includes planet gears 128 that rotate on a carrier 130 and mesh with the ring gear 126 and a sun gear 132. The carrier 130 is rotationally coupled to a gear 134 which meshes with a gear 136 that is rotationally coupled to an output shaft 138. A gear 140 is rotationally coupled to the output shaft 138 and meshes with an input gear 142 for a differential 144, in the illustrated example. In turn, the differential 144 is rotationally coupled to drive wheels 146 via axle shafts 148 (e.g., half shafts).
A clutch 150 is configured to connect the carrier 130 to the intermediate shaft 116 when engaged. Another clutch 152 is configured to ground the sun gear 132, when engaged. The clutches 150 and 152 may be inversely engaged and disengaged to operate the geartrain in different gear modes. To elaborate, the clutch 150 is engaged and the clutch 152 is disengaged in a higher speed mode. In another example, the functions of the clutches may be incorporated into a single clutch. For instance, one clutch may be configured to ground the sun gear 132 in one mode and rotationally coupled the carrier 130 and the sun gear 132 in another mode. Further, in such an example, the clutch may be configured to operate in a neutral mode.
In the electric axle 104 a park gear 160 may be coupled to the carrier 130 and a park device 162 is configured to selectively engage the park gear. In this way, the electric axle may space efficiently incorporate parking brake functionality.
The EV 100 may also include a control system 180 with a controller 182. The controller 182 includes a processor 184 and memory 186. The memory 186 holds instructions stored therein that when executed by the processor 184 cause the controller 182 to perform the various methods, control techniques, etc., described herein. The processor 184 may include a microprocessor unit and/or other types of circuits. The memory 186 includes known data storage mediums such as random access memory, read only memory, keep alive memory, combinations thereof, and the like.
The controller 182 may receive various signals from sensors 188 positioned in different locations in the EV 100 and the electric axle 104, more specifically. The sensors may include an electric machine speed sensor, clutch position sensors, energy storage device temperature sensor(s), an energy storage device state of charge sensor(s), wheel speed sensors, and the like. The controller 182 may also send control signals to various actuators 190 coupled at different locations in the EV 100, and the electric axle 104. For instance, the controller 182 may send signals to the inverter 108 to adjust the rotational speed of the electric machine 106. The other controllable components in the vehicle and powertrain may function in a similar manner with regard to command signals and actuator adjustment. For instance, the controller 182 may send signals to the clutches 150 and 152 to engage and disengage the clutches to operate the axle in different range modes, which are expanded upon herein. The controller and control system shown in
The EV 100 may also include one or more input device(s) 192 (e.g., an accelerator pedal, a brake pedal, a gear selector, a differential locker actuator, a console instrument panel, a touch interface, a touch panel, a keyboard, combinations thereof, and the like) in electronic communication with the controller 182. The input device(s) 192, responsive to operator input, may generate an acceleration adjustment request, a gear shift request, and the like.
An axis system is provided in
The electric axle 104 and the other electric axles described herein may implement a power shifting control strategy where one clutch is disengaged while the other clutch is engaged to reduce torque interruptions. A power shifting system is highly efficient in road operations since it results in zero meshing losses in the two-speed planetary gear set and reduces bearing losses substantially.
As shown in
Further, the planetary gear set 302 includes a ring gear 316 that is rotationally coupled to a gear 318 which meshes with a gear 320 on an output shaft 322 which includes another gear 324 which meshes with an input gear 326 in a differential. A park gear 330 is fixedly coupled to a shaft on which the gear 318 rotates. The park gear 330 may be engaged via a park mechanism 332.
The electric axles described herein achieve a highly efficient parallel axis geartrain for on-road and off-road capabilities that is able to shift either on stop, shift on the fly with the power off, or powershift the planetary gear set between a higher range mode with a decreased amount of meshing and bearing losses in the planetary gear set to a lower range mode that may be suitable for operating the vehicle in an off-road environment for instance.
The invention will be further described in the following paragraphs. In one aspect, a multi-speed electric axle assembly is provided that comprises an electric machine rotationally coupled an input shaft; a planetary gear set including: a ring gear rotationally coupled to the input shaft or an output shaft; and a carrier or the ring gear rotationally coupled to the input shaft or the output shaft; one or more clutches configured to selectively ground a sun gear or a carrier in the planetary gear set; and selectively rotationally couple the sun gear and the carrier. In one example, the multi-speed electric axle assembly may be a front multi-speed electric axle assembly. In another example, the ring gear may be rotationally coupled to the input shaft; the carrier may be rotationally coupled to the output shaft; and the one or more clutches may be configured to selectively ground the sun gear. In another example, the planetary gear set may be a simple planetary gear set. In another example, the ring gear may be rotationally coupled to the output shaft; the sun gear may be rotationally coupled to the input shaft; and the one or more clutches may be configured to selectively ground the carrier. In another example, the planetary gear set may be a meshed planet compound planetary gear set. In such an example, the one or more clutches may be a dog clutch. In one example, wherein planetary gear set may be positioned coaxial to an intermediate shaft. In yet another example, the output shaft may be coupled to a differential via a third gear that meshes with an input gear in the differential. In yet another example, the electric axle assembly may further comprise a park gear that is rotationally coupled to the ring gear. In one example, the multi-speed electric axle assembly further comprises a park gear that is rotationally coupled to the carrier.
In another aspect, a multi-speed electric beam axle is provided that comprises a traction motor rotationally coupled an input shaft; a meshed planet compound planetary gear set or a simple planetary gear set including: a ring gear, a carrier, and a sun gear; one or more clutches configured to selectively ground the sun gear or the carrier in the planetary gear set; and selectively rotationally couple the sun gear and the carrier. In example, the planetary gear set may be the simple planetary gear set; the ring gear may be rotationally coupled to the input shaft; the carrier may be rotationally coupled to the output shaft; and the one or more clutches may be configured to selectively ground the sun gear. In one example, the multi-speed electric beam axle may further comprise a park gear that is rotationally coupled to the ring gear. In one example, a gear ratio spread of the simple planetary gear set may be less than 1.6:1. In another example, the planetary gear set may be the meshed planet compound planetary gear set; the ring gear may be rotationally coupled to the output shaft; the sun gear may be rotationally coupled to the input shaft; and the one or more clutches may be configured to selectively ground the carrier. In another example, the multi-speed electric beam axle may further comprise a park gear that is rotationally coupled to the carrier. In another example, the multi-speed electric axle assembly may be a front multi-speed electric axle assembly. In another example, the one or more clutches may be a dog clutch. In another example, the planetary gear set is positioned coaxial to an intermediate shaft.
Note that the example control and estimation routines included herein can be used with various powertrain, transmission, and/or vehicle system configurations. The control methods and routines disclosed herein may be stored as executable instructions in non-transitory memory and may be carried out by the control system including the controller in combination with the various sensors, actuators, and other vehicle hardware. Further, the described actions, operations and/or functions may graphically represent code to be programmed into non-transitory memory of the computer readable storage medium in the vehicle control, where the described actions are carried out by executing the instructions in a system including the various hardware components in combination with the electronic controller. One or more of the method steps described herein may be omitted if desired.
While various embodiments have been described above, it should be understood that they have been presented by way of example, and not limitation. It will be apparent to persons skilled in the relevant arts that the disclosed subject matter may be embodied in other specific forms without departing from the spirit of the subject matter. The embodiments described above are therefore to be considered in all respects as illustrative, not restrictive. As such, these specific examples are not to be considered in a limiting sense, because numerous variations are possible. For example, the above technology can be applied to powertrains that include different types of propulsion sources including different types of electric machines and engines (e.g., internal combustion engines). The subject matter of the present disclosure includes all novel and non-obvious combinations and sub-combinations of the various systems and configurations, and other features, functions, and/or properties disclosed herein.
The following claims particularly point out certain combinations and sub-combinations regarded as novel and non-obvious. These claims may refer to “an” element or “a first” element or the equivalent thereof. Such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements. Other combinations and sub-combinations of the disclosed features, functions, elements, and/or properties may be claimed through amendment of the present claims or through presentation of new claims in this or a related application. Such claims, whether broader, narrower, equal, or different in scope to the original claims, also are regarded as included within the subject matter of the present disclosure.
The present application claims priority to U.S. Provisional Application No. 63/584,787, entitled “MULTI-SPEED ELECTRIC AXLE”, and filed on Sep. 22, 2023. The entire contents of the above-listed application are hereby incorporated by reference for all purposes.
Number | Date | Country | |
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63584787 | Sep 2023 | US |