Selectable differential drive for a vehicle

Patent metadata

Field	Value
Publication number	US-11766943-B2
Application number	US-202217984475-A
Country	US
Kind code	B2
Filing date	Nov 10, 2022
Priority date	Jul 26, 2021
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A drive system includes a first drive train and a second drive train coupled by a differential assembly. Each drive train include a motor, an output gear, and a clutch assembly that engages and disengages the output gear from respective halfshafts. The differential assembly is configured to couple the first and second halfshafts, and connect/disconnect the first output gear and the first halfshaft. The differential assembly includes, for example, side gears, a spider gearset, and an actuator for engaging and disengaging the differential casing from the first output gear. A control system is configured to actuate actuators of clutch assemblies and/or a differential assembly to achieve one or more drive modes for each drive axis. The control system determines the first drive mode, controls the clutch assemblies and differential assemblies, and controls one or more motors. The drive modes include, for example, torque vectoring, fully locked, single motor, and neutral.

First claim

What is claimed is:

1. A center disconnecting differential comprising:
differential elements coupled to a first output element and to a second output element; and
a differential actuator configured to:
engage the differential elements to a first output gear to transmit differentiated torque to both the first output element and the second output element, and
disengage the differential elements from the first output gear to enable the first output gear to transmit torque only to the first output element and not to the second output element.

2. The center disconnecting differential of claim 1 , wherein:
the first output gear is driven by a first motor;
a second output gear is driven by a second motor; and
when the differential elements are engaged to the first output gear in a single motor configuration, the first motor drives the first output element and the second output element.

3. The center disconnecting differential of claim 1 , wherein:
the differential elements comprise a spider gearset coupled to a differential casing;
the first output element comprises a first side gear engaged with the spider gearset; and
the second output element comprises a second side gear engaged with the spider gearset.

4. The center disconnecting differential of claim 1 , wherein the first output gear is driven by a first motor, and wherein a second output gear is driven by a second motor, further comprising:
a first clutch configured to engage and disengage the first output gear and the first output element; and
a second clutch configured to engage and disengage the second output gear and the second output element.

5. The center disconnecting differential of claim 4 , wherein, in a torque vectoring configuration:
the differential actuator disengages the differential elements from the first output gear;
the first clutch engages the first output gear with the first output element; and
the second clutch engages the second output gear with the second output element.

6. The center disconnecting differential of claim 4 , wherein, in a fully locked configuration:
the differential actuator engages the differential elements with the first output gear;
the first clutch engages the first output gear with the first output element; and
the second clutch engages the second output gear with the second output element.

7. A system comprising:
a first output element of a drive axis;
a second output element of the drive axis;
differential elements coupled to the first output element and to the second output element;
a differential actuator configured to engage and disengage the differential elements and a first output gear; and
control circuitry coupled to the differential actuator and configured to:
cause the differential actuator to engage the differential elements with the first output gear to transmit differentiated torque to both the first output element and the second output element, and
cause the differential actuator to disengage the differential elements from the first output gear to enable the first output gear to transmit torque only to the first output element and not the second output element.

8. The system of claim 7 , wherein:
the first output gear is driven by a first motor;
a second output gear is driven by a second motor; and
when the differential actuator engages the differential elements with the first output gear, the first motor drives the first output element and the second output element.

9. The system of claim 7 , wherein the control circuitry is further configured to:
determine a drive mode for the drive axis; and
cause the differential actuator to engage or disengage the differential elements and the first output gear based on the drive mode.

10. The system of claim 7 , wherein the first output gear is driven by a first motor, and wherein a second output gear is driven by a second motor, further comprising:
a first clutch configured to engage and disengage the first output gear and the first output element; and
a second clutch configured to engage and disengage the second output gear and the second output element, wherein the control circuitry is configured to control the first clutch and the second clutch.

11. The system of claim 10 , wherein, in a single drive configuration, the control circuitry causes:
the differential actuator to engage the differential elements with the first output gear;
the first clutch to disengage the first output gear from the first output element; and
the second clutch to disengage the second output gear from the second output element.

12. The system of claim 10 , wherein, in a torque-vectoring drive configuration, the control circuitry causes:
the differential actuator to disengage the differential elements from the first output gear;
the first clutch to engage the first output gear with the first output element; and
the second clutch to engage the second output gear with the second output element.

13. The system of claim 10 , wherein, in a fully-locked configuration, the control circuitry causes:
the differential actuator to engage the differential elements with the first output gear;
the first clutch to engage the first output gear with the first output element; and
the second clutch to engage the second output gear with the second output element.

14. The system of claim 10 , wherein, in a neutral configuration, the control circuitry causes:
the differential actuator to disengage the differential elements from the first output gear;
the first clutch to disengage the first output gear from the first output element; and
the second clutch to disengage the second output gear from the second output element.

15. A method for managing drive configurations of a drive axis, wherein a first output gear is driven by a first motor, and a second output gear is driven by a second motor, the method comprising:
achieving a torque-vectoring configuration by coupling the first output gear to a first output element arranged along the drive axis, coupling the second output gear to a second output element arranged along the drive axis, and disengaging differential elements from the first output gear such that the first output gear does not transmit torque to the second output element; and
achieving a single-motor configuration by decoupling the first output gear from the first output element, decoupling the second output gear from the second output element, and engaging the differential elements with the first output gear to transmit differentiated torque to the first output element and to the second output element.

16. The method of claim 15 , wherein:
coupling the first output gear to the first output element comprises causing a first clutch to engage the first output gear with the first output element; and
coupling the second output gear to a second output element comprises causing a second clutch to engage the second output gear with the second output element.

17. The method of claim 15 , wherein:
decoupling the first output gear from the first output element comprises causing a first clutch to disengage the first output gear from the first output element; and
decoupling the second output gear from the second output element comprises causing a second clutch to disengage the second output gear from the second output element.

18. The method of claim 15 , further comprising achieving a fully-locked configuration by coupling the first output gear to the first output element, coupling the second output gear to the second output element, and engaging differential elements

Assignees

• Rivian Ip Holdings Llc

Inventors

• Verbridge Mason
• Williams Cameron P
• Rahman Khwaja
• Huang Henry
• Kalyanaraman Vinaey

Classifications

• B60L15/2054 Primary

  by controlling transmissions or clutches · CPC title

• B60K7/0007

  the motor being electric · CPC title

• B60K17/02

  characterised by arrangement, location, or kind of clutch · CPC title

• B60K17/165

  provided between independent half axles (B60K17/18, B60K17/20 take precedence) · CPC title

• B60W50/08

  Interaction between the driver and the control system · CPC title