Electric propulsion system

Patent metadata

Field	Value
Publication number	US-12036855-B2
Application number	US-202318297528-A
Country	US
Kind code	B2
Filing date	Apr 7, 2023
Priority date	Sep 10, 2019
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

Methods and systems for electric propulsion are provided. An electric propulsion system, in one example, includes a first electric machine coupled to a first gear set with a first gear ratio, a second electric machine coupled to a second gear set with a second gear ratio different from the first gear ratio, and an axle including an axle interface. In the system, at least a first output gear of the first gear set and a second output gear of the second gear set are coupled in parallel to the axle interface.

First claim

The invention claimed is:

1. A system, comprising:
a plurality of electric machines;
a plurality of gear sets, wherein each gear set of the plurality of gear sets comprises a different gear ratio and is coupled to a different electric machine of the plurality of electric machines;
a plurality of clutches, each of the plurality of clutches is coupled to an electric machine of the plurality of electric machines and a gear set of the plurality of gear sets; and
a controller including executable instructions stored in non-transitory memory that, during operation of the electric propulsion system in a drive mode, cause the controller to adjust operation of the plurality of clutches and the plurality of electric machines based on operating efficiencies of the plurality of electric machines.

2. The system of claim 1 , further comprising an axle comprising an axle interface, wherein the axle interface is coupled to two or more output gears of the plurality of gear sets.

3. The system of claim 1 , wherein a gear ratio of a gear set of the plurality of gear sets corresponds to an efficiency curve of a corresponding electric machine, wherein efficiency curves are different for each of the plurality of electric machines and based on operating efficiencies of the corresponding electric machine.

4. The system of claim 1 , wherein each gear set of the plurality of gear sets includes a plurality of helical gears.

5. The system of claim 1 , wherein the plurality of electric machines are motor-generators.

6. A system for an electric powertrain, comprising:
a plurality of clutches coupled to a plurality of gear sets and a plurality of electric machines;
a drive axle shaft comprising a differential carrier coupled to multiple output gears of the plurality of gear sets; wherein
each clutch of the plurality of clutches is coupled to a gear set of the plurality of gear sets and an electric machine of the plurality of electric machines, and wherein pairs of the electric machines are coaxially arranged with one another; and
a controller with computer-readable instructions stored on memory thereof that when enabled cause the controller to adjust activation and deactivation of each of the plurality of electric machines in response to a vehicle speed; and
manage operation of the plurality of electric machines when the electric powertrain is in a regenerative mode based on energy recovery efficiencies of each of the plurality of electric machines.

7. The system of claim 6 , wherein an axis along which the pairs of electric machines are coaxial is parallel to the axle.

8. The system of claim 6 , wherein the instructions further cause the controller to adjust operation of the plurality of clutches based on operating efficiencies of the plurality of electric machines.

9. The system of claim 8 , wherein operating efficiencies of each of the plurality of electric machines are different.

10. The system of claim 6 , wherein the differential carrier is coupled to a plurality of gears, and wherein each of the plurality of gears is coupled to an output gear of the plurality of gear sets.

11. The system of claim 6 , further comprising an output shaft extending from a corresponding electric machine of the plurality of electric machines to a gear of the plurality of gear sets, wherein the output shaft is parallel to the axle.

12. The system of claim 6 , wherein at least two or more of the plurality of electric machines are a different size.

13. A system for an electric propulsion system, comprising:
a plurality of electric machines, each of the plurality of electric machines coupled to a gear set of a plurality of gear sets via an output shaft of a plurality of output shafts;
a plurality of clutches, each of the plurality of clutches configured to control a power output from an electric machine of the plurality of electric machines to a corresponding gear set of the plurality of gear sets;
a differential arranged on an axle parallel to the plurality of output shafts, wherein the differential is coupled to a plurality of gears, each of the plurality of gears coupled to one of the plurality of gear sets; and
a controller with computer-readable instructions stored on memory thereof that when executed cause the controller to:
manage operation of the plurality of electric machines and the plurality of clutches based on at least a vehicle speed and operating efficiencies of each of the plurality of electric machines.

14. The system of claim 13 , wherein the instructions further cause the controller to engage a clutch of an electric machine of the plurality of electric machines with a numerical gear ratio above a threshold value when a vehicle speed is greater than a threshold speed.

15. The system of claim 13 , wherein the instructions further cause the controller to initiate one or more of the plurality of electric machines in a drive mode based on operating efficiencies and a desired speed range of the plurality of electric machines.

16. The system of claim 13 , wherein the instructions further cause the controller to initiate one or more of the plurality of electric machines in a regenerative mode based on operating efficiencies and a desired speed range of the plurality of electric machines.

17. The system of claim 13 , wherein the instructions further cause the controller to operate at least two or more of the plurality of electric machines in a drive mode or a regenerative mode.

Assignees

• Dana Heavy Vehicle Sys Group

Inventors

• Trost Harry W
• Slesinski Steven G

Classifications

• B60W2710/021

  Clutch engagement state · CPC title

• B60W2510/08

  Electric propulsion units · CPC title

• B60W2520/10

  Longitudinal speed · CPC title

• B60W30/18127

  Regenerative braking · CPC title

• B60K17/16

  of differential gearing · CPC title