Electric power shift transmission and power shift method

Patent metadata

Field	Value
Publication number	US-12209658-B2
Application number	US-202218146734-A
Country	US
Kind code	B2
Filing date	Dec 27, 2022
Priority date	Dec 27, 2022
Publication date	Jan 28, 2025
Grant date	Jan 28, 2025

Abstract

Systems and methods for an electric powertrain. The method, in one example, includes responsive to receiving a shift command, engaging a second friction clutch while disengaging a first friction clutch to transition from a first operating gear ratio to a second operating gear ratio. The method, further includes during the gear ratio transition, operating a traction motor under a peak condition, the peak condition denotes a condition where the motor speed is greater than a maximum continuous torque curve of the motor.

First claim

The invention claimed is:

1. A method, comprising:
receiving a first shift command to initiate a first shift event in a transmission;
in response to receiving the first shift command, engaging a second friction clutch while disengaging a first friction clutch to transition from a first operating gear ratio to a second operating gear ratio; and
during the gear ratio transition, operating a traction motor under a peak condition;
wherein the peak condition includes a condition where a torque of the traction motor exceeds a maximum continuous torque threshold.

2. The method of claim 1 , wherein a torque of an output of the transmission that includes the first and second friction clutches is maintained at a substantially constant value during the engagement of the first friction clutch and the disengagement of the second friction clutch.

3. The method of claim 1 , wherein the second operating gear ratio is greater than the first operating gear ratio.

4. The method of claim 3 , further comprising:
receiving a second shift command to initiate a second shift event;
in response to receiving the second shift command, engaging the first friction clutch while disengaging the second friction clutch to transition from the second operating gear ratio to the first operating gear ratio; and
operating the traction motor under the peak condition.

5. The method of claim 4 , wherein:
the transmission includes a first synchronizer directly coupled to the first friction clutch and a second synchronizer directly coupled to the second friction clutch; and
the method further comprises:
prior to engaging the second friction clutch while disengaging the first friction clutch, engaging the second synchronizer while sustaining engagement of the first synchronizer; and
subsequent to engaging the second friction clutch while disengaging the first friction clutch, disengaging the first synchronizer while sustaining engagement of the second synchronizer.

6. The method of claim 1 , further comprising, during the first shift event, decreasing a torque of the traction motor to operate the traction motor at or below the maximum continuous torque threshold.

7. The method of claim 1 , wherein the first shift command that triggers initiation of the first shift event is automatically generated based on at least one of a change in vehicle speed and a change in vehicle load.

8. The method of claim 1 , wherein the traction motor is a three-phase electric motor.

9. The method of claim 1 , wherein the transmission includes an output shaft configured to couple to a front axle assembly and a rear axle assembly.

10. An electric powertrain system, comprising:
a first friction clutch configured to selectively engage a first operating gear ratio in a transmission;
a second friction clutch configured to selectively engage a second operating gear ratio; and
a controller including instructions that when executed, in response to receiving a shift command, cause the controller to:
engage the second friction clutch and disengage the first friction clutch at an overlapping interval to implement a first power shift event; and
during the overlapping interval, operate a traction motor under a peak condition;

wherein the peak condition includes a condition where a torque of the traction motor exceeds a maximum continuous torque threshold; and
wherein the second operating gear ratio is greater than the first operating gear ratio.

11. The electric powertrain system of claim 10 , wherein operating the traction motor under the peak condition occurs during an overlap phase of the first power shift event where torque handoff between the first friction clutch and the second friction clutch occurs.

12. The electric powertrain system of claim 10 , further comprising:
a first synchronizer directly coupled to the first friction clutch; and
a second synchronizer directly coupled to the second friction clutch.

13. The electric powertrain system of claim 12 , wherein:
the controller further includes instructions that when executed, prior to the engagement of the second friction clutch and disengagement of the first friction clutch, cause the controller to:
engage the second synchronizer while engagement of the first synchronizer is maintained; and

the controller further includes instructions that when executed, subsequent to the engagement of the second friction clutch and disengagement of the first friction clutch, cause the controller to:
disengage the first synchronizer while engagement of the second synchronizer is maintained.

14. The electric powertrain system of claim 10 , wherein the transmission is a two-speed transmission.

15. The electric powertrain system of claim 10 , wherein the electric powertrain system is included in an all-electric vehicle.

16. The electric powertrain system of claim 10 , wherein the electric powertrain system is included in an off-highway vehicle.

17. A method for operation of an electric powertrain system, comprising:
operating a traction motor above a maximum continuous torque threshold, during a torque hand-off between a second wet friction clutch and a first wet friction clutch in a power shift event; and
operating the traction motor at or below the maximum continuous torque threshold prior and subsequent to the power shift event.

18. The method of claim 17 , wherein operating the traction motor above the maximum continuous torque threshold includes operating the traction motor above the maximum continuous torque threshold to maintain an output torque of a transmission at a substantially constant value, wherein the first and second wet friction clutches are included in the transmission.

19. The method of claim 17 , wherein the first wet friction clutch is associated with a first gear ratio and the second wet friction clutch is associated with a second gear ratio, and wherein the first gear ratio is not equivalent to the second gear ratio.

20. The method of claim 17 , wherein a duration of the power shift event is less than three seconds (s).

Assignees

• Dana Belgium Nv

Inventors

• Coenen Pauwel
• Van Dingenen Joachim
• De Buyser Christophe
• Cattoor Kurt
• Hannon Bert

Classifications

• F16H2306/44

  Removing torque from current gears · CPC title

• F16H2200/0034

  the gear ratios comprising two forward speeds · CPC title

• F16H2306/52

  Applying torque to new gears · CPC title

• F16H2061/0425

  Bridging torque interruption · CPC title

• F16H61/04

  Smoothing ratio shift · CPC title