Off-axis motor with hybrid transmission method and system

Patent metadata

Field	Value
Publication number	US-9777798-B2
Application number	US-201514695443-A
Country	US
Kind code	B2
Filing date	Apr 24, 2015
Priority date	Dec 19, 2011
Publication date	Oct 3, 2017
Grant date	Oct 3, 2017

Abstract

A system and method for modifying a transmission in a gasoline-electric hybrid vehicle to couple the transmission to an off-axis electric motor. The transmission includes a motor-driven gear that replaces or modifies an engine-driven reverse gear. The motor-driven gear is hard-splined to an output shaft of the transmission. An electric motor is coupled to the output shaft of the transmission via the motor-driven gear. The electric motor may thus be oriented along an axis that differs from the axis of the transmission's output shaft.

First claim

What is claimed is:

1. A dual clutch transmission coupled to an off-axis electric motor in a gasoline-electric hybrid vehicle, comprising:
a motor-driven modified reverse gear that replaces an engine-driven reverse gear, the motor-driven modified reverse gear being hard-splined to an output shaft of the transmission in a same position as the engine-driven reverse gear; and
an off-axis electric motor coupled to the output shaft of the transmission via the motor-driven modified reverse gear, the electric motor including an electric motor driven gear directly coupled to the motor-driven modified reverse gear;
wherein the electric motor is configured to provide forward and reverse torque and an electric only reverse mode via its coupling to the motor-driven modified reverse gear.

2. The transmission of claim 1 , wherein the motor-driven modified reverse gear is positioned at a first end of the output shaft opposed to a second end of the output shaft adjacent dual clutches of the dual clutch transmission.

3. The transmission of claim 2 , further comprising a modified synchronizer that replaces a reverse and forward direction gear synchronizer positioned between the motor-driven modified reverse gear and forward direction gear, the modified synchronizer configured to synchronize with only the forward direction gear.

4. The transmission of claim 1 , further comprising an idler gear that couples the electric motor to the motor-driven modified reverse gear.

5. The transmission of claim 1 , further comprising chain sprockets that couple the electric motor to the motor-driven modified reverse gear.

6. The transmission of claim 1 , wherein the motor-driven modified reverse gear is configured to rotate the output shaft in both forward and backward directions.

7. The transmission of claim 1 , wherein the electric motor is coupled to the output shaft along an axis that differs from an axis defined by the output shaft.

8. The transmission of claim 1 , wherein the electric motor is configured to both provide and generate electric power.

9. The transmission of claim 1 , wherein only one electric motor is coupled to the transmission.

10. The transmission of claim 1 , wherein the transmission is a dry dual-clutch transmission.

11. The transmission of claim 1 , wherein the motor-driven modified reverse gear is sized to provide a torque ratio from the electric motor of between 5:1 and 8:1.

12. The transmission of claim 9 , wherein the motor-driven modified reverse gear is sized to provide a torque ratio from the electric motor of 5:1.

13. A method of modifying a dual clutch transmission in a gasoline-electric hybrid vehicle to couple the transmission to an off-axis electric motor, the method comprising:
replacing an engine-driven reverse gear of the transmission with a motor-driven reverse gear, the motor-driven reverse gear being non-rotatably fixed to an output shaft of the transmission in a same position as the engine-driven reverse gear;
coupling an electric motor drive unit directly to the motor-driven reverse gear to provide both forward and reverse torque to the output shaft of the transmission; and
coupling an off-axis electric motor to the transmission output shaft via the motor drive unit and the motor-driven reverse gear, the electric motor and drive unit configured to provide an electric-only reverse mode.

14. The method of claim 13 , wherein the motor-driven reverse gear being non-rotatably fixed to an output shaft of the transmission further comprises hard-splining the motor-driven gear to the transmission's output shaft.

15. The method of claim 13 , further comprising using an idler gear in the motor drive unit to couple the off-axis electric motor to the motor-driven gear.

16. The method of claim 13 , further comprising using chain sprockets in the motor drive unit to couple the off-axis electric motor to the motor-driven gear.

17. The method of claim 13 , wherein coupling the off-axis electric motor to the transmission output shaft comprises coupling the off-axis electric motor to the transmission output shaft along an axis that differs from an axis defined by the output shaft.

18. The method of claim 13 , further comprising using the off-axis electric motor to provide electric power and to generate electric power.

19. The method of claim 13 , wherein only one off-axis electric motor is coupled to the transmission.

20. The method of claim 13 , wherein replacing an engine-driven reverse gear of the transmission with a motor-driven reverse gear comprises using a motor-driven reverse gear sized to provide a torque ratio from the off-axis electric motor of between 5:1 and 8:1.

Assignees

• Klingston David E
• Miller Travis J
• Tamai Goro
• Fca Us Llc

Inventors

• Klingston David E
• Miller Travis J
• Tamai Goro

Classifications

• B60L15/2009

  for braking · CPC title

• Y10S903/902

  Prime movers comprising electrical and internal combustion motors · CPC title

• B60L2240/486

  Operating parameters · CPC title

• B60K2006/541

  without reverse ratio using instead electric reversing · CPC title

• Y02T10/6221

  Cross-Sectional Technologies · mapped topic