Power unit for a front-beam axle

Abstract

The invention provides a power unit for a front beam axle. Methods and systems for configuring a four-wheel drive high gross weight vehicle are presented. In one non-limiting example, the traction battery covers a lateral extension between the first frame rail and the second frame rail to provide higher storage capacity for the traction battery even if the vehicle is configured for four-wheel drive.

Description

Technical Field

[0001] The present description relates to a vehicle having a hybrid powertrain with a high towing capacity. Background Art

[0002] A vehicle may be designed with a higher towing capacity so that the vehicle can haul a larger load than a typical commuter vehicle can haul. A vehicle with a higher towing capacity may also be designed differently than a vehicle with a lower towing capacity. For example, a vehicle with a lower towing capacity may include a unibody structure and coil springs, while a vehicle with a higher towing capacity may include a body-on-frame construction. Unibody and body-on-frame vehicle configurations have performed well, but as vehicles move toward higher levels of electrification, existing powertrain and vehicle structures may not meet packaging and performance design goals. Therefore, it may be desirable to provide a vehicle configuration that accommodates higher towing capacity and electrification. Summary of the Invention

[0003] The inventors herein have recognized the aforementioned problems and have developed a vehicle system comprising: a steerable front beam axle; a rear beam axle; a first frame rail configured to support a chassis and extending from the rear beam axle to the steerable front beam axle; a second frame rail configured to support the chassis and extending from the rear beam axle to the steerable front beam axle; a power unit configured to generate electricity via output of an internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; and a traction battery extending laterally continuously between the first frame rail and the second frame rail.

[0004] By producing a vehicle that includes a traction battery extending continuously between two frame rails and a power unit configured to supply traction to a steerable front beam axle, the power unit and traction battery can be packaged in a vehicle capable of towing greater amounts of weight. Furthermore, the traction battery can be of sufficient size to provide power to the power unit and the electrified rear axle, allowing the vehicle to carry heavy loads and operate in four-wheel drive for extended periods of time.

[0005] The present disclosure can provide several advantages. Specifically, the method can enable a vehicle with a higher towing capacity to be a four-wheel drive hybrid vehicle with a traction battery having a higher charge storage capacity. Furthermore, the method can reduce the vehicle's unsprung mass, thereby providing a desired level of vehicle ride quality. Furthermore, the method allows for compact packaging of an internal combustion engine and an electric motor supported via a steerable axle without interfering with steering components.

[0006] The above advantages and other advantages and features of the present specification will be readily apparent from the following detailed description when taken alone or in conjunction with the accompanying drawings.

[0007] It will be understood that the above summary is provided to introduce a series of concepts further described in the detailed description in a simplified form. It is not meant to identify key features of the claimed subject matter, the scope of which is solely defined by the claims appended to the detailed description. Furthermore, the claimed subject matter is not limited to implementations that address any disadvantages noted above or in any part of this disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 A schematic depiction of a vehicle and powertrain is shown;

[0009] Figures 2 to 15 Shows that can be included in Figure 1 Various embodiments of a powertrain system in a vehicle of; and

[0010] Figure 16 Shown for building Figure 1 Flowchart of a method for a hybrid vehicle of the type shown. DETAILED DESCRIPTION

[0011] like Figure 1 As shown, a hybrid vehicle may include a traction battery 100 including a housing or casing 102 that extends continuously between a first frame rail and a second frame rail (e.g., without breaks or separations in the housing of the traction battery), wherein the traction battery covers at least sixty percent of a lateral distance between the first frame rail and the second frame rail. Figures 2 to 15 A hybrid vehicle can be powered by Figure 16 method to manufacture.

[0012] refer to Figure 1 , shows a hybrid vehicle 1. The hybrid vehicle 1 includes a chassis 50, a front side 2, and a rear side 3. When the hybrid vehicle 1 is engaged in a forward gear, the hybrid vehicle can travel in a forward direction, with the front side 2 guiding the hybrid vehicle. When the hybrid vehicle 1 is engaged in a reverse gear, the hybrid vehicle can travel in a reverse direction, with the rear side 3 guiding the hybrid vehicle.

[0013] The hybrid vehicle includes a first frame rail 14 (e.g., a left-hand frame rail) and a second frame rail 16 (e.g., a right-hand frame rail) extending between a steerable front beam axle 6 and a rear beam axle 22. The first and second frame rails may extend beyond the steerable front and rear beam axles, or they may extend within the steerable front and rear beam axles. The first and second frame rails 14, 16 are configured to support a chassis 50 and may be coupled to the steerable front and rear beam axles 6, 22. Furthermore, the first and second frame rails 14, 16 are configured to support a traction battery 100, which includes a housing or casing extending continuously between the first and second frame rails 14, 16. The traction battery 100 may extend at least sixty percent of the lateral distance between the first and second frame rails 14, 16, as indicated by guide arrow 55. There is no drive shaft passing through the traction battery 100 along the side in the longitudinal direction of the vehicle. This arrangement allows the charge storage capacity of the traction battery 100 to be increased, thereby increasing the driving range of the hybrid vehicle 1. The traction battery includes a plurality of battery cells 104 arranged in series and parallel.

[0014] The hybrid vehicle 1 includes a power unit 60 mounted in front of a traction battery 100 in the longitudinal direction of the hybrid vehicle from the front to the rear of the hybrid vehicle. The power unit 60 includes an internal combustion engine 10 coupled to an electrified transmission 12. Various options for the power unit 60 are described in Figures 2 to 15 . The power unit 60 provides a torque path as indicated by arrow 51. Thus, the torque path 51 is U-shaped, and it can transmit torque from the front portion 1 of the hybrid vehicle 1 to the rear portion 3 of the hybrid vehicle 1 in the longitudinal direction. Furthermore, the direction of the torque flow is reversed, allowing the hybrid vehicle 1 to transmit torque from the rear portion 3 of the hybrid vehicle 1 to the front portion 2 of the hybrid vehicle 1 in the longitudinal direction. The torque can be supplied from the power unit 60 to the universal joint 35, or alternatively, from the constant velocity joint 35 and the drive shaft 15 to the front axle differential 17.

[0015] When pushed by the steering link 33, the front wheels 26 can pivot about the kingpin 40. The steering link 33 can be mechanically coupled to the steering wheel, or alternatively, the position of the steering link 33 can be adjusted via an electric motor. Thus, the direction of travel of the hybrid vehicle 1 can be changed by adjusting the position of the steering link 33 and the front wheels 26. The power unit 60 can rotate the front wheels 26.

[0016] Hybrid vehicle 1 is also shown having a rear beam axle 22. Rear beam axle 22 is configured with a rear power unit 20, which includes an electric motor 25 and a gear set 26. The transmission 12 and the electric motor in the rear power unit 20 can receive power from a traction battery 100. Furthermore, when operating in generator mode, the transmission 12 and / or the electric motor 25 can supply charge to the traction battery 100. The electric motor 25 can rotate rear wheels 28.

[0017] The transverse direction of the hybrid vehicle 1 is indicated by an arrow 75 , and the longitudinal direction of the hybrid vehicle 1 is indicated by an arrow 76 .

[0018] Now refer to Figure 2 , shows a cross-sectional view of a first example of a power unit 60. In this example power unit, the internal combustion engine 10 is directly coupled (e.g., without an intermediate shaft or gears) to the input shaft 201, and the input shaft 201 is directly coupled to the shock absorber 202. The shock absorber 202 is directly coupled to the gear carrier 204c of the first planetary gear set 204. The first planetary gear set 204 also includes a ring gear 204r that is directly coupled to the transmission housing 235. In addition, the sun gear 204s of the first planetary gear set 204 is coupled to the first intermediate shaft 230. The first intermediate shaft 230 couples the first planetary gear set 204 to the generator 206. When the rotor of the generator 204 rotates via the internal combustion engine 10, the generator 204 can Figure 1 The illustrated traction battery 100 and / or motor 208 supplies the electrical charge. In this example, the generator 204 is not mechanically coupled to the motor 208.

[0019] Motor 208 is a traction motor which can be driven by Figure 1 The illustrated steerable front beam axle 6 provides propulsion to the front wheels 26. Motor 208 is directly coupled to sun gear 210s of second planetary gear set 210 via second intermediate shaft 236. Carrier 210c of second planetary gear set 210 is directly coupled to third intermediate shaft 214, and third intermediate shaft 214 is directly coupled to first chain drive sprocket 216. Chain 220 mechanically couples first chain drive sprocket 216 to second chain drive sprocket 218. Second chain drive sprocket 218 is directly coupled to output shaft 222, and output shaft 222 is directly coupled to universal joint 35.

[0020] In this configuration, the power unit 60 can receive input torque via the internal combustion engine 10 and convert the torque into an electrical charge via the generator 204. The electrical charge can be delivered to the traction motor 208 and / or the traction battery 100. The traction motor 208 can provide torque to provide propulsion to the front wheels 26 via the chain 220 and its associated gears.

[0021] The first planetary gear set 204 acts as a reduction gear between the internal combustion engine 10 and the generator 204. The second planetary gear set 210 operates as a reduction gear between the motor 208 and the third intermediate shaft 214.

[0022] Now refer to Figure 3 , shows a cross-sectional view of a second example of the power unit 60. In this example, Figure 3 Shown in Figure 2 Many parts shown. Figure 2 Zhongyu Figure 3 Components that are identical to the components shown are labeled with the same numerical identifiers. For example, Figure 2 The input shaft 201 is Figure 3 denoted as the input shaft 201. Therefore, for the sake of brevity, descriptions of the same components are omitted.

[0023] In this example, the engine direct drive shaft 301 is positioned within the first intermediate shaft 230 and the second intermediate shaft 236. The third intermediate shaft 214 is not included, and the coupling 302 can selectively couple the engine direct drive shaft 301 to the first chain drive sprocket 216 and the second intermediate shaft 236. The coupling 302 and the engine direct drive shaft 301 can allow the engine to supply torque directly to the first chain drive sprocket 216, which in turn can allow the internal combustion engine to use the first intermediate shaft 214. Figure 1 The front wheel 26 shown rotates. The coupling 302 can be selectively engaged and disengaged via the actuator 305. Thus, the internal combustion engine 10 and the traction motor 208 can simultaneously provide torque to the first chain drive sprocket 216. In addition, the internal combustion engine 10 can simultaneously Figure 1 The front wheels 26 and the generator 204 are shown supplying torque so that the traction battery can be used while the internal combustion engine 10 is propelling the vehicle. Figure 1 The hybrid vehicle 1 shown is being charged simultaneously.

[0024] Now refer to Figure 4 , shows a cross-sectional view of a third example of the power unit 60. In this example, Figure 4 Shown in Figure 2 Many parts shown. Figure 2 Zhongyu Figure 4 Components that are identical to the components shown are labeled with the same numerical identifiers. For example, Figure 2 The motor 208 is Figure 4 208. Therefore, for the sake of brevity, the description of the same components is omitted.

[0025] In this example, the first planetary gear set 204 has been removed, and the input shaft 401 directly couples the internal combustion engine 10 with the generator 206. This configuration allows the internal combustion engine 10 to rotate at the same speed as the generator 206.

[0026] Now refer to Figure 5 , shows a cross-sectional view of a fourth example of the power unit 60. In this example, Figure 5 Shown in Figure 2 and Figure 3 Many of the components shown in . Figure 2 and Figure 3 Zhongyu Figure 5 Components that are identical to the components shown are labeled with the same numerical identifiers. For example, Figure 2 The motor 208 is Figure 5 208. Therefore, for the sake of brevity, the description of the same components is omitted.

[0027] In this example, the first planetary gear set 204 has been removed, and the input shaft 502 directly couples the internal combustion engine 10 with the shock absorber 202. The input shaft 502 extends through the first intermediate shaft 230 and the second intermediate shaft 236. The input shaft 502 can be selectively coupled to the first chain drive sprocket 216 via the coupling 302. Figure 5 The configuration is omitted Figure 3 The configuration shown in the gear reduction.

[0028] Now refer to Figure 6 , shows a cross-sectional view of a fifth example of the power unit 60. In this example, Figure 6 Shown in Figure 2 Many parts shown. Figure 2 Zhongyu Figure 6 Components that are identical to the components shown are labeled with the same numerical identifiers. For example, Figure 2 The input shaft 201 is Figure 6 denoted as the input shaft 201. Therefore, for the sake of brevity, descriptions of the same components are omitted.

[0029] In this example, Figure 2 The second planetary gear set 210 is shown removed. The modified second intermediate shaft 636 couples the motor 208 directly to the reduced diameter first chain drive sprocket 616. Thus, the second planetary gear set 210 has been removed, allowing the motor to drive the reduced diameter first chain drive sprocket 616 without gear reduction.

[0030] Now refer to Figure 7 , shows a cross-sectional view of a sixth example of the power unit 60. In this example, Figure 7 Shown in Figure 3 and Figure 6 Many of the components shown in . Figure 3 and Figure 6 Zhongyu Figure 7The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0031] In this example, the second planetary gear set 210 has been removed, and the engine direct drive shaft 701 extends from the gear carrier 204c to the first chain drive sprocket 616. The engine direct drive shaft 701 extends through the first intermediate shaft 230 and the second intermediate shaft 636. The engine direct drive shaft 701 can be selectively coupled to the first chain drive sprocket 616 via the coupling 302. Figure 7 The configuration is omitted Figure 3 The configuration shown in FIG. 1 reduces the gears and provides direct engine drive capability.

[0032] Now refer to Figure 8 , shows a cross-sectional view of a seventh example of the power unit 60. In this example, Figure 8 Shown in Figure 7 Many parts shown. Figure 7 Zhongyu Figure 8 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0033] In this example, as Figure 7 In the example shown, the second planetary gear set 210 has been removed. However, in this example, the engine direct drive shaft 801 extends from the first intermediate shaft 230 to the first chain drive sprocket 616. The input shaft 502 directly couples the internal combustion engine 10 with the shock absorber 202. The engine direct drive shaft 801 extends from the first intermediate shaft 230 and the second intermediate shaft 636. The engine direct drive shaft 801 can be selectively coupled to the first chain drive sprocket 616 via the coupling 302. Therefore, Figure 8 The configuration includes a gear reduction provided via the first planetary gear set 204 .

[0034] Now refer to Figure 9 , shows a cross-sectional view of an eighth example of the power unit 60. In this example, Figure 9 Shown in Figure 8 Many parts shown. Figure 9 Zhongyu Figure 8 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0035] In this example, with Figure 2 Compared to the system shown, the second planetary gear set 210 and the first planetary gear set 204 have been removed. Figure 9 The power unit in the does not include the engine directly driving the shaft. Therefore, Figure 9The system does not provide a gear reduction between the internal combustion engine 10, the input shaft 901, and the first intermediate shaft 230 coupled to the input shaft 901. The crankshaft of the internal combustion engine 10 and the rotor of the generator 206 cannot be mechanically coupled to the motor 208. The second intermediate shaft 636 extends through the motor 208 and the first chain drive sprocket 616. Therefore, Figure 9 The configuration includes no gear reduction between the internal combustion engine 10 and the first chain drive sprocket 616. In this example, the motor 208 is the only source of tractive force.

[0036] Now refer to Figure 10 , shows a cross-sectional view of a ninth example of the power unit 60. In this example, Figure 10 Shown in Figure 9 Many parts shown. Figure 10 Zhongyu Figure 9 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0037] In this example, with Figure 2 Compared to the system shown, the second planetary gear set 210 and the first planetary gear set 204 have been removed, but this example includes an engine direct drive shaft 1001. The engine direct drive shaft 1001 extends from the internal combustion engine 10 to the first chain drive sprocket 616. Therefore, Figure 10 The system provides a gearless reduction between the internal combustion engine 10, the engine direct drive shaft 1001 and the intermediate shaft 230, which is coupled to the input shaft 901. However, the internal combustion engine 10 and the generator 206 can be coupled to the motor 208 and the first chain drive sprocket 616 via the engine direct drive shaft 1001 and the coupling 302. Thus, Figure 10 The configuration includes no gear reduction between the internal combustion engine 10 and the first chain drive sprocket 616 , but the configuration allows driving the wheels via the internal combustion engine 10 .

[0038] Now refer to Figure 11 , shows a cross-sectional view of a first example of a power unit 60. In this example power unit, the internal combustion engine 10 is directly coupled (e.g., without an intermediate shaft or gears) to the input shaft 201, and the input shaft 201 is directly coupled to the shock absorber 202. The shock absorber 202 is directly coupled to the gear carrier 204c of the first planetary gear set 204. The first planetary gear set 204 also includes a ring gear 204r that is directly coupled to the transmission housing 235. In addition, the sun gear 204s of the first planetary gear set 204 is coupled to the first intermediate shaft 230. The first intermediate shaft 230 couples the first planetary gear set 204 to the generator 206. When the rotor of the generator 204 rotates via the internal combustion engine 10, the generator 204 can Figure 1The illustrated traction battery 100 and / or motor 208 supplies the electrical charge. In this example, the generator 204 is not mechanically coupled to the motor 208.

[0039] Motor 208 is a traction motor which can be driven via the steerable front beam axle 6 to the Figure 1 Propulsion is provided to the front wheels 26 shown. Motor 208 is directly coupled to second countershaft gear 1102. Second countershaft gear 1102 meshes with first countershaft gear 1104, which is supported via countershaft 1108. Countershaft 1108 also supports second countershaft gear 1106, which meshes with output shaft gear 1110. Output shaft gear 1110 rotates together with output shaft 222.

[0040] In this configuration, the power unit 60 can receive input torque via the internal combustion engine 10 and convert the torque into charge via the generator 204. The charge can be delivered to the traction motor 208 and / or the traction battery 100. The traction motor 208 can provide torque to provide propulsion to the front wheels 26 via the layshaft 1108 and gears 1102, 1104, 1106, and 1110.

[0041] The first planetary gear set 204 acts as a reduction gear between the internal combustion engine 10 and the generator 204. The motor 208 can deliver torque to the front wheels 26 (such as the front wheels 26) by transmitting torque through gears rotating around the layshaft 1108 and the output shaft 222. Figure 1 shown).

[0042] Now refer to Figure 12 , shows a cross-sectional view of an eleventh example of the power unit 60. In this example, Figure 12 Shown in Figure 3 and Figure 11 Many parts shown. Figure 12 Zhongyu Figure 11 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0043] In this example, there is a first planetary gear set 204, but no chain drive. Figure 12 The system includes an engine direct drive shaft 1201, which allows the internal combustion engine 10 to supply torque directly to the gears of the layshaft, which in turn allows the internal combustion engine to Figure 1 The front wheels 26 shown rotate. The engine direct drive shaft 1201 connects the gear carrier of the first planetary gear set to the coupling 302. In addition, the coupling 302 can be selectively engaged and disengaged via the actuator 305. Therefore, the internal combustion engine 10 and the traction motor 208 can simultaneously provide torque to the second intermediate shaft gear 1102. This allows the internal combustion engine 10 to simultaneously Figure 1 The front wheels 26 and the generator 204 are shown supplying torque so that the traction battery can be used while the internal combustion engine 10 is propelling the vehicle. Figure 1 The hybrid vehicle 1 is shown being charged simultaneously. The generator and the internal combustion engine can rotate at different speeds.

[0044] Now refer to Figure 13 , shows a cross-sectional view of a twelfth example of the power unit 60. In this example, Figure 12 Shown in Figure 13 Many parts shown. Figure 13 Zhongyu Figure 12 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0045] In this example, there is an engine direct drive shaft 1301, which can allow the internal combustion engine 10 to supply torque directly to the gears of the countershaft, but the engine direct drive shaft is coupled to the first intermediate shaft 230, which is coupled to the sun gear 204s. This arrangement allows the internal combustion engine 10 to rotate at a different speed than the engine direct drive shaft 1301. The coupling 302 can be selectively engaged and disengaged via the actuator 305 to couple the engine direct drive shaft 1301 to the second intermediate shaft gear 1102. Therefore, the internal combustion engine 10 and the traction motor 208 can simultaneously provide torque to the second intermediate shaft gear 1102. This allows the internal combustion engine 10 to simultaneously Figure 1 The front wheels 26 and the generator 204 are shown supplying torque so that the traction battery can be used while the internal combustion engine 10 is propelling the vehicle. Figure 1 The hybrid vehicle 1 is shown being charged simultaneously. The generator and the internal combustion engine can rotate at different speeds.

[0046] Now refer to Figure 14 , shows a cross-sectional view of a thirteenth example of the power unit 60. In this example, Figure 14 Shown in Figure 9 and Figure 11 Many of the components shown in . Figure 14 Zhongyu Figure 9 and Figure 11 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0047] In this example, the second planetary gearset 210 and the first planetary gearset 204 have been removed, and a gear drive has been substituted for a chain drive. Input shaft 201 couples internal combustion engine 10 to generator 204. Second intermediate shaft 236 couples motor 208 to second intermediate gear 1102, which meshes with first countershaft gear 1104. Countershaft 1108 transfers torque from first countershaft gear 1104 to second countershaft gear 1106, which meshes with output shaft gear 1110. Output shaft gear 1110 rotates with output shaft 222. Thus, this example includes a gear reduction from internal combustion engine 10 to generator 206, as well as a gear transmission between traction motor 208 and output shaft 222. The internal combustion engine and generator 206 can supply electrical energy to motor 208 to propel the vehicle.

[0048] at last, Figure 15 A cross-sectional view of a fourteenth example of a power unit 60 is shown. In this example, Figure 15 Shown in Figure 3 and Figure 14 Many parts shown. Figure 15 Zhongyu Figure 3 and Figure 14 The same components as those shown are marked with the same numerical identifiers. Therefore, for the sake of brevity, the description of the same components is omitted.

[0049] In this example, coupling 302, coupling actuator 305, and engine direct drive shaft 1501 allow internal combustion engine 10 to directly drive second countershaft gear 1102. Torque from traction motor 208 and torque from internal combustion engine 10 can be combined to drive second countershaft gear 1102 and output shaft 222.

[0050] therefore, Figures 1 to 15A vehicle system is provided, comprising: a steerable front beam axle; a rear beam axle; a first frame rail configured to support a chassis and extending between the rear beam axle and the steerable front beam axle; a second frame rail configured to support the chassis and extending between the rear beam axle and the front beam axle; a power unit configured to generate electricity via output from an internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; and a traction battery extending continuously transversely between the first frame rail and the second frame rail (e.g., without breaks or separations in the traction battery housing or casing). In a first example, the vehicle system includes wherein the traction battery is housed in a bottom housing, and wherein a drive shaft does not extend from the power unit to the rear beam axle. In a second example, which may include the first example, the vehicle system includes wherein the single housing lacks a receptacle for an axle extending at least a portion of the distance between the power unit and the rear beam axle. In a third example, which may include one or both of the first and second examples, the vehicle system includes: wherein the bottom housing extends at least sixty percent of the lateral distance between the first and second frame rails. In a fourth example, which may include one or more of the first through third examples, the vehicle system includes: wherein the front beam axle includes two kingpins. In a fifth example, which may include one or more of the first through fourth examples, the vehicle system includes: wherein the bottom housing extends between the power unit and the rear beam axle. In a sixth example, which may include one or more of the first through fifth examples, the vehicle system includes: wherein the rear beam axle includes an electric motor.

[0051] in addition, Figures 1 to 15A system provides a vehicle system comprising: a front beam axle; a rear beam axle; a first frame rail extending between the rear beam axle and the front beam axle; a second frame rail extending between the rear beam axle and the front beam axle; a power unit configured to generate electricity via output from an internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; and wherein a torque path through the power unit changes from a front longitudinal direction to a rear longitudinal direction to a rear longitudinal direction to a front longitudinal direction; and a traction battery extending transversely between the first frame rail and the second vehicle frame rail. In a first example, the vehicle system includes: wherein the power unit includes a first electric motor and a second electric motor. In a second example, which may include the first example, the vehicle system includes: wherein the power unit includes two planetary gear sets. In a third example, which may include one or both of the first and second examples, the vehicle system includes: wherein the power unit includes a chain drive. In a fourth example, which may include one or more of the first to third examples, a vehicle system includes where the power unit includes a coupling for directly coupling the shock absorber to the chain drive.

[0052] Now turn Figure 16 , showing a method for building and assembling a hybrid vehicle. Figure 16 The method may be included as executable instructions in a non-transitory memory of one or more controllers. Figure 16 The method can be performed by humans and / or automated assembly systems. Figure 16 The method can also include taking measures to transform the physical world Figures 1 to 15 Actions that determine the operational status of the system.

[0053] At 1602, method 1600 includes longitudinally mounting an internal combustion engine to the front of a vehicle along with a transmission that reverses the direction of torque flow from the front of the vehicle to the rear of the vehicle and back to the front of the vehicle. The engine and transmission may be combined to create a power unit, and the power unit may have Figures 2 to 15 Method 1600 proceeds to 1604.

[0054] At 1604 , method 1600 couples a power unit including a transmission to a steerable front beam axle at a front side of the vehicle. Method 1600 proceeds to 1606 .

[0055] At 1606, method 1600 calls for installing a traction battery in the vehicle between the frame rails. The traction battery may extend transversely between the frame rails, with the traction battery extending at least 60 percent of the distance between the frame rails. Preferably, the traction battery may extend at least 90 percent of the distance between the frame rails to utilize the space provided by the battery pack, thereby allowing the battery pack to store a greater amount of charge. Method 1600 proceeds to 1608.

[0056] At 1608 , method 1600 calls for installing the electrified rear axle to the vehicle. The electrified rear axle may include one or more electric motors, gearing, and inverters. Method 1600 proceeds to 1610 .

[0057] At 1610, method 1600 electrically couples the traction battery to the power unit and the electrified rear axle. By electrically coupling the traction battery to the power unit and the electrified rear axle, one or both of the power unit and the electrified rear axle can receive power from the traction battery, and one or both of the power unit and the electrified rear axle can supply power to the traction battery. Method 1600 proceeds to exit.

[0058] In this way, the power unit can deliver mechanical power from the internal combustion engine or electric motor to the front wheels of the vehicle, and the rear wheels can receive power from the motor. The traction battery can span the distance between the frame rails to increase the charge storage capacity in the traction battery and prevent access to the rear axle via the drive shaft, but this limitation can be overcome by enabling the internal combustion engine and generator to provide power to the electrified rear axle.

[0059] Figure 16A method for a vehicle is provided, the method comprising: mounting a power unit longitudinally in the vehicle and coupling an engine to a front beam axle, the engine being mounted between a first frame rail and a second frame rail; a rear beam axle; and mounting a traction battery between the first frame rail and the second frame rail, wherein the traction battery extends at least sixty percent of a lateral distance between the first frame rail and the second frame rail, the first frame rail extending between the rear beam axle and the front beam axle, and wherein the traction battery is mounted between the rear beam axle and the front beam axle. In a first example, the method further comprises coupling the power unit to a differential of the front beam axle. In a second example, which may include the first example, the method comprises coupling the power unit to the differential via a drive shaft. In a third example, which may include one or both of the first and second examples, the method further comprises electrically coupling the power unit to the traction battery. In a fourth example, which may include one or more of the first to third examples, the method further comprises integrating an electric propulsion source with the rear beam axle. In a fifth example, which may include one or more of the first through fourth examples, the method further includes electrically coupling the electric propulsion source to the traction battery. In a sixth example, which may include one or more of the first through fifth examples, the method includes wherein the power unit includes a first electric machine and a second electric machine. In a seventh example, which may include one or more of the first through sixth examples, the method includes wherein the first electric machine is a generator and wherein the second electric machine is a traction motor.

[0060] This specification ends here. Numerous variations and modifications will occur to those skilled in the art upon reading this specification without departing from the spirit and scope of this specification. For example, single-cylinder, I2, I3, I4, I5, V6, V8, V10, V12, and V16 engines operating in natural gas, gasoline, diesel, or alternative fuel configurations may benefit from this specification.

[0061] According to the present invention, a vehicle system is provided, the vehicle system having: a steerable front beam axle; a rear beam axle; a first frame rail configured to support a chassis and extending between the rear beam axle and the steerable front beam axle; a second frame rail configured to support the chassis and extending between the rear beam axle and the steerable front beam axle; a power unit configured to generate electricity via an output of an internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; and a traction battery extending laterally continuously between the first frame rail and the second frame rail.

[0062] According to an embodiment, the traction battery is housed in the bottom housing and wherein the drive shaft does not extend from the power unit to the rear beam axle.

[0063] According to an embodiment, the bottom housing lacks a housing for a shaft extending at least a portion of the distance between the power unit and the rear beam axle.

[0064] According to an embodiment, the bottom shell extends at least sixty percent of the lateral distance between the first frame rail and the second frame rail.

[0065] According to an embodiment, the steerable front beam axle comprises two kingpins.

[0066] According to an embodiment, the bottom housing extends longitudinally between the power unit and the rear beam axle.

[0067] According to an embodiment, the rear beam axle comprises an electric motor.

[0068] According to the present invention, a method for a vehicle includes: mounting a power unit longitudinally in the vehicle and coupling the power unit to a front beam axle, the power unit mounted between a first frame rail and a second frame rail; a rear beam axle; and mounting a traction battery between the first frame rail and the second frame rail, wherein the traction battery extends at least sixty percent of a lateral distance between the first frame rail and the second frame rail, the first frame rail extending between the rear beam axle and the front beam axle, and wherein the traction battery is mounted between the rear beam axle and the front beam axle.

[0069] In one aspect of the invention, the method includes coupling the power unit to a differential of a front beam axle.

[0070] In one aspect of the invention, the power unit is coupled to the differential via a drive shaft.

[0071] In one aspect of the invention, the method includes electrically coupling the power unit to a traction battery.

[0072] In one aspect of the invention, the method includes integrating an electric propulsion source with a rear beam axle.

[0073] In one aspect of the invention, the method includes electrically coupling an electric propulsion source to a traction battery.

[0074] In one aspect of the present invention, the power unit includes a first motor and a second motor.

[0075] In one aspect of the invention, the first electric machine is a generator and wherein the second electric machine is a traction motor.

[0076] According to the present invention, a vehicle system is provided, the vehicle system having: a front beam axle; a rear beam axle; a first frame longitudinal rail extending between the rear beam axle and the front beam axle; a second frame longitudinal rail extending between the rear beam axle and the front beam axle; a power unit configured to generate electricity via output of an internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; and wherein a torque path through the power unit changes from a front longitudinal direction to a rear longitudinal direction to a rear longitudinal direction to a front longitudinal direction; and a traction battery extending transversely between the first frame longitudinal rail and the second frame longitudinal rail.

[0077] According to an embodiment, the power unit comprises a first electric machine and a second electric machine.

[0078] According to an embodiment, the power unit comprises two planetary gear sets.

[0079] According to an embodiment, the power unit comprises a chain drive.

[0080] According to an embodiment, the power unit comprises a coupling coupling the shock absorber directly to the chain drive.

Claims

1. A vehicle system comprising: Steerable front beam axle; rear beam axle; a first frame rail configured to support a chassis and extending between the rear beam axle and the steerable front beam axle; a second frame rail configured to support the chassis and extending between the rear beam axle and the steerable front beam axle; a power unit configured to generate electricity via an output of the internal combustion engine, the power unit further configured to supply propulsion to front wheels of the vehicle system; as well as A traction battery extends continuously transversely between the first frame rail and the second frame rail.

2. The vehicle system of claim 1 , wherein the traction battery is housed in a bottom housing, and wherein a drive shaft does not extend from the power unit to the rear beam axle.

3. The vehicle system of claim 2, wherein the bottom housing lacks a receptacle for an axle extending at least a portion of the distance between the power unit and the rear beam axle.

4. The vehicle system of claim 3, wherein the bottom housing extends at least sixty percent of the lateral distance between the first frame rail and the second frame rail.

5. The vehicle system of claim 4, wherein the steerable front beam axle includes two kingpins.

6. The vehicle system of claim 4, wherein the bottom housing extends longitudinally between the power unit and the rear beam axle.

7. The vehicle system of claim 1, wherein the rear beam axle includes an electric motor.

8. A method for a vehicle, comprising: mounting a power unit longitudinally in the vehicle and coupling the power unit to a front beam axle, the power unit mounted between a first frame rail and a second frame rail; rear beam axle; as well as A traction battery is mounted between the first frame rail and the second frame rail; wherein the traction battery extends at least sixty percent of a lateral distance between the first frame rail and the second frame rail, the first frame rail extending between the rear beam axle and the front beam axle, and wherein the traction battery is mounted between the rear beam axle and the front beam axle.

9. The method of claim 8, further comprising coupling the power unit to a differential of the front beam axle.

10. The method of claim 9, wherein the power unit is coupled to the differential via a drive shaft.

11. The method of claim 10, further comprising electrically coupling the power unit to the traction battery.

12. The method of claim 11 further comprising integrating an electric propulsion source with the rear beam axle.

13. The method of claim 12, further comprising electrically coupling the electric propulsion source to the traction battery.

14. The method of claim 8, wherein the power unit comprises a first electric machine and a second electric machine.

15. The method of claim 14, wherein the first electric machine is a generator and the second electric machine is a traction motor.

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