Vehicle generator module with transmission

Abstract

A vehicle (100) includes a combustion engine (102), a first axle assembly (104) rotationally connected to a first pair of driving wheels (106), and a vehicle generator module (108). The vehicle generator module (108) includes a rotor (110), a stator (114) circumscribing the rotor (110) and arranged for generating an electrical power when the rotor (110) is rotated by the combustion engine (102), a first clutch (116) for selectively rotationally connecting the rotor (110) to the first axle assembly (104), and a second clutch (246) for selectively rotationally connecting the combustion engine (102) to the rotor (110).

Description

VEHICLE GENERATOR MODULE WITH TRANSMISSIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Patent Application Nos. 63 / 656,418, filed June 5, 2024, and 63 / 786,234, filed April 9, 2025, and U.S. Nonprovisional Application No. 19 / 068,014, filed March 3, 2025, the disclosures of which are incorporated in their entirety by reference herein.TECHNICAL FIELD

[0002] The present disclosure relates generally to a vehicle generator module, and more specifically to a vehicle generator module with a transmission.BACKGROUND

[0003] Vehicle driving assemblies are known. One example is shown and described in United States Patent No. 10,844,934 titled VEHICLE DRIVING ASSEMBLY WITH TRANSVERSELY PLACED DOUBLE POWER SOURCES to Yu et al.SUMMARY

[0004] Example embodiments broadly comprise a vehicle including a combustion engine, a first axle assembly rotationally connected to a first pair of driving wheels, and a vehicle generator module. The vehicle generator module includes a rotor, a stator circumscribing the rotor and arranged for generating an electrical power when the rotor is rotated by the combustion engine, a first clutch for selectively rotationally connecting the rotor to the first axle assembly, and a second clutch for selectively rotationally connecting the combustion engine to the rotor.

[0005] In an example embodiment, the combustion engine is arranged transverse to a driving direction of the vehicle. In some example embodiments, the vehicle also includes a first transmission arranged in a torque path between the rotor and the first clutch or the second clutch. In some example embodiments, the first transmission is a single speed transmission. In some example embodiments, the rotor rotates about a first axis, the first transmission includes a gear that rotates about a second axis, parallel to and radially offset from the first axis, and the first axle assembly includes a differential assembly that rotates about a third axis. The third axis is parallel to and radially offset from the first axis, and parallel to and radially offset from the second axis. In an example embodiment, the first clutch rotates about the first axis, and the second clutch rotates about the first axis.

[0006] In an example embodiment, the rotor includes a rotor carrier, the first clutch includes a plurality of first clutch plates drivingly engaged with the rotor carrier, and thesecond clutch includes a plurality of second clutch plates drivingly engaged with the rotor carrier. In an example embodiment, the first clutch is hydraulically applied, and the second clutch is hydraulically applied. In some example embodiments, the vehicle also includes a second transmission arranged in a torque path between the first clutch or the second clutch, and the rotor. In an example embodiment, the second transmission is a single speed transmission.

[0007] In some example embodiments, the combustion engine is arranged aligned to a driving direction of the vehicle. In some example embodiments, the vehicle also includes a drive shaft arranged in a torque path between the first clutch and the first axle assembly. In an example embodiment, the drive shaft is arranged aligned to the driving direction of the vehicle. In some example embodiments, the vehicle also includes a transmission arranged in a torque path between the first clutch and the drive shaft. In an example embodiment, the transmission is a single speed transmission. In an example embodiment, the transmission includes a belt drive or a chain drive.

[0008] In an example embodiment, the first axle assembly is arranged at a front of the vehicle. In an example embodiment, the vehicle also includes a second axle assembly rotationally connected to a second pair of driving wheels, and an electric motor arranged for propelling the vehicle via the second axle assembly. In an example embodiment, the second axle assembly is arranged at a rear of the vehicle.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 illustrates a schematic view of a vehicle propulsion arrangement according to a first example embodiment.

[0010] Figure 2 illustrates a schematic view of an alternative embodiment of the vehicle propulsion arrangement of Figure 1.

[0011] Figure 3 illustrates a cross-sectional view of a transmission module of the vehicle propulsion arrangement of Figure 2.

[0012] Figure 4 illustrates a schematic view of a vehicle propulsion arrangement according to a second example embodiment.

[0013] Figure 5 illustrates a schematic view of a vehicle propulsion arrangement according to a third example embodiment.DETAIEED DESCRIPTION

[0014] Embodiments of the present disclosure are described herein. It should be appreciated that like drawing numbers appearing in different drawing views identify identical, or functionally similar, structural elements. Also, it is to be understood that thedisclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the embodiments. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations.

[0015] The terminology used herein is for the purpose of describing particular aspects only, and is not intended to limit the scope of the present disclosure. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although any methods, devices or materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the following example methods, devices, and materials are now described.

[0016] The following description is made with reference to Figure 1. Figure 1 illustrates a schematic view of a vehicle propulsion arrangement according to an example embodiment. Vehicle 100 includes combustion engine 102, axle assembly 104 rotationally connected to driving wheels 106 and vehicle generator module 108. The generator module includes rotor 110 rotationally connected to the combustion engine via shaft 112, for example, stator 114 circumscribing the rotor and arranged for generating an electrical power when the rotor is rotated by the combustion engine, and clutch 116 for selectively rotationally connecting the rotor to the first axle assembly as described in more detail below. Fuel from combustion engine 102 is provided by fuel tank 117 through fuel line 118. Although not shown, some embodiments may include a damper on shaft 112 to isolate combustion engine vibrations from the rotor.

[0017] The clutch operates to rotationally connect and disconnect the combustion engine from the axle assembly, but rotor 110 always remains connected to the engine. Clutch 116 may be a normally closed clutch in which an external operator (not shown) is required to disengage the engine from the axle assembly, or a normally open clutch in which an operator(not shown) is required to engage the engine with the axle assembly. The clutch operator may be a hydraulic piston, an electrohydraulic device, or an electric actuator, for example. Some embodiments may include a mechanical clutch operator manually engaged by a vehicle driver, for example.

[0018] Vehicle 100 also includes transmission 119 arranged in a torque path between the clutch and axle assembly 104. In the embodiment shown, transmission 119 is a single speed transmission. That is, the transmission includes pinion gear 120 driven by shaft 122, connected to the clutch, and spur gear 124 connecting the pinion gear to differential 126 of axle assembly 104. Although transmission 119 is shown as a pinion-spur transmission, other arrangements are possible. For example, other embodiments (not shown) may include transmission 119 as a planetary gear transmission with a chain or belt drive to the differential. The generator module, transmission and differential may be enclosed within a common housing (not shown).

[0019] As shown in the single figure, the combustion engine is arranged transverse to driving direction 128 of the vehicle and axle assembly 104 is arranged at a front of the vehicle, similar to the arrangement found in non-hybrid front- wheel-drive (FWD) vehicles. Other embodiments (not shown) may include the combustion engine and axle assembly 104 mounted at a rear of the vehicle as is common in some sports cars, for example.

[0020] Vehicle 100 also includes battery 130 for receiving the electrical power from the stator via electrical connections 131 and 132, and converter 134 for converting an alternating current (AC) from the stator into a direct current (DC) for the battery. That is, due to configuration of the generator module, the alternating current output cannot be stored directly into the batter because the battery only stores direct current. Hence, the converter is arranged in the power flow between the stator and the battery to convert the electrical power into a form that can be accepted by the battery.

[0021] Vehicle 100 also includes axle assembly 136 rotationally connected to driving wheels 138, and electric motor 140 arranged for propelling the vehicle via axle assembly 136. Electric motor 140 may be coaxial to axle assembly 136 and drivingly connected to the axle assembly via a planetary transmission, or radially offset from the axle assembly and drivingly connected via a pinion-spur gear arrangement similar to transmission 119 described above. In the embodiment shown, axle assembly 136 is arranged at a rear of vehicle 100 although axle assembly 136 may be arranged at a front of the vehicle in other embodiments (not shown) where axle assembly 104 is a rear axle, for example.

[0022] Motor 140 is electrically connected to battery 130 through inverter 142 and electrical connection 144. Opposite to converter 134 described above, inverter 142 inverts a direct current from the battery into an alternating current for the electric motor. That is, the electric motor may be an AC (e.g., three-phase) induction motor that generally operates more efficiently than a DC motor and the inverter provides the electrical power in a form that the motor can accept. The inverter may also include circuitry to adjust the electrical power to control vehicle speed, for example. Thus, there is no mechanical connection between front and rear tires and only an electrical connection between front and rear drive systems. Thus, vehicle 100 includes exactly one combustion engine, exactly one generator module and converter, and exactly one electric motor and inverter, while still providing power to both axles when required.

[0023] Operation of vehicle 100 will now be described. During normal operation of vehicle 100, the vehicle may be propelled by electric motor 140 via axle assembly 136. Power from battery 130 provides DC current that is inverted to AC current by inverter 142. Combustion engine 102 may be operated to rotate rotor 110 in stator 114 to provide additional power to the battery via converter 134. Under a high battery power demand (e.g., towing a trailer up an incline) or if the battery is depleted to a point where power from the generator module is insufficient to propel the vehicle through motor 140 due to sizing of the generator module and / or conversion losses through the converter and inverter, for example, clutch 116 may be engaged to rotationally connect the combustion engine to axle assembly 104 to provide additional propulsion. Clutch 116 may also be engaged in certain operating conditions when additional traction is required to provide an all-wheel-drive (AWD) or a four-wheel-drive (4WD) mode, for example, or to provide a fail-safe, limp-home mode to get the vehicle to a charging station or to a repair facility due to failure of the electric motor or axle assembly 136, for example.

[0024] The following description is made with reference to Figures 2-3. Figure 2 illustrates a schematic view of an alternative embodiment of the vehicle propulsion arrangement of Figure 1. Figure 3 illustrates a cross-sectional view of a transmission module of the vehicle propulsion arrangement of Figure 2. The configuration of vehicle 200 generally corresponds to vehicle 100 described above with 2XX reference numerals corresponding to 1XX reference numerals, except as described below. Vehicle 200 includes clutch 246 for selectively rotationally connecting combustion engine 102 to rotor 210. Vehicle 200 also includes transmission 219 arranged in a torque path between rotor 210 and clutch 216. As shown in the figure, transmission 219 is a single speed transmission.

[0025] As best shown in Figure 3, for example, rotor 210 rotates about axis 250, transmission 219 includes gear 224 that rotates about axis 254, parallel to and radially offset from axis 250, and axle assembly 204 includes differential assembly 226 that rotates about axis 256. Axis 256 is parallel to and radially offset from axis 250, and parallel to and radially offset from axis 254. Clutch 216 rotates about axis 250 and clutch 246 rotates about axis 250. Rotor 210 includes rotor carrier 258, clutch 216 includes clutch plates 260 drivingly engaged with the rotor carrier, and clutch 246 includes clutch plates 262 drivingly engaged with the rotor carrier. Clutch 216 is hydraulically applied (via piston 264, for example) and clutch 246 is hydraulically applied (via piston 266, for example).

[0026] The following description is made with reference to Figure 4. Figure 4 illustrates a schematic view of a vehicle propulsion arrangement according to a second example embodiment. The configuration of vehicle 300 generally corresponds to vehicles 100 and 200 described above with 3XX reference numerals corresponding to 1XX and 2XX reference numerals, except as described below. Vehicle 300 also includes transmission 368 arranged in a torque path between clutch 316 and clutch 346, and rotor 310. As shown in the figure, transmission 368 is a single speed transmission.

[0027] The following description is made with reference to Figure 5. Figure 5 illustrates a schematic view of a vehicle propulsion arrangement according to a third example embodiment. The configuration of vehicle 400 generally corresponds to vehicles 100, 200 and 300 described above with 4XX reference numerals corresponding to 1XX, 2XX and 3XX reference numerals, except as described below. Vehicle 400 includes combustion engine 402 arranged aligned to a driving direction of the vehicle. Vehicle 400 also includes drive shaft 470 arranged in a torque path between clutch 416 and axle assembly 404. Drive shaft 470 is arranged aligned to the driving direction of the vehicle. Vehicle 400 also includes transmission 419 arranged in a torque path between clutch 416 and the drive shaft. As shown in the figure, transmission 419 is a single speed transmission. Transmission 419 includes a belt drive or a chain drive indicated by dashed portion 472.

[0028] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the disclosure that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or beingpreferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, to the extent any embodiments are described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics, these embodiments are not outside the scope of the disclosure and can be desirable for particular applications.REFERENCE NUMERALS

[0029] 100, 200, 300, 400 Vehicle

[0030] 102, 402 Combustion engine

[0031] 104, 204, 404 Axle assembly (first)

[0032] 106 Driving wheels (first)

[0033] 108 Vehicle generator module

[0034] 110, 210, 310 Rotor

[0035] 112 Shaft (rotor to combustion engine)

[0036] 114 Stator

[0037] 116, 216, 316, 416 Clutch (first, rotor to first axle assembly)

[0038] 117 Fuel tank

[0039] 118 Fuel line

[0040] 119, 219, 419 Transmission (first)

[0041] 120 Pinion gear (transmission)

[0042] 122 Shaft (clutch to pinion gear)

[0043] 124, 224 Spur gear (transmission)

[0044] 126, 226 Differential (first axle assembly)

[0045] 128 Driving direction

[0046] 130 Battery

[0047] 131 Electrical connection (stator to converter)

[0048] 132 Electrical connection (converter to battery)

[0049] 134 Converter

[0050] 136 Axle assembly (second)

[0051] 138 Driving wheels (second)

[0052] 140 Electric motor

[0053] 142 Inverter

[0054] 144 Electrical connection (inverter to battery)

[0055] 246, 346 Clutch (second, combustion engine to rotor)

[0056] 250 Axis (first, rotor)

[0057] 254 Axis (second, gear)

[0058] 256 Axis (third, differential)

[0059] 258 Rotor carrier

[0060] 260 Clutch plates (first clutch)

[0061] 262 Clutch plates (second clutch)

[0062] 264 Piston (first clutch)

[0063] 266 Piston (second clutch)

[0064] 368 Transmission (second)

[0065] 470 Drive shaft

[0066] 472 Dashed portion (belt or chain)

Claims

WHAT IS CLAIMED IS:

1. A vehicle (100), comprising: a combustion engine (102); a first axle assembly (104) rotationally connected to a first pair of driving wheels (106); and a vehicle generator module (108) comprising: a rotor (110); a stator (114) circumscribing the rotor (110) and arranged for generating an electrical power when the rotor (110) is rotated by the combustion engine (102); a first clutch (116) for selectively rotationally connecting the rotor (110) to the first axle assembly (104); and a second clutch (246) for selectively rotationally connecting the combustion engine (102) to the rotor (110).

2. The vehicle (100) of claim 1 wherein the combustion engine (102) is arranged transverse to a driving direction (128) of the vehicle (100).

3. The vehicle (100) of claim 1 further comprising a first transmission (119) arranged in a torque path between: the rotor (110); and the first clutch (116) or the second clutch (246).

4. The vehicle (100) of claim 3 wherein the first transmission (119) is a single speed transmission.

5. The vehicle (100) of claim 4 wherein: the rotor (110) rotates about a first axis (250); the first transmission (119) comprises a gear (224) that rotates about a second axis (254), parallel to and radially offset from the first axis (250); andthe first axle assembly (104) comprises a differential assembly (126) that rotates about a third axis (256): parallel to and radially offset from the first axis (250); and parallel to and radially offset from the second axis (254).

6. The vehicle (100) of claim 5 wherein: the first clutch (116) rotates about the first axis (250); and the second clutch (246) rotates about the first axis (250).

7. The vehicle (100) of claim 1 wherein: the rotor (110) comprises a rotor carrier (258); the first clutch (116) comprises a plurality of first clutch plates (260) drivingly engaged with the rotor carrier (258); and the second clutch (246) comprises a plurality of second clutch plates (262) drivingly engaged with the rotor carrier (258).

8. The vehicle (100) of claim 1 wherein: the first clutch (116) is hydraulically applied; and the second clutch (246) is hydraulically applied.

9. The vehicle (100) of claim 1 further comprising a second transmission (368) arranged in a torque path between: the first clutch (116) or the second clutch (246); and the rotor (110).

10. The vehicle (100) of claim 9 wherein the second transmission (368) is a single speed transmission.

11. The vehicle (100) of claim 1 wherein the combustion engine (402) is arranged aligned to a driving direction (128) of the vehicle (100).

12. The vehicle (100) of claim 11 further comprising a drive shaft (470) arranged in a torque path between the first clutch (116) and the first axle assembly (104).

13. The vehicle (100) of claim 12 wherein the drive shaft (470) is arranged aligned to the driving direction (128) of the vehicle (100).

14. The vehicle (100) of claim 12 further comprising a transmission (419) arranged in a torque path between the first clutch (116) and the drive shaft (470).

15. The vehicle (100) of claim 14 wherein the transmission (419) is a single speed transmission.

16. The vehicle (100) of claim 14 wherein the transmission (419) comprises a belt drive or a chain drive.

17. The vehicle (100) of claim 1 wherein the first axle assembly (104) is arranged at a front of the vehicle (100).

18. The vehicle (100) of claim 1 further comprising: a second axle assembly (136) rotationally connected to a second pair of driving wheels (138); and an electric motor (140) arranged for propelling the vehicle (100) via the second axle assembly (136).

19. The vehicle (100) of claim 12 wherein the second axle assembly (136) is arranged at a rear of the vehicle (100).

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