Electrified Transfer Case Layout for Hybrid AWD Packaging
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Solution Overview
Problem
Existing hybrid powertrains for four-wheel drive vehicles require significant modifications to the existing powertrain, leading to expensive and difficult packaging due to additional length, and there is a need for a cost-effective solution that integrates conventional powertrain components.
Innovation Solution
An electrified transfer case with a gear set, synchronization member, and controllable clutch system that allows for multiple operating modes, including electric-only, hybrid, and flat tow, utilizing a planetary or layshaft arrangement to distribute power between front and rear axles, with a one-way clutch for smooth transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a P2 hybrid system is integrated with conventional powertrain components, then the vehicle achieves hybrid operation capability, but the packaging complexity and cost increase significantly
Solution Approach 1:
The patent merges the hybrid powertrain integration function into the existing transfer case by adding an electric motor and clutch assembly to the conventional four-wheel drive system. This allows the transfer case to perform both traditional power distribution and hybrid power integration, reducing packaging complexity by consolidating functions into a single component rather than adding separate hybrid integration components
Solution Approach 2:
The electrified transfer case is designed to perform multiple functions: traditional four-wheel drive power distribution, hybrid power integration, and electric-only operation. By making the transfer case a multi-functional component that can operate in conventional mode, hybrid mode, and electric-only mode, the system achieves versatility without requiring separate dedicated components for each function
2Adaptability or versatility
If additional components are added to achieve hybrid operation, then the vehicle gains electric motor propulsion capability, but the packaging space requirements increase
Solution Approach 1:
The electric motor and clutch assembly are nested within the existing transfer case structure. The motor is positioned within the transfer case housing, and the clutch assembly is integrated into the existing gear train, allowing additional components to occupy space within the volume of the conventional transfer case rather than requiring additional external packaging space
3Adaptability or versatility
If a controllable clutch assembly is added to the gear train, then the system achieves multiple operating modes, but the device complexity increases
Solution Approach 1:
The controllable clutch assembly acts as an intermediary component between the electric motor and the existing gear train. It provides a controlled connection or disconnection point that enables mode transitions without requiring complex integration throughout the entire powertrain, simplifying the overall control architecture by introducing a single controllable interface point
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient power distribution and mode transitions, reducing packaging complexity and cost while providing all-wheel drive and four-wheel drive capabilities, along with regenerative braking, in a hybrid vehicle powertrain.
Implementation Method 1
The synchronization member may be a one-way clutch to be utilized when transitioning from electric only to hybrid powered modes
Implementation Method 2
A friction material may be provided on at least one of the clutch plates
Data Source
AI summary
An electrified transfer case for a vehicle having an engine, a transmission, and front and rear drivelines is provided. The electrified transfer case includes a first output shaft adapted for connection to the rear driveline, a second output shaft adapted for connection to the front driveline, and an input shaft connected to the output of the transmission. The transfer case may further include a gear set engaged to an electric motor for torque multiplication, a multi-position torque transferring mode connection system, and a controllable torque transfer system between the first output shaft and the second output shaft. A synchronizing device is operatively connected between the input and first output shaft, which may utilize a one-way clutch.