Transfer Case Hybrid Powertrain for Flexible Power Diversion
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Solution Overview
Problem
Existing hybrid powertrains for commercial vehicles lack flexibility in power transfer modes and efficiency in energy management, particularly in auxiliary charge and hybrid operating modes, limiting their fuel economy and adaptability.
Innovation Solution
A hybrid powertrain with a vehicle-mounted electric motor-generator system and a transfer case assembly that allows for various operating modes, including direct power transfer, auxiliary charge, and hybrid drive modes, utilizing a torque transfer housing and axle disconnects to manage power distribution between the engine, transmission, and driven axles, with an onboard storage medium for energy management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional hybrid powertrain is used, then the vehicle can operate in multiple modes (engine-only, electric-only, hybrid), but the system lacks flexibility in power transfer modes and efficiency in energy management
Solution Approach 1:
The transfer case is designed with a two-way input/output port that allows the electric motor-generator to function in multiple roles: it can receive power from the engine to drive the front axle, or it can generate power from the front axle to charge the battery. This multi-functional design enables the system to operate in various modes (direct power transfer, auxiliary charge, hybrid drive) without requiring separate dedicated components for each function, thereby improving adaptability while managing complexity.
Solution Approach 2:
The system employs dynamically controllable axle disconnects that can selectively engage or disengage power transfer paths between the engine, transmission, electric motor-generator, and driven axles. This dynamic reconfiguration capability allows the powertrain to adapt its power transfer mode in real-time based on operating conditions, enabling flexible switching between different operational modes without permanent structural changes.
2Adaptability or versatility
If the electric motor-generator is integrated into the transfer case, then power can be diverted to driven axles and external circuits, but the system complexity increases with multiple axle disconnects and ports
Solution Approach 1:
The electric motor-generator is integrated directly into the transfer case assembly, merging what would otherwise be separate components. The motor-generator is positioned within the transfer case housing and connected to the existing power transfer paths, allowing it to utilize the same mechanical interface for both driving the front axle and generating electrical power. This consolidation reduces the number of separate components and simplifies the overall system architecture.
Solution Approach 2:
The two-way input/output port serves multiple functions: it can transmit mechanical power from the electric motor-generator to the front drive shaft, or it can transmit mechanical power from the front drive shaft to the electric motor-generator for electrical generation. This universal interface eliminates the need for separate dedicated ports for motor and generator functions, reducing complexity while maintaining power diversion capability.
3Adaptability or versatility
If multiple axle disconnects are used to control power flow, then operating mode flexibility is improved, but the device complexity and potential failure points increase
Solution Approach 1:
The axle disconnects are designed as dynamically controllable components that can engage or disengage based on real-time operating conditions and control signals. This dynamic control allows the system to optimize power flow paths for different operating modes (engine-only, electric-only, hybrid, auxiliary charge) while maintaining the ability to revert to simpler configurations if needed, balancing flexibility with reliability.
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
Enhances fuel efficiency and adaptability by enabling multiple power transfer modes, allowing regenerative energy capture and storage, and providing a mobile power source for external use, such as charging other vehicles.
Implementation Method 1
an onboard electric motor-generator system that acts as each of a modular drive unit and/or a generator to divert power to one or more of the driven axles of the vehicle and/or an external circuit
Implementation Method 2
an onboard storage medium such as a battery
Data Source
AI summary
A hybrid powertrain with a vehicle-mounted electric motor-generator and a transfer case assembly configured to control the transfer of power from the vehicle engine and transmission and an on-board electric motor-generator to the respective driven axles is provided. The transfer case assembly allows the hybrid powertrain to be capable of operating in a variety of operating modes including modes wherein the vehicle, at idle with the engine running, may supply power or rotational torque from the engine to the onboard electric motor-generator to power to an external payload or charge an onboard storage medium, and/or while driving or in motion, the engine powers the driven axle(s), but also provides additional power or rotational torque, in excess of that required to power or drive the driven axles, to the onboard electric motor-generator, such that the electric motor-generator may supply power to or charge the onboard storage medium.