Gm Global Technolgoy Operations, Inc.

Borgwarner Inc.

Keith D Van Maanen

Chandra S Namuduri

Roger Joseph Rademacher

Suresh Gopalakrishnan

Joel M Maguire

Craig J Hawkins

Bryan M Ludwig

Chengyun Guo

Christopher E Whitney

William Conrad Albertson

William Leonard Aldrich, Iii

Mike M McDonald

Matthew D Whitton

Bon Ho Bae

Sean E Gleason

Mark Buchanan

James E Tarchinski

Brian M Porto

Adam J Heisel

R Keith Martin

Steven A Tarnowsky

Christopher Spangler

Addison T Solak

Donald D Crites

Steven V Wybo

David Gordon Evans

Thomas J Foster

William J Omell

Eric Brian Schutt

Michael Chernyak

Jeffrey Kenneth Baran

Michael E Polom

Ryan M Meroz

A vehicular drive unit for a battery electric vehicle (BEV) includes an electric motor, for propelling the BEV, having an output shaft; a planetary gearbox, having an input and an output; a sprocket coupled to an output of the electric motor or an input of the planetary gearbox; and an endless loop rotatably coupled with the sprocket and the input of the planetary gearbox thereby configured to transmit rotational movement of the output shaft of the electric motor to a drive shaft of the BEV, wherein an axis of rotation of the drive shaft of the BEV is offset from an axis of rotation of the output shaft of the electric motor.

Modular electric vehicle drive module

An assembly for an electric vehicle includes an input shaft extending along a first axis and an electric motor rotatably coupled to the input shaft and co-axially aligned with the first axis. The assembly also includes an intermediate input shaft extending along a second axis and rotatably coupled to the input shaft. The assembly also includes an output shaft extending along the second axis and spaced from the intermediate input shaft along the second axis. The assembly further includes a planetary gearset rotatably coupled to the intermediate input shaft and to the output shaft, and co-axially aligned with the second axis. The assembly includes a final drive co-axially aligned with the first axis and rotatably coupled to the output shaft for providing rotational torque to at least one of a first and second set of wheels of the electric vehicle.

Assembly for use in an electric vehicle

A transmission system includes a transmission housing and a countershaft having no less than two gears, with the gears defining a plurality of gear ratios. The transmission system also includes a module housing, a first output shaft rotatably coupled to the countershaft, and a second output shaft rotatably coupled to the countershaft. The transmission system further includes a first clutch configured to selectively rotatably couple the first output shaft to the countershaft. The transmission system also includes a second clutch configured to selectively rotatably couple the second output shaft to the countershaft. The transmission system further includes an electric machine configured to deliver rotational power to at least one of the first and second output shafts to deliver rotational power to the countershaft. The countershaft is rotatably coupled to either of the first and second output shafts for all of the gear ratios.

Transmission system for use in a vehicle

A transmission system includes an input shaft, a transmission housing, and a planetary gear system rotatably coupled to the input shaft. The planetary gear system has a first and second gear ratio. The transmission system additionally includes an output shaft, a first electric machine, a second electric machine, and a shifting assembly. The shifting assembly includes a first stationary clutch element and a second stationary clutch element. The first electric machine is configured to apply rotational torque to the planetary gear system to synchronize rotational speed of the planetary gear system when moving between the first and second gear ratios, and the second electric machine is configured to provide rotational torque to the output shaft when the first electric machine applies rotational torque to the planetary gear system to synchronize rotational speed of the planetary gear system when moving between the first and second gear ratio.

Transmission system for use in a hybrid vehicle and method of controlling the same

A method of executing a downshift in a fixed-gear powertrain having an input node and an output node related by a starting speed ratio before the downshift and a finishing speed ratio after is provided. The downshift includes a torque phase and an inertia phase. A starting output torque is calculated as a function of a starting driver request. An electric machine applies a starting regenerative input torque which is calculated as substantially equal to the starting output torque divided by the starting speed ratio. A finishing output torque is calculated as a function of a finishing driver request. The electric machine applies a finishing regenerative input torque which is calculated as substantially equal to the finishing output torque divided by the finishing speed ratio.

Negative-torque downshift execution for fixed-gear transmissions

A vehicle includes an engine having autostart functionality, a source of fluid pressure when the engine is off, a flow control solenoid that outputs a variable clutch pressure, a transmission, an electric motor, and a controller. The transmission includes a clutch in fluid communication with the solenoid. The clutch applies via the clutch pressure to establish a first gear launch state. The motor is powered via a rechargeable energy storage system. The controller executes a method to transmit pulse width modulation (PWM) control signals to the solenoid upon detection of a set of conditions triggering the autostart event to lower clutch pressure to a first calibrated level. Restart of the engine is commanded, and the clutch pressure increases toward a second calibrated level while engine speed is increasing. The controller discontinues the PWM control signals and increases clutch pressure to line pressure when the input speed exceeds a calibrated threshold.

Transmission oil pressure control during engine autostart

A powertrain system includes an electric motor/generator unit. Upon detecting an open high-voltage switch associated with a high-voltage DC electrical bus, low-voltage electrical power is employed to energize the high-voltage DC electrical bus, control parameters are adjusted to operate the electric motor/generator unit in a fault tolerant electric generation mode, an internal combustion engine is operated to spin the electric motor/generator unit, and the electric motor/generator unit is operated in the fault tolerant electric generation mode.

Method and apparatus to operate a powertrain system including an electric machine having a disconnected high-voltage battery

A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV device having HVIL source and return (SR) pins and an HV receptacle, an HV cable, and an HV terminal assembly. The assembly includes a tray portion and retainer for aligning the HV cables with the HV receptacle. An HVIL jumper device is connected to the tray portion and electrically connectable to the HVIL SR pins. The assembly includes a cover portion removably mountable to the tray portion to provide a suitable EMF shield and weather seal. The cover portion includes an HVIL shorting plug. HV electrical energy is supplied from said ESS to the HV device only when all three of the HVIL components, i.e., the HVIL SR pins, the HVIL jumper device, and the HVIL shorting plug, are electrically interconnected to form a closed HVIL circuit, while at the same time the HV cable is properly connected.

High-voltage terminal assembly with integral high-voltage interlock

A hybrid powertrain system includes an electric motor/generator unit having a multiphase asynchronous AC machine electrically connected to a multiphase bridge inverter. A high-voltage capacitor is electrically connected between positive and negative sides of a high-voltage DC power bus. High-voltage DC bus pre-charge circuits are electrically connected between gate drive bias power supplies and the multiphase bridge inverter. A low-voltage battery electrically charges the high-voltage DC link capacitor via the gate drive bias power supplies and the high-voltage DC bus pre-charge circuits when the high-voltage energy storage system is disconnected from the high-voltage DC power bus.

Control of an alternator-starter for a hybrid electric vehicle having a disconnected high-voltage battery

A system includes an auxiliary pump that provides pressurized fluid to a transmission during an engine auto stop/start event. A mechanical pump provides pressurized fluid to a transmission during engine operation after the engine auto stop/start event. An auxiliary pump diagnostic system includes a slip determination module that determines slip of a torque converter based on an engine speed and a transmission input speed. A fault determination module diagnoses a fault in the auxiliary pump in response to an engine auto start and based on the slip of the torque converter.

Auxiliary pump diagnostic systems and methods

A method for determining the thermal efficiency of a heat sink for an electrical component includes determining an estimated temperature of the heat sink, determining an actual temperature of the heat sink, and determining a thermal efficiency of the heat sink based on a comparison of the estimated temperature of the heat sink to the actual temperature of the heat sink. A related diagnostic system is provided.

Air-cooled power electronics service algorithm

A method sustains auxiliary power generation aboard a mild hybrid electric vehicle (HEV) in response to a high-voltage (HV) electrical fault condition and executes one of a pair of default limp-home modes depending on the state of the engine at the time of the fault. Each limp-home mode sustains auxiliary power generation during the fault, and at least one mode charges capacitors in the HV bus circuit to provide magnetizing current to a motor generator unit (MGU). An HEV includes a controller and algorithm for sustaining auxiliary power generation during the above fault condition, with the algorithm adapted to control output of an auxiliary power module (APM) and execute one of a pair of default limp-home modes, including a mode in which the APM charges the capacitors to enable a power inverter module (PIM) to provide an initial excitation current to the MGU after the starter motor restarts the engine.

Control of a starter-alternator during a high-voltage battery fault condition

A method for variable operation of a vehicle transmission using rough road sensing includes defining a first set of parameters to calibrate the vehicle transmission for a smooth road condition and a second set of parameters to calibrate the vehicle transmission for a rough road condition. The method includes sensing a road condition, generating a road condition signal corresponding to the road condition, and measuring a magnitude of the road condition signal. The method includes switching from the first set of parameters to the second set of parameters to operate the vehicle transmission when the magnitude of the road condition signal exceeds a first predetermined threshold. The method includes switching from the second set of parameters to the first set of parameters to operate the vehicle transmission when the magnitude of the road condition signal is less than a second predetermined threshold that is different than the first predetermined threshold.

Variable operation of vehicle transmissions using rough road sensing

A powertrain includes a rotary input member such as an engine crankshaft, a torque coupling such as a hydraulic torque converter, a drive plate, such as a flex plate or spider, connecting the input member to the coupling, and an annular generator rotor having an electrical power annulus, such as an annular induction member extending around the coupling, and a mounting ring fixed to the power annulus and including means extending inward for securing the mounting ring to the coupling and to the drive plate. Several embodiments of mounting rings and assemblies are disclosed which improve methods for assembly of the powertrain.

Powertrain with motor generator rotor having torque transmission mounting ring

A hybrid powertrain has an internal combustion engine, a power transmission and an electric drive. The electric drive includes a stator secured in the housing of the power transmission and a rotor secured to the outer periphery of the torque converter of the power transmission. Both the rotor and the impeller of the torque converter are directly connected with the engine. A torque converter clutch is disposed for selective engagement between the impeller and turbine of the torque converter.

Growing community of inventors

Birmingham, MI, United States of America

Keith D Van Maanen