Dual mode continuously variable transmission for a all wheel drive vehicle

Abstract: An automatic transmissiorn for an automotive vehicle includes a continually variable drive mechanism (16) having one sheave assembly (54,56) fixed to an input shaft (12) and an output sheave assembly (58,60) supported on an intermediate shaft (26), a low speed gearset (22) driveably connected to the input shaft (12) and an output shaft (14), a fixed ratio drive mechanism (18) in the form of a chain drive providing a torque delivery path between the intermediate shaft (26) and the output shaft (14), a transfer clutch (102) for connecting and releasing the first sheave assembly (54,56) of the variable drive mechanism (16) and the input shaft (12), a low clutch (98), a reverse gearset (20), and a reverse clutch (100) for connecting and releasing alternately the output shaft (14) and the reverse gearset (20), and a clutch (104) for selectively driveably connecting the output of the fixed ratio drive mechanism and a front output shaft (15).

Description: This invention relates to automatic transmissions for automotive vehicles. More particularly it pertains to such transmissions having a fixed ratio drive mechanism and a variable ratio drive mechanism. A conventional multiple speed transmission has a number of spaced speed ratio changes produced by selectively holding and releasing components of a planetary gear set. An infinitely variable transmission that employs two variable diameter pulleys, and a drive belt engaging the pulleys provides a continuously variable speed ratio over a broad range of engine speeds. A bladed hydrokinetic torque converter located in the drive path between an engine and the planetary gearing provides additional torque multiplication for accelerating a motor vehicle from rest. A stall torque ratio of about 2.5:1 may be realised using a torque converter. A continuously variable transmission combining a fixed drive unit, variable drive unit, and torque converter is described in UK Patent application GB-2180020, assigned to the assignee of the present invention. After the torque converter reaches its coupling phase, when the ratio of the hydrokinetic unit is 1:1, the drive ratio for the powertrain is reduced to 8:1 from approximately 20:1 when the fixed drive ratio is 2:1 and the final drive and axle system ratio is 4:1. At that time the variable ratio drive is activated. Upon further acceleration of the vehicle, the overall transmission ratio may be controlled from 8:1 down to 2:1. U.S. Patents 4,856,369, 4,836,049 and 3,203,277 describe continually variable transmissions that employ a variable drive mechanism and a fixed drive mechanism in combination with a torque converter and planetary gearing. U.S. Patent 4,294,137 discloses a transmission with a variator which can be disconnected at high vehicle speed by engaging a constant-ratio direct drive. The transmission comprises an input shaft, an intermediate shaft and an output shaft. A variable ratio drive mechanism or variator has its input connected to the input shaft and its output connected to the intermediate shaft to produce a continuously variable ratio of the input speed to the output speed. In addition, a fixed ratio drive mechanism is provided that has a first element driveably connected to the intermediate shaft drive and a second element driveably connected to the first element and to the output shaft. A first gearset is driveably connected to the input shaft and the output shaft. A transfer clutch alternately driveably connects and disconnects the input of the variable ratio drive mechanism and the input shaft while a clutch alternately driveably connects and disconnects an element of the first gearset and the input shaft. The transmission of the present invention differs from that of U.S. Patent No. 4,294,137 in that the fixed ratio drive mechanism includes a first sprocket driveably fixed to the output shaft, a second sprocket driveably fixed to the intermediate shaft, and a flexible continuous element driveably engaging the two sprocket wheels. A transmission embodying this invention has an advantage that it is able to accelerate a motor vehicle from rest through a speed reduction drive that bypasses a belt driven variable ratio drive mechanism so that the relatively large starting torque is carried by robust mechanical components and not by torque limited components, such as a drive belt. The transmission produces a continuously variable speed ratio over a range from the first gear (starting gear) ratio to the highest ratio, an overdrive ratio. The transmission is optionally able to drive both front and rear wheels from two output shafts and without need for a transfer case to divide output torque carried on a single output shaft and to transmit torque to front and rear driveshafts. The invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a schematic diagram of the kinematic arrangement for an automatic transmission according to the present invention; and Figure 2 is a chart showing the engaged and disengaged state of clutches and brakes of the transmission of Figure 1. Referring first to Figure 1, a continuously variable transmission according to this invention includes an input shaft 12, rear output shaft 14, front output shaft 15, variable ratio drive mechanism 16, fixed ratio drive mechanism 18, layshaft reverse gearing 20, layshaft gearset 22, and various clutches for controlling the mechanical elements of the transmission. Fixed ratio drive mechanism 18 driveably connects output shaft 14, which rotatably supports a first sprocket wheel 24, and intermediate shaft 26, which supports a second sprocket wheel 28, sprockets 24, 28 being mutually driveably engaged through a chain 30. Alternatively, but not claimed in this application, shaft 26 can be driveably connected to shaft 14 through another fixed ratio gear mechanism, such as a simple layshaft arrangement including gears in place of sprockets 24, 28 and an idler gear meshing with those gears so that shaft 26 turns in the same direction as shaft 14. The first sprocket 24 is fixed to and rotatably supported on shaft 14; the second sprocket 28 is fixed to and rotatably supported on intermediate shaft 26. Preferably the speeds of sprockets 24 and 23 are substantially equal. The engine crankshaft 40 is driveably connected to a hydrokinetic torque converter 46 that includes a bladed impeller wheel 42 arranged in a toroidal fluid flow path with a bladed turbine wheel 44, arranged to be driven hydrodynamically by fluid exiting the impeller wheel. A bladed stator wheel 48 is located in the flow path between fluid entrance to the impeller and the fluid exit of the turbine. A one-way clutch 50 rotatably supports the stator wheel in one direction about the axis of shaft 12. In a conventional way the torus of the torque converter is filled with hydraulic fluid and the turbine wheel 44, is supported rotatably on a turbine hub 52, which is connected driveably to input shaft 12. A hydraulically operated bypass clutch 54 alternately mechanically connects engine shaft 40 to input shaft 12 when clutch 54 is engaged, and allows shaft 40 to drive the impeller hydraulically when clutch 54 is disengaged. The torque converter produces torque amplification and speed reduction until it reaches coupling speed. Input shaft 12 is connected, preferably through torque converter 46, to a source of power, such as an internal combustion engine or electric motor. Rear output shaft 14 is driveably connected to the drive wheels of a motor vehicle, preferably to the rear wheels. Front output shaft 14 is driveably connected to the drive wheels of a motor vehicle, preferably to the front wheels. Alternatively, output shaft 14 can be connected to the front axles, and output shaft 15 can be connected to the rear axles. Variable ratio drive mechanism 16 includes a first sheave assembly, which includes pulleys 54, 56 supported rotatably on input shaft 12, and a second sheave assembly, which includes pulleys 58, 60 supported rotatably on intermediate shaft 26. The axial position of one of the first pair of pulleys 54, 56 is fixed on the input shaft, the other pulley of the pair is moveable axially along the shaft, preferably in response the hydraulic pressure applied to an actuating device, so that the radial position of the drive belt 62 moves in accordance with the axial position of the axially displaceable pulley due to the inclined surfaces of the pulley faces that engage driveably the lateral surfaces of the drive belt 62. Similarly, one of the pulleys 58, 60 on shaft 26 is fixed in its axial position, and the other pulley is axially displaceable so that the inclined inner faces of the pulleys are continually engaged at a variable radial position on the lateral surfaces of drive belt 62. Movement of the displaceable pulleys is mutually co-ordinated so that they maintain driving contact with the belt. In this way the speed ratio produced by mechanism 16 is continuously variable. The layshaft gearset 22 includes a pinion 63 coaxial with input shaft 12; a gear 64, supported by a overrunning clutch 66 on shaft 14; and an idler 68, driveably engaged continually with the pinion and gear. Idler 68 causes the rotational direction of gear 64 to be the same as that of the engine. Overrunning clutch 66 provides a one-way drive connection of gear 64 and shaft 14. Alternatively gear 64 may be rotatably fixed to shaft 14 without use of clutch 66. The reverse gearset includes a pinion 70 fixed to shaft 12, and a gear 72 in continuous meshing engagement with pinion 70 and journalled on shaft 14. Consequently gear 72 rotates in the opposite direction from that of the engine and shaft 12. The elements of the transmission according to this invention are controlled operatively by various clutches and brakes, preferably hydraulically actuated friction devices, including low clutch 98, reverse clutch 100, transfer clutch TRF 102, and torque on demand (TOD) clutch 104. These clutches may be hydraulically, mechanically or electrically operated. Low clutch 98 alternately driveably connects and releases pinion 63 and shaft 12; reverse clutch 100 alternately driveably connects and releases reverse gear 72 and shaft 14; transfer clutch TRF 102 alternately driveably connects and releases pulleys 54, 56 and shaft 12; and torque on demand (TOD) clutch 104 alternately driveably connects and releases shafts 26 and 15. First gear is produced by engaging low clutch 98 and releasing all the other friction elements, except that clutch 104 is engaged when both front and rear axles are driven, as discussed below. The rear wheels are driven by shaft 14 at a reduced speed in relation to that of shaft 12 through operation of pinion 63 and gear 64, and in the same direction as that of shaft 12 due to the effect of idler 68. Gear 64 is connected to sprocket 24 either directly through shaft 14, to which sprocket 64 is fixed, or through overrunning clutch 66 and shaft 14. In either case, if both axles are to be driven, intermediate shaft 26 is driven through fixed ratio mechanism 18 in the same direction as that of the engine. TOD clutch 104 is engaged to directly connect front output shaft 15 to the power source, or that clutch is modulated to control the magnitude of torque transmitted to shaft 15. An upshift to the continuously variable range is accomplished by engaging transfer clutch 102, disengaging the other friction elements, except if a one-way clutch, such as clutch 66, is used. These actions will cause the one-way clutch 68 to overrun; consequently the upshift is non-synchronous, and the low clutch can be left engaged. However, if the connection between sprocket 24 and gear 64 is fixed, a gear ratio change between low gear and the CVT mode is a synchronous shift and the low clutch must be disengaged to produce an upshift and engaged to produce a downshift. In the CVT mode, TRF clutch 102 connects input shaft 12 to a first sheave, whose pulleys 54, 56 drive the pulleys 58, 60 of a second sheave through belt 62 at a variable speed ratio that depends on the relative diameters of the sheaves. Shaft 26 drives sprocket 28, which drives the rear output shaft 14 and the rear wheels due to engagement of chain 30 with sprockets 28, 24. The TOD clutch 104 can be used to driveably connect the pulleys 58,60 of the second sheave to the front output shaft 15. Preferably the speed ratio produced in first or low gear through operation of gear unit 22 is spaced slightly from the speed ratio at the lowest end of the continually variable range produced through operation of the variable ratio drive 16. In this way the transition from first gear to the lowest variable gear ratio is an upshift. Preferably the speed ratio in low gear is 2.90 at the low end of the CVT mode it is 2.018, at the mid-range of the CVT mode where both sheaves rotate at the same speed it is 2.018, and at the high end of the CVT mode it is 0.525. The speed ratio in low gear, therefore, is 1.437 times greater than at the low end of the CVT range. Reverse drive is produced by engaging reverse clutch 100, and disengaging the other friction elements, except that TOD clutch 104 may be engaged to drive the front wheels when desired, as explained below. These actions cause OWC 66 to overrun. Therefore, gear 72 is driven in the opposite direction with respect to that of shaft 12 and at a reduced speed relative to that of shaft 12. Clutch 100 connects gear 72, shaft 14, through which the rear wheels are driven, and sprocket 24, from which the front wheels are driven through the fixed ratio mechanism 18, TOD clutch 104 and front output shaft 15. Preferably the speed ratio in reverse drive is -3.20.

Claims: A continuously variable transmission comprising: an input shaft (12); an intermediate shaft (26); an output shaft (14); a variable ratio drive mechanism (16) having an input, and an output driveably connected to the input shaft (12) and the intermediate shaft (26), for producing a continuously variable ratio of the input speed to the output speed; a fixed ratio drive mechanism (18) having a first element (28) driveably connected to the intermediate shaft drive (26) and a second element (24) driveably connected to the first element (28) and to the output shaft (14); a first gearset (22) driveably connected to the input shaft (12) and the output shaft (14); a transfer clutch (102) for alternately driveably connecting and disconnecting the input of the variable ratio drive mechanism (16) and the input shaft (12); and a low clutch (98) for alternately driveably connecting and disconnecting an element (63) of the first gearset (22) and the input shaft (12); characterised in that said first element (28) and said second element (24) are sprockets, the first sprocket (24) driveably fixed to the output shaft (14), the second sprocket (28) driveably fixed to the intermediate shaft, and a flexible continuous element (30) driveably engaging the two sprocket wheels (24,28). A transmission as claimed in claim 1, wherein the variable ratio drive includes a first sheave (54,56), a second sheave (58,60) driveably fixed to the intermediate shaft (26), and a flexible continuous element (62) driveably engaging the input sheave and output sheave at steplessly variable radial positions. A transmission as claimed in claim 1 or 2, further comprising: a second output shaft (15); and a transfer clutch (104) for alternately driveably connecting and disconnecting the intermediate shaft (26) and second output shaft (15). A transmission as claimed in any preceding claim, further comprising: a torque converter (46) having an impeller (42) adapted for a driveable connection to a power source, a turbine (44) adapted for a hydrokinetic drive connection to the impeller (42) and driveably connected to the input shaft (12). A transmission as claimed in any preceding claim, further comprising: a second gearset (20) driveably connected to the input shaft (12) and output shaft (14), for driving the output shaft (14) in a reverse drive direction at a slower speed than the speed of the input shaft (12); and a reverse clutch (100) for alternately driveably connecting and disconnecting and the output shaft (14) and an element (72) of the second gearset (20). A transmission as claimed in any preceding claim, wherein the first gearset includes: a pinion (63) supported on the input shaft (12); a gear (64) supported on the output shaft (14); an overrunning clutch (66) located in a torque delivery path between the output shaft (14) and the gear (64) for producing a one-way drive connection therebetween; and an idler (68) meshing with the pinion (63) and gear (64).

Inventors: BEIM RUDOLF, MCCARRIK DANIEL WARREN, MELHORN BARRY JOHN, BEIM, RUDOLF, MCCARRIK, DANIEL WARREN, MELHORN, BARRY JOHN
Applicants: FORD GLOBAL TECH INC, FORD GLOBAL TECHNOLOGIES, INC.
Application year: 1999
Main classification: F16H37
IPC codes: B60K17, F16H37