Patent Description:
To use a conventional clutch mechanism which disconnects the input shaft of the gear box from the combustion engine during gear changing processes in the gear box involves disadvantages. When a stationary vehicle starts, the discs of the clutch mechanism slide against each other. Thereby heating of the discs is provided. This heating results in an increased fuel consumption and a wear of the clutch discs. A conventional clutch mechanism is also relatively heavy and expensive. It occupies also a relatively large space in the vehicle. To use a hydraulic moment converter also results in losses.

Hybrid vehicles can be driven by a primary motor which can be a combustion engine and a secondary motor which can be an electric machine. The electric machine is equipped with at least one energy storage for storing electric energy and control equipment for controlling the flow of electric energy between the energy storage and the electric machine. The electric machine can thereby alternately work as motor and generator in dependence on the operation state of the vehicle. When the vehicle is braked, the electric machine generates electric energy which is stored in the energy storage. The stored electric energy is used later, for example, for driving the vehicle and operating different auxiliary systems in the vehicle.

The Swedish patent application <CIT>, which has not been made public, shows a hybrid drive system with a planetary gear which comprises three components, namely a sun wheel, a planet wheel holder and a ring wheel. One of the three components of the planetary gear is connected to an output shaft of the combustion engine, a second component of the planetary gear is connected to an input shaft to the gear box and a third component of the planetary gear is connected to a rotor of an electric machine. The electric machine is connected to an energy storage such that it alternately can work as motor and generator. The rotation speed of electric machines can be controlled in a stepless manner. By controlling the rotation speed of the electric machine, the input shaft to the gear box can be given a desired rotation speed. With a hybrid system according to <CIT> no clutch mechanism needs to be used in the drive line of the vehicle.

With a hybrid system according to <CIT> no clutch mechanism needs to be used in the drive line of the vehicle. The hybrid drive system is however dependent on that the hybrid battery functions in order to make it possible to start the vehicle.

<CIT> shows a power system including an engine and an electric motor connected to an input shaft of a transmission via a planetary gear. The electric motor may be connected to a battery or a resistive grid.

The object of the present invention is to provide a drive system for a vehicle of the initially mentioned kind, where it essentially always is possible to start the vehicle.

This object is achieved with a drive system according to claim <NUM>.

When the combustion engine is starting, a first of the components of the planetary gear rotates with the idle running rotation speed of the combustion engine. The second of the components of the planetary gear which is connected to the gear box is at rest as long as the vehicle is stationary. The third of the components of the planetary gear which is connected to the rotor of the electric machine rotates backwards with a negative rotation speed. In order for a driving moment to be transferred from the combustion engine to the gear box, it is required that the rotor of the electric machine provides a braking moment. According to the invention, the electric machine is connected to an electric circuit with a resistor. Thereby a resistance is created which brakes the rotor and the third component of the planetary gear. Because of this, a driving moment can be transferred to the gear box which results in that the vehicle starts. Such an electric circuit with a resistor constitute simple components which to a relatively low cost can be applied in the vehicle.

According to an embodiment of the present invention, the electric circuit comprises a variable resistor. With such a component, the electric resistance can be varied and thereby the braking moment with which the rotor is braked. A control unit may with advantage control the variable resistor such that the vehicle obtains a desired speed increase during a starting process of the vehicle. The starting process can be defined as the time it takes for the vehicle to obtain a speed such that a higher gear can be engaged in the gear box. Alternatively, the starting process can be defined as a time period and can be in the order of <NUM> to <NUM> seconds or another suitable time period.

According to an embodiment of the present invention, the drive system comprises a motor control function, wherein a control unit is adapted to control the combustion engine with the help of the motor control function at operation occasions when gears are shifted in the vehicle. After that the starting process has ended, the rotor of the electric machine obtains a positive rotation speed. It is thereby no longer possible to use the electric circuit with the resistor for supplying a driving moment to the input shaft of the gear box. With information about the speed of the vehicle and the actual gear in the gear box, the control unit can calculate the rotation speed with which the output shaft of the combustion engine is to rotate in order to create a momentless state in the gear box. The control unit thereafter controls the motor control function such that the combustion engine obtains the calculated rotation speed, after which the actual gear in the gear box is disengaged. When a new gear is to be engaged in the gear box, the control unit calculates, with knowledge of the speed of the vehicle and the new gear, the rotation speed of the combustion engine at which the new gear can be engaged. The control unit thereafter controls the motor control function such that the combustion engine obtains the calculated rotation speed, after which the new gear is engaged.

The drive system comprises an energy storage which is connectable to the electric machine such that it is possible to store and consume, respectively, electric energy at different operation conditions of the vehicle. In this case, the vehicle is a hybrid vehicle which is driven by a primary motor in the form of a combustion engine and a secondary motor in the form of said electric machine. Except for the energy storage, the vehicle comprises control equipment in order to control the flow of electric energy between the energy storage and the electric machine. The electric machine has thereby, in addition to the function to enable the control of the rotation speed of the input shaft of the gear box, also the ability to alternately work as motor and generator in dependence on the operation state of the vehicle.

The energy storage is used for braking the rotor such that a driving moment can be transferred from the combustion engine to the gear box at the start of the vehicle. The braking energy which acts on the rotor is generated as electric energy in the energy storage. If the energy storage is estimated to be out of operation, the vehicle cannot start. The electric machine is connected to the electric circuit and the resistor. Thereby the vehicle can start and be driven to a service place or the like where it is possible to repair or exchange the energy storage.

According to another preferred embodiment of the invention, the control unit is adapted to receive information concerning a parameter in order to determine if the energy storage has an undesired function. The control unit may, for example, receive information from an electric measurement instrument which measures a parameter which is related to the electric energy which is led between the regular energy storage and the electric machine. The electric measurement instrument may measure a parameter which concerns the current and/or voltage of the electric energy. If the energy storage does substantially not deliver or receive electric energy during operation, it probably has an undesired function.

According to the invention, the drive system comprises an indication member which indicates when the energy storage has an undesired function. The indication member can be a warning lamp or a sound alarm which is activated if the energy storage does not function. With the help of such an indication member, the driver becomes immediately informed that the energy storage does not function. According to the invention, the driver manually sets the electric switch with a button or the like when the indication member indicates that the energy storage has an undesired function.

According to another preferred embodiment of the invention, the output shaft of the combustion engine is connected to the sun wheel of the planetary gear, the input shaft of the gear box is connected to the planet wheel holder of the planetary gear and the rotor of the electric machine is connected to the ring wheel of the planetary gear. With such a design, the included components may be given a compact construction. The sun wheel and the planet wheel holder may be connected to the output shaft of the combustion engine and the input shaft of the gear box, respectively, with the help of spline joints or the like. It is thereby guaranteed that the sun wheel rotates with the same rotation speed as the output shaft of the combustion engine and that the planet wheel holder rotates with the same rotation speed as the input shaft of the gear box.

The rotor of the electric machine may be fixedly arranged on an external peripheral surface of the ring wheel. The internal peripheral surface of the ring wheel is normally provided with cogs. The external peripheral surface of the ring wheel is normally smooth and very well suited for carrying the rotor of the electric machine. The ring wheel and the rotor of the electric machine thereby form a rotatable unit. Alternatively, the rotor of the electric machine may be connected to the ring wheel via a transmission. It is however possible to connect the output shaft of the combustion engine, the input shaft of the gear box and the rotor of the electric machine with any of the other components of the planetary gear.

The initially mentioned object is achieved also by the method according to claims <NUM> to <NUM>.

In the following preferred embodiments of the invention are described, as examples, with reference to the annexed drawings, on which:.

<FIG> shows a drive line for a heavy vehicle <NUM>. The drive line comprises a combustion engine <NUM>, a gear box <NUM>, a number of drive shafts <NUM> and drive wheels <NUM>. An intermediate part <NUM> is arranged between the combustion engine <NUM> and the gear box <NUM>. The intermediate part <NUM> is shown in more detail in <FIG>. The intermediate part <NUM> comprises an output shaft 2a of the combustion engine <NUM> and an input shaft 3a of the gear box <NUM>.

The output shaft 2a of the combustion engine is coaxially arranged in relation to the input shaft 3a of the gear box. The output shaft 2a of the combustion engine and the input shaft 3a of the gear box are rotatably arranged around a common axis of rotation <NUM>. The intermediate part <NUM> comprises a housing <NUM> which encloses an electric machine <NUM> and a planetary gear. The electric machine <NUM> comprises in a customary manner a stator 9a and a rotor 9b. The stator 9a comprises a stator core which is attached in a suitable manner on the inside of the housing <NUM>. The stator core comprises the windings of the stator. The electric machine <NUM> is adapted to during certain operation occasions use stored electric energy for supplying drive power to the input shaft 3a of the gear box and to during other operation occasions use the kinetic energy of the input shaft <NUM> of the gear box for extracting and storing electric energy.

The planetary gear is arranged substantially radially inside of the stator 9a and rotor 9b of the electric machine. The planetary gear comprises in a conventional manner a sun wheel <NUM>, a ring wheel <NUM> and a planet wheel holder <NUM>. The planet wheel holder <NUM> carries a number of cog wheels <NUM> which are rotatably arranged in a radial space between the cogs of the sun wheel <NUM> and the ring wheel <NUM>. The sun wheel <NUM> is attached on a peripheral surface of the output shaft 2a of the combustion engine. The sun wheel <NUM> and the output shaft 2a of the combustion engine rotate as a unit with a first rotation speed n<NUM>. The planet wheel holder <NUM> comprises an attachment portion 12a which is attached on a peripheral surface of the input shaft 3a of the gear box with the help of a spline joint <NUM>. With the help of this joint, the planet wheel holder <NUM> and the input shaft 3a of the gear box can rotate as a unit with a second rotation speed n<NUM>. The ring wheel <NUM> comprises an external peripheral surface on which the rotor 9b is fixedly mounted. The rotor 9b and the ring wheel <NUM> constitute a rotatable unit which rotates with a third rotation speed n<NUM>.

The vehicle comprises a locking mechanism which is movable between a first open position in which the three components <NUM>-<NUM> of the planetary gear are allowed to rotate with different rotation speeds and a second locked position in which it locks together two of the components <NUM>, <NUM> of the planetary gear such that the three components <NUM>-<NUM> of the planetary gear rotate with the same rotation speed. In this embodiment, the locking mechanism comprises a displaceable coupling member <NUM>. The coupling member <NUM> is attached on the output shaft 2a of the combustion engine with the help of a spline joint <NUM>. The coupling member <NUM> is in this case arranged, secured against turning, on the output shaft 2a of the combustion engine and displaceably arranged in an axial direction on the output shaft 2a of the combustion engine. The coupling member <NUM> comprises a coupling portion 15a which is connectable to a coupling portion 12b of the planet wheel holder <NUM>. The locking mechanism comprises a schematically shown displacement member <NUM> is adapted to displace the coupling member <NUM> between the first free position I<NUM> when the coupling portions 15a, 12b are not in engagement with each other and the second locked position I<NUM> when the coupling portions 15a, 12b are in engagement with each other. In the first open position, the output shaft <NUM> of the combustion engine and the input shaft <NUM> of the gear box can rotate with different rotation speeds. When the coupling portions 15a, 12b are in engagement with each other, the output shaft <NUM> of the combustion engine and the input shaft <NUM> of the gear box will rotate with the same rotation speed.

An electric control unit <NUM> is adapted to control the displacement member <NUM>. The control unit <NUM> is also adapted to decide at which occasions the electric machine is to work as motor and at which occasions it is to work as generator. In order to decide this, the control unit <NUM> can receive actual information from suitable operation parameters. The control unit <NUM> can be a computer with a suitable software for this purpose. The control unit <NUM> can of course constitute one or more separate control units. The control unit <NUM> also controls a schematically shown control equipment <NUM> which controls the flow of electric energy between an energy storage <NUM> and the stator 9a of the electric machine. At occasions when the electric machine <NUM> works as motor, stored electric energy from the energy storage <NUM> is supplied to the stator 9a. At occasions when the electric machine works as generator, electric energy from the stator 9a is supplied to the energy storage <NUM>. The energy storage <NUM> delivers and stores electric energy with a voltage which is in the order of <NUM>-<NUM> Volt. Since the intermediate part <NUM> between the combustion engine <NUM> and the gear box <NUM> in a vehicle is limited, it is required that the electric machine and the planetary gear constitute a compact unit. The components <NUM>-<NUM> of the planetary gear are here arranged substantially radially inside of the stator 9a of the electric machine. The rotor 9b of the electric machine, the ring wheel <NUM> of the planetary gear, the output shaft 2a of the combustion engine and the input shaft 3a of the gear box are here rotatably arranged around a common axis of rotation <NUM>. With such a design, the electric machine <NUM> and the planetary gear occupy a relatively small space. The vehicle comprises an electric circuit <NUM> with a variable resistor <NUM>. The electric circuit <NUM> is connectable to the stator 9a of the electric machine via an electric switch <NUM>.

During the operation of the electric machine <NUM>, the control unit <NUM> receives information from an electric meter <NUM> which senses a parameter which is related to the electric energy which is transported to and from the energy storage <NUM>. If the measured electric energy is below an expected value, the energy storage <NUM> does probably not function in the intended manner. If substantially no electric energy is transported to and from the energy storage <NUM> during the operation of the vehicle, it is estimated to be out of operation. If the control unit <NUM> estimates that the energy storage <NUM> is out of operation, it activates an indication member <NUM> in the driver's cab. The indication member <NUM> may be a flashing lamp or a sound alarm of the like. The task of the indication member <NUM> is to make the driver aware of the fact that the energy storage <NUM> is out of operation. The driver manually activates with a button or the like the connection between the electric circuit <NUM> with the variable resistor <NUM> and the electric machine <NUM>. The vehicle <NUM> is equipped with a motor control function <NUM> with which the rotation speed n<NUM> of the combustion engine <NUM> can be controlled. The control unit <NUM> thereby has the possibility to activate the motor control function <NUM> when gears are engaged and disengaged in the gear box <NUM> in order to create a momentless state in the gear box <NUM>.

<FIG> show an example of how the rotation speed n and the moment T may vary with time t for the output shaft 2a of the combustion engine, the rotor 9b of the electric machine and the input shaft 3a of the gear box during a starting process of the vehicle <NUM> when the energy storage <NUM> is out of operation. Rotation speed n<NUM> and moment T<NUM> of the output shaft 2a of the combustion engine are shown with dashed lines, rotation speed n<NUM> and moment T<NUM> of the input shaft <NUM> of the gear box are shown with continuous lines and rotation speed n<NUM> and moment T<NUM> of the electric machine <NUM> are shown with dotted lines. The relationship between the number of cogs z<NUM> of the sun wheel <NUM> and the number of cogs z<NUM> of the ring wheel <NUM> is in this example z<NUM>/z<NUM> = <NUM>.

If the energy storage <NUM> is estimated to be out of operation, the driver sets the electric switch <NUM> in the position in which the electric circuit <NUM> with the variable resistor <NUM> is connected to the electric machine <NUM>. The combustion engine <NUM> starts at the time t = <NUM>. The combustion engine <NUM> runs initially idle with the rotation speed n<NUM> = <NUM> rpm and the torque T<NUM> = <NUM>. The input shaft 3a of the gear box is at rest and has thus initially the rotation speed n<NUM> = <NUM> rpm. Since all the components in the planetary gear are connected to each other with a predetermined transmission ratio, the ring wheel <NUM> obtains an initial rotation speed n<NUM> which is determined by the two other rotation speeds n<NUM>, n<NUM>. With the above transmission ratio z<NUM>/z<NUM> = <NUM>, the ring wheel obtains the rotation speed n<NUM> = -<NUM> rpm. The ring wheel <NUM> will here rotate in an opposite direction in relation to the sun wheel <NUM>.

The control unit <NUM> thereafter controls the variable resistor such that the electric machine <NUM> provides a braking moment T<NUM> which in this case is <NUM>. Since the ring wheel <NUM> rotates in the opposite direction in relation to the sun wheel <NUM>, this braking moment T<NUM> is supplied to the input shaft 3a of the gear box. The input shaft of the gear box here obtains a driving moment which is the sum of the moment T<NUM> of the output shaft of the combustion engine and the braking moment T<NUM> of the ring wheel. The input shaft 3a of the gear box here obtains the driving moment T<NUM> = <NUM>. The driving moment T<NUM> gets the input shaft 3a of the gear box going such that it starts to rotate, i.e. n<NUM> becomes larger than zero. Thereby the opposite rotation speed n<NUM> of the ring wheel is simultaneously reduced.

At the time A, the rotation speed n<NUM> of the combustion engine is increased. Thereby it is ensured that the ring wheel <NUM> can rotate with an opposite rotation speed n<NUM> of a suitable magnitude such that it also thereafter can put a load on the combustion engine <NUM> and ensure that the input shaft 3a of the gear box obtains an increasing rotation speed n<NUM> and the vehicle <NUM> a successively increasing speed until the time B. The speed of the vehicle increases linearly up to the time B. The moments T<NUM>, T<NUM>, T<NUM> present constant values during the whole starting process up to the time B. At the time B, the combustion engine <NUM> is braked with an exhaust brake, a controllable turbo or is retarded in another manner such that the rotation speed n<NUM> is reduced. The rotation speed n<NUM> of the combustion engine <NUM> sinks at the same time as the input shaft 3a of the gear box maintains a constant rotation speed n<NUM>. The control unit <NUM> disconnects the electric machine <NUM> from the electric circuit <NUM> with the resistor <NUM>. The vehicle <NUM> is now driven with a constant speed. When the rotation speed n<NUM> of the combustion engine <NUM> sinks at the same time as the rotation speed n<NUM> of the gear box is constant, the rotation speed n<NUM> of the electric machine <NUM> increases. The rotation speed n<NUM> of the rotor changes from being a negative rotation speed to a positive rotation speed. At the time C all components in the planetary gear rotate with the same rotation speed. The control unit <NUM> activates the displacement member <NUM> which displaces the coupling member <NUM> such that the coupling portions 15a, 12b get into engagement with each other. The output shaft <NUM> of the combustion engine and the input shaft <NUM> of the gear box are now locked in relation to each other and will thereby rotate with the same rotation speed. After that the components included in the planetary gear have been locked, only the combustion engine <NUM> is responsible for driving the vehicle <NUM>. The electric machine <NUM> rotates with the same rotation speed n<NUM> as the output shaft <NUM> of the combustion engine and the input shaft <NUM> of the gear box.

At the continued journey, a higher gear needs to be engaged in the gear box <NUM>. The control unit <NUM> activates the displacement member <NUM> which displaces the coupling member <NUM> to a disengaged position. The connection between the output shaft <NUM> of the combustion engine and the input shaft <NUM> of the gear box ceases. The control unit <NUM> calculates the rotation speed n<NUM> which the input shaft 2a of the combustion engine needs to be driven with in order to achieve a momentless state in the gear box <NUM>. The control unit <NUM> activates the motor control function <NUM> which gives the combustion engine <NUM> the calculated rotation speed n<NUM>, after which the gear is disengaged. After that the gear has been disengaged, a new gear is to be engaged. The control unit <NUM> calculates here the rotation speed n<NUM> which the output shaft <NUM> of the combustion engine needs to be driven with in order for it to rotate with the same rotation speed as the input shaft 3a of the gear box. The control unit <NUM> activates the motor control function <NUM> which gives the combustion engine <NUM> the calculated rotation speed n<NUM>, after which the new gear is engaged. The control unit <NUM> thereafter activates the motor control function <NUM> again in order to control the rotation speed n<NUM> such that all the components in the planetary gear obtain the same rotation speed n<NUM>, n<NUM>, n<NUM>. When all the components in the planetary gear rotate with the same rotation speed, the control unit <NUM> activates the displacement member <NUM> which displaces the coupling member <NUM> such that the coupling portions 15a, 12b get into engagement with each other. After locking the planetary gear, only the combustion engine <NUM> is responsible for driving the vehicle.

In this case an electric circuit <NUM> with a variable resistor <NUM> is used instead of the energy storage <NUM> and an electric machine in order to brake the rotor 9b during a starting process of the vehicle <NUM>. The vehicle <NUM> can thereby be started even if the energy storage is out of operation and can be driven to a service place or the like where the energy storage <NUM> can be exchanged or repaired.

<FIG> shows a drive system not falling under the scope of the appended claims, in which, the vehicle does not comprise any energy storage. Except for that, the drive system comprises the same components as in the embodiment in <FIG>. The planetary gear, the electric machine and the electric circuit <NUM> with the resistor <NUM> here replace a conventional clutch mechanism. In this case, the vehicle <NUM> is always started with the help of the electric circuit <NUM> and the resistor <NUM>, after which the motor control function <NUM> is used when gears are shifted in the vehicle. Alternatively, gear shifting can be performed in the following manner. Since the resistor <NUM> only works as a load, the possibility to change direction of the moment of the electric machine is lost when no energy storage is used. It can be remedied by giving the combustion engine a higher initial rotation speed before a gear shifting process is performed. The rotary speed is then successively reduced in a downward direction towards the idle speed when it is loaded by the electric machine by means of the resistor <NUM>. During the way down to the idle speed, a synchronous rotation speed is obtained between the combustion engine and the input shaft of the gear box. When this occurs, the gear is pushed in whereupon the rotation speed of the engine in increased such as during a normal acceleration of the vehicle.

Claim 1:
Drive system for a vehicle (<NUM>), wherein the drive system comprises a combustion engine (<NUM>) with an output shaft (2a), a gear box (<NUM>) with an input shaft (3a), an electric machine (<NUM>) which comprises a stator (9a) and a rotor (9b), and a planetary gear which comprises a sun wheel (<NUM>), a ring wheel (<NUM>) and a planet wheel holder (<NUM>) and a hybrid energy storage (<NUM>) which is connectable to the electric machine (<NUM>) such that it is possible to store and consume, respectively, electric energy at different operation conditions of the vehicle (<NUM>), wherein the output shaft (2a) of the combustion engine is connected to a first of said components of the planetary gear such that a rotation of this shaft (2a) leads to a rotation of this component, wherein the input shaft (3a) of the gear box is connected to a second of said components of the planetary gear such that a rotation of this shaft leads to a rotation of this component and the rotor (9b) of the electric machine is connected to a third of said components of the planetary gear such that a rotation of the rotor (9b) leads to a rotation of this component, wherein the drive system comprises an electric circuit (<NUM>) with a resistor (<NUM>) and an electric switch (<NUM>) with which the electric machine (<NUM>) is connectable to the electric circuit (<NUM>) and the resistor (<NUM>), characterized in that that the electric switch (<NUM>) is configured to be manually moved to a position in which it connects the electric circuit (<NUM>) to the electric machine during a starting process of the vehicle (<NUM>) when the hybrid energy storage (<NUM>) is estimated to have an undesired function, the drive system comprising an indication member (<NUM>) which indicates when the hybrid energy storage (<NUM>) is estimated to have an undesired function.