Patent ID: 12203534

DESCRIPTION

As previously discussed, there exists an opportunity for improvement in the art of winches configured on electrified vehicles. Electrified vehicles is used herein to comprise any vehicle that has at least one electric motor that delivers drive torque to a drive wheel such as gasoline hybrid electric, plug-in hybrid electric, range-extended electric, and battery electric. As described herein, an electric drive module (EDM) is configured to provide a rotatable input to an electric drive gearbox assembly. The electric drive gearbox assembly is configured to selectively and alternatively provide torque to drive wheels of the vehicle (in a first drive mode) or rotate a spool used as a winch (in a second winch mode). The spool can rotate to spool and unspool a cable having a tow hook during a winch event. A planetary gearset is configured in the electric drive gearbox assembly that provides a reduction allowing increased torque to rotate the spool. The configuration of the electric drive gearbox assembly leverages the electric power input already incorporated on an electrified vehicle to act as a driving force on a winch. In this regard, a supplemental electric motor and related winch mounting hardware including enhanced bumpers used to support the electric motor can be avoided.

With initial reference toFIG.1, an electrified vehicle10is partially shown in accordance with the principles of the present disclosure. The electrified vehicle10is a unibody style vehicle. In the example embodiment, the electrified vehicle10includes an electric drive module (EDM)12configured to generate and transfer drive torque to a driveline16for vehicle propulsion. The EDM12generally includes one or more electric drive units or motors20(e.g., electric traction motors), an electric drive gearbox assembly22, and power electronics including a power inverter module (PIM)24. The electric motor20is selectively connectable via the PIM24to a high voltage battery system26for powering the electric motor20. The electrified vehicle10includes a vehicle charging inlet28provided at a charging port30for receiving a charge plug32during a charging event. The present disclosure is advantageous as it can be implemented in a unibody style vehicle (e.g., less than full frame vehicles) because the EDM12is mounted to cradle or sub-frame and not hanging over the front axle.

The electric drive gearbox assembly22is configured to transfer the generated drive torque to the driveline16, including a first or left axle shaft34and a second or right axle shaft36. In the example shown, the EDM12is configured for use on a front axle of a two-wheel drive vehicle. It is appreciated however that the EDM12can be alternatively configured for use on a rear axle of a two-wheel drive vehicle. In other examples an EDM12can be provided on both of the front and rear axles for a four-wheel drive or all-wheel drive driveline vehicle.

In the example embodiment, the electric motor20generally includes an electric motor output shaft40. The electric motor output shaft40drives a transfer gear42that in turn drives an output gear44on a differential50. In the first drive mode, the differential50drives the vehicle axles34,36(e.g., half shafts) and therefore respective drive wheels51,52. In the illustrated example, the EDM12is configured for a front axle (axles34,36) of the vehicle10, but it will be appreciated that the systems and methods described herein are equally applicable to a rear axle EDM configuration, and can be replicated on the front and rear axles for four wheel drive. A first wheel end disconnect56can be configured between the front axle34and the drive wheel51. A second wheel end disconnect58can be configured between the front axle36and the drive wheel52. The first and second wheel end disconnects56,58can selectively disconnect drive torque from the axles34,36to the drive wheels51,52during the winch mode.

The electric drive gearbox assembly22further includes a planetary gearset60and a winch68having a rotating drum or spool70. The planetary gearset60and winch68are used when in the second winch mode for operating the winch68. The planetary gearset60can be selectively driven off of the differential50and acts as a reduction for delivering increased torque to the spool70during the winch mode. In examples, an actuator72can actuate to engage the planetary gearset60for rotation with the differential50. As used herein, the actuator72can be any electrical, mechanical, electromechanical or other device that selectively routes torque through the planetary gearset60and ultimately to the winch68and spool70. In this regard, the actuator72can be a clutch, shift mechanism and/or other device suitable for routing torque to the winch68and spool70in the winch mode. By way of non-limiting example, the planetary gearset60can provide a 32.1:1 reduction. Other configurations are contemplated. In implementations, the spool70defines spool defines a pass-through bore78that accommodates the shaft36.

The planetary gearset60includes a sun gear80, a planetary carrier82that supports planet gears, and a ring gear84. In one implementation, the output shaft36passes through the sun gear80. In the example shown, the planetary carrier82is configured as the drive output to the winch68in the second winch mode. In examples, the ring gear60can be locked or fixed from rotation. In some examples, the ring gear60can be splined to a housing.

In examples, the winch68and spool70is disposed in an engine compartment88of the electrified vehicle10. A cable92is configured to wind and unwind from the spool70during operation of the electric drive gearbox assembly in the second winch mode. A distal end of the cable92can include a tow hook94that can be configured to extend outward from a passage100defined in a bumper102of the electric vehicle10. When the winch68is in an undeployed condition (cable92spooled onto the spool70), the tow hook94can be coupled at a post104or other feature on the bumper102. Other configurations are contemplated. Of note however, because the winch68and spool70are disposed in the engine compartment88, the winch68and spool70reside generally behind a front fascia of the electrified vehicle10in a non-obtrusive manner providing further protection of the winch68and spool70from the elements.

According to examples, the electrified vehicle10includes a controller90that receives vehicle inputs92. In examples, the controller90can provide signals to the electric drive gearbox assembly22for changing operating modes between the first drive mode and the second winch mode. Vehicle inputs92can include a winch mode activation input. The winch mode can be activated such as by a button provided outside the electrified vehicle10(such as on or near the front bumper), inside the electrified vehicle10(such as on a steering wheel or through an infotainment system), or initiated through a smart device (phone, tablet, etc.) that is wirelessly connected to the electrified vehicle. When winch mode is selected, the controller130sends a signal to the actuator72that actuates to engage the planetary gearset60(and therefore the winch68and spool70) for rotation with the differential50.

With additional reference now toFIG.4, an exemplary method for operating the winch in the electrified vehicle according to various examples of the present disclosure will be described. The method is generally referred to at reference numeral100. The method100starts at110. At114control determines whether the winch mode has been activated. Again, winch mode can be activated in a number of ways such as, but not limited to actuation of a button (at the vehicle inputs132) provided outside the electrified vehicle10(such as on or near the front bumper), inside the electrified vehicle10(such as on a steering wheel or through an infotainment system), or initiated through a smart device (phone, tablet, etc.) that is wirelessly connected to the electrified vehicle10.

If winch mode has not been activated, control loops to114. If winch mode has been activated at114, control locks the wheels51,52at120. When winch mode is activated, the vehicle10will secure itself with the rear park brake and the front axles34,36will disconnect from the wheels. This allows for the vehicle10to be stable and not drive toward the obstacle or rescue vehicle during a winching event. In examples, the controller130can engage a park brake or other feature that locks the wheels51,52. In additional features, all wheels including other driven or undriven wheels can be locked. At124, torque from the motor20is diverted from the drive wheels51,52to the winch68for rotating the spool70. As explained above, the planetary gearset60is driven off of the differential50such as by actuation of the actuator72causing drive torque to flow through the planetary carrier82and to the winch68. At128the winch68is driven228. The method ends at130. It is contemplated that winch mode can end based on an input from the user (e.g., actuation of the button, etc.).

As used herein, the term controller or module refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and/or other suitable components that provide the described functionality.

It will be understood that the mixing and matching of features, elements, methodologies, systems and/or functions between various examples may be expressly contemplated herein so that one skilled in the art will appreciate from the present teachings that features, elements, systems and/or functions of one example may be incorporated into another example as appropriate, unless described otherwise above. It will also be understood that the description, including disclosed examples and drawings, is merely exemplary in nature intended for purposes of illustration only and is not intended to limit the scope of the present disclosure, its application or uses. Thus, variations that do not depart from the gist of the present disclosure are intended to be within the scope of the present disclosure.