Patent Document

BACKGROUND OF THE INVENTION 
     This invention is related to vehicle transmissions. More specifically, this invention relates to a split-power transmission with automatic mode shifts. 
     There are a number of vehicles that desire to have “automatic” transmission for ease of driving and for increased utility. These include various construction vehicles, tractors, utility vehicles, recreational vehicles and automobiles. These vehicles have common requirements for low cost, high efficiency, good control ability and continuous ratio change throughout the entire speed range. Some of these vehicles have a requirement for low noise. Many vehicles have a small battery that is only used for starting and emergency use. 
     Split-power transmissions are characterized by a continuously variable transmission power path in parallel with a fixed mechanical power path, arranged in a manner to decrease the average power flow through the variable portion and thereby increase operating efficiency. Typically, the mechanical power path includes a planetary gear set which acts to sum the power flow at either the input or output end of the transmission. 
     Multi mode split-power transmissions are usually accomplished by reusing the variable power units and clutching to a different mechanical component. Usually the modes are arranged so that there is no ratio change during the mode change in order to have continuous speed or torque delivery. This is accomplished by making the mode shifts at a near synchronous speed conditioned for the incoming clutch. 
     Variable power units within a multi mode split-power transmission are normally operated up to near to their full speed range including both forward and reverse directions. For a pair of variable power units, the unit that decreases speed relative to the other unit, absorbs power (a generator or pump) and the unit that increases speed relative to the other delivers power (a motor). When one of the units changes direction of rotation, the direction of power flow also changes. This does not necessarily result in any interruption of power in the transmission or any speed shift in the variable power units as the direction of torque may not change. 
     When changing modes the variable power units could reverse the direction of power flow if the direction of torque changes. This may be observed by the variable power units reversing the relative rate of speed change; i.e., if one unit was increasing speed (relative to the other) before mode change as output speed increased and decreasing relative speed after mode change, the direction of torque has to change in order to delivery power. The same is true if one unit was decreasing speed relative to the other and then increased after mode change. A power unit torque reversal normally happens during a mode change for a split-power transmission as the mechanical elements that are changed with clutches remain in the same functional relationship, i.e., the variable power units remain in an input summer or an output summer relationship. A torque direction change in the variable power units may require a stepped shift in speed differential between them in order to account for a reversal and slip in a closed circuit system. 
     Therefore, it is a principal object of the present invention to provide a split-power transmission within a vehicle that provides automatic mode shifts. 
     Yet another object of the present invention is to provide a light weight and compact split-power transmission for a vehicle. 
     These and other objects, features or advantages of the present invention will become apparent from the specification and claims. 
     BRIEF SUMMARY OF THE INVENTION 
     A compact vehicle using an automatic transmission to rotate the axle and wheels of the vehicle. The vehicle has either an engine with a crank shaft positioned parallel to the direction of the vehicle motor or positioned transverse to the direction of the vehicle motor. In either case, the engine is rotatably connected to the transmission that uses an output shaft in order to rotate the axles and wheels of the vehicle. The transmission itself uses a power summing device in association with a plurality of clutches and a plurality of variable power units in order to shift the transmission between first and second operating modes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a plan top view of a vehicle having an engine with a crank shaft positioned transversely to the direction of the vehicle motion; 
         FIG. 2  is a top plan view of a vehicle having an engine with a crank shaft positioned parallel to the direction of the vehicle motion; 
         FIG. 3  is a schematic diagram of a vehicle system having a split-power transmission; 
         FIG. 4  is a graph of transmission output torque versus transmission output speed in a transmission; 
         FIG. 5  is a schematic block diagram of a split-power transmission; 
         FIG. 6  is a speed diagram for a gear planetary within a split-power transmission where the vertical axial axis represents speed and the horizontal axis represents planetary ratio; 
         FIG. 7  is a power graph of a split-power transmission wherein the Y axis shows variable power for variable power units and output speed is on the horizontal axis; 
         FIG. 8  is a speed diagram wherein the horizontal axis shows output speed and the vertical axis shows variable unit speed; 
         FIG. 9  is a schematic block diagram of a three mode split-power transmission; 
         FIG. 10  is a speed diagram of a three mode split-power transmission wherein the vertical axis is speed and the horizontal axis is planetary ratio; 
         FIG. 11  is a graph of a three mode split-power transmission wherein the horizontal axis is output speed and the vertical axis shows transmitted power of variable power units; and 
         FIG. 12  is a graph of the speed of a three mode split-power transmission wherein the horizontal axis is output speed and the vertical axis represents variable unit speed. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       FIGS. 1 and 2  show a vehicle  6  with a frame  8  that represents a compact vehicle such as a forklift, lawn tractor, or the like. Attached to the frame  8  is a vehicle system  10  having an engine  12  and transmission  14  that are connected with a crank shaft  16 , or input shaft. In a first embodiment ( FIG. 1 ) the input shaft  16  is positioned transversely to the direction of the vehicle motion, whereas in a second embodiment ( FIG. 2 ) the input shaft  16  is positioned parallel to the direction of the vehicle motion. The transmission  14  additionally has an output shaft  18 . In the embodiment wherein the crank shaft  16  of engine  12  is transverse to the direction of motion ( FIG. 1 ) a right angle gear box  19  is connected to the output shaft  18  and to the axle  20  that rotates wheels  21 . In the second embodiment ( FIG. 2 ) a power take off device  23  or accessory such as an auxiliary pump, other engine, or the like is mounted to the engine  12  on the side of the engine opposite that of the split-power transmission  14  to provide an auxiliary function. 
       FIG. 3  shows a schematic block diagram of the vehicle system  10  having an engine  12  that is mechanically connected to a split-power transmission (SPT)  14  with the crank shaft  16  that represents an input shaft of the split-power transmission  14 . The split-power transmission  14  has a continuously variable ratio from full reverse speed to maximum forward speed. This allows the engine  12  to be connected to the split-power transmission  14  without a clutch and allows full control of the transmission to achieve optimum power delivery, maximized fuel economy, obtain cruise control and a number of other vehicle performance enhancing features. 
     Additionally, the split-power transmission  14  has an output shaft  18  that mechanically connects the split-power transmission  14  to axle  20 . Electrically connected to the split-power transmission  14  is a controller  22  that is additionally electrically connected to a fuel control device  24 , a power demand device  26  a range select device  28 , an engine start device  30 , optional devices  32 , engine braking device  34 , first and second mode change clutches  36  and  38 , battery  40  and input and output shafts  16  and  18 . Though shown with only first and second mode change clutches  36  and  38 , additional clutches can be used. 
     By being electrically connected to the components listed the controller  22  is able to perform a plurality of functions. For example, the controller  22  operates the fuel control device  24  to send a fuel signal  42  to the engine  12 . Additionally, the controller can send current  44  to the split-power transmission  14 . Other signals and readings received include an input speed signal  46  from the input shaft  16 , voltage  48  measured internally within the controller  22 , a rotor position signal  50  from the split-power transmission  14  and an output speed signal  52  from the output shaft  18 . The controller  22  also sends and receives other signals from the all of the components discussed above. 
     Typical vehicle performance of this system  10  is shown in  FIG. 4 . In  FIG. 4  the transmission output torque  54  is on the vertical axis and output speed  56  is on the horizontal axis. The maximum torque limit  58  occurs near zero speed. Above this speed, the torque is limited by engine power on line  60 . For a two forward mode transmission, mode change would occur at approximately 25%-40% of output speed, depending on the particular gear scheme. Maximum reverse speed is in the range of approximately 25%-50% of maximum forward speed, depending on the vehicle. 
       FIG. 5  shows one embodiment of a split power transmission  14 . In this embodiment the drive line or input shaft  16  is mechanically connected to a gear planetary  62 . The gear planetary  62  has first, second, third and fourth elements  62 W,  62 X,  62 Y and  62 Z. The split-power transmission  14  additionally has first and second variable power units  72  and  74  that are electrically connected to the controller  22 . The variable power unit speeds may be calculated by the controller  22  if the input and output speeds are known along with the mode range. Additionally, first and second variable power units  72  and  74  in one embodiment are electrical motor generators whereas in another embodiment they are hydraulic pump motors. The controller  22  is also electrically connected to first and second clutches  76  and  78  within the split-power transmission  14 . 
     In the embodiment shown in  FIG. 5  the input shaft  16  is mechanically connected within the third element  62 Y of gear planetary  62  while the first element  62 W is connected to the first variable power unit  72 . When the first clutch  76  is engaged, the fourth element  62 Z connects with the second variable power unit  74 . Meanwhile, when the second clutch  78  is engaged the second element  62 X is mechanically connected to the output shaft  18 . 
     Therefore, engine power enters the transmission at drive line or input  16  only at third summer element  62 Y, thus defining an input summer. Consequently, when the first clutch  78  is engaged, the split-power transmission is considered in a first mode wherein the first clutch  76  connects output shaft  18  and variable power unit  74  to the fourth summer element  62 Z. Meanwhile, in a second mode the second clutch  78  is engaged to connect second summer element  62 X to the output shaft  18  and variable power unit  74 . 
     In an embodiment wherein the first and second variable power units  72  and  74  are motor generator units, in order to control transmission ratio and engine power delivery, the control  72  sets current  44  in the motor generator units  72  and  74 . The controller  72  additionally sets the direction of current  44  to control the variable power units  72  and  74  rotational direction and whether each unit  72  and  74  function as a motor or generator. 
     Thus, the controller  22  functions automatically to regulate transmission ratio in response to programmed instructions and the operator commands. As a bi-product the controller  22  may also regulate engine speed, output speed, output torque, fuel delivery, and vehicle acceleration or deceleration. The controller  22  also qualifies and then makes mode shifts, keeps the battery  40  charged, and starts the engine  12  with one of the motor generator units  72  or  74 . Additionally, these control functions can reside in more than one physical control unit  22  and the controller  22  can be electrical and may contain digital logic. 
     In  FIG. 6  a speed diagram for gear planetary  62  is shown. The speed diagram is a graphical illustration of the speed relationships for all the elements of the gear planetary  62 . In  FIG. 6  the vertical axes  80 ,  82 ,  84 ,  86  represent speed and the horizontal axis  88  is planetary ratio. The length between the vertical axes lines  80 ,  82 ,  84 ,  86  represents the ratio of the planetary gears. For example, if axis  80  representing first element  62 W is a ring gear, axis  82  for second element  62 X, a carrier, and axis  86  for fourth element  62 Z a sun, then the ratio D-C represents the ratio of ring teeth to sun teeth. If the speed of second element  62 X was zero and the ratio D-C is −2, and the ratio B-A would be −2 as shown with line  90 . Thus, sun speed would be twice the ring speed and in the opposite direction. 
     For the split-power transmission  14  shown in  FIG. 5  the first mode starts with fourth element  62 Z at zero speed as shown by line  92  intersecting zero speed at axis  86 . Element  62 Y is at input speed as shown by line  92  at axis  84 . When controller  22  causes the variable power units  72  and  74  to change, the ratio of the split-power transmission  14  can drive forward, fourth element  62 Z speeds up and element  62 X slows down and goes negative as shown by line  94  at axis  80 . At this speed condition, the second mode is engaged with the second clutch  78  by changing output shaft  18  and second variable power unit  74  from fourth element  62 Z to second element  62 X. This includes a ratio change at second variable power unit  74 /output shaft  18  to achieve synchronous speed shifts. This allows a further increase in output speed up to line  95  at axis  84  by reversing the speed change of the first variable power unit  72 . Maximum reverse speed is also line  95  but is at axis  80  with first clutch  76  engaged in the first mode. 
     The particular gear scheme required would depend on the design of the first and second variable power units  72  and  74 . The gear scheme would also depend on the design of the input shaft  16  and the output shaft  18  spatial configurations. 
       FIG. 7  shows a graph of variable power for first and second variable power units  72  and  74  of the split-power transmission  14  shown in  FIG. 5  shown on an axis  96 . Meanwhile, the horizontal axis is represented with the same output speed  56  as shown in  FIG. 4 . In operation, starting forward from zero speed, first variable power unit  72  acts as a generator or pump supplying power to second variable power unit  74 . Positive power flows from unit  72  to unit  74  in the direction of engine power delivery. Power is also delivered to output shaft  18  by planetary  62  through first clutch  76  and is additive to the second variable power unit  74  power. As output shaft  18  speeds up, unit  72  slows down and reverses direction. This is shown as point  98  in  FIG. 6 . Near zero speed for unit  72 , unit  74  becomes a generator or pump and beyond zero speed unit  72  becomes a motor. With unit  72  at a negative speed, power flows in the opposite direction of the engine and recirculates through planetary summer  62 . This is shown as negative power between point  98  and point  100  of  FIG. 7 . Thus point  100  represents the shift point between the first and second modes. 
     The gear arrangement provides for near synchronous speed of second clutch  78  at the shift point  100  producing no ratio change in the split-power transmission  14 . After shift, unit  72  speed becomes less negative and then increases positively as the output speeds up. Unit  74  continues to increase speed as output speed increases. After shift, the units  72  and  74  reverse their direction of power flow as unit  72  again becomes a generator or a pump and unit  74  a motor as graphically shown in  FIG. 7  from point  100  to point  102 . 
     Because of the electrical slip when delivering power, a variable power unit, for example a generator, may need to operate faster than a motor if the generator is sized similarly. Because a battery  40  is not large enough to supply the needed transmission power, unit  72  may be required to make a speed increase during the shift in order to maintain continuous power delivery. This may be done by making a pre synchronous shift by using second clutch  78  to effect the speed change. On  FIG. 8 , line  104  is at the shift speed. The speed of unit  72  before shift is represented by line  106  and the speed of the unit  72  after the shift is represented by line  108 . When the second clutch  78  is engaged pre-synchronously, a speed shift from point  100 - 1  to point  100 - 2  occurs that allows unit  72  to change from a motor to a generator and deliver continuous power. This enables first and second variable power units  72  and  74  to remain in a closed circuit without external power or exceeding voltage or current limits. As electrical motor generators have a relatively large inertia for the amount of power delivered, a high energy, multiple disc clutch may be required. 
     Reverse speed is achieved by reversing the direction of current to unit  72  with controller  22  when first clutch  76  is engaged. This causes the output to rotate in the opposite direction. Unit  72  is a generator or pump and unit  74  is a motor turning in the opposite direction from that in forward. Continuous power is delivered from the engine to the wheels with continuous ratio change, from full reverse to full forward speed even though the transmission changes modes between zero and maximum speed. 
     For down shifts, the process is reversed and shifts would be post synchronous, on the low speed side of synchronous. If braking, the power flow in the variable power units  72  and  74  is reversed and the shifts take place on the opposite side of synchronous as for driving. Controller  22  may integrate engine braking with mechanical service brakes. 
     The engine starting function is accomplished by mechanically blocking rotation of either of the first or second clutches  76  or  78  and supplying electrical power through controller  22  to unit  72 . The battery charging function is accomplished by bleeding electrical power from the unit  72  or  74  that is acting as a generator through controller  22 . Transmission control functions are accomplished in a manner similar to that in U.S. Pat. No. 5,560,203 that is incorporated herein, except that variable power unit current is controlled instead of unit displacement. Shift points are made based on unit  72  and  74  speed and power delivery, both of which are sensed by controller  22 . 
       FIG. 9  shows an alternative embodiment of a split-power transmission  14  wherein the split-power transmission  14  has three modes with an output power summer  120  having first, second, third and fourth output power summer elements  120 W,  120 X,  120 Y, and  120 Z. The output power summer  120 , in one embodiment, is a gear planetary that works in association with the input shaft  16 , first and second variable units  72  and  74 , and controller  22  to produce an output speed upon output shaft  18 . 
     Specifically, the output summer  120  works in association with first, second and third clutch elements  122 ,  124 , and  126  and reversing gear  128  to provide the output speed. Engine power enters the transmission  14  at drive line or input shaft  16  and splits between variable power unit  72  and either first, second or third clutch elements  122 ,  124 , and  126 . Output shaft  18  is connected only to summer second element  120 X, thus the defining an output summer. Additionally, variable power unit  74  is connected to fourth summer element  120 Z. 
     In a first mode, the first clutch element  122  connects the input shaft  16  to the first summer element  120 W. In a second mode the second clutch element  124  connects the third summer element  120 Y to the input shaft  16  wherein reverse is achieved by connecting the second summer element  23 Y to input shaft  16  through the reversing gear  128 . 
     The speed diagram for the split-power transmission  14  of  FIG. 9  is shown in  FIG. 10 . As shown by line  130 , the first mode starts with element  120 X at zero speed wherein element  120 W is at the input shaft speed and element  120 Z is at a negative speed. When controller  22  causes units  72  and  74  to change the ratio of the split-power transmission  14  to drive the vehicle forward element  120 Z reduces its negative speed and then increases speed positively causing element  120 X to increase in speed. As shown by line  132 , a complete speed direction change of element  120 Z raises element  120 Y to near input shaft speed. By engaging the second clutch element  124  the transmission  14  is placed in a second mode at line  132  by changing the input shaft  16  connection from element  120 W to element  120 Y, including a ratio change if necessary to achieve near synchronous speed shifts. This allows a further increase in output speed up to line  134  by reversing the speed change of unit  74  and element  120 Z. Maximum reverse speed shown by line  138  wherein the third clutch element, or reverse mode clutch  126  is engaged. 
     Again, similar to the transmission  14  of  FIG. 5  the particular gear scheme required for the transmission  14  of  FIG. 7  would depend on the design of the first and second variable power units  72  and  74 . The gear scheme would also depend on the design of the input shaft  16  and the output shaft  18  spatial configurations. 
       FIG. 11  shows transmitted power for units  72  and  74  for split-power transmission of  FIG. 9  wherein power  140  is shown on the vertical axis and output speed  56  on the horizontal axis. The output speed  56  of  FIG. 11  is identical to the output speed  56  shown in  FIG. 4 . In operation, when starting forward from zero speed, unit  74  acts as generator or pump that supplies power to unit  72 . Negative, recirculating power flows from unit  74  to unit  72 , opposite the direction of engine power delivery. This power plus power from the engine  12  is delivered to summer  120  through first clutch element  122  and split to output shaft  18 . As the output shaft  18  speeds up, unit  74  slows down and reverses direction. This is shown as point  142  in  FIG. 11 . Near zero speed for unit  74 , unit  72  becomes a generator or pump and beyond zero speed unit  74  becomes a motor. With unit  74  at positive speed, power flows in the same direction of the engine. This is shown as positive power between points  142  and  144 . Thus, point  144  is considered the shift point between the first and second modes. 
     The gear arrangement provides for near synchronous speed of second clutch element  124  at the shift point  144 , producing no ratio change in split-power transmission  14 . After the shift, the speed of unit  74  reduces and then increases negatively as the output shaft increases speed. Unit  74  continues to increase speed negatively as the output shaft speed increases. 
     After the shift, the units  72  and  74  reverse their direction of power flow causing unit  74  again to become a generator or pump and unit  72  a motor. This is shown graphically in  FIG. 11  as a shift in power from point  144  to point  146 . As with the split-power transmission of  FIG. 5 , a pre-synchronous shift is made using the second clutch element  124  to effect this speed change. 
     As shown in  FIG. 12 , line  148  is at the shift speed. The speed of unit  74  before shift is represented by line  150 , and the speed of unit  74  after shift is represented by line  152 . When second clutch element  124  is engaged pre-synchronously, a speed shift from point  144 - 1  to  144 - 2  occurs that allows unit  74  to change from a motor to a generator. This enables units  72  and  74  to remain in a closed circuit without external power and without exceeding voltage or current limits. 
     Reverse speed is achieved by engaging reverse mode clutch  126 . This connects planetary element  120 Y to input shaft  16  through the reversing direction of unit  74 . Unit  74  is a generator or pump and unit  18  is a motor, both turning in the same direction as that in forward. When making dynamic mode shifts from forward to reverse, most shifts occur transitioning from braking in forward to driving in reverse. This constitutes a power reversal in the variable power units and is accommodated with a pre-synchronous shift that occurs near zero output speed. 
     Continuous power is delivered from the engine to the wheels, with continuous ratio change, from full reverse to full forward speed even though the transmission changes modes between zero and maximum speed forward, and at zero speed for reverse. Other functions are accomplished as in discussed above regarding the split-power transmission of  FIG. 5 . 
     The choice of either of the split-power transmissions described depends upon how the power flows in the transmission match up to the duty cycle of the vehicle. Typically, recirculating power in the transmission is less efficient and lower life than non-recirculating power. The length of time and the power being delivered at various vehicle speeds would be considered. In either case, the vehicle has a continuous speed ratio from maximum reverse speed to maximum forward speed with any of the transmissions. 
     The same block diagrams and speed diagrams shown in  FIGS. 5-7  and  9 - 11  may be applied to split power transmissions having either electrical or hydrostatic units for the variable power delivery portion. The power flows and unit speeds before and after shift would be similar, as in  FIGS. 5-7  and  9 - 11 . 
     Thus, the disclosed transmission provides a continuous ratio from full reverse to full forward speed. By providing a controlled output speed through zero, the transmission eliminates the need for any clutch between the engine  12  and the transmission  14 . As shown above, the embodiments provided contemplate approaches that vary the location of a power summing planetary  62  and  120  and show transmissions with two forward modes. Furthermore, versions having a single forward mode or with three or more modes, could be used by altering the gear scheme and the sizing of the variable power units  72  and  74 . 
     Additionally disclosed is a control system  22  that performs functions for controlling the transmission and vehicle. This includes controlling transmission ratio, modes shifts, engine fuel delivery, engine braking and providing the engine start and battery recharge functions. Thus, at the very least, all of the stated objectives have been met. 
     It will be appreciated by those skilled in the art that other various modifications could be made to the device without the parting from the spirit in scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby.

Technology Category: 7