Abstract: A hybrid transmission that is operatively connected with an engine includes an input member operatively connected with the engine, at least one intermediate member, and an output member. A plurality of selectively engagable torque-transmitting mechanisms enable the input member to be selectively operatively connected to the at least one intermediate member through the first gearing arrangement by engagement of different ones of a first set of the torque-transmitting mechanisms. A single motor/generator is operatively connectable to the at least one intermediate member and is selectively operatively connected to the output member in two alternative ways through the second gearing arrangement by selective engagement of two respective ones of a second set of the torque-transmitting mechanisms to establish two different torque ratios between the at least one intermediate member and the output member.

Abstract: A powertrain includes a plurality of torque generative devices and a transmission having an output shaft, a plurality of planetary gear sets connecting the torque generative devices to the output shaft, and a selectable one-way clutch connected to a first of the planetary gear sets. A method to control the powertrain includes monitoring a desired transmission setting selection comprising one of a low range continuously variable gear mode, a high range continuously variable gear mode, and a fixed gear mode, determining a desired state for the selectable one-way clutch based upon the desired transmission setting selection, and actuating the selectable one-way clutch to effect the desired state for the selectable one-way clutch.

Abstract: A transmission has a motor assembly with a stationary portion surrounding a rotor. The transmission also includes a clutch housing. A transmission casing surrounds the motor and the clutch housing. The stationary portion is rigidly connected to and supported by the clutch housing. Thus, a separate housing for the motor/generator is avoided. The housing may also support one or more motor bearings, seals, clutch pistons, or clutch plates.

Abstract: A control system for a hybrid powertrain determines operator demands, a powertrain operating state, and operating conditions based upon the inputs; selects an operating strategy based upon the operator demands, the powertrain operating state, and the operating conditions; determines a preferred powertrain operating state; and controls the powertrain to the preferred powertrain operating state based upon the selected operating strategy, the operator demands and the operating conditions.

Abstract: A hybrid transmission is provided that has both a hybrid series operating mode and a compound-split operating mode. The transmission includes an input member operatively connected with the engine, an output member, and a plurality of selectively engageable torque-transmitting mechanisms. A gearing arrangement and first and second motor/generators operatively connected with the gearing arrangement are also provided. The gearing arrangement includes a first, a second, and a third planetary gear set, each having a first, a second, and a third member. A pair of interconnecting members connect two respective ones of the members of one of the planetary gear sets for common rotation with two respective ones of the members of another of the planetary gear sets. Another interconnecting member connects a third of the members of the one of the planetary gear sets for common rotation with one of the members of still another of the planetary gear sets.

Abstract: A dual clutch transmission is provided including a transmission input member, a first output member, a first, second, third and fourth gear sets, a first and second countershafts, and a first and second sleeve shafts. In operation, the first countershaft is engaged to the first sleeve shaft or the second countershaft is engaged to the second sleeve shaft, at least one of the first and second gears of the first and second gear sets is engaged to at least one of the first and second sleeve shafts, and at least one of the first and second gears of the third and fourth gear sets is engaged to at least one of the first and second countershafts to establish at least eight forward speed ratios between the transmission input member and the output shaft.

Abstract: A vehicle includes a high-voltage (HV) energy storage system (ESS), an HV power bus, a DC-DC power converter electrically connected to the HV power bus, an HV bus connector, a low voltage (LV) battery power bus, and a pair of LV bus connectors. The vehicle includes a vehicle module electrically connected to the HV and LV bus connectors, an LV power bus electrically connected to the DC-DC power converter and to the module, and a controller. The controller has an algorithm that controls the converter to power the module via one of the LV bus connectors during a transient LV condition. The converter and a method of controlling the same are also provided, with the method including determining the LV condition, powering the vehicle module via one of the LV bus connectors during the transient LV condition, and powering the module via the other LV connector otherwise.

Abstract: An electric torque converter has a torque converter input member connected to the first node of a differential gear set representable by a lever diagram having first, second, and third nodes. A motor/generator is connected to the second node. The third node is connected to an input member of a transmission gearing arrangement. A brake is selectively engagable to ground the first node to a stationary member. Engagement of the brake provides a regenerative braking mode and an electric-only driving mode, with the motor/generator connected to the transmission gearing arrangement through the differential gear set. Various clutches may be provided for lock-up or selective connection of the engine, including arrangements which reduce motor/generator torque required for engine starting while in electric-only driving. A method of operating a vehicle maintains the engine speed at an optimum level to the extent possible given battery charge levels and operator commands.

Abstract: A hybrid transmission having an input member, an output member, and a single motor/generator is characterized by a plurality of fixed-ratio modes of operation and at least one electrically variable mode of operation. In the fixed-ratio modes of operation, the speed ratio between the input member and the output member is independent of the speed of the motor/generator. In the electrically variable mode of operation, the speed ratio between the input member and the output member is dependent upon the speed of the motor/generator.

Abstract: A vehicle includes first and second battery packs having respective first and second banks of contactors. The packs are wired in electrical parallel. A propulsion system is driven using electrical power from the packs. A controller determines which pack has the highest state of charge (SOC), and balances the SOC of the packs by controlling an open/closed state of the contactors. Contactors open to disconnect the pack having the highest SOC, and close again when a voltage difference between the packs is approximately zero. A system for use in the vehicle includes the packs, contactors, and controller. A method for controlling power flow in the vehicle includes determining which pack has the highest SOC, opening designated contactors during a near zero current event to disconnect the battery pack having the highest SOC, and closing the designated contactors when a voltage difference between the packs is approximately zero.

Abstract: A hybrid transmission is provided with a motor and a torque-transfer device is operable to transfer torque from the motor to a transmission input member upstream in power flow from the transmission gearing arrangement. The torque transfer device may be a fluid coupling, such as a torque converter, including a torque converter lock-up clutch. In other embodiments, the torque transfer device is a launch clutch that may be either a wet clutch engagable via pressurized transmission fluid, or a dry clutch, such as used in a manual transmission. A disconnect clutch is selectively engagable to operatively connect an engine connection member with the motor to permit the motor to start the engine, such as after a stop. Many embodiments of the transmission include a one-way clutch arranged in parallel with the disconnect clutch. A method of starting the engine using such a transmission is also provided.

Abstract: A squirrel cage rotor structure used in connection with an electrical machine is formed from a high-strength, high-conductivity, and heat-treatable aluminum alloy, e.g., a T61 tempered aluminum alloy, such as A6101-T61. The resulting structure has improved strength compared to conventional pure aluminum structures, while at the same time limiting the reduction in electrical conductivity.

Abstract: A transmission has an input member and an output member, first and second intermediate shafts having substantially identical gear sets with gears concentric with and selectively connectable for rotation with the first and second intermediate shafts, respectively. Output gears are concentric with and rotatable with the output member and mesh with the substantially identical gear sets. First and second torque-transmitting devices are operable for transmitting torque from the input member to the first and second intermediate shafts, respectively. Torque-transmitting mechanisms are mounted concentric with, rotatable about and selectively engagable with the gears mounted on the intermediate shafts. A controller is operatively connected to the torque-transmitting mechanisms and to at least one of the torque-transmitting devices.

Abstract: An electrically-variable transmission is provided with substantially identical motor modules to simplify assembly and realize economies of scale in purchasing and testing the motor modules. First and second motor modules are packaged within a transmission casing and are operatively connecting the input member and the output member and coaxially arranged about the axis of rotation. Each motor module includes a respective motor/generator with a rotor rotatable about the axis of rotation and defining a rotor cavity. A planetary gear set is packaged within the cavity and has a first, a second and a third member. A rotor hub supports the rotor and has first and second annular end portions at opposing ends of the rotor hub, and an annular midportion connected for common rotation with the first member of the planetary gear set. A selectively engagable rotating-type clutch is packaged within the cavity and connected with the rotor hub.

Abstract: A hybrid control system for a hybrid electric vehicle (HEV) includes a hybrid control module. The hybrid control module includes a first motor control module that controls output torque of a first motor. A second motor control module controls output torque of a second motor based on a second motor torque request signal. The second motor torque request signal is generated based on a transmission output torque request signal prior to startup of an engine of the HEV. An override module generates a torque override request signal during the startup. The first motor control module controls output torque of the first motor to crank the engine during the startup. The second motor control module adjusts output torque of the second motor based on the torque override request signal and not the transmission output torque request signal during the startup to minimize vehicle jerk during the engine start.

Abstract: A hybrid powertrain system for a vehicle includes an engine and a transmission. The transmission includes a transmission input member, first and second electric machines, first and second planetary gear sets, and a plurality of selectively engageable torque transfer devices enabling configuring the powertrain in variously to operate in electric drive, electrically variable, fixed gear and neutral charging operating states.

Abstract: A stator assembly for an electric motor includes an annular core centered about an axis of rotation of an inner rotor which the stator assembly surrounds. The stator assembly has a plurality of electrical windings, each wound in a respective spiral around the outer surface of the core and arranged for current to flow in the windings. In some embodiments, the respective spirals are spaced from and parallel with one another. The stator assembly may have pole pieces that substantially enclose the core and windings. The pole pieces may be configured to taper both radially outward and axially inward to thereby concentrate flux from the core to an inner surface of the pole pieces facing the rotor.

Abstract: An input shaft for a hybrid transmission includes a cylindrical hollow shaft portion having internal and external surfaces. The internal surface defines an internal cavity coaxial with the hollow shaft portion and has a splined portion configured to allow power to be transferred to the hollow shaft portion. The input shaft may further include a freeze plug press-fit in the internal cavity, configured to fluidly seal the inner cavity in embodiments with a cavity extending throughout the input shaft. The splined portion may be a broached spline. A method of manufacturing a hybrid powertrain includes forming a hollow transmission input shaft and press-fitting a plug into it, such that the shaft is internally fluid sealed. The shaft is mated to the transmission which may then be filled with fluid and tested for operability. The shaft may be dry-mated to an engine output member for common rotation therewith.

Abstract: An automatic dual clutch transmission includes an input clutch which selectively connects a prime mover to an electric motor. The electric motor, in turn, is connected to the inputs of a pair of coaxial friction clutches. Each of the coaxial outputs of the friction clutches drives an input gear with meshes with a pair of gears, one of which is associated with each of a respective pair of layshafts or countershafts. On each countershaft, between the pair of gears driven by the outputs of the two clutches, are a pair of synchronizer clutches which selectively synchronize and connect one of the two gears to the associated countershaft. A similar arrangement of a second pair of gears separated by synchronizer clutches connects the countershafts through a selected gear to a pair of output gears coupled to and driving a differential cage or spool.

Abstract: A vehicle has a powertrain including an engine and at least one electric machine. A method for maximizing range capability of the vehicle while operating in an electric vehicle operating state includes determining an incipient electric vehicle operating state of the powertrain, setting a preferred charge/discharge rate of an electric energy storage device to a maximum charging rate, and controlling the powertrain to an operating state including an engine state that is ON to effect charging the electrical energy storage device based on the maximum charging rate.