Abstract: Methods and apparatus are provided for operating a free-piston linear alternator. The apparatus includes a linear machine having first and second coils wound around a path for a linearly-moving mass and a rotating machine having a rotating mass and third and fourth coils. The first coil is coupled to the third coil, and the second coil is coupled to the fourth coil, such that movement of the linearly-moving mass with respect to the first and second coils imparts a first magnetic field upon the rotating mass via the third and fourth coils. Further, movement of the rotating mass with respect to the third and fourth coils creates a second magnetic field upon the linearly-moving mass to position the linearly moving mass for combustion.

Abstract: An electric motor power connection assembly diverts heat from an electrical conductor that carries electrical current between a power source and an electric motor. The electrical conductor is characterized by an effective cross-sectional area perpendicular to the direction of current flow and a length in the direction of current flow that is greater than the radius of a circle having the effective cross-sectional area. The “effective cross-sectional area” is the area perpendicular to the direction of current flow over which current is carried and thus depends on the cross-sectional shape and number of conductive components of the electrical conductor, which could be one or more wires. A heat diverting mechanism is positioned in thermal contact along the length of the electrical conductor to divert heat from the electrical conductor. The electric motor power connection assembly is suitable for use in a hybrid electro-mechanical transmission.

Abstract: An electrically-variable transmission is provided with input member and output member, first and second motor/generators, a first planetary gear set and a final drive gearset. Two or three torque-transmitting mechanisms that are selectively engagable alone or in different combinations to establish at least one forward electric-only operating mode including a series mode, an output split mode, and at least one neutral mode including a purely neutral mode and a neutral battery charge mode. The transmission optionally includes a one-way clutch selected from the group of friction clutch and dog clutch, or is a lockable one-way clutch, for enabling low loss forward operation, regenerative braking functionality, and/or reverse vehicle operation.

Abstract: A method of making a motor stator core having a back iron and a plurality of teeth extending radially inward from the back iron includes providing the plurality of teeth and the back iron from oriented steel so that a magnetic flux transmission path is formed with superior properties in essentially one direction. At least one of the plurality of teeth and the back iron is annealed in selected portions so as to improve magnetic flux transmission in a second direction, different from the one direction.

Abstract: A powertrain is provided with an input clutch that is disengagable to allow a transmission input member to rotate independently of engine speed under power of a motor and provide an alternative way to power vehicle accessories otherwise driven by engine torque, while still allowing the motor to start the engine. A powertrain having a parallel combination of input clutches including a friction input clutch and a selectable one-way clutch is provided, as well as a method of control of such a powertrain. Another method of controlling a hybrid vehicle powertrain includes starting the engine via torque from a motor with the input clutch biased in an engaged position. If vehicle operating conditions are more efficiently met without operating the engine, the input clutch is disengaged to so that torque is provided only by the motor to the output member and to vehicle accessories operatively connected to the input member.

Abstract: An electric motor assembly in a vehicle powertrain is provided with a generally annular stator fit within an interior cavity of the powertrain defined by a housing. Roll pins are fit between the housing and the stator. The stator may have a plurality of first geometric features and the housing a plurality of second geometric features. The first geometric features are be configured to align with the second geometric features when the stator is fit within the cavity, with the roll pins fit between the housing and the stator at the aligned first and second geometric features. A method of assembling the electric motor assembly is also provided.

Abstract: A method of operating a hybrid powertrain is provided that permits operation in multiple fixed ratio modes appropriate for towing and other vehicle operating conditions in which relatively high output torque is required. The method includes establishing three different electrically-variable operating modes by engaging different torque-transmitting mechanisms in response to different respective vehicle operating conditions. The method further includes establishing at least two different fixed ratio modes by engaging another torque-transmitting mechanism in addition to the respective different torque-transmitting mechanisms engaged to establish the electrically-variable operating modes. A hybrid powertrain having a controller configured to control the powertrain to operate according to the method is also provided.

Abstract: A hybrid powertrain for a vehicle is provided that includes an engine having a crankshaft and a motor/generator operatively connected to the crankshaft. An elastic member is operatively connected to the crankshaft and configured to be wound by one of the engine or the motor/generator. A one-way torque-transmitting mechanism is operatively connected to a first end portion of the elastic member and configured to overrun prior to winding of the elastic member. The elastic member is configured to be releasable to allow unwinding of the elastic member to rotate the crankshaft to restart the engine. A method of starting an engine on a hybrid vehicle is also provided.

Abstract: An input brake assembly is provided for selectively grounding a transmission input member. The packaging location of the input brake assembly does not interfere with, and thus still allows the option of providing a bypass clutch for a flex plate-type flywheel connecting the engine with the transmission input member. The input brake assembly includes a flywheel, preferably a flex plate, for transferring rotary torque between the engine and the transmission input member and a ring gear secured to the outer periphery of the flex plate. A pinion gear is axially movable into and out of meshing engagement with the ring gear. A grounding device is operatively connected to the pinion gear and is operable to prevent rotation of the pinion gear, thereby braking the flex plate as well as the transmission input member operatively connected thereto when the pinion gear is in meshing engagement with the ring gear.

Abstract: Various embodiments of electrically-variable transmissions have first and second motor-generators, first and second planetary gear sets, and two torque-transmitting mechanisms, including a rotating-type torque-transmitting mechanism and a stationary-type torque-transmitting mechanism. An input member is connected for common rotation with a ring gear of the first planetary gear set. Carrier members of both of the planetary gear sets are connected for common rotation with one another, and with an output member, via one or more radial-extending hub members and an axial-extending member or shaft. The first motor/generator is connected for common rotation with the sun gear of the first planetary gear set. The second motor/generator is connected for common rotation with the sun gear member of the second planetary gear set. In each embodiment, the various components of the transmission are positioned relative to one another to minimize the number and/or size of interconnecting shafts and shells.

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: The present invention provides an accessory drive system for a hybrid vehicle. The accessory drive system includes an inverter operatively connected to a direct current battery. The inverter is configured to convert the direct current from the battery into three-phase alternating current. The accessory drive system also includes a transmission having a first motor/generator operable to drive the hybrid vehicle. The first motor/generator is a Y-connected three phase motor/generator that defines a first neutral point. A second motor/generator is connected to an accessory and to the first neutral point. Output from the battery is transferable through the first neutral point to the second motor/generator such that the accessory is driven at a selectable rate.

Abstract: A hybrid powertrain is provided including an internal combustion engine sufficiently configured for operation in a homogeneous charge compression ignition mode of operation. An electric motor and an electric storage device are provided in parallel hybrid combination with the internal combustion engine. A transmission is operatively connected to the internal combustion engine and the electric motor. The engine may operate in one of a two-stroke and a four-stroke cycle.

Abstract: An electrically variable transmission includes an input member, an output member, two planetary gear sets, two electric motors, a plurality of coupling members and a plurality of torque transmitting devices. Each of the planetary gear sets includes first, second and third members. The torque transmitting devices include a rotating clutch and a brake. The rotating clutch and the brake share a common fixed connection. The rotating clutch is released by a stationary actuator that engages a rotatable release plate. The actuator is engaged to release the rotating clutch when the brake is engaged.

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: An automatic dual clutch transmission includes an input clutch which selectively connects a prime mover to an electric motor. The electric motor output, in turn, drives a pair of gears, one of which is in constant mesh with a first gear on a first quill and a second gear on a second quill, the other being in constant mesh with a third gear on the first quill and a fourth gear on the second quill. On each quill, between each pair of gears driven by the input is a pair of dog clutches which connect one of the two gears to the associated quill. Each of the quills drives an input of a respective pair of friction clutches which drive a respective pair of layshafts or countershafts. A similar arrangement of a second pair of gears flanked by dog clutches connects each layshaft or countershaft through one of a pair of gears which are in constant mesh with a pair of output gears coupled to and driving a differential cage.

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 powertrain includes a hybrid electro-mechanical transmission and a power source. A planetary gear set having a first, a second, and a third member connects the power source with a first and a second motor/generator. A battery is operatively connected to the motor/generators for receiving power therefrom and delivering power thereto. An input member rotates with the first member, the first motor/generator rotates with the second member, and the second motor/generator rotates with the output member. A first torque-transmitting mechanism is engagable to connect the second motor/generator for rotation with the third member. The battery and the second motor/generator provide an electric-only operating mode to power the output member when the first torque-transmitting mechanism is not engaged; the power source, planetary gear set and first motor/generator thereby being disconnected from the output member during the electric-only operating mode to prevent parasitic drag.

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: There is provided a transmission device having an electrically variable output that employs three electrically powered motor-generators, or machines. The electrically-variable transmission device comprises first, second and third electrical machines coaxial to and coupled to a plurality of planetary gear sets. Each planetary gear set coupled to a main shaft operative to transmit torque therebetween and operative to transmit torque to an output. There is an input mechanically coupled to one of the planetary gear sets. This transmission device can transmit mechanical power with a continuously variable ratio of the input shaft speed to the output shaft speed using two of the electric motors at a time, forming an input-split or either an output-split or a compound-split. A selectively actuable brake device is operative to multiply torque output from the second electrical machine.