Driveline assembly including torque vectoring system

A driveline assembly for a vehicle, including:

• an electric motor;
• a differential coupled with the electric motor to receive torque from the electric motor;
• a pair of primary shafts disposed along an axis and rotatably coupled with the differential for receiving torque from the differential;
• a pair of reducers each coupled with one of the primary shafts, each reducer including:
• a sun gear fixed about the primary shaft for rotating with the primary shaft;
• a plurality of planet gears meshed with and rotatable about the sun gear;
• a ring positioned about and meshed with the planet gears;
• a planet carrier connected to each of the planet gears and rotatable about the axis with the planet gears;
• a wheel output fixed to the planet carrier and rotatable about the axis with the planet carrier;
• a low gear clutch moveable between an engaged position and a disengaged position, wherein the low gear clutch fixes the ring to a ground in the engaged position to provide a first gear reduction between the primary shaft and the wheel output, and wherein the low gear clutch disconnects the ring from the ground in the disengaged position to provide a second gear reduction between the primary shaft and the wheel output, wherein the second gear reduction is smaller than the first gear reduction;
• an upshift clutch separate from the low gear clutch and moveable between a contact position and a released position, wherein the upshift clutch fixes the primary shaft to the wheel output in the contact position and provides a 1:1 ratio between the primary shaft and the wheel output, and wherein the upshift clutch disconnects the primary shaft from the wheel output in the released position to provide a gear reduction between the primary shaft and the wheel output;
• wherein the upshift clutch rotationally fixes the ring to the planet carrier in the contact position, and wherein the upshift clutch spaces the ring from the planet carrier in the released position to allow independent rotational speeds of the ring relative to the planet carrier;
• a controller connected with the low gear clutch and the upshift clutch of each of the reducers for selectively shifting the low gear clutch and the upshift clutch.

A method for operating a driveline assembly for a vehicle,

• the method including:
• identifying a torque vectoring event for a first wheel output during a low range drive operation with a controller;
• shifting a center clutch of a differential from an unlocked position to a locked position during the torque vectoring event, wherein a first primary shaft and a second primary shaft are coupled to the differential and able to rotate at different speeds than one another while the center clutch is in the unlocked position, and wherein the first and second primary shafts are fixed for rotation at a 1:1 ratio relative to one another while the center clutch is in the locked position;
• and
• shifting a first upshift clutch of a first reducer that is coupled to the first primary shaft from a contact position toward a released position during the torque vectoring event, wherein the first upshift clutch fixes the first primary shaft to a first wheel output in the contact position to provide a 1:1 gear ratio between the first primary shaft and the first wheel output while in the contact position, and wherein the first upshift clutch provides a gear reduction between the first primary shaft and the first wheel output in the released position to provide a low speed and high torque output to the first wheel output while in the released position;
• wherein the first reducer includes:
• a sun gear fixed about the first primary shaft for rotating with the first primary shaft;
• a plurality of planet gears meshed with and rotatable about the sun gear;
• a ring positioned about and meshed with the planet gears;
• a planet carrier rotatably connected to each of the planet gears and rotatable about the axis with the planet gears and fixed to the first wheel output;
• a low gear clutch moveable between an engaged position and a disengaged position, wherein the low gear clutch fixes the ring to a ground in the engaged position, and wherein the low gear clutch disconnects the ring from the ground in the disengaged position;
• and
• the first upshift clutch;
• wherein the first upshift clutch rotationally fixes the ring to the planet carrier in the contact position, and wherein the first upshift clutch spaces the ring from the planet carrier in the released position to allow independent rotational speeds of the ring relative to the planet carrier.

A method for operating a driveline assembly for a vehicle, wherein the driveline assembly includes a differential coupled with an electric motor to receive torque from the electric motor, a first primary shaft and a second primary shaft each rotatably coupled with the differential for receiving torque from the differential, the differential including a center clutch configured to be switched between a locked position causing the first and second primary shafts to rotate at the same speed as one another and an unlocked position allowing the first and second primary shafts to rotate at different speeds relative to one another, a first reducer coupled with the first primary shaft and a second reducer coupled with the second primary shaft, the first reducer connected to a first wheel output and the second reducer connected to a second wheel output, wherein the first and second reducers are configured to selectively provide different gear ratios at the first and second wheel outputs, wherein the first reducer includes a first sun gear fixed about the first primary shaft, a plurality of first planet gears meshed with and rotatable about the first sun gear, a first planet carrier connected to each of the first planet gears and rotatable about the axis with the first planet gears and fixed to the first wheel output, and wherein the second reducer includes a second sun gear fixed about the second primary shaft, a plurality of second planet gears meshed with and rotatable about the second sun gear, a second planet carrier connected to each of the second planet gears and rotatable about the axis with the second planet gears and fixed to the second wheel output, the method including:

• identifying a torque vectoring event for the first wheel output during a high range drive operation with a controller;
• shifting the center clutch of the differential from the unlocked position to the locked position during the torque vectoring event;
• shifting a second upshift clutch of the second reducer that is coupled to the second primary shaft from a contact position into a released position while shifting the center clutch to the locked position, wherein the second upshift clutch fixes the second sun gear of the second reducer assembly to the second wheel output in the contact position, providing a 1:1 ratio to provide a high speed and low torque output to the second wheel output while in the contact position, and wherein the second upshift clutch spaces the second sun gear from the second wheel output while in the released position, providing a gear reduction between the second primary shaft and the second wheel output in the released position to provide a low speed and high torque output to the second wheel output while in the released position;
• increasing torque to an output shaft of the electric motor, wherein the torque is increased to a level required by the first wheel output to overcome the torque vectoring event;
• modulating a first upshift clutch of the first reducer from a contact position into a released position, wherein the first upshift clutch directly fixes the first sun gear of the first reducer assembly to the first wheel output in the contact position, providing a 1:1 ratio to provide a high speed and low torque output to the first wheel output while in the contact position, and wherein the first upshift clutch spaces the first sun gear from the first wheel output while in the released position, providing a gear reduction between the first primary shaft and the first wheel output in the released position to provide a low speed and high torque output to the first wheel output while in the released position;
• shifting the second upshift clutch into the contact position and shifting the center clutch into the unlocked position after the torque event is over.