Method and control apparatus for recuperating energy in a hybrid vehicle

• US 10,166,969 B2
• Filed: 05/18/2016
• Issued: 01/01/2019
• Est. Priority Date: 05/19/2015
• Status: Active Grant

• Current Assignee: MAN Truck & Bus AG (Volkswagen AG)
• Original Assignee: MAN Truck & Bus AG (Volkswagen AG)
• Inventors: Fischer, Detlef, Pfau, Stefan, Hierlmeier, Matthias
• Primary Examiner(s): Smith, Jelani A
• Assistant Examiner(s): Williams, Kelly D
• Application Number:
  US15/157,629
• Publication Number:
  US 20160339901A1
• Time in Patent Office: 958 Days
• Field of Search: None
• CPC Class Codes: B60K 2006/268 Electric drive motor starts the engine, i.e. used as starter motor
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60L 58/13 Maintaining the SoC within a determined range
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/14 in conjunction with braking regeneration
• CPC Class Codes: B60W 2510/244 Charge state
• CPC Class Codes: B60W 2520/10 Longitudinal speed
• CPC Class Codes: B60W 2710/248 Current for loading or unloading
• CPC Class Codes: B60W 50/0097 Predicting future conditions
• CPC Class Codes: F02N 11/0825 related to prevention of engine restart failure, e.g. disabling automatic stop at low battery state
• CPC Class Codes: F02N 11/0866 comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 2011/0896 Inverters for electric machines, e.g. starter-generators
• CPC Class Codes: F02N 2200/046 Energy or power necessary for starting
• CPC Class Codes: F02N 2200/061 Battery state of charge [SOC]
• CPC Class Codes: F02N 2200/0801 Vehicle speed
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements

Abstract

A method and apparatus for recuperating energy in a hybrid vehicle, having an internal combustion engine an electrical machine, and on-board electrical system with an energy store that can be charged with electrical energy during a recuperation operation. A recuperation power for a recuperation operation of the electrical machine is set to a first value that allows a recuperation operation with a maximum generator capacity of the electrical machine if an actual energy level of the energy store is lower than or equal to a threshold value. However, the recuperation power for a recuperation operation is set to a second value lower than the first value and allows a recuperation operation with a reduced generator capacity of the electrical machine if the actual energy level of the energy store is greater than the threshold value.

Claims

1. A method for recuperating energy in a hybrid vehicle having an internal combustion engine, an electrical machine, an automatic stop/start apparatus configured to be automatically turned off and start the internal combustion engine under predetermined conditions, and an on-board electrical system with an energy store configured to be charged with electrical energy by the electrical machine during a recuperation operation, comprising:

(a) setting a recuperation power (P_act) for the recuperation operation of the electrical machine to a first value (P_max) which allows the recuperation operation with a maximum generator capacity of the electrical machine if an actual energy level (E_act) of the energy store is lower than or equal to a threshold value (E_3);

(b) setting the recuperation power (P_act) for the recuperation operation of the electrical machine to a second value (P_lim) which is lower than the first value (P_max) and allows the recuperation operation with a reduced generator capacity of the electrical machine if the actual energy level (E_act) of the energy store is greater than the threshold value (E_3); and

(c) predicting a predicted recuperation energy (E_rec) for an actual operating state of the hybrid vehicle, the predicted recuperation energy indicating how much energy would be able to be recuperated if the hybrid vehicle were to be braked starting from a current driving state at least to a speed threshold value (v_min).

2. The method according to claim 1, wherein the speed threshold value indicates a speed limit above which energy is recuperated during the recuperation operation and below which a recuperation operation is not possible.

3. The method according to claim 2, wherein the threshold value (E_3) is a difference between a maximum energy level (E_max) of the energy store and the predicted recuperation energy (E_rec).

4. The method according to claim 3, wherein the predicted recuperation energy (E_rec) is determined based at least in part on an actual vehicle speed, an average vehicle deceleration, an on-board electrical system load, and a maximum generator capacity (P_max) of the recuperation operation.

5. The method according to claim 2, wherein the predicted recuperation energy (E_rec) is determined based at least in part on an actual vehicle speed, an average vehicle deceleration, an on-board electrical system load, and a maximum generator capacity (P_max) of the recuperation operation.

6. The method according to claim 1, wherein the threshold value (E_3) is continuously calculated during driving.

7. The method according to claim 2, wherein a minimum threshold value (E_min) for an energy level of the energy store is determined based at least in part on the predicted recuperation energy (E_rec) and a minimum energy (E_stop) required on average for a motor stop phase of a stop/start operation.

8. The method according to claim 7,

wherein the minimum energy (E_stop) required on average for a motor stop phase of a stop/start operation is determined as a sum of a motor start energy (E_1) for a start/stop operation and an energy requirement (E_2) for an on-board electrical system supply during the motor stop phase of the stop/start operation,

wherein the energy requirement (E_2) for the on-board electrical system supply is determined depending on an average stationary time for the hybrid vehicle in the motor stop phase and an average on-board electrical system load.

9. The method according to claim 8, wherein the minimum threshold value (E_min) is set to a value below the minimum energy (E_stop) required on average for a motor stop phase of a stop/start operation if the sum of the actual energy level (E_act) of the energy store and the predicted recuperation energy (E_rec) is greater than the minimum energy (E_stop).

10. The method according to claim 7, wherein the minimum threshold value (E_min) is set to a value below the minimum energy (E_stop) required on average for a motor stop phase of a stop/start operation if a sum of the actual energy level (E_act) of the energy store and the predicted recuperation energy (E_rec) is greater than the minimum energy (E_stop).

11. The method according to claim 7, wherein at least one of:

(a) the minimum threshold value (E_min) is continuously recalculated during driving;

(b) the energy level (E_act) of the energy store is increased by raising a load point of the internal combustion engine when the minimum threshold value (E_min) of the energy store is undershot during driving; and

(c) the internal combustion engine is started in a stop phase if the energy level (E_act) in the energy store drops to a value which corresponds to a motor start energy (E_1) during a stop phase.

12. The method according to claim 1, wherein:

(a) the second value (P_lim) for the recuperation power (P_act) of the recuperation operation of the electrical machine is set such that the energy store is fully charged at an end of a subsequent recuperation process if the hybrid vehicle were to be braked from a current driving state at least to a speed threshold value (v_min), wherein the speed threshold value preferably indicates a speed limit above which energy is recuperated during the recuperation operation and below which a recuperation operation is not possible; and

/or

(b) the second value (P_lim) for the recuperation power (P_act) of the recuperation operation of the electrical machine is calculated in accordance with;

P_lim=((E_max−

E_act)+P_on-board*t_rec))/t_rec,

Where;

E_max indicates a maximum energy level;

E_act indicates an actual energy level of the energy store;

P_on-board indicates an average on-board electrical system load; and

t_rec indicates an estimate for a duration of a recuperation process estimated from a difference between an actual vehicle speed (v_act) and the speed threshold value (v_min) divided by an assumed average vehicle deceleration.

13. An apparatus for controlling a recuperation operation in a hybrid vehicle, which hybrid vehicle includes an internal combustion engine, an electrical machine and an automatic stop/start apparatus configured to automatically turned off and start the internal combustion engine under predetermined conditions, and an on-board electrical system comprising an energy store configured to be charged with electrical energy by the electrical machine during the recuperation operation, wherein the apparatus is configured to:

(a) set a recuperation power (P_act) for the recuperation operation of the electrical machine to a first value (P_max) which allows the recuperation operation with a maximum generator capacity of the electrical machine if an actual energy level (E_act) of the energy store is lower than or equal to a threshold value (E_3);

(b) set the recuperation power (P_act) for the recuperation operation of the electrical machine to a second value (P_lim) which is lower than the first value (P_max) and allows the recuperation operation with a reduced generator capacity of the electrical machine if the actual energy level (E_act) of the energy store is greater than the threshold value (E_3); and

(c) predicting a predicted recuperation energy (E_rec) for an actual operating state of the hybrid vehicle, the predicted recuperation energy indicating how much energy would be able to be recuperated if the hybrid vehicle were to be braked starting from a current driving state at least to a speed threshold value (v_min).

14. A motor vehicle comprising:

an internal combustion engine;

an electrical machine;

an automatic stop/start apparatus configured to be automatically turned off and start the internal combustion engine under predetermined conditions;

an on-board electrical system comprising an energy store configured to be charged with electrical energy by the electrical machine during the recuperation operation; and

an apparatus for controlling the recuperation operation configured to;

(a) set a recuperation power (P_act) for the recuperation operation of the electrical machine to a first value (P_max) which allows the recuperation operation with a maximum generator capacity of the electrical machine if an actual energy level (E_act) of the energy store is lower than or equal to a threshold value (E_3);

(b) set the recuperation power (P_act) for the recuperation operation of the electrical machine to a second value (P_lim) which is lower than the first value (P_max) and allows the recuperation operation with a reduced generator capacity of the electrical machine if the actual energy level (E_act) of the energy store is greater than the threshold value (E_3); and

(c) predicting a predicted recuperation energy (E_rec) for an actual operating state of the hybrid vehicle, the predicted recuperation energy indicating how much energy would be able to be recuperated if the hybrid vehicle were to be braked starting from a current driving state at least to a speed threshold value (v_min).