Front end motor-generator system and hybrid electric vehicle operating method

• US 10,239,516 B2
• Filed: 12/14/2016
• Issued: 03/26/2019
• Est. Priority Date: 12/14/2016
• Status: Active Grant

• Current Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Original Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Inventors: Colavincenzo, David D., Venegas Diaz, Fernando
• Primary Examiner(s): Lin, Abby Y
• Assistant Examiner(s): Kim, Kyung J
• Application Number:
  US15/378,699
• Publication Number:
  US 20180162373A1
• Time in Patent Office: 832 Days
• Field of Search: None
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60K 2006/4833 Step up or reduction gearing driving generator, e.g. to operate generator in most efficient speed range
• CPC Class Codes: B60K 6/448 Electrical distribution type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/42 Voltage source inverters
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/443 Torque
• CPC Class Codes: B60L 2240/507 Operating parameters
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/20 having different nominal voltages
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: B60L 7/22 Dynamic electric resistor braking, combined with dynamic electric regenerative braking
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• 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 20/20 : Control strategies involving selection of hybrid configuration, e.g. selection between series or parallel configuration
• CPC Class Codes: B60Y 2300/91 : Battery charging
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: B60Y 2400/162 : Flywheels
• CPC Class Codes: B60Y 2400/421 : Dog type clutches or brakes
• CPC Class Codes: B60Y 2400/47 : Starter generator drive systems
• CPC Class Codes: F02N 11/04 : the motors being associated with current generators
• CPC Class Codes: F02N 11/0866 : comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 15/022 : the starter comprising an intermediate clutch
• CPC Class Codes: F02N 15/025 : of the friction type
• CPC Class Codes: F02N 2011/0896 : Inverters for electric machines, e.g. starter-generators
• CPC Class Codes: F02N 7/00 : Starting apparatus having fluid-driven auxiliary engines or apparatus
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements
• CPC Class Codes: Y10S 903/951 : Assembly or relative location of components

Abstract

A system and method are provided for hybrid electric internal combustion engine applications in which a motor-generator, a narrow switchable coupling and a torque transfer unit therebetween are arranged and positioned in the constrained environment at the front of an engine in applications such as commercial vehicles, off-road vehicles and stationary engine installations. The motor-generator is preferably positioned laterally offset from the switchable coupling, which is co-axially-arranged with the front end of the engine crankshaft. The switchable coupling is an integrated unit in which a crankshaft vibration damper, an engine accessory drive pulley and a disengageable clutch overlap such that the axial depth of the clutch-pulley-damper unit is nearly the same as a conventional belt drive pulley and engine damper. The front end motor-generator system includes an electrical energy store that receives electrical energy generated by the motor-generator when the coupling is engaged. When the coupling is disengaged, the motor-generator may drive the pulley portion of the clutch-pulley-damper to drive the engine accessories using energy returned from the energy store, independent of the engine crankshaft.

Claims

1. A hybrid electric front end motor-generator system, comprising:

an internal combustion engine including an engine crankshaft having a front end opposite a rear end at which an engine flywheel is located, the engine being configured to transfer torque from the rear end of the crankshaft to a torque consumer;

a motor-generator having a motor-generator rotation axis parallel to and laterally offset from a rotation axis of the crankshaft;

a torque transfer segment having a motor-generator end configured to receive the motor-generator and to transfer torque between the motor-generator end and a coupling end of the torque transfer segment; and

an integrated switchable coupling having a coupling rotation axis and being located co-axially along the crankshaft rotation axis between the coupling end of the torque transfer segment and the front end of the engine crankshaft in a region adjacent to a front end of the engine, the integrated switchable coupling including

an engine-side portion coupled to the engine crankshaft,

a drive-side portion coupled to the torque transfer segment coupling end, and

an engagement actuator configured to selectively engage the engine-side portion with the drive-side portion, at least a portion of the engagement actuator being concentrically surrounded by the drive portion along the coupling rotation axis;

an engine accessory drive arranged to be driven by the drive-side portion of the integrated switchable coupling and to drive at least one engine accessory;

an energy storage system, the energy storage system including

an energy store configured to store electrical energy generated by the motor-generator and to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the integrated switchable coupling, and

an electrical energy conversion and distribution network configured to convert a current type of the electrical energy transferred between the motor-generator and the energy store between alternating current and direct current when the electrical energy is transferred from the motor-generator to the energy store and between direct current and alternating current when the electrical energy is transferred from the energy store to the motor-generator;

a front end motor-generator system controller configured to switch the integrated switchable coupling actuator between engaged and disengaged states and control operation of the electrical energy conversion and distribution network during transfer of electrical energy between the motor-generator and the energy store; and

a pneumatic engine starter motor,

wherein the pneumatic starter motor and the front end motor-generator are sized such that

a torque output capacity of the front end motor-generator and a torque output capacity of the pneumatic starter motor are each less than a total torque required to cold start the engine, and

a sum of the torque output capacity of the front end motor-generator and the torque output capacity of the pneumatic starter motor is at least as high as the total torque required to cold start the engine.