HYBRID ELECTRIC CONVERSION KIT FOR REAR-WHEEL DRIVE, ALL WHEEL DRIVE, AND FOUR WHEEL DRIVE VEHICLES

• US 20090223725A1
• Filed: 02/14/2008
• Published: 09/10/2009
• Est. Priority Date: 02/14/2008
• Status: Active Grant

• Current Assignee: Turntide Technologies, Inc.
• Original Assignee: Illinois Institute of Technology
• Inventors: Emadi, Ali, Lukic, Srdjan M., Rodriguez, Fernando, Wirasingha, Sanjaka G.
• Granted Patent: US 8,011,461 B2
• Time in Patent Office: Days
• US Class Current: 180/65.210
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 2200/36 Vehicles designed to transport cargo, e.g. trucks
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2200/46 Vehicles with auxiliary ad-on propulsions, e.g. add-on electric motor kits for bicycles
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/12 Speed
• 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 2250/26 by pedal actuation
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• 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: Y10T 29/49716 : Converting

Abstract

This invention relates to a parallel hybrid electric conversion kit for a vehicle with an internal combustion engine, a driveshaft and a transmission, such as, rear wheel drive vehicles, four-wheel drive vehicles, heavy duty multiple-driven-axle vehicles and/or all-wheel drive vehicles. The conversion kit includes a motor-generator, a torque coupler, a battery, a power electronics module and a controller. Suitable torque couplers include transfer cases and/or rear-through differentials. The conversion kit provides an aftermarket solution to increased performance, fuel economy and/or reduced emissions by modifying the drivetrain after the transmission. According to one embodiment of this invention, the control scheme of the installed conversion kit receives input signals from the engine and the motor-generator, but only sends control signals to the motor-generator, facilitating installation of the conversion kit.

Claims

1. A parallel hybrid electric vehicle retrofit kit for a vehicle with an internal combustion engine connected to a driveshaft by a transmission, the retrofit kit comprising:

a motor-generator;

a torque coupler, wherein the torque coupler is adapted for connecting the motor-generator to the driveshaft;

a battery;

a power electronics module having a first electrical connector adapted to electrically connect to the battery and a second electrical connector adapted to electrically connect to the motor-generator; and

a controller having a first communication connection adapted to receive signals from the internal combustion engine and a second communication connection adapted to connect to the motor-generator, the controller including a decision circuit adapted to activate the motor-generator to transfer electrical energy to or from the battery into mechanical energy to or from the driveshaft.

2. The retrofit kit of claim 1 wherein the torque coupler includes at least one clutch.

3. The retrofit kit of claim 1 wherein the torque coupler includes a fixed gear ratio.

4. The retrofit kit of claim 1 wherein the torque coupler comprises at least one of the group consisting of a transfer case, a rear-through differential and combinations thereof.

5. The retrofit kit of claim 1 wherein the vehicle is selected from the group consisting of rear wheel drive vehicles, four-wheel drive vehicles, heavy duty multiple-driven-axle vehicles and all-wheel drive vehicles.

6. The retrofit kit of claim 1 wherein the assembled retrofit kit operates in generating mode, motoring mode, braking mode and electric only mode.

7. The retrofit kit of claim 1 further comprising:

a plug for connection to an alternating current power supply; and

a rectifier electrically connected to the plug and the battery providing plug-in hybrid electric vehicle functionality.

8. The retrofit kit of claim 1 wherein the power electronics module comprises an inverter.

9. The retrofit kit of claim 1 wherein:

the transmission comprises a manual transmission with a clutch; and

the controller includes a clutch sensor detecting a position of the clutch.

10. A parallel hybrid electric vehicle, the vehicle comprising:

an internal combustion engine supplying mechanical energy;

a driveshaft;

a transmission connecting the internal combustion engine to the driveshaft;

a torque coupler connected to the driveshaft on a side of the transmission opposite the internal combustion engine;

a motor-generator mechanically connected to the torque coupler, the motor-generator for converting one of mechanical energy and electrical energy to one of mechanical energy and electrical energy;

a battery electrically connected to the motor-generator; and

a controller in communication with the internal combustion engine and the motor-generator.

11. The vehicle of claim 10 wherein the controller exclusively sends signals to the motor-generator.

12. The vehicle of claim 10 wherein the controller does not send signals to the internal combustion engine.

13. The vehicle of claim 10 wherein the torque coupler includes a first portion of a driveshaft connected to the transmission and a second portion of the driveshaft connected to an axle.

14. The vehicle of claim 10 wherein the torque coupler comprises a rear-through differential connected to the driveshaft from the transmission opposite a connection to the motor-generator.

15. The vehicle of claim 10 wherein the vehicle is selected from the group consisting of rear wheel drive vehicles, four-wheel drive vehicles, heavy duty multiple-driven-axle vehicles and all-wheel drive vehicles.

16. A method of retrofitting a vehicle to a parallel hybrid electric vehicle, the method comprising:

providing a vehicle with an internal combustion engine, a transmission and a driveshaft;

connecting a torque coupler to the driveshaft downstream from the transmission;

connecting a motor-generator to the torque coupler;

connecting a battery to the motor-generator using a power electronics module;

connecting an input signal from the internal combustion engine and the motor-generator to a controller; and

connecting an output signal from the controller to the motor-generator.

17. The method of claim 16 wherein the controller defines hybrid electric modes comprising a generating mode, a motoring mode, a braking mode and an electric only mode.

18. The method of claim 16 further comprising:

powering the vehicle with the internal combustion engine;

powering the vehicle with the motor-generator and the battery;

charging the battery with the internal combustion engine and the motor-generator; and

charging the battery while slowing the vehicle with the motor-generator.

19. The method of claim 16 wherein installing the torque coupler includes replacing a differential with a rear-through differential.

20. The method of claim 16 wherein the method does not modify a control system of the internal combustion engine.