Conversion kit for a hybrid electric drive vehicle

• US 20130091694A1
• Filed: 10/18/2011
• Published: 04/18/2013
• Est. Priority Date: 10/18/2011
• Status: Abandoned Application

• Current Assignee: Fuel Motion, Inc.
• Original Assignee: Fuel Motion, Inc.
• Inventors: Hussain, Agha Bakhtiar, Hussain, Agha Shaheryar, Lautzenheiser, David P.
• Application Number:
  US13/317,433
• Publication Number:
  US 20130091694A1
• Time in Patent Office: Days
• US Class Current: 29/593
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• 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 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/11 using model predictive control [MPC] strategies, i.e. control methods based on models predicting performance utilising navigation and traffic information in the control strategy B60W20/12
• CPC Class Codes: B60W 20/12 using control strategies taking into account route information estimation or calculation of non-directly measurable driving parameters B60W40/00
• CPC Class Codes: B60W 20/20 Control strategies involving selection of hybrid configuration, e.g. selection between series or parallel configuration
• CPC Class Codes: B60W 2050/0075 Automatic parameter input, automatic initialising or calibrating means
• CPC Class Codes: B60W 2556/10 Historical data
• CPC Class Codes: B60W 2556/50 of positioning data, e.g. GPS [Global Positioning System] data
• CPC Class Codes: B60Y 2304/076 by add-on parts, e.g. retrofit
• 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: Y10T 29/49002 : Electrical device making
• CPC Class Codes: Y10T 29/49004 : including measuring or testing of device or component part

Abstract

A Conversion kit apparatus for converting a hydrocarbon fuel drive vehicle into a Hybrid Electric Drive Vehicle is disclosed wherein electric motors, a battery and a Vehicle Control Unit (VCU) are used to replace the mechanical components of a standard hydrocarbon fuel drive vehicle, and wherein these replacement units are within the weight and size constraints of the vehicle to be converted. Also disclosed is a conversion kit comprising a two motor electrical generator and drive motor system designed to replace conventional hydrocarbon fuel powered mechanical drive system components, and a Vehicle Control Unit (VCU) electronically coupled to the engine, battery system, and the two motor electrical generator and drive motor system, for controlling the converted vehicle in a manner whereby hydrocarbon fuel consumption is minimized with respect to distance and time traveled and converted vehicle performance is not impaired.

Claims

1. A Conversion kit apparatus for converting a hydrocarbon fuel drive vehicle into a Hybrid Electric Drive Vehicle, the conversion kit comprising:

a. a two motor electrical generator and drive motor system designed to replace conventional hydrocarbon fuel powered mechanical drive system components, the two motor electrical generator and drive motor system coupled to an engine, a battery system and a differential for driving one or more wheels of a converted vehicle and maintaining a charge in the battery system, the two motor electrical generator and drive motor system having an overall weight equal to or less than a weight of conventional hydrocarbon fuel powered mechanical drive system components being replaced by the two motor electrical generator and drive motor system; and

b. a Vehicle Control Unit (VCU) comprising a central processing unit (CPU), a memory and electronic connections to monitor performance of, to issue commands to and to calculate electrical power required by the engine, the battery system, and the two motor electrical generator and drive motor system; and

c. the VCU further comprising a Start-up/Shut-down Processor for determining Historical Route Data and operating parameter settings for the engine, the battery system, and the two motor electrical generator and drive motor system of the Hybrid Electric Drive Vehicle;

d. whereby hydrocarbon fuel consumption in the Hybrid Electric Drive vehicle is minimized with respect to distance and time traveled and vehicle performance is not impaired.

2. The Conversion kit apparatus of claim 1 wherein the VCU further comprises a Run-time Control and Monitor Processor for storing vehicle data comprising current route data and operating parameters for units of the Hybrid Electric Drive Vehicle.

3. The Conversion kit apparatus of claim 1 wherein VCU further comprises a computer controlled process to determine power settings for battery state of charge (SOC) maintenance during operation of the converted vehicle.

4. The Conversion kit apparatus of claim 3 wherein the VCU further comprises a computer controlled process to determine power settings for on/off control of the engine during converted vehicle operation.

5. The Conversion kit apparatus of claim 4 wherein the VCU further comprises a computer controlled process to determine power settings for control of the two motor electrical generator and drive motor system during converted vehicle operation.

6. The Conversion kit apparatus of claim 5 wherein the VCU further comprises a computer controlled process to use the determined power settings for control of the two motor electrical generator and drive motor system to control the operation of each motor of the two motor electrical generator and drive motor system individually during converted vehicle operation.

7. The Conversion kit apparatus of claim 5 wherein the VCU further comprises a computer controlled process to use the determined power settings for control of each motor of the two motor electrical generator and drive motor system individually by monitoring the power settings historically used for a similar route and destination by the converted vehicle.

8. The Conversion kit apparatus of claim 7 wherein the Start-up/Shut-down Processor further comprises embedded mechanisms to transfer Route Data and Operating parameter settings for units of the Hybrid Electric Drive Vehicle to the Run-time Control and Monitor Processor.

9. The Conversion kit apparatus of claim 8 wherein the Start-up/Shut-down Processor further comprises embedded mechanisms to obtain GPS data with which to update Route Data and operating parameter settings for units of the Hybrid Electric Drive Vehicle during Vehicle operation.

10. The Conversion Kit apparatus of claim 5 wherein the Run-time Control and Monitor Processor further comprises embedded mechanisms to calculate power parameters for each electric motor based on current power used combined with historical power used for a similar route.

11. The Conversion kit apparatus of claim 10 further comprises mechanisms to allow the Two Motor Tandem Configuration to operate as two separate motors, independent of each other, or as a coupled pair forming a single unit.

12. A method for converting a hydrocarbon fuel drive vehicle into a Hybrid Electric Drive Vehicle (the converted vehicle), and for operating the converted vehicle in a manner to minimize hydrocarbon fuel consumption while providing required vehicle performance, the method comprising the acts of:

a. removing conventional hydrocarbon fuel powered mechanical drive system components from a target vehicle, the mechanical drive system components comprising an old transmission system, an old battery system;

b replacing the removed mechanical drive system components with a two motor electrical generator and drive motor system coupled to an engine, a battery system and a differential for driving one or more wheels of the target vehicle and maintaining a charge in the battery system, the two motor electrical generator and drive motor system having an overall weight equal to or less than a weight of the conventional hydrocarbon fuel powered mechanical drive system components being replaced by the two motor electrical generator and drive motor system;

c. installing a Vehicle Control Unit (VCU) comprising a central processing unit (CPU), a memory and electronic connections to the engine, the battery system, and the two motor electrical generator and drive motor system, the VCU further comprising a Start-up/Shut-down Processor for determining Historical Route Data and operating parameter settings for the engine, the battery system, and the two motor electrical generator and drive motor system of the Hybrid Electric Drive Vehicle; and

d. using the VCU to monitor performance of, to issue commands to and to calculate power required by the engine, the battery system, and the two motor electrical generator and drive motor system of the Hybrid Electric Drive Vehicle based upon the determined Historical Route Data and operating parameter settings;

e. whereby hydrocarbon fuel consumption in the Hybrid Electric Drive vehicle is minimized with respect to distance and time traveled and vehicle performance is not impaired.

13. The method of claim 12 comprising the additional acts of storing vehicle data comprising current route data and operating parameters for units of the Hybrid Electric Drive Vehicle within the VCU.

14. The method of claim 12 comprising the additional acts of determining power settings for battery state of charge (SOC) maintenance during operation of the converted vehicle within the VCU.

15. The method of claim 14 comprising the additional acts of determining power settings for on/off control of the engine during converted vehicle operation.

16. The method of claim 15 comprising the additional acts of determining power settings for control of the two motor electrical generator and drive motor system during converted vehicle operation.

17. The method of claim 16 comprising the additional acts of using the determined power settings for control of the two motor electrical generator and drive motor system to control the operation of each motor of the two motor electrical generator and drive motor system individually during converted vehicle operation.

18. The method of claim 16 comprising the additional acts of using the determined power settings for control of each motor of the two motor electrical generator and drive motor system individually by monitoring the power settings historically used for a similar route and destination by the converted vehicle.

19. The method of claim 16 comprising the additional acts of maintaining Route Data and Operating parameter settings for units of the Hybrid Electric Drive Vehicle in a Run-time Control and Monitor Processor in the VCU.

20. The method of claim 19 comprising the additional acts of obtaining GPS data with which to update Route Data and operating parameter settings for units of the Hybrid Electric Drive Vehicle during Vehicle operation.

21. The method of claim 16 comprising the additional acts of calculating power parameters for each electric motor based on current power used combined with historical power used for a similar route.

22. The method of claim 21 comprising the additional acts of generating control signals from the VCU to allow the Two Motor Tandem Configuration to operate as two separate motors, independent of each other, or as a coupled pair forming a single unit.

23. The method of claim 21 comprising the additional acts of generating control signals from the VCU to allow the Two Motor Tandem Configuration to operate as a coupled pair forming a single unit to drive the converted vehicle, or as a coupled pair forming a single unit and coupled to the engine to drive the converted vehicle when maximum drive power is needed.