Hybrid car with electric and heat engine

• US 4,351,405 A
• Filed: 11/30/1979
• Issued: 09/28/1982
• Est. Priority Date: 10/12/1978
• Status: Expired due to Term

• Current Assignee: Hybricon Corp. (Celestica Incorporated)
• Original Assignee: Hybricon Corp. (Celestica Incorporated)
• Inventors: Metzner, Robert G., Fields, Gerald M.
• Primary Examiner(s): Bertsch, Richard A.
• Assistant Examiner(s): Smith, Milton L.
• Application Number:
  US06/098,930
• Time in Patent Office: 1,033 Days
• Field of Search: 180/65 R, 180/65 C, 180/65 A, 180/65 F, 180/65 E, 180/60, 180/68.5, 180/315, 180/335, 290/16, 290/17, 290/21, 290/9, 290/10, 290/13, 290/18, 290/19, 74/478, 310/181, 318/139
• US Class Current: 180/65.225
• CPC Class Codes: B60K 1/00 Arrangement or mounting of electrical propulsion units B60K7/00 takes precedence; arrangement or mounting of plural diverse prime-movers for mutual or common propulsion B60K6/00; electric transmission arrangements B60K17/12; electric equipment or propulsion of electrically-propelled vehicles per se B60L; current-collectors for power supply lines of electrically-propelled vehicles B60L5/00
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 6/387 Actuated clutches, i.e. clutches engaged or disengaged by electric, hydraulic or mechanical actuating means
• CPC Class Codes: B60K 6/44 Series-parallel type
• 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 15/2009 for braking
• CPC Class Codes: B60L 15/2054 by controlling transmissions or clutches
• CPC Class Codes: B60L 2220/46 Wheel motors, i.e. motor connected to only one wheel
• CPC Class Codes: B60L 2240/12 Speed
• CPC Class Codes: B60L 2240/32 Driving direction
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/547 Voltage
• CPC Class Codes: B60L 2240/549 Current
• CPC Class Codes: B60L 2250/24 by lever actuation
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0061 : relating to electrical machines
• 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: B60L 50/66 : Arrangements of batteries
• CPC Class Codes: B60L 58/15 : Preventing overcharging
• CPC Class Codes: B60L 58/21 : having the same nominal voltage
• CPC Class Codes: B60L 7/12 : for vehicles propelled by dc motors
• 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 20/00 : Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/10 : Controlling the power contribution of each of the prime movers to meet required power demand
• 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: Y02T 10/92 : Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y10S 903/914 : Actuated, e.g. engaged or disengaged by electrical, hydraulic or mechanical means
• CPC Class Codes: Y10S 903/916 : with plurality of drive axles
• CPC Class Codes: Y10S 903/946 : Characterized by control of driveline clutch
• CPC Class Codes: Y10T 74/20189 : Foot operated

Abstract

An apparatus for economical travel and minimization of atmospheric degradation by internal combustion exhaust products. A car which has, in combination, a heat engine driving a set of front wheels, storage batteries and an electric motor driving a set of rear wheels. There is also a system for selecting electric or heat engine drive either manually or automatically and a single accelerator for controlling either mode of drive. A battery charging system supplies a constant power charge rate. Battery charging power is derived from the electric motors acting as generators driven by the rear wheels while the vehicle is in heat engine drive, and the battery charging rate is selected by the operator. Also in combination is a regenerative braking system to recover expended energy in the form of vehicle motion and an overdrive system to increase vehicle speed in the electric drive mode by field weakening. Protective systems are included to prevent overcharge of the storage batteries and to provide safe closing at high speeds of the electric clutches connecting the electric motors to the rear wheels. Changeover from electric drive to heat engine drive is simplified by a changeover system, and excessive loading of the heat engine by the battery charging system is eliminated on hills and during acceleration by a hill and acceleration sensing system. The car is designed for low speed and stop and go driving powered by the electric motors while the heat engine may be used for high speed and long distance travel.

Claims

1. A vehicle comprising

a supporting structure having wheels rotatably mounted relative to said supporting structure;

a heat engine mounted on said supporting structure for driving at least a first said wheel, and having a fuel metering device;

a battery powered electric motor mounted on said supporting structure for driving at least a second said wheel, said electric motor having an armature winding;

means for controlling average power flowing through said armature winding and having a control input and power terminals through which the current in said armature winding flows responsive to a control signal at said control input;

a mode select input;

means for heat engine and electric motor speed control having a single accelerator pedal for alternately controlling either said fuel metering device or said control signal at said control input in accordance with a signal at said mode select input; and

a mode selection means for selecting which of said fuel metering device or said control signal said means for heat engine and electric motor speed control is to control and for sending said signal to said mode select input.

2. The vehicle of claim 1 wherein said means for heat engine and electric motor speed control further include a cable linkage between said single accelerator pedal and said fuel metering device, said cable linkage including a length of cable creating a slack cable linkage between said single accelerator pedal and said fuel metering device, and means for tensioning said cable linkage to remove said slack.

3. The vehicle of claim 2 wherein said means tensioning said cable includes a movable carriage having a pulley associated with said cable to effectively lengthen the guided path of said cable.

4. The vehicle of claim 1 wherein said means for heat engine and electric motor speed control include a potentiometer driven by said single accelerator pedal, said potentiometer being selectively electrically activated by said mode select input.

5. The vehicle of claim 1 wherein said mode select input includes an actuator and linkage, the vehicle further comprising a clutch associated with said heat engine and an ignition switch associated with said heat engine, said linkage being associated with said ignition switch, said clutch, and said single accelerator pedal such that said clutch is disengaged, said ignition switch is open and said single accelerator pedal is disabled with said fuel metering device in a first position and said ignition switch is closed, said clutch is engaged and said single accelerator pedal is enabled with said fuel metering device in a second position, and means for electrically redirecting said control input when said linkage is in said second position.

6. The vehicle of claim 5 further including

a motor clutch for selectively engaging said motor with at least said second said wheel;

means for sensing the speed of said second said wheel and for producing a wheel speed signal responsive thereto;

means for sensing the speed of said motor and for producing a motor speed signal responsive thereto; and

comparator means for sensing said wheel speed signal and said motor speed signal to determine when the speed of the motor side of said motor clutch and the speed of the wheel side of said motor clutch are substantially equal, said comparator means producing a signal enabling engagement of said motor when said speeds are substantially equal.

7. The vehicle of claim 1 wherein said means for heat engine and electric motor speed control includes a linkage pivotally and slideably mounted relative to said supporting structure such that a first end of said linkage is coupled with said single accelerator pedal throughout its arc of pivotal movement, said fuel metering device being positioned to encounter said linkage with said linkage at a first end of said arc and said control input being positioned to encounter said linkage with said linkage at the other end of said arc, said means for heat engine and electric motor speed control further including means for selectively pivoting said linkage to said first and second ends of said arc.

8. The vehicle of claim 1 wherein said control input includes a gradient tint mask coupled with said single accelerator pedal, a light source and a photoelectric cell, said photoelectric cell providing the control voltage for said means for controlling average power, said gradient tint mask slideably extending to and between said light source and said photoelectric cell for selectively variable transmission of light from said light source to said photoelectric cell.

9. A vehicle comprising

a supporting structure having wheels rotatably mounted relative to said supporting structure;

a heat engine mounted on said supporting structure for driving at least a first said wheel;

a battery powered electric motor mounted on said supporting structure for driving at least a second said wheel, said electric motor having an armature winding and at least two magnetic fields through which said armature winding rotates, at least one of said magnetic fields being created by a permanent magnet, another of said at least two magnetic fields being created by a field winding;

means for controlling the magnetic field produced by said field winding by reducing the current in said field winding at increased vehicle speed; and

means for controlling average power flowing through said armature winding by chopping and having a control input and power terminals through which the current in said armature winding flows responsive to a control signal at said control input.

10. The vehicle of claim 9 wherein said electric motor further includes

a pole piece with a recess formed therein, said pole piece being of a magnetically conductive material;

a permanent magnet formed in the same shape and size as said recess and inset therein for generating a magnetic field in said pole piece and through said armature winding;

shielding formed of non-magnetic material inserted between said permanent magnet and said pole piece for preventing the magnetic flux lines from one pole of said permanent magnet from taking the shortest path of least magnetic reluctance back to the opposite pole of said permanent magnet and forcing the magnetic flux to spread out to the extremities of said pole piece; and

a start field winding wrapped about said pole piece with said permanent magnet inset for creating a second magnetic field in said pole piece and through said armature winding when current is passed through said start field winding.

11. The vehicle of claim 10 wherein said motor includes multiple pole pieces and wherein at least two said permanent magnets are inserted in recesses located at opposite extremities of said pole pieces.

12. The vehicle of claim 10 wherein said recess in said pole piece is a slot through the center of said pole piece separating said pole piece into segments, the long axis of said slot being parallel to the direction of rotation of said armature winding and where said permanent magnet is formed in the shape of a cylinder of the same approximate width and length as said slot, said permanent magnet inserted and affixed therein and a non-magnetic shield material located between said permanent magnet and the wall of said slot.

13. The vehicle of claim 9 wherein said field winding is a shunt wound field winding, said other of said at least two magnetic fields being caused by the flow of current through said field winding and said means for controlling the magnetic field produced by said field winding includes overdrive means for overdrive by reducing the current flowing through said field winding as motor speed increases, said current being reduced to zero by said overdrive means at a predetermined speed.

14. The vehicle of claim 13 wherein said means for overdrive includes

means for sensing vehicle speed, said means including signal generating means proportional to said vehicle speed;

means for sensing said speed signal and generating a first trigger signal when said speed signal exceeds a preselected level; and

means responsive to said trigger signal for interrupting the path of current through said start field winding.

15. A vehicle comprising

a supporting structure having wheels rotatably mounted relative to said supporting structure;

a heat engine mounted on said supporting structure for driving at least a first wheel;

a battery powered electric motor mounted on said supporting structure for driving at least a second said wheel, said electric motor having an armature winding and at least one shunt wound field winding for a magnetic field through which said armature winding rotates;

means for sensing vehicle speed including means for generating a speed signal responsive to vehicle speed;

means for controlling current to said shunt wound field winding including a chopper responsive to said speed signal to reduce current with increased vehicle speed; and

means for providing at least a minimum of current in said shunt wound field winding at increased vehicle speed.

16. A vehicle comprising

a supporting structure having a plurality of wheels rotatably mounted relative to said supporting structure;

a heat engine mounted on said supporting structure for driving at least a first said wheel;

a battery powered electric motor mounted on said supporting structure for driving at least a second said wheel, said electric motor having an armature winding and a magnetic field through which said armature winding rotates;

a main battery mounted on said supporting structure for applying power to said electric motor;

a means for sensing the vehicle speed and for generating a DC signal proportional to said speed;

a means for charge rate selection including an operator control transducer for producing a first control signal in proportion to the setting selected by the operator and an operator control means for producing an offset signal of opposite polarity from said first control signal electrically responsive to said means for sensing vehicle speed and mechanically responsive to the movement of said operator controlled transducer such that the offset signal varies both with the rotational speed of said armature winding and with the operator'"'"'s selected rate of charge; and

means for summing said first control signal and said offset signal so that the resultant control signal varies inversely and in predetermined proportion to the power output from said armature winding as said power output varies with changing vehicle speed to maintain a substantially constant charging rate at said main battery when said motor-generator is in the generating mode.

17. A vehicle comprising

a supporting structure having a plurality of wheels rotatably mounted relative to said supporting structure;

a heat engine mounted on said supporting structure for driving at least a first said wheel and having a fuel metering device;

an electric motor mounted on said supporting structure for driving at least a second said wheel and being driven by said wheel, said electric motor having an armature winding and at least two magnetic fields through which said armature winding rotates, at least one of said magnetic fields being created by a permanent magnet, and said electric motor acting as a generator driven by said wheel when desired by the vehicle operation;

a main battery mounted on said supporting structure for supplying power to said electric motor;

an inductor electrically connected to said armature winding for stepping up the output voltage therefrom above the main battery voltage at substantially all rotational speeds of said armature winding when said electric motor is acting as a generator;

a means for controlling power by chopping having power terminals and a control input for controlling the average power entering or leaving said armature winding through said power terminals in proportion to a control signal at said control input;

means for switching the connections of said power terminals from controlling power flowing from said main battery through said inductor and into said armature winding in an electric drive configuration to controlling power flowing out of said armature winding through said inductor and into said main battery in a battery charging configuration, said means for switching being connected between said inductor and armature winding on one side and said power terminals and said main battery on the other side and having an input for receiving a signal causing said switching to occur;

a means for power plant speed control having a single accelerator pedal for alternately controlling either said fuel metering device or the control signal at said control input of said means for controlling power, but not both simultaneously, and having a mode select input for receiving a signal indicating which device is to be controlled, and for directing a signal to said input for said means for switching for causing it to switch to the battery charging configuration when said accelerator pedal is undepressed or when said fuel metering device is being controlled and to switch to the electric drive configuration when the accelerator pedal is depressed and control of said means for controlling power has been selected as indicated by the signal at said mode select input and having a means for electrically interlocking;

a mode switch for selecting which device said means for power plant speed control controls and for sending a signal to said mode select input of said means for power plant speed control;

a mechanical braking system connected to said wheels and having a brake pedal;

a means for regenerative braking mechanically connected to said brake pedal and electrically interlocked with said means for electrically interlocking in said means for power plant speed control for sensing when said accelerator pedal is undepressed or when said vehicle is in heat engine drive and for sensing pressure on said brake pedal and the amount thereof, and when these conditions are met, for sending a control signal to said control input of said means for controlling power to increase the charging rate in proportion to increasing braking pressure for causing increasing mechanical load on the wheel driving said electric motor and having a second means for interlocking; and

means for charging said main battery at a substantially constant, operator selected rate of power from energy derived from said electric motor and electrically interlocked with said means for electrically interlocking in said means for power plant speed control and with said second means for electrically interlocking in said means for regenerative braking for controlling the signal at said control input in such a manner that the average rate of power flowing into said main battery remains constant over a range of vehicle speeds when said means for switching is in the battery charging configuration and said brake pedal is undepressed.

18. The vehicle of claim 17 further including

a voltage sensing means for sensing the main battery voltage;

and

means for substantially reducing the charging rate to said main battery when the main battery voltage exceeds a first predetermined level and regaining the initial charging rate when the main battery voltage reaches a second predetermined level below said first predetermined level.