Hybrid electric propulsion system

• US 5,172,784 A
• Filed: 04/19/1991
• Issued: 12/22/1992
• Est. Priority Date: 04/19/1991
• Status: Expired due to Fees

• Current Assignee: Arthur A. Varela Jr
• Original Assignee: Arthur A. Varela Jr
• Inventors: Varela, Arthur A. Jr.
• Primary Examiner(s): Mitchell, David M.
• Application Number:
  US07/688,117
• Time in Patent Office: 613 Days
• Field of Search: 180/65.4, 180/65.3, 180/65.1, 180/65.2, 180/65.6, 180/965, 180/76, 180/62, 290/1 A, 290/1 R, 290/2, 318/126, 310/156
• US Class Current: 180/65.245
• 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 2015/03157 for supply different types of fuel to the motor
• CPC Class Codes: B60K 6/24 characterised by the combustion engines
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60L 15/2036 Electric differentials, e.g. for supporting steering vehicles
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: F02B 2075/1816 four
• CPC Class Codes: F02G 1/0435 the engine being of the free piston type
• CPC Class Codes: F02G 2244/50 Double acting piston machines
• CPC Class Codes: H02K 16/02 Machines with one stator and two or more rotors
• CPC Class Codes: H02K 35/00 Generators with reciprocating, oscillating or vibrating coil system, magnet, armature or other part of the magnetic circuit arrangements for handling mechanical energy structurally associated with generators H02K7/00, e.g. H02K7/06
• CPC Class Codes: H02K 7/1884 structurally associated with free piston engines
• 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 903/902 Prime movers comprising electrical and internal combustion motors

Abstract

A hybrid electric vehicle propulsion system having an external combustion free-piston engine is provided with an integral linear electric current generator and a pulse frequency controller. The system includes a power integration processor, a frequency modulator circuit and a pulse width modulator circuit, the power integration processor controls the frequency modulator circuit and the pulse width modulator circuit to produce both a frequency modulated pulsed current and an auxiliary power current which varies in pulse width. Both the frequency modulated pulsed current and the pulse width modulated auxiliary current are combined to power an electric drive motor having an integral electronic differential. A small auxiliary power source, such as a rechargeable battery pack, is provides the auxiliary current for acceleration and hill climbing power. The external combustion engine may burn any pollution free fuel (such as natural gas, alcohol, propane, etc.) and runs at a constant peak efficiency speed to generate constant frequency electric current from coils integrated into the engine. The generator current is sufficient to propel the vehicle in ordinary driving situations with smooth speed control of the drive motor. The propulsion motor combines one fixed stator, and two axially opposed permanent magnet or induction-type rotors, one for each output propulsion shaft.

Claims

1. An electro-mechanical propulsion system for a vehicle comprising:

an external combustion, free piston multiple-cylinder engine;

linear electric generator means for generating electric power from said engine including linear element generator means integrally mounted in said engine for converting mechanized to electrical power;

means for adjusting a mechanical and electrical phase relationship between said engine and said generator means;

a manual accelerator and an electric traction motor;

means for controlling the electric output of the linear generator means corresponding to an accelerator position, and motor speed;

an auxiliary power source comprising means for controlling output of said auxiliary power source corresponding to the load on said motor, said auxiliary power source being synchronized with the said means for controlling output of said linear generator means;

said electric traction motor being connected as the prime mover means for propelling said vehicle, said motor being connected to be actuated by said linear generator and said auxiliary power supply, said electric motor including two independent and synchronized rotors, each of said rotors including an output shaft for connection to the vehicle propulsion means.

2. The propulsion system of claim 1, wherein there are at least two linear electric generator means, one of which is connected to said auxiliary power source and the remaining linear electric generating means are connected to said controlling means.

3. The electro-mechanical propulsion system as in claim 1, wherein said armature coils are configured to produce single phase alternating current.

4. The propulsion system of claim 1, wherein there are four electric generating means, and wherein three of said four linear electric generating means are connected to said controlling means and the fourth linear electric generating means is connected to said auxiliary electric power supply.

5. The propulsion system as in claim 1, wherein said linear electric generating means are configured so as to produce single phase, phase-synchronized electric current.

6. The propulsion system as in claim 1, wherein said linear electric generating means are configured so as to produce multi-phase, phase-synchronized electric current.

7. The propulsion system as in claim 1, wherein the external combustion free piston engine is a single-acting, four cylinder diametrically-opposed Stirling-type engine.

8. The system as in claim 1, wherein the external combustion free piston engine is a diametrically-opposed, four cylinder Siemens/Rinia-type engine.

9. The electric traction motor as in claim 1, wherein each of said rotors are permanent magnet pancake-type rotors.

10. The electric traction motor as specified in claim 1, wherein each of said rotors is a permanent magnet disc rotor.

11. The electric traction motor as specified in claim 1, wherein each of said rotors is a double shell-type permanent magnet rotor.

12. The electric traction motor as specified in claim 1, wherein each of said rotors are induction rotors.

13. The motor as specified in claim 1, wherein each rotor includes a drive shaft comprising means for sensing rotor speed and position of said first and said second rotors and means for sensing the rotational speed and position of the motor magnetic field;

processor means for comparing a difference between said rotor speeds and switching means for controlling said motor speed.

14. An electro-mechanical propulsion system for vehicles comprising:

an electro-mechanical converter means including an external combustion, free piston four-cylinder engine;

said engine comprising a plurality of cylinders and pistons connected by a plurality of shafts, said plurality of shafts being connected to said pistons; and

an integral linear electric generator means for converting power from said engine, one such means associated with each of said four cylinders;

each of said four linear generator means comprising a plurality of permanent magnetic elements, at least one of said permanent magnet element fixed to at least one said plurality of pistons and piston shafts and a plurality of cylindrical armature coils at least one of which is fixed to each of said plurality of cylinders located in said engine, said linear generator means generating a linear generator electric signal frequency;

a manual accelerator and an electric traction motor;

means for controlling the linear generator electric signal of the linear generator means, the output of said controlling means corresponding to an accelerator position, motor speed, and motor load;

an auxiliary electric power supply to supply auxiliary electric power comprising means for modulating said electric power into a pulsed signal, a width of said pulsed signal corresponding to the load on said motor, and means for synchronizing said pulsed signal with said linear generating signal;

said electric traction motor being connected as the prime mover means for propelling said vehicle, said electric motor operating on current correlated to the frequency of said linear generator, said electric motor being connected to the auxiliary electric power supply and linear generator means through said controlling means;

said electric motor including one common wound stator generating a rotating magnetic field, and two opposing rotor elements, each including a first end and a second end, said first end of said opposing rotor elements being connected to a pilot bearing, said second end being connected to a propulsion shaft;

said two opposing rotors including a first rotor and a second rotor, said first and said second rotor rotating in the same magnetic field;

transducer means for sensing said field speed and the rotational speed of said first rotor and said second rotor, said transducer means being connected to said controller means;

means for synchronizing the speed of said first rotor and said second rotor.

15. The propulsion system of claim 14, wherein there are at least two linear electric generator means, one of which is connected to said auxiliary power source and the remaining linear electric generating means are connected to said controlling means.

16. The electro-mechanical propulsion system as in claim 14, wherein said armature coils are configured to produce single phase alternating current.

17. The propulsion system of claim 14, wherein three of said four linear electric generating means are connected to said controlling means and the fourth linear electric generating means is connected to said auxiliary electric power supply.

18. The propulsion system as in claim 14, wherein the armature coils are configured so as to produce single-phase, phasesynchronized electric current.

19. The propulsion system as in claim 14, wherein the coils are configured so as to produce multi-phase, phase-synchronized electric current.

20. The propulsion system as in claim 14, wherein the external combustion free piston engine is a single-acting, four cylinder diametrically-opposed Stirling-type engine.

21. The system as in claim 14, wherein the external combustion free piston engine is a diametrically-opposed, four cylinder Siemens/Rinia-type engine.

22. The system as in claim 14, wherein said plurality of shafts comprising a piston rod for each piston, each said rod having its proximal end secured to its respective piston and its distal end adjustably secured to he distal end of the piston rod opposed thereto;

23. The electric traction motor as specified in claim 14, wherein each of said rotors are permanent magnet pancake-type rotors.

24. The electric traction motor as specified in claim 14, wherein each of said rotors is a permanent magnetic disc rotor.

25. The electric traction motor as specified in claim 14, wherein each of said rotors is a double shell-type permanent magnet rotor.

26. The electric traction motor as specified in claim 14, wherein each of said rotors are induction rotors.

27. The motor as specified in claim 14, wherein each rotor includes a drive shaft comprising means for sensing rotor speed and position of aid first and second rotors and means for sensing the rotational speed and position of the motor magnetic field, processor means for comparing a difference between said rotor speed and switching means for controlling said motor speed.