Power electronics cooling for a hybrid electric vehicle

• US 6,450,275 B1
• Filed: 11/02/2000
• Issued: 09/17/2002
• Est. Priority Date: 11/02/2000
• Status: Expired due to Term

• Current Assignee: Ford Motor Company
• Original Assignee: Ford Motor Company
• Inventors: Gabriel, David, Kotre, Stephen John
• Primary Examiner(s): Dickson, Paul N.
• Assistant Examiner(s): Rosenberg, Laura B.
• Application Number:
  US09/705,024
• Time in Patent Office: 684 Days
• Field of Search: 702/99, 702/130, 236/3, 236/35, 417/243, 180/65.1, 180/65.2, 180/68.1, 180/68.4, 180/68.2, 180/65.6, 180/65.3, 180/65.4, 165/42, 165/43, 165/41, 165/51, 123/41.31, 123/41.29, 123/41.49
• US Class Current: 180/65.23
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/22 characterised by apparatus, components or means specially adapted for HEVs
• CPC Class Codes: B60K 6/383 One-way clutches or freewheel devices
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: F01P 2005/105 Using two or more pumps
• CPC Class Codes: F01P 2005/125 Driving auxiliary pumps electrically
• CPC Class Codes: F01P 2023/08 Microprocessor; Microcomputer
• CPC Class Codes: F01P 2025/08 Temperature
• CPC Class Codes: F01P 2025/32 Engine outcoming fluid temperature
• CPC Class Codes: F01P 2025/33 Cylinder head temperature
• CPC Class Codes: F01P 2025/40 Oil temperature
• CPC Class Codes: F01P 2025/46 Engine parts temperature
• CPC Class Codes: F01P 2050/24 Hybrid vehicles
• CPC Class Codes: F01P 2050/30 Circuit boards
• CPC Class Codes: F01P 2060/14 Condenser
• CPC Class Codes: F01P 7/048 using electrical drives
• CPC Class Codes: F01P 7/165 characterised by systems with two or more loops
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10S 903/903 having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/904 : Component specially adapted for hev
• CPC Class Codes: Y10S 903/913 : One way

Abstract

This invention is a method and system for cooling Hybrid Electric Vehicle (“HEV”) components. The present invention cools HEV components, including an A/C system, an Internal Combustion Engine and its associated parts, an electric drive system and its associated parts, including an inverter, a DC/DC Converter, a generator motor, and a traction motor. Cooling these components, is accomplished by implementing a cooling system that is comprised of fluid filled cooling loops, radiators, fans, pumps, an air conditioning condenser and a controller. The pumps move the fluid through the cooling loops, allowing the fluid to absorb heat from the components and vent through the radiators with help from the fan'"'"'s airflow. The controller monitors component temperature data by measuring actual component temperature or corresponding coolant temperature and compares the component temperature data to a calibratable threshold to determine whether the fan should operate. By controlling fan speed, the controller regulates airflow across the radiator and air condenser, to maintain coolant temperature, and subsequently component temperatures within acceptable parameters.

Claims

1. A method of operating a Hybrid Electric Vehicle (HEV) having an internal combustion engine and a plurality of electronic components, the engine and the electronic components each having a corresponding desired operating temperature, the method comprising the steps of:

determining a temperature of the internal combustion engine;

determining a temperature of each of the electronic components;

controlling simultaneously a plurality of separately controllable cooling loops corresponding to the internal combustion engine and the electronic components; and

determining a desired speed for a cooling fan based on the temperatures of the electronic components and the internal combustion engine.

2. The method of operating an HEV according to claim 1, wherein the method further comprises the steps of:

determining air conditioning compressor head pressure; and

determining a desired speed for a cooling fan based on the temperatures of the electronic components, the internal combustion engine and the air conditioning compressor head pressure.

3. The method of operating an HEV according to claim 2, wherein the step of determining a desired speed for a cooling fan comprises the steps of:

determining if internal combustion engine temperature exceeds first and second calibratable thresholds;

determining if electronic component temperature exceeds third and fourth calibratable thresholds;

determining if air conditioning compressor head pressure exceeds fifth and sixth calibratable thresholds; and

setting a fan state.

4. The method of operating an HEV according to claim 1, wherein the plurality of cooling loops comprises a first cooling loop and a second cooling loop.

5. The method of operating an HEV according to claim 4, wherein the first cooling loop comprises:

a first radiator;

a first pump;

a DC/DC converter; and

an electric drive system.

6. The method of operating an HEV according to claim 5, wherein the electric drive system comprises:

a traction motor;

a generator motor;

a transmission/transaxle; and

an inverter.

7. The method of operating an REV according to claim 4, wherein the second cooling loop comprises:

a second radiator;

a second pump; and

the internal combustion engine.

8. The method of operating an HEV according to claim 4, wherein the step of determining a temperature of each of the electronic components comprises the step of:

determining a temperature of a cooling fluid in the first cooling loop.

9. The method of operating an REV according to claim 4, wherein the step of determining a temperature of the internal combustion engine comprises the step of:

determining a temperature of a cooling fluid in the second cooling loop.

10. The method of operating an HEV according to claim 1, wherein the step of determining a temperature of each of the electronic components comprises the steps of:

determining a transmission/transaxle oil temperature;

determining an inverter die temperature;

determining a DC/DC converter temperature;

determining a traction motor winding temperature; and

determining a generator motor winding temperature.

11. The method of operating an REV according to claim 1, wherein the step of determining a temperature of the internal combustion engine comprises the step of:

determining a temperature of a cylinder head of the internal combustion engine.

12. A system to operate a Hybrid Electric vehicle (HEV), comprising:

an internal combustion engine;

a plurality of electronic components;

the internal combustion engine and the electronic components each having a corresponding desired operating temperature;

means to determine a temperature of the internal combustion engine;

means to determine a temperature of each of the electronic components;

a plurality of separately controllable cooling loops corresponding to the internal combustion engine and the electronic components;

means to determine a desired speed for a cooling fan based on the temperatures of the electronic components and the internal combustion engine.

13. The system to operate an HEV according to claim 12, further comprising:

an air conditioning compressor;

means to determine air conditioning compressor head pressure; and

means to determine a desired speed for a cooling fan based on the temperatures of the electronic components, the internal combustion engine and the air conditioning head pressure.

14. The system to operate an HEV according to claim 13, wherein the means to determine a desired speed for a cooling fan comprises:

means to determine if internal combustion engine temperature exceeds first and second calibratable thresholds;

means to determine if electronic component temperature exceeds third and fourth calibratable thresholds;

means to determine if air conditioning compressor head pressure exceeds fifth and sixth calibratable thresholds; and

means to set a fan state.

15. The system to operate an REV according to claim 12, wherein the plurality of cooling loops comprises a first cooling loop and a second cooling loop.

16. The system to operate an HEV according to claim 15, wherein the first cooling loop comprises:

a first radiator;

a first pump;

a DC/DC converter; and

an electric drive system.

17. The system to operate an HEV according to claim 16, wherein the electric drive system comprises:

a traction motor;

a generator motor;

a transmission/transaxle; and

an inverter.

18. The system to operate an HRV according to claim 15, wherein the second cooling loop comprises:

a second radiator;

a second pump; and

the internal combustion engine.

19. The system to operate an HEV according to claim 15, wherein the means to determine a temperature of each of the electronic components comprises:

means to determine a temperature of a cooling fluid in the first cooling loop.

20. The system to operate an HEV according to claim 15, wherein the means to determine a temperature of the internal combustion engine comprises:

means to determine a temperature of a cooling fluid in the second cooling loop.

21. The system to operate an HEV according to claim 12, wherein the means to determine a temperature of each of the electronic components comprises:

means to determine transmission/transaxle oil temperature;

means to determine an inverter die temperature;

means to determine a DC/DC converter temperature;

means to determine a traction motor winding temperature; and

means to determine a generator motor winding temperature.

22. The system to operate an HEV according to claim 12, wherein the means to determine a temperature of the internal combustion engine comprises:

means to determine a temperature of a cylinder head of the internal combustion engine.

23. An article of manufacture to operate a Hybrid Electric Vehicle (HEV), comprising:

a controller; and

a control system embodied within the controller to determine a desired speed for a cooling fan by

determining if internal combustion engine temperature exceeds first and second calibratable thresholds,

determining if electronic component temperature exceeds third and fourth calibratable thresholds,

determining if air conditioning compressor head pressure exceeds fifth and&

;

sixth calibratable thresholds, and setting a fan state.

24. An automotive vehicle, comprising:

an internal combustion engine;

a plurality of electronic components;

the internal combustion engine and the electronic components each having a corresponding desired operating temperature;

means to determine a temperature of the internal combustion engine;

means to determine a temperature of each of the electronic components;

a plurality of separately controllable cooling loops corresponding to the internal combustion engine and the electronic components;

means to determine a desired speed for a cooling fan based on the temperatures of the electronic components and the internal combustion engine.

25. The automotive vehicle according to claim 24, further comprising:

an air conditioning compressor;

means to determine air conditioning compressor head pressure; and

means to determine a desired speed for a cooling fan based on the temperatures of the electronic components, the internal combustion engine and the air conditioning head pressure.

26. The automotive vehicle according to claim 25, wherein the means to determine a desired speed for a cooling fan comprises:

means to determine if internal combustion engine temperature exceeds first and second calibratable thresholds;

means to determine if electronic component temperature exceeds third and fourth calibratable thresholds;

means to determine if air conditioning compressor head pressure exceeds fifth and sixth calibratable thresholds; and

means to set a fan state.

27. The automotive vehicle according to claim 24, wherein the plurality of cooling loops comprises a first cooling loop and a second cooling loop.

28. The automotive vehicle according to claim 27, wherein the first cooling loop comprises:

a first radiator;

a first pump;

a DC/DC converter; and

an electric drive system.

29. The automotive vehicle according to claim 28, wherein the electric drive system comprises:

a traction motor;

a generator motor;

a transmission/transaxle; and

an inverter.

30. The automotive vehicle according to claim 27, wherein the second cooling loop comprises:

a second radiator;

a second pump; and

the internal combustion engine.

31. The automotive vehicle according to claim 27, wherein the means to determine a temperature of each of the electronic components comprises:

means to determine a temperature of a cooling fluid in the first cooling loop.

32. The automotive vehicle according to claim 27, wherein the means to determine a temperature of the internal combustion engine comprises:

means to determine a temperature of a cooling fluid in the second cooling loop.

33. The automotive vehicle according to claim 24, wherein the means to determine a temperature of each of the electronic components comprises:

means to determine transmission/transaxle oil temperature;

means to determine an inverter die temperature;

means to determine a DC/DC converter temperature;

means to determine a traction motor winding temperature; and

means to determine a generator motor winding temperature.

34. The automotive vehicle according to claim 24, wherein the means to determine a temperature of the internal combustion engine comprises:

means to determine a temperature of a cylinder head of the internal combustion engine.