Hybrid electric vehicle powertrain with an alternate operating mode without a high voltage system

• US 6,978,854 B1
• Filed: 07/28/2004
• Issued: 12/27/2005
• Est. Priority Date: 07/28/2004
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Lockwood, Tony, Kuang, Ming
• Primary Examiner(s): PHAN, HAU VAN
• Application Number:
  US10/710,674
• Time in Patent Office: 517 Days
• Field of Search: 180/65.1, 180/65.2, 180/65.3, 180/65.4, 180/65.8, 180/65.7, 180/285, 180/278, 180/277, 477/5, 477/6, 477/87, 477/86, 477/176, 290/40.B, 290/40.C, 290/40.F
• US Class Current: 180/65.235
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• 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 10/10 including control of change-speed gearings
• 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: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A hybrid electric powertrain and control method for an automotive vehicle having mechanical and electro-mechanical power flow paths from an engine to a power output member. A mechanical power flow path is maintained when the electro-mechanical power flow path is disabled.

Claims

1. A hybrid electric powertrain for an automotive vehicle comprising:

an engine, an electric motor, a battery, a generator and transmission gearing;

the transmission gearing defining in part a first power flow path from the engine to a power output member;

the generator being mechanically coupled to the engine by the transmission gearing;

the motor, the battery and the generator being electrically coupled and defining in part an electro-mechanical power flow path to the power output member;

a generator torque reaction brake means for anchoring the generator when the electro-mechanical power flow path is disabled; and

a slipping clutch mechanically connecting a torque reaction element of the gearing to the generator whereby a mechanical power flow path from the engine to the power output member is maintained when the electro-mechanical power flow path is disabled.

2. The hybrid electric powertrain set forth in claim 1 wherein the battery is a high voltage battery;

the battery, the generator and the motor forming an electrical power delivery sub-system for satisfying a power demand; and

a vehicle controller including means for controlling electrical current transfer between the motor and the generator as the battery functions as an electrical energy storage medium;

the electro-mechanical power flow path being disabled when the battery is in an open circuit state.

3. The hybrid electric powertrain set forth in claim 2 wherein the vehicle controller includes means for disabling the generator and the motor when the battery is in an open circuit state.

4. The hybrid electric powertrain set forth in claim 2 wherein the transmission gearing includes a planetary gearset having a ring gear element, a sun gear element and a carrier element with planet pinions engaged with the sun ear element and the ring gear element;

the generator being mechanically coupled to one element of the gearset and the engine being mechanically coupled to a second element of the gearset, a third element of the gearset being mechanically coupled to the power output member;

the slipping clutch defining in part a mechanical connection between the generator and the one element of the gearset.

5. The hybrid electric powertrain set forth in claim 1 wherein the transmission gearing includes a planetary gearset having a ring gear element, a sun gear element and a carrier element with planet pinions engaged with the sun gear element and the ring gear element;

the generator being mechanically coupled to one element of the gearset and the engine being mechanically coupled to a second element of the gearset, a third element of the gearset being mechanically coupled to the power output member;

the slipping clutch defining in part a mechanical connection between the generator and the one element of the gearset.

6. A hybrid electric powertrain for an automotive vehicle comprising:

an engine, an electric motor, a battery, a generator and transmission gearing;

the transmission gearing defining in part a first power flow path from the engine to a power output member;

the generator being mechanically coupled to the engine by the transmission gearing;

the motor, the battery and the generator being electrically coupled and defining in part an electro-mechanical power flow path to the power output member;

means for controlling generator speed by regulating current transfer between the motor and the generator as the battery functions as an electrical storage medium;

a generator torque reaction brake means for anchoring the generator to effect a mechanical power flow path from the engine to the power output member when the electro-mechanical power flow path to the power output member is disabled; and

a slipping clutch in a mechanical connection between the engine and the generator whereby a mechanical power flow path is established between the engine and the power output member, reaction torque for the gearing being developed by the slipping clutch.

7. A hybrid electric powertrain for an automotive vehicle comprising:

an engine, an electric motor, a high voltage battery, a generator and transmission gearing;

the transmission gearing defining in part a first power flow path from the engine to a power output member;

the generator being mechanically coupled to the engine by the transmission gearing;

the motor, the high voltage battery and the generator being electrically coupled and defining in part an electro-mechanical power flow path to the power output member;

a generator torque reaction brake means for anchoring the generator when the electro-mechanical power flow path is disabled;

a slipping clutch mechanically connecting a torque reaction element of the gearing to the generator whereby a mechanical power flow path from the engine to the power output member is maintained when the electro-mechanical power flow path is disabled;

a low voltage battery and alternator forming a low voltage power source for the vehicle; and

an alternator drive clutch means for connecting the alternator to the engine as the slipping clutch is activated.

8. The hybrid electric powertrain set forth in claim 7 wherein the high voltage battery, the generator and the motor form an electrical power delivery sub-system for satisfying a power demand;

and

a vehicle controller including means for controlling electrical current transfer between the motor and the generator as the high voltage battery functions as an electrical energy storage medium;

the electro-mechanical power flow path being disabled when the high voltage battery is in an open circuit state as low voltage needs are supplied by the low voltage battery.

9. A method for controlling a hybrid electric powertrain for an automotive vehicle, the powertrain having an engine, an electric motor, a high voltage battery, a generator and transmission gearing defining in part a mechanical power flow path from the engine to a power output member, the motor, the high voltage battery and the generator being electrically coupled and defining in part an electro-mechanical power flow path to the power output member, the method comprising the steps of:

establishing a driving connection between the generator and the engine;

braking the generator to provide reaction torque for a reaction element of the gearing as a mechanical power flow path is established between the engine and the power output member; and

establishing a variable speed connection between the reaction element of the gearing and the generator when the generator is braked, whereby the engine is allowed to operate at speeds above a stall speed when the mechanical power flow path is established.

10. The method set forth in claim 9 wherein the step of braking the generator occurs in response to disablement of the electro-mechanical power flow path.

11. The method set forth in claim 9 including the step of establishing a low voltage source for the vehicle;

and

activating the low voltage source when the generator is braked as a mechanical power flow path is established from the engine to the power output member.