AC drive system for electrically operated vehicle

• US 7,332,881 B2
• Filed: 10/27/2005
• Issued: 02/19/2008
• Est. Priority Date: 10/28/2004
• Status: Active Grant

• Current Assignee: Textron Inc
• Original Assignee: Textron Inc
• Inventors: Bell, Oliver A., Clark, Warren
• Primary Examiner(s): Leykin; Rita
• Application Number:
  US11/260,867
• Publication Number:
  US 20060108956A1
• Time in Patent Office: 845 Days
• Field of Search: 318/139, 318/34, 318/138, 320/132, 320/134, 303/3, 188/18.R, 188/2.R, 180/165
• US Class Current: 318/139
• CPC Class Codes: B60L 15/10 for automatic control superimposed on human control to limit the acceleration of the vehicle, e.g. to prevent excessive motor current electric devices for safety purposes B60L3/00
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2200/22 Microcars, e.g. golf cars
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/30 Universal machines
• CPC Class Codes: B60L 2250/26 by pedal actuation
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 3/108 whilst braking, i.e. ABS
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 53/14 Conductive energy transfer
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60L 7/26 Controlling the braking effect
• CPC Class Codes: B60T 13/586 the retarders being of the electric type
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/18 including control of braking systems
• CPC Class Codes: H04L 2012/40215 Controller Area Network CAN
• CPC Class Codes: H04L 2012/40273 the transportation system being a vehicle
• 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 90/12 : Electric charging stations
• CPC Class Codes: Y02T 90/14 : Plug-in electric vehicles

Abstract

A drive system for an electric vehicle includes a motor for providing a drive torque and an electrically actuated brake for providing a braking torque to the motor. The system includes a controller that receives a plurality of inputs which may include a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal input. The controller may generate a drive signal for the motor based on some or all of the inputs.

Claims

1. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and the drive signal includes at least one of a pulse width modulation signal and a pulse frequency modulation signal.

2. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and determines a maximum speed of the motor based on the battery voltage input.

3. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and

wherein the controller further receives a run/tow input indicative of the vehicle being configured to be driven and configured to be towed, and wherein the controller determines a maximum speed of the motor based on the tow switch input and the FNR input.

4. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and slows the motor when the brake pedal position input indicates greater than 0% braking command regardless of the battery voltage input, throttle pedal position input, and FNR input.

5. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and

wherein the controller determines a SOC of a battery and determines a maximum speed of the motor based on the SOC.

6. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs, wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and

a contactor that selectively connects the drive signal and the motor, wherein the controller further generates a PWM contactor control signal that is communicated to the contactor wherein the controller generates the contactor control signal at a first PWM duty cycle when closing the contactor and generates the contactor control signal at a second PWM duty cycle after the contactor is closed.

7. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller generates and sends a brake control signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, the brake control signal generated at a first PWM duty cycle when applying the electrically actuated brake and generates the brake control signal at a second PWM duty cycle after the electrically actuated brake is applied.

8. The drive system of claim 7 wherein the electrically actuated brake provides a parking brake function when the motor is stopped.

9. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and reduces the speed of the motor at a predetermined rate when the brake pedal position input indicates 0% braking command and the throttle pedal position input indicates 0% throttle command.

10. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs, wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and

a locking differential that receives and redirects the drive torque to a pair of axles, wherein the locking differential locks and unlocks in accordance with a differential control signal that is generated by the controller at a first PWM duty cycle when locking the locking differential and at a second PWM duty cycle after the locking differential is locked.

11. A drive system for a vehicle comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and the electrically actuated brake is deenergized to apply a braking torque to the motor.

12. A drive system for a vehicle comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and the electrically actuated brake is deenergized to apply a braking torque to the motor when the brake pedal has been depressed to within a predetermined percentage of its full stroke.

13. A drive system for a vehicle comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and the electrically actuated brake is deenergized to apply a braking torque to the motor when the brake full stroke sensor input to the controller indicates that the brake pedal has been depressed to within a predetermined percentage of its full stroke.

14. A drive system for a vehicle comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor; and

a controller that receives a battery voltage input, a throttle pedal position input, a brake pedal position input, a key switch input, a forward/neutral/reverse (FNR) input, and a brake full-stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the controller sends a signal to the electrically actuated brake based on the brake pedal position input and the brake full-stroke input, and the controller is configured to vary electrical energy applied to the electrically actuated brake based on the brake pedal position input.

15. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a brake full stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the electrically actuated brake is operated in accordance with the brake full stroke input and is actuated independently of the controller.

16. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a brake full stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the electrically actuated brake is operated in accordance with the brake full stroke input and is deenergized to apply a braking torque to the motor.

17. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a brake full stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the electrically actuated brake is operated in accordance with the brake full stroke input and is deenergized to apply a braking torque to the motor when the brake pedal has been depressed to within a predetermined percentage of its full stroke.

18. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a brake full stroke input in addition to the brake pedal position input, the controller generating a drive signal for the motor based on the inputs;

wherein the electrically actuated brake is operated in accordance with the brake full stroke input and is deenergized to apply a braking torque to the motor when the brake full stroke sensor input indicates that the brake pedal has been depressed to within a predetermined percentage of its full stroke.

19. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a run/tow input indicative of the vehicle being configured to be driven or being configured to be towed, the controller generates a drive signal for the motor based on the inputs, the controller generating a drive signal for the motor and a brake control signal for the electrically actuated brake,

wherein when the run/tow input is switched to tow mode, the controller energizes the electrically actuated brake.

20. The drive system of claim 19 wherein the controller energizes the electrically actuated brake to limit the speed of the vehicle when in tow mode.

21. The drive system of claim 19 wherein when the run/tow input is in tow mode, the controller further generates a signal to the motor to limit power dissipation and consumption by the motor during towing.

22. The drive system of claim 19 wherein the controller deenergizes a main contactor of the system when the run/tow input indicates a tow mode.

23. The drive system of claim 19 wherein the controller generates the drive signal when the key switch is in an on position, the FNR switch is in one of the forward and reverse positions, the run/tow input indicates a run mode, the brake pedal position input is indicative of 0% braking command, and a battery state of charge (SOC) is greater than a predetermined SOC.

24. The drive system of claim 19 wherein the controller slows the motor when the brake pedal position input indicates greater than 0% braking command regardless of the battery voltage input, throttle pedal position input, and FNR input.

25. The drive system of claim 19 wherein the controller minimizes the drive torque in forward and reverse directions when the run/tow indicates a tow mode for the vehicle.

26. The drive system of claim 19 wherein the controller generates the brake control signal for controlling the electrically actuated brake based on the brake pedal position input, the key switch input, and the run/tow input.

27. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

an electrically actuated brake for providing a braking torque to the motor;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a run/tow input indicative of the vehicle being configured to be driven or being configured to be towed, the controller generating a drive signal for the motor based on the inputs,

wherein when the run/tow input indicates a tow mode, the controller generates a signal to the motor to limit power dissipation and consumption by the motor during towing.

28. The drive system of claim 27 wherein when the run/tow input indicates tow mode, the controller generates a signal to the motor to cause the motor to generate a forward-EMF substantially equal to a back-EMF generated during a tow operation of the vehicle.

29. The drive system of claim 27 wherein the controller operates the motor to maintain a state of charge (SOC) of the battery during the tow mode.

30. The drive system of claim 27 wherein the controller selectively activates the electrically actuated brake to limit tow speed below a predetermined value.

31. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, a forward/neutral/reverse input, and a run/tow input indicative of the vehicle being configured to be driven or being configured to be towed, the controller generating a drive signal for the motor based on the inputs,

wherein when the run/tow input is in tow mode, the controller energizes a main contactor of the motor.

33. The drive system of a vehicle of claim 31 wherein the controller decreases the speed of the vehicle to a stop position and wherein when the vehicle comes to a stop, the controller engages an electrically actuated brake.

34. The drive system of a vehicle of claim 33 wherein the controller decreases the speed of the vehicle and deenergizes an electrically actuated brake when the vehicle comes to a stop.

32. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, and a forward/neutral/reverse input, the controller generating a drive signal for the motor based on the inputs,

wherein the controller sends a signal to the motor to decrease the speed of the motor when the vehicle is moving and neither the throttle pedal nor the brake pedal is engaged.

35. A drive system for a vehicle, comprising:

a motor for providing a drive torque;

a controller that receives a battery voltage input, a throttle pedal position input that varies in accordance with a position of the throttle pedal, a brake pedal position input that varies in accordance with a position of the brake pedal, a key switch input, and a forward/neutral/reverse input, the controller generating a drive signal for the motor based on the inputs,

wherein the controller deenergizes a main contactor of the system when the throttle pedal is not engaged.

36. The drive system of a vehicle of claim 35 further comprising a throttle enable sensor for detecting whether the throttle pedal is depressed.

37. The drive system of a vehicle of claim 36 wherein the throttle enable sensor determines a pedal up position and the controller deenergizes the main contactor in response to the detected pedal up position.

38. The drive system of a vehicle of claim 35 wherein when the main contactor is deenergized, the motor cannot be energized.