Hybrid vehicles

• US 7,392,871 B2
• Filed: 05/08/2006
• Issued: 07/01/2008
• Est. Priority Date: 09/14/1998
• Status: Expired due to Fees

• Current Assignee: Abell Foundation Incorporated
• Original Assignee: Paice LLC
• Inventors: Louckes, Theodore, Severinsky, Alex J.
• Primary Examiner(s): RESTIFO, JEFFREY J
• Application Number:
  US11/429,446
• Publication Number:
  US 20060237247A1
• Time in Patent Office: 785 Days
• Field of Search: 180/65.2, 180/65.3, 180/65.8, 180/233, 903/930, 903/941
• US Class Current: 180/65.28
• CPC Class Codes: B60H 1/004 for vehicles having a combustion engine and electric drive means, e.g. hybrid electric vehicles
• CPC Class Codes: B60H 1/3222 characterised by the compressor driving arrangements, e.g. clutches, transmissions or multiple drives B60H1/3208, B60H1/3226 take precedence
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 2006/268 Electric drive motor starts the engine, i.e. used as starter motor
• CPC Class Codes: B60K 6/22 characterised by apparatus, components or means specially adapted for HEVs
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/485 Motor-assist type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• CPC Class Codes: B60L 15/2045 for optimising the use of energy
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/12 Induction machines
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/16 DC brushless machines
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/443 : Torque
• CPC Class Codes: B60L 2240/445 : Temperature
• CPC Class Codes: B60L 2260/28 : Four wheel or all wheel drive
• CPC Class Codes: B60L 2270/145 : Structure borne vibrations
• 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 53/00 : Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60L 53/20 : characterised by converters located in the vehicle
• CPC Class Codes: B60L 58/10 : for monitoring or controlling batteries
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 7/18 : Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B60L 7/26 : Controlling the braking effect
• CPC Class Codes: B60T 11/18 : Connection thereof to initiating means
• CPC Class Codes: B60T 13/586 : the retarders being of the electric type
• CPC Class Codes: B60T 2270/60 : Regenerative braking
• CPC Class Codes: B60T 2270/604 : Merging friction therewith; Adjusting their repartition
• CPC Class Codes: B60T 7/06 : Disposition of pedal
• CPC Class Codes: B60T 8/17 : Using electrical or electronic regulation means to control braking detecting or indicating faulty operation B60T8/885
• CPC Class Codes: B60T 8/172 : Determining control parameters used in the regulation, e.g. by calculations involving measured or detected parameters B60T8/17551 takes precedence
• 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 10/18 : including control of braking systems
• 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: B60W 20/10 : Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60W 20/14 : in conjunction with braking regeneration
• CPC Class Codes: B60W 20/15 : Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 20/30 : Control strategies involving selection of transmission gear ratio control of change speed gearings, together with other vehicle sub-units B60W10/10; HEV transmission gearing B60K6/36; gearings and control thereof F16H
• CPC Class Codes: B60W 2510/0633 : Turbocharger state
• CPC Class Codes: B60W 2510/0657 : Engine torque
• CPC Class Codes: B60W 2510/244 : Charge state
• CPC Class Codes: B60W 2530/16 : Driving resistance
• CPC Class Codes: B60W 2540/12 : Brake pedal position
• CPC Class Codes: B60W 2710/08 : Electric propulsion units
• CPC Class Codes: B60W 2710/18 : Braking system
• CPC Class Codes: B60W 2710/244 : Charge state
• CPC Class Codes: B60W 30/18127 : Regenerative braking
• CPC Class Codes: B60Y 2200/91 : Electric vehicles
• CPC Class Codes: B60Y 2200/92 : Hybrid vehicles
• CPC Class Codes: B60Y 2300/18125 : Regenerative braking
• CPC Class Codes: B60Y 2300/91 : Battery charging
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: B60Y 2400/435 : Supercharger or turbochargers
• CPC Class Codes: B60Y 2400/81 : Braking systems
• CPC Class Codes: F01N 3/2013 : using electric or magnetic heating means
• CPC Class Codes: F02B 37/00 : Engines characterised by provision of pumps driven at least for part of the time by exhaust
• CPC Class Codes: F02B 37/16 : by bypassing charging air
• CPC Class Codes: F02B 37/18 : by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
• CPC Class Codes: F02D 2250/18 : Control of the engine output torque
• CPC Class Codes: F02D 41/0007 : for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02M 35/10157 : Supercharged engines
• CPC Class Codes: F02M 35/10163 : having air intakes specially adapted to selectively deliver naturally aspirated fluid or supercharged fluid
• CPC Class Codes: F02N 11/0818 : Conditions for starting or stopping the engine or for deactivating the idle-start-stop mode
• CPC Class Codes: F02N 2200/061 : Battery state of charge [SOC]
• CPC Class Codes: H01M 10/4207 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• 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 90/14 : Plug-in electric 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 903/907 : Electricity storage, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements
• CPC Class Codes: Y10S 903/946 : Characterized by control of driveline clutch
• CPC Class Codes: Y10S 903/947 : Characterized by control of braking, e.g. blending of regeneration, friction braking

Abstract

A hybrid vehicle comprises an internal combustion engine, a traction motor, a starter motor, and a battery bank, all controlled by a microprocessor in accordance with the vehicle'"'"'s instantaneous torque demands so that the engine is run only under conditions of high efficiency, typically only when the load is at least equal to 30% of the engine'"'"'s maximum torque output. In some embodiments, a turbocharger may be provided, activated only when the load exceeds the engine'"'"'s maximum torque output for an extended period; a two-speed transmission may further be provided, to further broaden the vehicle'"'"'s load range. A hybrid brake system provides regenerative braking, with mechanical braking available in the event the battery bank is fully charged, in emergencies, or at rest; a control mechanism is provided to control the brake system to provide linear brake feel under varying circumstances.

Claims

1. A hybrid vehicle, comprising:

at least two pairs of wheels, each pair of wheels operable to receive power to propel said hybrid vehicle;

a first alternating current (AC) electric motor, operable to provide power to a first pair of said at least two pairs of wheels to propel said hybrid vehicle;

a second alternating current (AC) electric motor, operable to provide power to a second pair of said at least two pairs of wheels to propel said hybrid vehicle

a third AC electric motor;

an engine coupled to said third electric motor, operable to provide power to at least one of said two pairs of wheels to propel the hybrid vehicle, and/or to said third electric motor to drive the third electric motor to generate electric power;

a first alternating current-direct current (AC-DC) converter having an AC side coupled to said first electric motor, operable to accept AC or DC current and convert the current to DC or AC current respectively;

a second alternating current-direct current (AC-DC) converter having an AC side coupled to said second electric motor, operable to accept AC or DC current and convert the current to DC or AC current respectively;

a third alternating current-direct current (AC-DC) converter coupled to said third electric motor, at least operable to accept AC current and convert the current to DC;

an electrical storage device coupled to a DC side of said AC-DC converters, wherein the electrical storage device is operable to store DC energy received from said AC-DC converters and provide DC energy to at least said first and second AC-DC converters for providing power to at least said first and second electric motors; and

a controller, operable to start and stop the engine to minimize fuel consumption.

2. The hybrid vehicle of claim 1, wherein relative amounts of power directed to said first and second pairs of wheels by the first and second electric motors, respectively, are controlled by said controller.

3. The hybrid vehicle of claim 1, wherein a torque range-broadening transmission is interposed between said engine and said at least said two wheels to which said engine is operable to provide power.

4. The hybrid vehicle of claim 1, wherein a maximum torque provided to said first and second pairs of two wheels by said first and second electric motors, or by said first and second electric motors and said third electric motor, is larger than a maximum torque on at least said two wheels produced by said engine.

5. The hybrid vehicle of claim 1, wherein a maximum rotational speed of at least said first electric motor is at least 50% larger than a maximum rotational speed of said engine.

6. The hybrid vehicle of claim 1, wherein said engine comprises a turbocharger operable to increase the maximum torque output by said engine, and wherein said turbocharger is so operated when the power required of said engine exceeds a predetermined value for at least a predetermined period of time.

7. The hybrid vehicle of claim 1, wherein said engine is preheated prior to starting.

8. The hybrid vehicle of claim 7, wherein said engine is preheated by being driven by a starting motor, whereby said engine is heated by compression of air in its cylinders.

9. The hybrid vehicle of claim 1, wherein said third AC-DC converter is operable to accept DC and convert said DC to AC, and to supply said AC to said third motor, whereby said third motor is operable to start said engine.

10. The hybrid vehicle of claim 1, wherein said engine is rotated at a speed of 300-600 rpm for starting, and wherein a near-stoichiometric fuel:

air ratio is supplied for starting said engine.

11. The hybrid vehicle of claim 10, wherein said engine is preheated prior to starting.

12. The hybrid vehicle of claim 11, wherein said engine is preheated by being driven by a starting motor, whereby said engine is heated by compression of air in its cylinders.

13. A method of control of a hybrid vehicle, said vehicle comprising:

at least two pairs of wheels, each pair of wheels operable to receive power to propel said hybrid vehicle;

a first alternating current (AC) electric motor, operable to provide power to a first pair of said at least two pairs of wheels to propel said hybrid vehicle;

a second alternating current (AC) electric motor, operable to provide power to a second pair of said at least two pairs of wheels to propel said hybrid vehicle

a third AC electric motor;

an engine coupled to said third electric motor, operable to provide power to said at least two wheels to propel the hybrid vehicle, and/or to said third electric motor to drive the third electric motor to generate electric power;

a first alternating current-direct current (AC-DC) converter having an AC side coupled to said first electric motor, operable to accept AC or DC current and convert the current to DC or AC current respectively;

a second alternating current-direct current (AC-DC) converter having an AC side coupled to said second electric motor, operable to accept AC or DC current and convert the current to DC or AC current respectively;

a third alternating current-direct current (AC-DC) converter coupled to said third electric motor, at least operable to accept AC current and convert the current to DC;

an electrical storage device coupled to a DC side of said AC-DC converters, wherein the electrical storage device is operable to store DC energy received from said AC-DC converters and provide DC energy to at least said first and second AC-DC converters for providing power to at least said first and second electric motors; and

a controller, operable to start and stop the engine to minimize fuel consumption;

wherein relative amounts of power directed to said first and second pairs of wheels by the first and second electric motors, respectively, are controlled by said controller.

14. The method of claim 13, wherein a torque range-broadening transmission is interposed between said engine and said at least said two wheels to which said engine is operable to provide power, and said controller operates said transmission in response to detection of high vehicle loading for an extended time.

15. The method of claim 13, wherein said engine comprises a turbocharger operable to increase the maximum torque output by said engine, and wherein said controller causes said turbocharger to be so operated when the power required of said engine exceeds a predetermined value for at least a predetermined period of time.

16. The method of claim 13, comprising the further step of preheating said engine prior to starting.

17. The method of claim 16, wherein said step of preheating said engine is performed by driving said engine using a starting motor, whereby said engine is heated by compression of air in its cylinders.

18. The method of claim 13, wherein said third AC-DC converter is operable to accept DC and convert said DC to AC, and to supply said AC to said third motor, whereby said third motor is operable to start said engine.

19. The method of claim 13, wherein said engine is rotated at a speed of 300-600 rpm for starting, and wherein a near-stoichiometric fuel:

air ratio is supplied for starting said engine.

20. The method of claim 19, wherein said engine is preheated prior to starting.

21. The method of claim 20, wherein said engine is preheated by being driven by a starting motor, whereby said engine is heated by compression of air in its cylinders.

22. A method for controlling a hybrid vehicle, comprising:

operating a first alternating current (AC) electric motor comprised in the hybrid vehicle to propel the hybrid vehicle, comprising;

providing direct current (DC) from an electrical storage device to a DC side of a first alternating current-direct current (AC-DC) converter;

the first AC-DC converter converting the DC to AC;

providing the AC to the first AC electric motor to drive the AC electric motor; and

providing power to a first pair of wheels of the hybrid vehicle in response to said step of providing the AC to the first AC electric motor;

starting and operating an engine comprised in the hybrid vehicle to propel the vehicle and/or drive a second AC electric motor comprised in the hybrid vehicle to generate electric power, comprising providing power to the at least two wheels and/or the second AC electric motor respectively;

converting the generated electric power from AC to DC using a second AC-DC converter;

storing the converted electric power in the electrical storage device, wherein the electrical storage device is coupled to a DC side of the second AC-DC converter; and

operating a third AC electric motor to provide power to a second pair of wheels of the hybrid vehicle to propel the hybrid vehicle.

23. The method of claim 22, further comprising:

operating a turbocharger coupled to the engine of the hybrid vehicle to increase maximum torque output (MTO) produced by the engine when torque required of the engine exceeds a predetermined value for at least a predetermined period of time.