Regeneration and brake management system

• US 7,647,997 B2
• Filed: 01/04/2007
• Issued: 01/19/2010
• Est. Priority Date: 11/16/2004
• Status: Active Grant

• Current Assignee: Eaton Intelligent Power Limited (Eaton Corporation PLC.)
• Original Assignee: Eaton Corp. (Wisconsin) (Eaton Corporation PLC.)
• Inventors: Oliver, James L.
• Primary Examiner(s): Dickson; Paul N
• Assistant Examiner(s): MEYER, JACOB B
• Application Number:
  US11/649,548
• Publication Number:
  US 20070107958A1
• Time in Patent Office: 1,111 Days
• Field of Search: 180/65.2, 180/165, 903/947, 701/22, 303/152
• US Class Current: 180/165
• CPC Class Codes: B60K 6/12 by means of a chargeable fluidic accumulator
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• CPC Class Codes: B60L 7/26 Controlling the braking effect
• CPC Class Codes: B60T 1/10 by utilising wheel movement for accumulating energy, e.g. driving air compressors
• CPC Class Codes: B60T 2270/604 Merging friction therewith; Adjusting their repartition
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/184 with wheel brakes
• 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 20/13 in order to stay within battery power input or output limits; in order to prevent overcharging or battery depletion
• CPC Class Codes: B60W 30/18127 Regenerative braking
• CPC Class Codes: F16D 61/00 Brakes with means for making the energy absorbed available for use F16D57/00 takes precedence
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10S 903/947 Characterized by control of braking, e.g. blending of regeneration, friction braking

Abstract

A regeneration and brake management system includes a prime mover, an energy storage device associated with the prime mover, and a regenerative braking system including a controller and at least one friction brake, wherein the regenerative braking system is configured to at least partially disable the at least one friction brake during regenerative braking.

Claims

1. A vehicular hybrid powertrain system comprising:

a first prime mover;

a second prime mover;

an energy storage device associated with said second prime mover; and

a regenerative braking system including a controller and friction brakes associated with said powertrain system, wherein said regenerative braking system is configured to at least partially disable said friction brakes during regenerative braking; and

wherein said controller is configured to engage said friction brakes to an initial non-zero pressure level prior to regenerative braking and maintaining said friction brakes at a pressure level at least equal to said initial non-zero pressure level during regenerative braking.

2. The vehicular hybrid powertrain system of claim 1, wherein said second prime mover comprises an electric motor and an inverter associated with said electric motor, and wherein said regenerative braking comprises providing negative torque to said electric motor operating as a generator.

3. The vehicular hybrid powertrain system of claim 2, wherein said second prime mover comprises a hydraulic motor.

4. The vehicular hybrid powertrain system of claim 1, further comprising:

a multi-ratio transmission including an input; and

a clutch configured to selectively couple said first prime mover to said multi-ratio transmission, said clutch being configured to un-couple said first prime mover from said multi-ratio transmission during regenerative braking.

5. The vehicular hybrid powertrain system of claim 1, wherein said controller is further configured to:

disable further friction braking until a limit of said regenerative braking system is met;

said regenerative braking system being configured to produce a regenerative current during operation.

6. The vehicular hybrid powertrain system of claim 5, wherein said limit of said regenerative braking system comprises one of an energy storage device operating at capacity, a thermal limit of said regenerative braking system, or a wheel slippage.

7. The vehicular hybrid powertrain system of claim 5 wherein said limit of said regenerative braking system is varied based on one of a grade rolling resistance, a surface condition change, a weight distribution and variance, an absorbing generator torque variation, or a requested deceleration rate.

8. The vehicular hybrid powertrain system of claim 5, wherein said limit of said regenerative braking system is determined from a regenerative braking current.

9. The vehicular hybrid powertrain system of claim 6, further comprising:

a pressure transducer configured to detect a fluid pressure in said regenerative braking system;

a wheel speed pick-up unit configured to sense a rotational velocity of a vehicle wheel; and

wherein said limit of said regenerative braking system is determined from said regenerative current, a detected fluid pressure, and a sensed wheel velocity.

10. The vehicular hybrid powertrain system of claim 1, further comprising a proportional valve disposed in said regenerative brake system configured to selectively apply an actuating brake fluid to said friction brakes;

and

wherein said at least partial disabling of said friction brakes comprises limiting a fluid pressure passed through said brake system proportional valve.

11. The vehicular hybrid powertrain system of claim 1, wherein said regenerative braking system is configured to enable friction braking when a regenerative limit of said regenerative braking system is met.

12. The vehicular hybrid powertrain system of claim 11, wherein said controller is configured to balance said enablement of the friction braking.

13. The vehicular hybrid powertrain system of claim 12, wherein said balancing comprises enabling a friction braking of a set of front wheels on a front-wheel driven vehicle.

14. The vehicular hybrid powertrain system of claim 1, wherein said controller is configured to at least partially disable said friction brakes and to initiate regenerative braking in response to one of an increased brake fluid pressure, an electrical brake light signal, or a throttle pedal.

15. A vehicular hybrid powertrain system comprising:

a first prime mover including an internal combustion engine;

a second prime mover including an electric motor and an inverter;

an energy storage device associated with said second prime mover;

a multi-ratio transmission including an input;

a regenerative braking system including a controller and friction brakes associated with said powertrain system, and wherein said regenerative braking system is configured to at least partially disable said friction brakes during regenerative braking, wherein said regenerative braking comprises providing negative torque to said electric motor operating as a generator; and

a clutch configured to selectively couple said first prime mover to said multi-ratio transmission, said clutch being configured to un-couple said first prime mover from said multi-ratio transmission during said regenerative braking; and

wherein said controller is configured to engage said friction brakes to an initial non-zero pressure level prior to regenerative braking and maintaining said friction brakes at a pressure level at least equal to said initial non-zero pressure level during regenerative braking.

16. The vehicular hybrid powertrain system of claim 15, wherein said controller is further configured to:

disable further friction braking until a limit of said regenerative braking system is met;

said regenerative braking system being configured to produce a regenerative current during operation;

wherein said limit of said regenerative braking system comprises one of an energy storage device operating at capacity, a thermal limit of said regenerative braking system, or a wheel slippage.

17. The vehicular hybrid powertrain system of claim 16, wherein said limit of said regenerative braking system is varied based on one of a grade rolling resistance, a surface condition change, a weight distribution and variance, an absorbing generator torque variation, or a requested deceleration rate.

18. The vehicular hybrid powertrain system of claim 16, further comprising:

a pressure transducer configured to detect a fluid pressure in said regenerative braking system;

a wheel speed pick-up unit configured to sense a rotational velocity of a vehicle wheel; and

wherein said limit of said regenerative braking system is determined from said regenerative current, a detected fluid pressure, and a sensed wheel velocity.

19. The vehicular hybrid powertrain system of claim 15, wherein said controller is configured to at least partially disable said friction brakes and to initiate regenerative braking in response to one of an increased brake fluid pressure, an electrical brake light signal, or a throttle pedal position.

20. A regenerative vehicle powertrain system comprising:

a prime mover;

an energy storage device associated with said prime mover; and

a regenerative braking system including a controller and at least one friction brake, wherein said regenerative braking system is configured to at least partially disable said at least one friction brake during regenerative braking;

wherein said controller is configured to initially engage said friction brakes to a non-zero pressure level prior to regenerative braking and maintaining said at least one friction brake at a pressure level at least equal to said initial non-zero pressure level during regenerative braking.

21. The regenerative vehicle powertrain system of claim 20, wherein said prime mover comprises an electric motor and an inverter, wherein said regenerative braking comprises providing negative torque to said electric motor operating as a generator.

22. The regenerative vehicle powertrain system of claim 20, wherein said at least partially disabling said at least one friction brake during regenerative braking comprises:

disabling further friction braking until a limit of said regenerative braking system is met;

said regenerative braking system being configured to produce a regenerative current during operation.

23. The regenerative vehicle powertrain system of claim 20, wherein said at least partially disabling said at least one friction brake during regenerative braking comprises completely disabling said at least one friction brake during regenerative braking.