Method and apparatus for power electronics and control of plug-in hybrid propulsion with fast energy storage

• US 7,740,092 B2
• Filed: 09/12/2006
• Issued: 06/22/2010
• Est. Priority Date: 09/23/2005
• Status: Expired due to Fees

• Current Assignee: AFS Trinity Power Corporation, FAS Trinity Power Corporation
• Original Assignee: AFS Trinity Power Corporation
• Inventors: Bender, Donald Arthur
• Primary Examiner(s): VANAMAN, FRANK BENNETT
• Application Number:
  US11/519,350
• Publication Number:
  US 20070068714A1
• Time in Patent Office: 1,379 Days
• Field of Search: 180/65.21, 180/65.22, 180/65.245, 180/65.29, 320/124, 320/125, 320/140, 903/907
• US Class Current: 180/65.29
• CPC Class Codes: B60K 2006/268 Electric drive motor starts the engine, i.e. used as starter motor
• CPC Class Codes: B60K 6/105 the accumulator being a flywheel
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/52 Driving a plurality of drive axles, e.g. four-wheel drive
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• 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 10/24 including control of energy storage means
• 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: Y02T 10/62 : Hybrid vehicles
• 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 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor

Abstract

A plug-in hybrid propulsion system includes a fast energy storage device that preserves battery life, where the energy storage elements of the hybrid drive train may be charged with externally supplied electricity as well as energy from the engine or regenerative braking. Electronic switches, passive electronics, an enclosure, controller circuitry, and/or control algorithms are used to manage the flow of power between a fuel powered engine, a battery, a fast energy storage system, traction motors; a charger, ancillary systems, an electrical distribution system, and/or a drive train.

Claims

1. A system for powering a plug-in hybrid electric vehicle comprising a vehicle drivetrain having an internal combustion engine and one or more motor-generators connected to the drivetrain, wherein the one or more motor-generators supply power to the drivetrain to propel the vehicle or start the engine or absorb power to regeneratively recharge one or more energy storage devices;

said system comprising a first electrical energy storage device;

a second electrical energy storage device; and

power electronics;

wherein the first electrical energy storage is a battery that delivers electrical energy to the drivetrain for traction power or to start the engine, or absorbs electrical energy from the drivetrain;

wherein the second electrical energy storage device is a flywheel, capacitor, ultracapacitor, supercapacitor, or battery; and

the second electrical energy storage device only absorbs or delivers current as necessary to protect the first electrical energy storage device from current above a damage threshold for the first electrical energy storage device; and

wherein the power electronics include a polyphase power converter with a plurality of phase legs, wherein each phase leg comprises two electronic switches with diodes;

wherein both ends of each phase leg are connected to a DC bus;

wherein a center of each phase leg is connected to another electrical device;

wherein one or more capacitors are connected across the DC bus;

wherein a first of said plurality of phase legs is used as a DC-DC converter for the second electrical energy storage device; and

wherein one or more sets of three phase legs from the power converter function as one or more three phase motor drives.

2. The system set forth in claim 1 configured so that the first electrical energy storage device is connected directly to the DC bus.

3. The system set forth in claim 1 configured so that the second electrical energy storage device is a capacitor that is connected to the DC bus through the DC-DC converter.

4. The system set forth in claim 1 configured so that the second electrical energy storage device is a battery that is connected to the DC bus through the DC-DC converter.

5. The system set forth in claim 1 configured so that phase legs are used as a charger for either or both of the first electrical energy storage device and the second electrical energy storage device.

6. The system set forth in claim 1 configured so that the DC-DC converter uses inductance of connected motors and transformers to smooth current ripple.

7. The system set forth in claim 1 configured with a single motor connected to the drivetrain.

8. The system set forth in claim 1 configured as a series hybrid with two or more motor-generators.

9. The system set forth in claim 1 configured with separate front and rear drive, where the front drive and rear drive are not mechanically connected to one another via an axle or shaft.

10. The system set forth in claim 1 configured with engine powered front wheel drive and motor-generator powered rear wheel drive.

11. The system set forth in claim 1 configured with DC output ports that provide power to vehicle equipment and subsystems.

12. The system set forth in claim 1 configured with an AC charging port and an active rectifier that supplies charging power to the DC bus.

13. The system set forth in claim 1 configured with a separate battery charger for the first electrical energy storage device.

14. The system set forth in claim 1 including a control algorithm hosted by a microprocessor or a digital signal processor.

15. The system set forth in claim 1 configured where the DC-DC converter is a single phase leg having a single-phase.

16. The system set forth in claim 1 configured with phase legs connected as an active rectifier that produce AC voltage which is transformed to lower or higher voltage and rectified to DC.

17. The system set forth in claim 1 configured so that the second electrical energy storage device is connected directly to the DC bus.