Hybrid vehicles

• US 8,214,097 B2
• Filed: 03/29/2011
• Issued: 07/03/2012
• Est. Priority Date: 09/14/1998
• Status: Expired due to Term

• Current Assignee: Abell Foundation Incorporated
• Original Assignee: Abell Foundation Incorporated, Paice LLC
• Inventors: Louckes, Theodore, Severinsky, Alex J.
• Primary Examiner(s): Trammell, James
• Assistant Examiner(s): Shafi, Muhammad
• Application Number:
  US13/065,704
• Publication Number:
  US 20110190971A1
• Time in Patent Office: 462 Days
• Field of Search: 340988-996
• US Class Current: 701/22
• 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 method for controlling a hybrid vehicle, said vehicle comprising a battery, a controller, wheels, an internal combustion engine and at least one electric motor, wherein both the internal combustion engine and motor are capable of providing torque to the wheels of said vehicle, and wherein said engine has an inherent maximum rate of increase of output torque, said method comprising the steps of:

operating the internal combustion engine of the hybrid vehicle to provide torque to operate the vehicle;

operating said at least one electric motor to provide additional torque when the amount of torque provided by said engine is less than the amount of torque required to operate the vehicle; and

employing said controller to control the engine such that a rate of increase of output torque of the engine is limited to less than said inherent maximum rate of increase of output torque, and wherein said step of controlling the engine such that the rate of increase of output torque of the engine is limited is performed such that combustion of fuel within the engine occurs at a substantially stoichiometric ratio; and

comprising the further steps of;

operating said internal combustion engine to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is between a setpoint SP and a maximum torque output (MTO) of the engine, wherein the engine is operable to efficiently produce torque above SP, and wherein SP is substantially less than MTO;

operating both the at least one electric motor and the engine to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is more than MTO;

and operating the at least one electric motor to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is less than SP.

2. The method of claim 1, wherein the amount of oxygen in an exhaust stream from said engine is monitored to ensure that combustion of fuel within the engine occurs at a substantially stoichiometric ratio.

3. The method of claim 1, wherein when it is desired to start said engine, said engine is rotated at at least 300 rpm, whereby the engine is heated prior to supply of fuel for starting the engine.

4. The method of claim 3, wherein fuel and air are supplied to said engine at a fuel:

air ratio of no more than 1.2 of the stoichiometric ratio for starting the engine.

5. The method of claim 1, wherein said at least one electric motor produces torque at least equal to the engine'"'"'s maximum torque output (MTO).

6. The method of claim 1, comprising the further steps of:

operating said at least one electric motor to provide additional torque when the torque required to operate the vehicle is greater than the engine'"'"'s instantaneous torque output (ITO), and

operating said electric motor as a generator to accept torque from said engine to charge said battery when the torque required to operate the vehicle is less than ITO.

7. The method of claim 1, further comprising the step of operating the engine at torque output levels less than SP under abnormal and transient conditions.

8. The method of claim 1, further comprising the step of:

operating the engine to charge the battery responsive to the state of charge of the battery, wherein the engine is operable to provide torque at least equal to SP to propel the hybrid vehicle, to drive the at least one electric motor to charge the battery, or both, wherein torque produced by the engine equal to the torque required to propel the vehicle (RL) is used to propel the hybrid vehicle, and torque produced by the engine in excess of RL is used to drive the at least one electric motor to charge the battery.

9. The method of claim 1, wherein energy is supplied to the motor from the battery at a voltage of at least 500 volts under peak load conditions.

10. The method of claim 1, wherein energy is supplied to the motor from the battery at no more than about 75 amperes under peak load conditions.

11. A method for controlling a hybrid vehicle, said vehicle comprising a battery, a controller, wheels, an internal combustion engine and at least one electric motor, wherein both the internal combustion engine and motor are capable of providing torque to the wheels of said vehicle, wherein said engine has an inherent maximum rate of increase of output torque, said method comprising the steps of:

operating the internal combustion engine of the hybrid vehicle to provide torque to operate the vehicle;

operating said at least one electric motor to provide additional torque when the amount of torque being provided by said engine is less than the amount of torque required to operate the vehicle; and

employing said controller to control the engine such that a rate of increase of output torque of the engine is limited to less than said inherent maximum rate of increase of output torque, and such that combustion of fuel within the engine occurs at a substantially stoichiometric ratio; and

comprising the further steps of;

operating said internal combustion engine to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is between a setpoint SP and a maximum torque output (MTO) of the engine, wherein the engine is operable to efficiently produce torque above SP, and wherein SP is substantially less than MTO;

operating both the at least one electric motor and the engine to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is more than MTO;

and operating the at least one electric motor to provide torque to the hybrid vehicle when the torque required to operate the hybrid vehicle is less than SP.

12. The method of claim 11, wherein the amount of oxygen in an exhaust stream from said engine is monitored to ensure that combustion of fuel within the engine occurs at a substantially stoichiometric ratio.

13. The method of claim 11, wherein when it is desired to start said engine, said engine is rotated at at least 300 rpm, whereby the engine is heated, prior to supply of fuel for starting the engine.

14. The hybrid vehicle of claim 13, wherein fuel and air are supplied to said engine at a fuel:

air ratio of no more than 1.2 of the stoichiometric ratio for starting the engine.

15. The method of claim 11, wherein said at least one electric motor produces torque at least equal to the engine'"'"'s maximum torque output (MTO).

16. The method of claim 11, comprising the further step of:

operating said electric motor as a generator to accept excess torque from said engine to charge said battery when the torque required to operate the vehicle is less than the engine'"'"'s ITO.

17. The method of claim 11, further comprising the step of operating the engine at torque output levels less than SP under abnormal and transient conditions.

18. The method of claim 11, further comprising the step of:

operating the engine to charge the battery responsive to the state of charge of the battery, wherein the engine is operable to provide torque at least equal to SP to propel the hybrid vehicle, to drive the at least one electric motor to charge the battery, or both, wherein torque produced by the engine equal to the torque required to propel the vehicle (RL) is used to propel the hybrid vehicle, and torque produced by the engine in excess of RL is used to drive the at least one electric motor to charge the battery.

19. The method of claim 11, wherein energy is supplied to the motor from the battery at a voltage of at least 500 volts under peak load conditions.

20. The method of claim 11, wherein energy is supplied to the motor from the battery at a current of no more than about 75 amperes under peak load conditions.

21. A method for controlling a hybrid vehicle, said vehicle comprising a battery, a controller, wheels, an internal combustion engine and at least one electric motor, wherein both the internal combustion engine and motor are capable of providing torque to the wheels of said vehicle, and wherein said engine has an inherent maximum rate of increase of output torque, comprising the steps of:

determining instantaneous road load (RL) required to propel the hybrid vehicle;

operating at least one electric motor to propel the hybrid vehicle when RL is less than a setpoint (SP);

operating an internal combustion engine of the hybrid vehicle to propel the hybrid vehicle when RL is between SP and a maximum torque output (MTO) of the engine, wherein the engine is operable to efficiently produce torque above SP, and wherein SP is substantially less than MTO;

operating both the at least one electric motor and the engine to propel the hybrid vehicle when RL is more than MTO; and

employing said controller to control the engine such that a rate of increase of output torque of the engine is limited to less than said inherent maximum rate of increase of output torque, and, if the engine is incapable of supplying instantaneous torque required to propel the hybrid vehicle, supplying additional torque from the at least one electric motor, and wherein said step of controlling the engine such that the rate of change of output torque of the engine is limited is performed such that combustion of fuel within the engine occurs at a substantially stoichiometric ratio; and

operating the engine to charge the battery responsive to the state of charge of the battery, wherein the engine is operable to provide torque at least equal to SP to propel the hybrid vehicle, to drive the at least one electric motor to charge the battery, or both, and wherein torque produced by the engine equal to RL is used to propel the hybrid vehicle, and torque produced by the engine in excess of RL is used to drive the at least one electric motor to charge the battery.

22. The method of claim 21, wherein the amount of oxygen in an exhaust stream from said engine is monitored to ensure that combustion of fuel within the engine occurs at a substantially stoichiometric ratio.

23. The method of claim 21, wherein when it is desired to start said engine, said engine is rotated at at least 300 rpm, whereby the engine is heated, prior to supply of fuel for starting the engine.

24. The method of claim 23, wherein fuel and air are supplied to said engine at a fuel:

air ratio of no more than 1.2 of the stoichiometric ratio for starting the engine.

25. The method of claim 21, wherein said at least one electric motor produces torque at least equal to MTO.

26. The method of claim 21, comprising the further steps of:

operating said electric motor as a generator powered by said engine to charge said battery when RL is less than the engine'"'"'s instantaneous torque output (ITO); and

operating said at least one electric motor to provide additional torque when RL is greater than the engine'"'"'s instantaneous torque output (ITO).

27. The method of claim 21, further comprising the step of operating the engine at torque output levels less than SP under abnormal and transient conditions.

28. The method of claim 21, wherein energy is supplied to the motor from the battery at a voltage of at least 500 volts under peak load conditions.

29. The method of claim 21, wherein energy is supplied to the motor from the battery at a current of no more than about 75 amperes under peak load conditions.

30. A hybrid vehicle, comprising:

one or more wheels;

an internal combustion engine operable to propel the hybrid vehicle by providing torque to the one or more wheels, wherein said engine has an inherent maximum rate of increase of output torque;

at least one electric motor operable to propel the hybrid vehicle by providing torque to the one or more wheels;

a battery coupled to the at least one electric motor, operable to provide electrical power to the at least one electric motor; and

a controller, operable to control the flow of electrical and mechanical power between the engine, the at least one electric motor, and the one or more wheels, responsive to an operator command;

wherein said controller controls said at least one electric motor to provide additional torque when the amount of torque being provided by said engine is less than the amount of torque required to operate the vehicle; and

wherein said controller controls said engine such that a rate of increase of output torque of said engine is limited to less than said inherent maximum rate of increase of output torque, and wherein the controller is operable to limit the rate of change of torque produced by the engine such that combustion of fuel within the engine occurs at a substantially stoichiometric ratio.

31. The hybrid vehicle of claim 30, wherein the amount of oxygen in an exhaust stream from said engine is monitored to ensure that combustion of fuel within the engine occurs at a substantially stoichiometric ratio.

32. The hybrid vehicle of claim 30, wherein when it is desired to start said engine, said engine is rotated at at least 300 rpm, whereby the engine is heated, prior to supply of fuel for starting the engine.

33. The hybrid vehicle of claim 32, wherein fuel and air are supplied to said engine at a fuel:

air ratio of no more than 1.2 of the stoichiometric ratio for starting the engine.

34. The hybrid vehicle of claim 30, wherein the controller stops the engine when the torque required to propel the vehicle, to charge the battery, or both, is less than SP.

35. The hybrid vehicle of claim 30, wherein the at least one electric motor is operable to charge the battery when the instantaneous torque output of the internal combustion engine is greater than the amount of torque required to propel the vehicle, when the amount of torque required to propel the vehicle is negative, or when braking is initiated by the operator.

36. The hybrid vehicle of claim 30, wherein the maximum torque available for supply to the one or more wheels from the at least one electric motor is at least equal to the maximum torque available for supply to the one or more wheels from the engine.

37. The hybrid vehicle of claim 30, wherein the controller is operable to start and operate the engine at torque output levels less than SP under abnormal and transient conditions.

38. The hybrid vehicle of claim 30, wherein energy is supplied from the battery to the motor at a peak of at least 500 volts under peak load conditions.

39. The hybrid vehicle of claim 30, wherein energy is supplied from the battery to the motor at no more than about 75 amperes under peak load conditions.