Hybrid vehicle drive system and method and idle reduction system and method

• US 8,408,341 B2
• Filed: 02/22/2010
• Issued: 04/02/2013
• Est. Priority Date: 07/12/2007
• Status: Active Grant

• Current Assignee: Power Technology Holdings LLC
• Original Assignee: Odyne Systems, LLC
• Inventors: Dalum, Joseph Thomas, Jarmuz, Matthew J., Myers, Daniel Francis, Ambrosio, Joseph Mario
• Primary Examiner(s): Walters, John
• Assistant Examiner(s): SWENSON, BRIAN L
• Application Number:
  US12/710,247
• Publication Number:
  US 20100219007A1
• Time in Patent Office: 1,135 Days
• Field of Search: 180/65.22, 180/65.25, 180/65.23, 180/65.26, 180/65.275, 180/65.285
• US Class Current: 180/65.22
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 17/28 characterised by arrangement, location, or type of power take-off
• CPC Class Codes: B60K 2025/065 the transmission being fluidic, e.g. hydraulic
• CPC Class Codes: B60K 25/00 Auxiliary drives B60K16/00 takes precedence; arrangements of tyre-inflating pumps mounted on vehicles B60C23/10; driving tyre-inflating pumps B60C; driving engine auxiliaries F02B
• CPC Class Codes: B60K 25/06 from the transmission power take-off transmissions having power-take-off B60K17/28
• CPC Class Codes: B60K 6/12 by means of a chargeable fluidic accumulator
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 1/00 Supplying electric power to auxiliary equipment of vehicles circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/90 using propulsion power supplied by specific means not covered by groups B60L50/10 - B60L50/50, e.g. by direct conversion of thermal nuclear energy into electricity
• 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 10/10 including control of change-speed gearings
• CPC Class Codes: B60W 10/18 including control of braking systems
• CPC Class Codes: B60W 10/30 including control of auxiliary equipment, e.g. air-conditioning compressors or oil pumps
• 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 20/20 : Control strategies involving selection of hybrid configuration, e.g. selection between series or parallel configuration
• CPC Class Codes: B60W 30/1888 : Control of power take off [PTO]
• CPC Class Codes: B60Y 2200/14 : Trucks; Load vehicles, Busses
• 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 90/16 : Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements
• CPC Class Codes: Y10T 29/49009 : Dynamoelectric machine

Abstract

One embodiment relates to a hybrid vehicle drive system for a vehicle including a first prime mover, a first prime mover driven transmission, a rechargeable power source, and a PTO. The hybrid vehicle drive system further includes a hydraulic pump in direct or indirect mechanical communication with the PTO. The hybrid vehicle drive system further includes an electric motor in direct or indirect mechanical communication with the hydraulic pump. The electric motor can receive power from the prime mover driven transmission through the PTO. The hydraulic pump can receive power from the electric motor when the electric motor rotates, the electric motor using power from the rechargeable energy source, or from the prime mover driven transmission through the PTO.

Claims

1. A vehicle drive system for a vehicle including a first prime mover, a first prime mover driven transmission, a rechargeable energy source, the vehicle drive system comprising:

an electric motor in direct or indirect mechanical communication with the first prime mover through a PTO, wherein the electric motor can provide power via the PTO to the prime mover driven transmission and can receive power from the first prime mover driven transmission via the PTO, wherein an electrical control system operates in at least two modes of operation, wherein in a first mode of operation for use when grid-in charging is available, the electric control system causes the first prime mover to operate and rotate the electric motor to generate power through the PTO and charge the first rechargeable energy source to a first level, and in a second mode of operation for use when the grid charging is not available, the electric control system causes the first prime mover to operate and rotate the electric motor via the PTO and charge the first rechargeable energy source to a second level, the second level being more than the first level; and

a hydraulic pump in mechanical communication with the electric motor and in direct or in direct communication with the PTO, the hydraulic pump being powered by rotation of the electric motor, wherein the electric motor can be rotated using power from the rechargeable energy source or be rotated using power from the first prime mover via the PTO, the hydraulic pump being coupled to an end of the electric motor, the electric motor being coupled to the PTO via a through shaft.

2. The vehicle drive system of claim 1, wherein the first level and the second level are less than 100 percent.

3. The electric vehicle drive system of claim 2, wherein the electric control system causes the prime mover to rotate the electric motor via the PTO to charge the first rechargeable energy source to 100 percent on a periodic basis for conditioning.

4. The electric vehicle system of claim 3 further comprising a hydraulic motor coupled to a clutch, the clutch being disposed between the electric motor and the hydraulic motor, the clutch disengaging the electric motor from the hydraulic motor during charging and/or during driving.

5. The vehicle drive system of claim 1, wherein the PTO includes a torque converter and the electric motor is coupled to the torque converter via a through shaft coupled through the electric motor.

6. The vehicle drive system of claim 1, wherein the PTO includes a clutch and the clutch disengages the PTO from the electric motor when the speed of the PTO exceeds a threshold associated with an accessory attached to the electric the hydraulic motor.

7. The vehicle drive system of claim 1, wherein the first level is lower for a 220V charging station than for a 120V charging station.

8. The vehicle drive system of claim 1, wherein the hydraulic motor and the electric motor is disconnected from the first prime mover during steady state highway use via a clutch between the PTO and the electric motor.

9. The vehicle drive system of claim 1, wherein the system is configured so that the first rechargeable energy source can be charged by any of:

the first prime mover, an electrical grid, an auxiliary power source, or regenerative braking.

10. The hybrid vehicle drive system of claim 1, wherein the system is configured so that equipment can be powered during recharging of the first rechargeable energy source by driving the electric motor.

11. The system according to claim 1, wherein the electric control system causes the prime mover to rotate the electric motor via the PTO interface to charge the first rechargeable power source to 100 percent on a periodic basis for conditioning.

12. The system according to claim 1, wherein the second prime mover operates the accessory when the first prime mover is off for idle reduction.

13. The system according to claim 1, wherein the accessory is coupled to a hydraulic accumulator.

14. The system according to claim 1, wherein the accessory is a variable volume displacement hydraulic motor coupled to a second rechargeable energy source and provides power to equipment.

15. The system according to claim 1, wherein the accessory is an air compressor.

16. A hybrid vehicle drive system for use with a first prime mover and a first transmission driven by the first prime mover, the system comprising:

a second prime mover coupled to a rechargeable energy source;

a PTO interface, wherein the first prime mover is configured to provide power through the PTO interface to the second prime mover to operate the second prime mover, and the second prime mover is configured to provide power to a drive shaft through the PTO interface; and

an accessory configured to be coupled to the second prime mover, so the accessory is operated through the operation of the second prime mover, wherein a clutch is disposed between the second prime mover and the accessory, wherein the second prime mover is an electric motor and is electrically coupled to a first rechargeable energy source, wherein an electrical control system operates in two modes of operation, wherein the clutch disengages the accessory from the electric motor when charging in a first mode of operation for use when grid charging is available and in a second mode of operation for use when grid charging is not available, the electric control system causing the first prime mover to operate and rotate the electric motor to generate power through the PTO interface and charge the first rechargeable energy source to a first level in the first mode of operation, and the electric control system causing the first prime mover to operate and rotate the electric motor via the PTO interface and charge the first rechargeable energy source to a second level more than the first level in the second mode of operation, the accessory being a hydraulic pump in direct or indirect communication with the PTO, the hydraulic pump in mechanical communication with the electric motor, the hydraulic pump being powered by rotation of the electric motor, wherein the electric motor can be rotated using power from the rechargeable energy source or be rotated using power from the first prime mover via the PTO, the hydraulic pump being coupled to an end shaft of the electric motor, the electric motor being coupled to the PTO via a through shaft.

17. A method of using a vehicle with a hybrid vehicle drive system, the vehicle includes a first prime mover, an electric motor, a first rechargeable energy source, a prime mover driven transmission, the method comprising:

using the electric motor coupled to a PTO to charge the first rechargeable energy source in a first mode via the first prime mover through the PTO to a first level when grid charging is available, wherein a hydraulic pump is in direct or indirect communication with the PTO, and in mechanical communication with the electric motor, wherein the electric motor can be rotated using power from the first rechargeable energy source or be rotated using power from the first prime mover via the PTO, the hydraulic pump being coupled to an endshaft of the electric motor, the electric motor being the PTO coupled to via a through shaft;

using the electric motor to charge the first rechargeable energy source via the first prime mover through the PTO to a second level more than the first level when the grid charging is not available; and

using the electric motor to rotate the hydraulic pump using power from the first rechargeable energy source; and

using the PTO to rotate the electric motor and the hydraulic pump via power from the first prime mover when the first rechargeable energy source is below a third level, the third level being less than the first level.

18. The method of claim 17, further comprising:

providing a clutch and an accessory, the clutch being between the electric motor and the accessory and disengaging the accessory during the using steps.

19. The method of claim 17, further comprising operating the first prime mover to simultaneously to provide power to a vehicle drive shaft and the second prime mover.

20. The method of claim 17, further comprising operating the first prime mover to provide power to the accessory through the operation of the second prime mover.