Over the road/traction/cabin comfort retrofit

• US 8,565,969 B2
• Filed: 03/10/2010
• Issued: 10/22/2013
• Est. Priority Date: 04/03/2007
• Status: Active Grant

• Current Assignee: Clean Emissions Technologies, Inc.
• Original Assignee: Clean Emissions Technologies, Inc.
• Inventors: Diehl, Joel Craig, Harris, Dan Warner, Harris, Warner Allen, Harris, Warner Olan, Nazzaro, Steward B., Turnbow, Wayne, Bradley, Bill
• Primary Examiner(s): Amin, Bhavesh V
• Application Number:
  US12/721,537
• Publication Number:
  US 20110202234A1
• Time in Patent Office: 1,322 Days
• Field of Search: 180/68.4
• US Class Current: 701/36
• CPC Class Codes: B60K 17/28 characterised by arrangement, location, or type of power take-off
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• 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 10/11 Stepped gearings
• 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 30/19 Improvement of gear change, e.g. by synchronisation or smoothing gear shift
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y10T 29/49716 Converting

Abstract

A vehicle includes a drive train having a manual transmission. An internal combustion engine is coupled to the manual transmission via a clutch. Auxiliary devices operate auxiliary systems of the vehicle. A battery energizes electric drivers for the auxiliary devices. A power exchange unit is coupled to the manual transmission via a power takeoff port. An electric generator is coupled to the power exchange unit, and the internal combustion engine drives the generator via the power exchange unit. The battery is energized by the generator via a battery charger.

Claims

1. A vehicle comprising:

a drive train, including a manual transmission;

an internal combustion engine coupled to the drive train for propelling the vehicle;

a radiator configured for cooling the internal combustion engine;

a battery;

auxiliary devices for operating auxiliary systems of the vehicle, the auxiliary devices including an air-conditioning coolant compressor and a fan for the radiator;

electric drivers for the auxiliary devices, wherein the electric drivers are energized by the battery;

an electric generator coupled to the internal drive train via an external connection to the internal combustion engine; and

a battery charger, wherein the battery is energized by the generator via the battery charger, and wherein the internal combustion engine drives the generator, wherein the auxiliary devices include an air compressor for vehicle brakes and the electric drivers for the auxiliary devices include an electric driver for the air compressor, the vehicle further comprising an air compressor drive gear coupled to the internal combustion engine, wherein the electric generator is coupled to the internal combustion engine and the external connection is via the air compressor drive gear, wherein the internal combustion engine drives the generator via the air compressor drive gear instead of driving the air compressor.

2. The vehicle of claim 1, wherein the electric generator is coupled to the manual transmission and the external connection is via a power takeoff port of the manual transmission.

3. The vehicle of claim 1, wherein the electric generator is coupled to the internal combustion engine and the external connection is via a cog belt.

4. The vehicle of claim 1, comprising:

at least one electric converter energized by the battery, wherein the electric drivers are energized by the battery via the at least one electric converter.

5. The vehicle of claim 1, wherein the internal combustion engine is the sole source for charging the battery.

6. The vehicle of claim 1 comprising:

a clutch in the drive train for disengaging the internal combustion engine from the manual transmission responsive to a clutch pedal being depressed;

a vehicle speed sensor;

a clutch pedal position sensor; and

a control device configured to automatically shut off the internal combustion engine in response to detecting an idling condition, wherein the idling condition includes a first condition wherein the control device receives a signal from the vehicle speed sensor indicating the vehicle is in a stationary state and a second condition wherein the control device receives a signal from the clutch pedal position sensor indicating the clutch pedal is in a released state.

7. The vehicle of claim 6, wherein the idling condition detected by the control device further includes a third condition wherein a predetermined time interval has expired after the first or second condition.

8. The vehicle of claim 6, wherein the control device is configured to automatically restart the internal combustion engine responsive to receiving a signal from a clutch pedal position sensor indicating the clutch pedal is depressed.

9. The vehicle of claim 6, wherein the control device is configured to automatically activate an alarm responsive to detecting a condition wherein the vehicle has been in the stationary state for a predetermined time interval and wherein the clutch pedal has not been released during the predetermined time interval.

10. The vehicle of claim 6, wherein the control device is configured to automatically generate a notification to a driver responsive to detecting a condition wherein the vehicle has been in a stationary state for a predetermined time interval and wherein the clutch pedal been not released during the predetermined time interval.

11. The vehicle of claim 1, wherein the control device is configured to regulate a base charging rate load of the generator on the internal combustion engine to provide a base rate of battery recharge responsive to a user selected recharge time interval.

12. The vehicle of claim 1 comprising:

an accelerator pedal configured for driver control of mechanical output of the internal combustion engine, wherein the control device is configured to receive a signal from an accelerator pedal position sensor indicating a physical position of the accelerator pedal and to regulate a regenerative braking output of the generator responsive to the accelerator pedal position signal.

13. The vehicle of claim 1, wherein the control device is configured to regulate a base charging rate load of the generator on the internal combustion engine to provide a base rate of battery recharge responsive to a predetermined recharge time interval and wherein the vehicle comprises:

an accelerator pedal configured for driver control of mechanical output of the internal combustion engine, wherein the control device is configured to receive a signal from an accelerator pedal position sensor indicating a physical position of the accelerator pedal and to regulate a regenerative braking output of the generator responsive to the accelerator pedal position signal, wherein the control device is configured to regulate the base charging rate load independently of the accelerator pedal position.

15. The vehicle of claim 1, the vehicle comprising:

a parking brake position sensor, wherein the control device is configured to receive a signal from the parking brake position sensor indicating that the parking brake is in a set position, and wherein the permissive condition includes the control device receiving the parking brake set indication.

14. A vehicle comprising:

a drive train, including a manual transmission;

an internal combustion engine coupled to the drive train for propelling the vehicle;

a radiator configured for cooling the internal combustion engine;

a battery;

auxiliary devices for operating auxiliary systems of the vehicle, the auxiliary devices including an air-conditioning coolant compressor and a fan for the radiator;

electric drivers for the auxiliary devices, wherein the electric drivers are energized by the battery;

an electric generator coupled to the internal drive train via an external connection to the internal combustion engine or;

a battery charger, wherein the battery is energized by the generator via the battery charger, and wherein the internal combustion engine drives the generator; and

a user interface configured to receive a user selection of a battery charge rate, wherein a control device is configured to regulate output of the internal combustion engine and loading of the generator on the internal combustion engine to provide a predetermined battery recharge rate responsive to receiving a user selected charge rate from the user interface and responsive to detection of a permissive condition.

16. A vehicle comprising:

a drive train, including a manual transmission;

an internal combustion engine coupled to the drive train for propelling the vehicle;

a radiator configured for cooling the internal combustion engine;

a battery;

auxiliary devices for operating auxiliary systems of the vehicle, the auxiliary devices including an air-conditioning coolant compressor and a fan for the radiator;

electric drivers for the auxiliary devices, wherein the electric drivers are energized by the battery;

an electric generator coupled to the internal drive train via an external connection to the internal combustion engine;

a battery charger, wherein the battery is energized by the generator via the battery charger, and wherein the internal combustion engine drives the generator, and

a cruise controller configured for generating a cruise control torque demand signal when in a cruise control mode to regulate output of the internal combustion engine responsive to a vehicle speed and a cruise control set point, wherein the regulating of a regenerative braking load by the control device in response to accelerator pedal position occurs when a cruise controller is not in the cruise control mode, and wherein when the cruise controller is in the cruise control mode the control device is configured to enable regenerative braking in response to a vehicle speed exceeding the cruise control set point by more than a predetermined speed, wherein the control device is configured to provide a reduced regenerative braking response to the accelerator pedal position for a first post-cruise control time interval after the cruise control mode is terminated.

17. The vehicle of claim 16, wherein the control logic is configured to restore the regenerative braking response to the accelerator pedal position over a second post-cruise control time interval, wherein the restoring is responsive to expiration of the first post-cruise control time interval.

18. A vehicle comprising:

a drive train, including a manual transmission;

an internal combustion engine coupled to the drive train for propelling the vehicle;

a radiator configured for cooling the internal combustion engine;

a battery;

auxiliary devices for operating auxiliary systems of the vehicle, the auxiliary devices including an air-conditioning coolant compressor and a fan for the radiator;

electric drivers for the auxiliary devices, wherein the electric drivers are energized by the battery;

an electric generator coupled to the internal drive train via an external connection to the internal combustion engine; and

a battery charger, wherein the battery is energized by the generator via the battery charger, and wherein the internal combustion engine drives the generator, wherein the electric generator is coupled to the manual transmission and the external connection is via a power takeoff port of the manual transmission.

19. The vehicle of claim 18, wherein the electric generator is coupled to the internal combustion engine and the external connection is via a cog belt.

20. The vehicle of claim 18, wherein the auxiliary devices include an air compressor for vehicle brakes and the electric drivers for the auxiliary devices include an electric driver for the air compressor, the vehicle further comprising an air compressor drive gear coupled to the internal combustion engine, wherein the electric generator is coupled to the internal combustion engine and the external connection is via the air compressor drive gear, wherein the internal combustion engine drives the generator via the air compressor drive gear instead of driving the air compressor.

21. The vehicle of claim 18, comprising:

at least one electric converter energized by the battery, wherein the electric drivers are energized by the battery via the at least one electric converter.

22. The vehicle of claim 18, wherein the internal combustion engine is the sole source for charging the battery.

23. The vehicle of claim 18, comprising:

a clutch in the drive train for disengaging the internal combustion engine from the manual transmission responsive to a clutch pedal being depressed;

a vehicle speed sensor;

a clutch pedal position sensor; and

a control device configured to automatically shut off the internal combustion engine in response to detecting an idling condition, wherein the idling condition includes a first condition wherein the control device receives a signal from the vehicle speed sensor indicating the vehicle is in a stationary state and a second condition wherein the control device receives a signal from the clutch pedal position sensor indicating the clutch pedal is in a released state.

24. The vehicle of claim 23, wherein the idling condition detected by the control device further includes a third condition wherein a predetermined time interval has expired after the first or second condition.

25. The vehicle of claim 23, wherein the control device is configured to automatically restart the internal combustion engine responsive to receiving a signal from a clutch pedal position sensor indicating the clutch pedal is depressed.

26. The vehicle of claim 23, wherein the control device is configured to automatically activate an alarm responsive to detecting a condition wherein the vehicle has been in the stationary state for a predetermined time interval and wherein the clutch pedal has not been released during the predetermined time interval.

27. The vehicle of claim 23. wherein the control device is configured to automatically generate a notification to a driver responsive to detecting a condition wherein the vehicle has been in a stationary state for a predetermined time interval and wherein the clutch pedal been not released during the predetermined time interval.

28. The vehicle of claim 18, wherein a control device is configured to regulate a base charging rate load of the generator on the internal combustion engine to provide a base rate of battery recharge responsive to a user selected recharge time interval.

29. The vehicle of claim 18, comprising:

an accelerator pedal configured for driver control of mechanical output of the internal combustion engine, wherein a control device is configured to receive a signal from an accelerator pedal position sensor indicating a physical position of the accelerator pedal and to regulate a regenerative braking output of the generator responsive to the accelerator pedal position signal.

30. The vehicle of claim 18, wherein a control device is configured to regulate a base charging rate load of the generator on the internal combustion engine to provide a base rate of battery recharge responsive to a predetermined recharge time interval and wherein the vehicle comprises:

an accelerator pedal configured for driver control of mechanical output of the internal combustion engine, wherein the control device is configured to receive a signal from an accelerator pedal position sensor indicating a physical position of the accelerator pedal and to regulate a regenerative braking output of the generator responsive to the accelerator pedal position signal, wherein the control device is configured to regulate the base charging rate load independently of the accelerator pedal position.

31. The vehicle of claim 18, comprising a user interface configured to receive a user selection of a battery charge rate, wherein a control device is configured to regulate output of the internal combustion engine and loading of the generator on the internal combustion engine to provide a predetermined battery recharge rate responsive to receiving a user selected charge rate from the user interface and responsive to detection permissive condition.

32. The vehicle of claim 18, the vehicle comprising a parking brake position sensor, wherein a control device is configured to receive a signal from the parking brake position sensor indicating that the parking brake is in a set position, and wherein the permissive condition includes the control device receiving the parking brake set indication.

33. The vehicle of claim 18, comprising a cruise controller configured for generating a cruise control torque demand signal when in a cruise control mode to regulate output of the internal combustion engine responsive to vehicle speed and a cruise control set point, wherein the regulating of the regenerative braking load by the control device in response to accelerator pedal position occurs when the cruise controller is not in the cruise control mode, and wherein when the cruise controller is in the cruise control mode the control device is configured to enable regenerative braking in response to vehicle speed exceeding the cruise control set point by more than a predetermined speed.

34. The vehicle of claim 33, wherein the control device is configured to provide a reduced regenerative braking response to the accelerator pedal position for a first post-cruise control time interval after the cruise control mode is terminated.

35. The vehicle of claim 34, wherein a control logic is configured to restore the regenerative braking response to the accelerator pedal position over a second post-cruise control time interval, wherein the restoring is responsive to expiration of the first post-cruise control time interval.