Open modular electric powertrain and control architecture

• US 9,108,528 B2
• Filed: 04/06/2011
• Issued: 08/18/2015
• Est. Priority Date: 04/06/2011
• Status: Active Grant

• Current Assignee: GM Global Technology Operations LLC (General Motors Company)
• Original Assignee: GM Global Technology Operations LLC (General Motors Company)
• Inventors: Yang, Hong, Bucknor, Norman K.
• Primary Examiner(s): Nguyen, John Q
• Assistant Examiner(s): Fei, Jordan S
• Application Number:
  US13/081,448
• Publication Number:
  US 20120259490A1
• Time in Patent Office: 1,595 Days
• Field of Search: 701/22, 180/65.1, 180/65.21, 180/65.22, 180/65.225, 180/65.23, 180/65.24, 180/65.25, 180/65.26, 180/65.275, 180/65.28, 180/65.285, 180/65.29
• US Class Current: 1/1
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/445 Differential gearing distribution type
• CPC Class Codes: B60L 15/2045 for optimising the use of energy
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 58/10 for monitoring or controlling batteries
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• CPC Class Codes: B60L 7/10 Dynamic electric regenerative braking B60L7/22 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 10/115 with planetary gears
• 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 2050/0006 Digital architecture hierarchy
• CPC Class Codes: B60Y 2400/114 Super-capacities
• CPC Class Codes: H02J 1/14 Balancing the load in a network
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 10/92 Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/40 : Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

A system to control a powertrain includes an energy management layer monitoring a plurality of potential energy storage devices and determining a reference available power for each of the potential energy storage devices. The system further includes a power management layer monitoring the reference available power for the potential energy storage devices, a power demanded of the powertrain, and an electric power constraint for the potential energy storage devices, and determining a power split based upon the monitored reference available power for the potential energy storage devices, the power demanded of the powertrain, and the electric power constraint for the potential energy storage devices. The system further includes a torque control layer controlling torque generation based upon the determined power split.

Claims

1. System to control a powertrain, the system comprising:

an energy management layer comprising a friction module, a mechanical module, a motor generator module, and an open energy storage module, each module comprising a respective controller and an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain;

adaptively monitoring, at the open energy storage module controller, an adaptable plurality of available modular energy sources, including a plurality of modularly operated available potential energy storage devices, wherein the plurality of modularly operated available potential energy storage devices adaptively include one or more extra potential energy storage devices added during the lifespan of the powertrain as needed in addition to potential energy storage devices originally equipped by the powertrain, and wherein the open energy storage module controller is configured to adaptively monitor additional potential energy storage devices replacing any of the potential energy storage devices originally equipped by the powertrain during the lifespan of the powertrain;

adaptively monitoring, at the friction module controller, the mechanical module controller and the motor generator module controller, the respective adaptable plurality of available modular energy sources, each module controller monitoring alternative types of available modular energy sources;

adaptively determining, at each of the open energy storage module controller, the friction module controller, the mechanical module controller and the motor generator module controller a respective reference available power for each of the available modular energy sources; and

adaptively outputting, at each of the open energy storage module controller, the friction module controller, the mechanical module controller and the motor generator module controller, the respective reference available power for each of the available modular energy sources to a centralized powertrain controller via a power bus;

a power management layer comprising the centralized powertrain controller;

adaptively monitoring, at the centralized powertrain controller, the reference available power for each of the available modular energy sources output from each of the open energy storage module controller, the friction module controller, the mechanical module controller and the motor generator module controller, a power demanded of the powertrain, and an electric power constraint for the available modular energy sources;

adaptively monitoring, at the central powertrain controller, at least one modularly operated torque generative device of the powertrain capable of generating torque to meet the power demanded of the powertrain, wherein the at least one modularly operated torque generative device adaptively includes one or more extra torque generative devices added during the lifespan of the powertrain in addition to at least one torque generative device originally equipped by the powertrain;

adaptively determining, at the centralized powertrain controller, a power split command based upon the adaptively monitored reference available power for each of the available modular energy sources, the power demanded of the powertrain, the electric power constraint for the available modular energy sources, and the at least one modularly operated torque generative device; and

outputting, at the centralized powertrain controller, the power split command to the friction module controller, the mechanical module controller, the motor generator module controller, and the open energy storage module controller, wherein the power split command is operative to condition either one of electrical power flowing to or from each available modular energy sources; and

a torque control layer comprising the friction module, the mechanical module, the motor generator module, and the open energy storage module, the torque control layer adaptively controlling torque generation of the at least one modularly operated torque generative device based upon the determined power split command received by the friction module controller, the mechanical module controller, the motor generator module controller, and the open energy storage module controller.

2. The system of claim 1, wherein the plurality of modularly operated available potential energy storage devices comprises a first alternative energy storage device and a second alternative energy storage device.

3. The system of claim 2, wherein the first alternative energy storage device and the second alternative energy storage device are operator interchangeable and interact with the energy management layer according to a common protocol.

4. The system of claim 1, wherein the plurality of modularly operated available potential energy storage devices comprises a primary energy storage device and a modular auxiliary energy storage device.

5. The system of claim 1, wherein the plurality of modularly operated available potential energy storage devices comprises a first battery device with a first chemical composition and a second battery device with a second chemical composition.

6. The system of claim 1, wherein the plurality of modularly operated available potential energy storage devices comprises an ultra-capacitor device.

7. The system of claim 1, wherein the plurality of available modular energy sources of each module are concurrently available to the powertrain.

8. The system of claim 7, wherein the system further comprises a physical communication layer communicating between each of the friction module controller, the mechanical module controller, the motor generator module controller and the open energy storage module controller in the energy management layer, and the power management layer.

9. The system of claim 7, wherein the energy management layer further comprises:

the open energy storage module controller managing an energy storage device;

the motor generator module controller managing a motor generator device;

the mechanical module controller managing an internal combustion engine; and

the friction module controller managing a friction power device; and

further comprising a physical communication layer communicating between the open energy storage module controller, the motor generator controller, the mechanical controller, the friction controller, and the power management layer.

10. The system of claim 7, wherein the plurality of available modular energy sources of each module concurrently available to the powertrain are electrically connected to a high-voltage DC bus.

11. The system of claim 7, wherein the open energy storage module comprises:

an electronic control layer controlling a DC/DC converter regulating voltage and current for each of the plurality of modularly operated available potential energy storage devices concurrently available to the powertrain; and

a module controller unit balancing current and performing diagnostics and prognostics for each of the plurality of available modular energy sources of the open energy storage module concurrently available to the powertrain.

12. The system of claim 1, wherein the system further comprises a physical communication layer wherein a signal flow is communicated between the centralized powertrain controller and the plurality of available modular energy sources of each module utilizing a power bus common protocol.

13. System to control a powertrain comprising:

an open energy storage module controller adaptively managing a plurality of available modular energy sources that can be selectively added or removed from the powertrain, including a plurality of modularly operated available potential energy storage devices, wherein the plurality of modularly operated available potential energy storage devices adaptively include one or more extra potential energy storage devices added during the lifespan of the powertrain as needed in addition to potential energy storage devices originally equipped by the powertrain, and wherein the open energy storage module controller is configured to adaptively monitor additional potential energy storage devices replacing any of the potential energy storage devices originally equipped by the powertrain during the lifespan of the powertrain;

a motor generator module including a motor generator controller managing a motor generator device and a plurality of available modular generator energy sources that can be selectively added or removed from the powertrain;

a mechanical module including a mechanical module controller managing an internal combustion engine and a plurality of available modular mechanical energy sources that can be selectively added or removed from the powertrain; and

a friction module including a friction module controller managing a friction power device and a plurality of available modular frictional energy sources that can be selectively added or removed from the powertrain;

an energy management layer;

adaptively monitoring, at the open energy storage module controller, the motor generator module controller, the mechanical module controller, and the friction module controller, the respective adaptable plurality of available modular energy sources, each module controller monitoring alternative types of available modular energy sources; and

adaptively determining a reference available power for each of the available modular energy sources of each of the open energy storage module, the motor generator module, the mechanical module, and the friction module and adaptively outputting the reference available powers to a centralized powertrain controller;

a power management layer comprising the centralized powertrain controller;

adaptively monitoring the reference available power for each of the available modular energy sources of the open energy storage module, the motor generator module, the mechanical module, and the friction module, a power demanded of the powertrain, and an electric power constraint for each of the open energy storage module, the motor generator module, the mechanical module, and the friction module;

adaptively monitoring at least one modularly operated torque generative device of the powertrain capable of generating torque to meet the power demanded of the powertrain, wherein the at least one modularly operated torque generative device adaptively includes one or more extra torque generative devices added during the lifespan of the powertrain in addition to at least one torque generative device originally equipped by the powertrain;

adaptively determining a power split command based upon the adaptively monitored reference available power for each of the available modular energy sources of the open energy storage module, the motor generator module, the mechanical module, and the friction module, the power demanded of the powertrain, and the electric power constraint for each of the open energy storage module, the motor generator module, the mechanical module, and the friction module; and

a torque control layer adaptively controlling torque generation of the at least one modularly operated torque generative device based upon the power split command.

14. The system of claim 13, wherein the plurality of modularly operated available potential energy storage devices comprise a battery of a first chemical composition and a battery of a second chemical composition.

15. The system of claim 13, wherein the plurality of modularly operated available potential energy storage devices comprise a battery and an ultra-capacitor device.

16. The system of claim 13, wherein the motor generator device comprises an at-Wheel motor.

17. The system of claim 13, wherein the internal combustion engine comprises an auxiliary power unit.

18. Method to control a powertrain, comprising:

connecting an energy storage device controller of an open energy storage module adaptively managing an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain, the available modular energy sources including a plurality of modularly operated available potential energy storage devices, a motor generator controller of a motor generator module adaptively managing an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain, a mechanical controller of a mechanical module adaptively managing an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain, a friction controller of a friction module adaptively managing an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain, and an energy and power management centralized controller through a physical communication layer, wherein the adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain adaptively include one or more extra potential energy storage devices added during the lifespan of the powertrain as needed in addition to available modular energy sources originally equipped by the powertrain, and wherein the open energy storage module,the friction module, the mechanical module and the motor generator module are configured to adaptively monitor additional available modular energy sources replacing any of the available modular energy sources originally equipped by the powertrain during the lifespan of the powertrain;

within each of the energy storage device controller, the motor generator controller, the mechanical controller, and the friction controller, adaptively generating a reference power available signal to the energy and power management centralized controller of the physical communication layer;

within the energy and power management centralized controller, adaptively determining a power split command based upon the adaptively generated reference power available signals from each of the energy storage device controller, the motor generator controller, the mechanical controller, and the friction controller and a power demanded of the powertrain; and

utilizing the power split command from the energy and power management centralized controller to command torque generation of at least one torque generative device within the powertrain.

19. System to control a powertrain, the system comprising:

an energy management layer comprising;

a mechanical module comprising a mechanical module controller and an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain;

a motor generator module comprising a motor generator module controller and an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain;

a friction module comprising a friction module controller and an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain;

each of the friction module controller, the mechanical module controller and the motor generator module controller, configure to adaptively monitor the respective adaptable plurality of available modular energy sources, each module controller monitoring alternative types of available modular energy sources;

an open energy storage module comprising a open energy storage module controller and an adaptable plurality of available modular energy sources that can be selectively added or removed from the powertrain, the open energy storage module controller adaptively monitoring the adaptable plurality of available modular energy sources, including a plurality of modularly operated available potential energy storage devices, wherein the plurality of modularly operated available potential energy storage devices adaptively include one or more extra potential energy storage devices added during the lifespan of the powertrain as needed in addition to potential energy storage devices originally equipped by the powertrain, and wherein the open energy storage module controller is configured to adaptively monitor additional potential energy storage devices replacing any of the potential energy storage devices originally equipped by the powertrain during the lifespan of the powertrain; and

an energy and power management controller;

communicating with the energy management layer through a power bus common protocol;

adaptively receiving a reference available power for each of the available modular energy sources from each of the friction module, the mechanical module, the motor generator module, and the open energy storage module; and

adaptively outputting a power split command to the friction module, the mechanical module, the motor generator module, and the open energy storage module for controlling operation of the powertrain.

20. The system of claim 19, wherein each of the mechanical module, the motor generator module, the friction module, and the open energy storage module comprises a separate controller.