System and method for power management during regeneration mode in hybrid electric vehicles for H-3000

• US 9,296,385 B2
• Filed: 08/27/2015
• Issued: 03/29/2016
• Est. Priority Date: 03/14/2013
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Runde, Jeffrey K., West, Stephen T.
• Primary Examiner(s): CAMBY, RICHARD M
• Application Number:
  US14/837,399
• Publication Number:
  US 20150367834A1
• Time in Patent Office: 215 Days
• Field of Search: 701/22
• US Class Current: 1/1
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60L 15/2009 for braking
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• 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 10/18 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 20/11 using model predictive control [MPC] strategies, i.e. control methods based on models predicting performance utilising navigation and traffic information in the control strategy B60W20/12
• CPC Class Codes: B60W 20/14 in conjunction with braking regeneration
• CPC Class Codes: B60W 2400/00 Indexing codes relating to detected, measured or calculated conditions or factors
• CPC Class Codes: B60W 2510/1095 Inertia
• CPC Class Codes: B60W 2520/105 Longitudinal acceleration
• CPC Class Codes: B60W 2530/16 Driving resistance
• CPC Class Codes: B60W 2540/10 Accelerator pedal position
• CPC Class Codes: B60W 2540/12 Brake pedal position
• CPC Class Codes: B60W 2710/08 Electric propulsion units
• CPC Class Codes: B60W 2710/086 Power
• CPC Class Codes: B60W 2710/18 Braking system
• CPC Class Codes: B60W 30/18127 : Regenerative braking
• CPC Class Codes: B60W 40/1005 : Driving resistance
• CPC Class Codes: B60W 40/12 : related to parameters of the vehicle itself , e.g. tyre models
• CPC Class Codes: B60W 50/0097 : Predicting future conditions
• CPC Class Codes: B60Y 2200/92 : Hybrid vehicles
• CPC Class Codes: B60Y 2300/60 : Control of electric machines, e.g. problems related to electric motors or generators
• CPC Class Codes: B60Y 2300/64 : Drag run or drag torque compensation, e.g. motor to drive engine with drag torque or engine speed is brought to start speed before injection and firing
• CPC Class Codes: B60Y 2300/91 : Battery charging
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• 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: Y10S 903/906 : Motor or generator
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements
• CPC Class Codes: Y10S 903/947 : Characterized by control of braking, e.g. blending of regeneration, friction braking

Abstract

A system and method for recovering the optimum power level during regenerative mode is disclosed. Equations for determining the optimum regenerative power level receivable by an energy storage system, for example for any given deceleration event, are derived and disclosed. The equations consider various losses such as the efficiency of the electric motor generator in the generator mode, wind resistance, rolling resistance, transmission losses, engine losses, and losses in the energy storage system. Also disclosed is at least one embodiment of a procedure for controlling a hybrid drive system to achieve the optimum energy recovery.

Claims

1. A method of controlling regenerative braking in a hybrid electric vehicle, comprising:

detecting a deceleration state of the vehicle, wherein detecting the deceleration state includes detecting a torque provided from a transmission to the electric motor generator, and wherein the electric motor generator is coupled to the transmission;

calculating a predicted vehicle energy loss for a vehicle using a vehicle controller, wherein the vehicle has an electric motor generator and an energy storage system, and wherein the electric motor generator is electrically connected to the energy storage system;

calculating an expected electric motor operating efficiency using the vehicle controller;

calculating a predicted electrical power to supply to the energy storage system using the vehicle controller and the predicted vehicle energy loss; and

generating a regenerative braking power using the electric motor generator operating as a generator, wherein the regenerative braking power is less than or equal to the predicted electrical power to supply to the energy storage system.

2. The method of claim 1, wherein the predicted vehicle energy loss includes losses caused by an expected change in vehicle kinetic energy.

3. The method of claim 1, wherein the predicted electrical power to supply to the energy storage system includes a predicted electrical power loss resulting from an expected transfer of the predicted electrical power to the energy storage system.

4. The method of claim 1, wherein the act of calculating the predicted vehicle energy loss includes calculating an engine compression force loss.

5. The method of claim 1, wherein the act of calculating the predicted vehicle energy loss includes calculating an engine frictional force loss.

6. The method of claim 1, wherein the act of calculating the predicted vehicle energy loss includes calculating a wind resistance loss, wherein the wind resistance loss is calculated by the vehicle controller using a vehicle velocity and a vehicle aerodynamic coefficient.

7. The method of claim 1, wherein the act of calculating the predicted vehicle energy loss includes calculating a rolling resistance loss, wherein the rolling resistance loss is calculated by the vehicle controller using a vehicle mass, a vehicle velocity, and a vehicle rolling resistance coefficient.

8. The method of claim 1, wherein calculating the predicted vehicle energy loss includes calculating a transmission inertia loss and/or a transmission friction loss.

9. The method of claim 1, wherein the act of calculating the predicted vehicle energy loss includes calculating an accessory loss.

10. The method of claim 1, wherein the act of calculating the expected electric motor operating efficiency includes accessing a previous vehicle activity stored in a memory in the vehicle controller and calculating the expected electric motor operating efficiency based on the previous vehicle activity.

11. The method of claim 1, wherein the act of calculating the expected electric motor operating efficiency is calculated using an electric motor speed and an electric motor torque.

12. A method of calculating regenerative braking power, comprising:

calculating a predicted vehicle energy loss using a vehicle controller in a vehicle having a hybrid system that includes an internal combustion engine, an electric motor generator, and an energy storage system with at least one battery cell, the energy storage system coupled to the electric motor generator, wherein the vehicle controller is configured to calculate the predicted vehicle energy loss using a current rate of deceleration of the vehicle;

calculating a predicted electrical power supplied to the energy storage system using the vehicle controller, the vehicle controller calculating the predicted electrical power using the predicted vehicle energy loss;

calculating a predicted electrical power loss using the vehicle controller, the vehicle controller calculating the electrical power loss using the predicted electrical power supplied to the energy storage system;

calculating a predicted regenerative braking power using the vehicle controller, the vehicle controller calculating the predicted regenerative braking power using the predicted vehicle energy loss, the predicted electrical power supplied to the energy storage system, and the predicted electrical power loss.

13. The method of claim 12 further comprising,

calculating an expected electric motor operating efficiency using the vehicle controller, wherein calculating the expected electric motor operating efficiency includes accessing one or more previous electric motor operating efficiency values stored in a memory in the vehicle controller and using the vehicle controller to calculate the expected electric motor operating efficiency using the one or more previous electric motor operating efficiency values.

14. The method of claim 13, wherein the act of calculating the expected electric motor operating efficiency is calculated by the vehicle controller using an electric motor speed and an electric motor torque.

15. The method of claim 12, wherein the act of calculating the predicted electrical power loss includes calculating a predicted change in the temperature of one or more components within the energy storage system.

16. The method of claim 12, wherein the act of calculating the predicted vehicle energy loss includes calculating a wind resistance loss, wherein the wind resistance loss is calculated by the vehicle controller using a vehicle speed and a vehicle aerodynamic coefficient.

17. The method of claim 12, wherein the act of calculating the vehicle energy loss includes calculating a rolling resistance loss, wherein the rolling resistance loss is calculated by the vehicle controller using a vehicle mass, a vehicle speed, and a vehicle rolling resistance coefficient.

18. The method of claim 12, further comprising detecting a deceleration state.

19. The method of claim 18, wherein the act of detecting a deceleration state further comprises using the vehicle controller to detect a torque provided from a transmission to the electric motor generator, wherein the electric motor generator is coupled to the transmission.

20. The method of claim 18, wherein the act of detecting a deceleration state further comprises using the vehicle controller to detect a brake pedal input signal, and an accelerator pedal input signal.

21. The method of claim 12, wherein the act of calculating the predicted vehicle energy loss includes using the controller to calculate an engine compression force loss and/or an engine frictional force loss.

22. The method of claim 12, wherein the hybrid system includes a transmission coupled to the electric motor generator, and wherein the act of calculating the vehicle energy loss includes using the vehicle controller to calculate a vehicle transmission loss using a transmission inertia resistance and a transmission friction resistance.

23. The method of claim 12, further comprising:

generating a regenerative braking power using the electric motor generator operating in a generator mode, wherein the regenerative braking power is less than or equal to the predicted regenerative braking power;

delivering the regenerative braking power to the energy storage system.