Service disconnect interlock system and method for hybrid vehicles

• US 9,555,800 B2
• Filed: 01/19/2015
• Issued: 01/31/2017
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Original Assignee: Allison Transmission Incorporated (Allison Transmission Holdings Incorporated)
• Inventors: Hynes, William J., Morey, Steven
• Primary Examiner(s): Khatib, Rami
• Application Number:
  US14/599,764
• Publication Number:
  US 20150151740A1
• Time in Patent Office: 743 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B60K 2001/0455 Removal or replacement of the energy storages
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2240/80 Time limits
• CPC Class Codes: B60L 2250/12 by confirmation, e.g. of the input
• 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 2270/40 related to technical updates when adding new parts or software
• CPC Class Codes: B60L 3/003 relating to inverters
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 3/0069 relating to the isolation, e.g. ground fault or leak current
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 3/12 Recording operating variables ; Monitoring of operating variables
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 58/26 : by cooling
• CPC Class Codes: B60W 20/50 : Control strategies for responding to system failures, e.g. for fault diagnosis, failsafe operation or limp mode
• CPC Class Codes: B60W 2050/043 : Testing equipment at KEY-ON
• CPC Class Codes: B60W 50/0205 : Diagnosing or detecting failures; Failure detection models
• CPC Class Codes: B60W 50/035 : Bringing the control units into a predefined state, e.g. giving priority to particular actuators
• CPC Class Codes: B60W 50/04 : Monitoring the functioning of the control system
• 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 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor

Abstract

A method of servicing a hybrid system is disclosed wherein the hybrid system includes a detected fault. As a result of the detected fault the hybrid system has been disabled. The hybrid system includes a controller and a service detection interlock (SDI). The method steps include first powering up the controller and then assessing a special fault flag status. If a special fault flag is set, the next step is to check to see if the SDI is removed. If the SDI is removed then the special fault flag is cleared while the hybrid system remains disabled. The controller is then powered down with the key-off input and with the next key-on input, the hybrid system can be enabled.

Claims

1. A method of servicing a hybrid system with a detected fault, said hybrid system having a controller and a service detection interlock (SDI), said method comprising the following steps:

a) powering up said controller;

b) assessing a service action fault flag status;

c) if a service action fault flag is set, checking to see if the SDI is removed;

d) if the SDI is removed, clearing the service action fault flag;

e) disabling said hybrid system; and

f) powering down the controller with a key-off input.

2. The method of claim 1 which further includes, when a service action fault flag is not set, the step of allowing the controller to monitor for other faults.

3. The method of claim 2 which further includes, if a fault is detected by the controller, the step of disabling the hybrid system.

4. The method of claim 3 wherein, if a fault is not detected, maintaining the hybrid system in an enabled status until either a fault is detected or there is a key-off event.

5. The method of claim 1 which further includes, if a fault is detected, the step of allowing the controller to assess whether the fault is a service action fault which requires the setting of a flag.

6. The method of claim 5 which further includes, if the detected fault is not a service action fault, the step of checking a key-off status.

7. The method of claim 6 which includes the step of cyclically checking the key-off status.

8. The method of claim 5, which further includes, if the detected fault is a service action fault, the step of setting a flag for said service action fault which must be cleared to enable the disabled hybrid system.

9. The method of claim 8 which includes the step of cyclically checking the key-off status.

10. The method of claim 1 which further includes, if a fault is detected by the controller, the step of disabling the hybrid system.

11. The method of claim 1 wherein, if a fault is not detected, maintaining the hybrid system in an enabled status until either a fault is detected or there is a key-off event.

12. The method of claim 1 which further includes, if a fault is detected, the step of allowing the controller to assess whether the fault is a service action fault which requires the setting of a flag.

13. A method of servicing a disabled hybrid system which includes a controller and a service disconnect interlock (SDI) component and which has a service action fault flag set, said method comprising the following steps:

a) removing said SDI;

b) powering up the controller;

c) clearing the service action fault flag in conjunction with servicing of the disabled hybrid system;

d) replacing said SDI; and

e) executing a key-off command.

14. An energy storage module for use in a hybrid electric vehicle, said energy storage module comprising:

an enclosure;

means for storing energy generated by said hybrid electric vehicle, said means being interior to said enclosure;

a voltage junction box exterior to said enclosure; and

a removable service disconnect interlock electrically connected between said means for storing energy and said voltage junction box, said removable service disconnect interlock being constructed and arranged to break a current path between said means for storing energy and said voltage junction box when removed, wherein said removable service disconnect interlock is controlled by fault detection logic which is constructed and arranged to detect a fault which requires a repair to be performed in order to protect a portion of the hybrid electric vehicle.

15. The energy storage module of claim 14 wherein when a fault is detected, the fault detection logic is constructed and arranged to require a key-on/key-off cycle to be performed before the hybrid electric vehicle can be re-enabled.

16. The energy storage module of claim 14 which further includes a low-voltage connector.

17. The energy storage module of claim 16 wherein said removable service disconnect interlock is controlled by fault detection logic.

18. An energy storage module for use in a hybrid electric vehicle, said energy storage module comprising:

an enclosure;

means for storing energy generated by said hybrid electric vehicle, said means being interior to said enclosure;

a voltage junction box exterior to said enclosure; and

a removable service disconnect interlock electrically connected between said means for storing energy and said voltage junction box, said removable service disconnect interlock being constructed and arranged to break a current path between said means for storing energy and said voltage junction box when removed, wherein said removable service disconnect interlock is controlled by fault detection logic which is constructed and arranged to distinguish a service action category of faults from other faults which are not in said service action category.

19. The energy storage module of claim 18 which further includes a low-voltage connector.

20. The energy storage module of claim 19 wherein said removable service disconnect interlock is controlled by fault detection logic.