System and method for optimizing power consumption in a hybrid electric vehicle

• US 9,561,791 B2
• Filed: 08/31/2015
• Issued: 02/07/2017
• 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., Hynes, William J.
• Primary Examiner(s): Troost, Aaron L
• Application Number:
  US14/840,078
• Publication Number:
  US 20150367838A1
• Time in Patent Office: 526 Days
• US Class Current: 1/1
• CPC Class Codes: B60K 2006/4825 Electric machine connected or connectable to gearbox input shaft
• CPC Class Codes: B60K 6/48 Parallel type
• 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 10/26 for electrical energy, e.g. batteries or capacitors
• 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 20/15 Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 2050/0075 Automatic parameter input, automatic initialising or calibrating means
• CPC Class Codes: B60W 2556/10 Historical data
• CPC Class Codes: B60W 2710/0666 Engine torque
• CPC Class Codes: B60W 2710/083 Torque
• CPC Class Codes: B60W 2710/244 Charge state
• CPC Class Codes: B60W 30/18127 Regenerative braking
• CPC Class Codes: B60W 50/0097 Predicting future conditions
• CPC Class Codes: Y02T 10/40 Engine management systems
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/84 Data processing systems or methods, management, administration
• CPC Class Codes: Y10S 903/93 Conjoint control of different elements

Abstract

A system and method for optimizing the consumption of fuel in a hybrid electric vehicle is disclosed. A Hybrid Efficiency Index (HEI) is used to quantify a relative efficiency advantage achievable with the expenditure of electrical energy at a given power level. Also disclosed is a minimum efficiency threshold useful for determining which HEI values will result in the optimum use of electrical energy throughout the operation of the vehicle. Methods for adjusting the minimum efficiency threshold with respect to regenerative braking events, storage capacity in the energy storage system, along with other aspects are disclosed as well.

Claims

1. A method of controlling a hybrid system, comprising:

calculating a fuel consumption rate for an engine using a controller in communication with the engine, the engine configured to consume a fuel to produce an engine output torque;

calculating a target electric motor output torque using the controller, the target electric motor output torque calculated by the controller using a predicted change in a fuel consumption rate and a predicted change in a stored electrical energy caused by a predicted consumption of the stored electrical energy by an electric motor generator;

controlling the electric motor generator to produce an actual electric motor output torque that is substantially equal to the target electric motor output torque using the controller; and

controlling the engine to reduce the engine output torque by an amount corresponding to the target electric motor output torque using the controller.

2. The method of claim 1, wherein the predicted change in the stored electrical energy is a difference between a stored energy reduction and a minimum stored energy reduction.

3. The method of claim 1, wherein the predicted change in the fuel consumption is a difference between the fuel consumption rate and a minimum evaluation fuel consumption rate.

4. The method of claim 1, wherein the act of calculating the target electric motor output torque includes calculating an electric motor output torque producible by the electric motor generator, the controller calculating the electric motor output torque using an available energy representing a quantity of energy stored in an energy storage system electrically connected to the electric motor generator, wherein the energy storage system and the electric motor generator are responsive to the controller.

5. The method of claim 1, wherein the act of calculating the target electric motor output torque includes calculating a stored energy reduction representing a reduction in the quantity of energy stored in the energy storage system that would result from withdrawing an input power from the energy storage device.

6. The method of claim 1, wherein the act of calculating the target electric motor output torque includes calculating an engine torque, wherein the engine and electric motor generator operate together to provide an output torque sufficient to fulfill an operator torque request.

7. The method of claim 6, wherein the act of calculating the target electric motor output torque includes calculating the fuel consumption rate using the engine torque.

8. The method of claim 1, wherein the act of calculating the target electric motor output torque includes calculating a Hybrid Efficiency Index (HEI) equal to the predicted change in the fuel consumption divided by the predicted change in the stored electrical energy, wherein the electrical energy is stored in an energy storage system electrically connected to the electric motor generator and responsive to the controller.

9. The method of claim 8, further comprising:

calculating a minimum efficiency threshold using the controller;

determining if the energy storage system is fully charged using the controller;

determining an energy recovered by the energy storage system from the electric motor generator operating in a generator mode using the controller, wherein the energy storage system is not fully charged;

calculating an unrecovered energy not recovered by the electric motor generator operating in the generator mode using the controller, wherein the energy storage system is in the fully charged state; and

reducing the minimum efficiency threshold using the controller if the energy unrecovered exceeds at least a fraction of the energy recovered.

10. The method of claim 9, further comprising:

calculating an expected energy recovery using the controller, the expected energy recovery calculated using a current vehicle kinetic energy and an expected energy recovery ratio;

reducing the minimum efficiency threshold using the controller if the expected energy recovery is greater than a current storage capacity and the expected energy recovery does not exceed a maximum storage capacity.

11. The method of claim 10, wherein the expected energy recovery ratio is calculated using the controller by calculating an average of two or more recovered energy quotients, wherein the recovered energy quotients are calculated as a ratio of an actual recovered energy divided by a maximum recoverable energy.

12. The method of claim 8, further comprising:

calculating an actual energy withdrawn from the energy storage system when the electric motor generator is operating in the electric motor mode and the hybrid efficiency index is greater than or equal to the minimum efficiency threshold using the controller;

calculating an evaluation energy using the controller, wherein the evaluation energy represents energy that would have been withdrawn from the energy storage system if the electric motor generator was operating in the electric motor mode when the hybrid efficiency index was greater than or equal to an evaluation efficiency threshold that is higher than the minimum efficiency threshold;

using the controller to increase the minimum efficiency threshold if the evaluation energy is greater than the actual energy withdrawn from the energy storage system and the expected energy recovery is less than the current storage capacity; and

using the controller to reduce the minimum efficiency threshold if the evaluation energy is less than the actual energy withdrawn from the energy storage system and the expected energy recovery is greater than or equal to the current storage capacity.

13. The method of claim 8, further comprising:

using the controller to calculate a maximum evaluation power and a minimum evaluation power;

using the controller to calculate a plurality of motor discharge power values, wherein the plurality of motor discharge power values are less than or equal to the maximum evaluation power and greater than or equal to the minimum evaluation power;

using the controller to calculate a plurality of HEI values, wherein the controller uses the plurality of motor discharge power values to calculate corresponding HEI values;

using the controller to determine a maximum HEI value from the plurality of HEI values wherein the maximum HEI value has the highest corresponding motor discharge power value of one or more HEI values that are greater than the minimum efficiency threshold; and

setting the target electric motor output torque to correspond with the motor input power used to calculate the maximum HEI value using the controller.

14. The method of claim 8, wherein the controller does not operate the electric motor generator in the electric motor mode if the hybrid efficiency index is less than the minimum efficiency threshold.

15. A method of controlling a hybrid system, comprising:

calculating one or more fuel consumption rates for an engine sufficient to produce corresponding one or more engine output torque values using a controller, wherein the engine is configured to consume fuel to produce an engine output torque;

calculating one or more electric power input levels for an electric motor generator operating in electric motor mode sufficient to produce corresponding one or more target electric motor output torque levels, wherein the engine and the electric motor generator are responsive to the controller, wherein the engine, electric motor generator, and the controller are included in the hybrid system, and wherein the controller calculates engine output torque values to correspond with electric motor output torque levels to determine one or more predicted hybrid system output torque values;

using the one or more fuel consumption rates and the one or more electric power input levels to calculate one or more predicted changes in the fuel consumption rates and one or more predicted changes in stored electrical energy corresponding to the one or more electric power input levels;

using the controller to select a target engine output torque value and a corresponding target electric motor output torque level based on the corresponding predicted changes in fuel consumption rates and predicted changes in stored electrical energy, wherein the corresponding combined hybrid system output torque value is sufficient to fulfill an operator output power request;

controlling the electric motor generator to produce an actual electric motor output torque that is substantially equal to the selected target electric motor output torque using the controller; and

controlling the engine to produce an actual engine output torque that is substantially equal to the corresponding target engine output torque using the controller.

16. The method of claim 15, further comprising:

calculating a maximum evaluation power and a minimum evaluation power using the controller, wherein the one or more target electric motor output torque levels are less than or equal to the maximum evaluation power and greater than or equal to the minimum evaluation power;

wherein the maximum evaluation power is calculated using the minimum of the following;

A maximum storage system output power for an energy storage system providing power to the electric motor generator, a maximum electric motor input power, and an electrical power sufficient to cause the electric motor generator to produce an electric motor power output substantially equal to a current engine power output.

17. The method of claim 15, wherein the one or more electric motor torques are calculated by converting the corresponding one or more electric motor power levels to an equivalent mechanical energy level and dividing by an electric motor speed.

18. The method of claim 15, further comprising:

calculating one or more stored energy reduction values using the controller, the one or more stored energy reduction values calculated using corresponding target electric motor output torque values from the one or more target electric motor output torque values.

19. The method of claim 18, wherein the one or more stored energy reduction values are calculated by computing one or more reductions in a stored energy that would result from operating the electric motor generator to produce the one or more corresponding target electric motor output torque levels.

20. The method of claim 18, wherein calculating the one or more stored energy reduction values includes calculating a corresponding heat energy loss caused by an energy storage system resistance of an energy storage system electrically connected to the electric motor generator, an energy storage system voltage, and an energy storage system current.

21. The method of claim 18, further comprising:

calculating a minimum stored energy reduction using the controller, wherein the minimum stored energy reduction is calculated by calculating the reduction in the stored energy that would result from operating the electric motor generator using an electric power input level substantially equal to a minimum evaluation power.

22. The method of claim 21, further comprising:

calculating one or more stored energy reduction differentials using the controller, the stored energy reduction differentials defining a difference between corresponding stored energy reduction values and the minimum stored energy reduction.

23. The method of claim 15, further comprising:

calculating a minimum fuel consumption rate using the controller;

calculating one or more fuel consumption differentials using the controller, the fuel consumption differentials defining a difference between corresponding fuel consumption rates and the minimum fuel consumption rate.

24. The method of claim 15, further comprising:

calculating a minimum fuel consumption rate using the controller;

calculating one or more fuel consumption differentials using the controller, the fuel consumption differentials defining a difference between corresponding one or more fuel consumption rates and the minimum fuel consumption rate;

calculating one or more stored energy reduction values using the controller, the one or more stored energy reduction values calculated using the corresponding one or more electric power input levels, wherein the one or more stored energy reduction values represent one or more predicted reductions in stored energy caused by the corresponding one or more electric power input levels;

calculating a minimum stored energy reduction using the controller;

calculating one or more stored energy reduction differentials using the controller, the one or more stored energy reduction differentials defining a difference between corresponding one or more stored energy reduction values and the minimum stored energy reduction; and

calculating one or more efficiency indexes using the controller, the controller calculating the one or more efficiency indexes by dividing the corresponding one or more fuel consumption differentials by the corresponding one or more stored energy reduction differentials.

25. The method of claim 15, further comprising:

calculating an expected energy recovery using the controller, the expected energy recovery calculated using a current vehicle kinetic energy and an expected energy recovery ratio, wherein the expected energy recovery ratio is calculated by averaging together two or more recovered energy quotients, and wherein the two or more recovered energy quotients are calculated as a ratio of an actual recovered energy divided by a maximum recoverable energy;

calculating a minimum efficiency threshold using the controller, wherein the minimum efficiency threshold is calculated using an energy recovered by the electric motor generator, and an energy unrecovered by the electric motor generator, the electric motor generator operating in the generator mode; and

reducing the minimum efficiency threshold using the controller if the energy unrecovered exceeds at least a fraction of the energy recovered, or if the expected energy recovery is greater than a current electrical energy storage capacity in the hybrid system and the expected energy recovery does not exceed a maximum storage capacity.

26. The method of claim 25, further comprising:

calculating one or more efficiency indexes using the corresponding one or more predicted changes in the fuel consumption rate and the one or more predicted changes in stored electrical energy using the controller by dividing the individual predicted changes in the fuel consumption by the corresponding predicted change in the stored electrical energy;

wherein the actual electric motor output torque and the actual engine output torque correspond to a target efficiency index selected by the controller that is greater than or equal to the minimum efficiency threshold.