Hybrid electric vehicle

• US 9,878,607 B2
• Filed: 11/01/2015
• Issued: 01/30/2018
• Est. Priority Date: 02/25/2013
• Status: Active Grant

• Current Assignee: Fairfield Manufacturing Company, Inc. (Oerlikon USA, Inc. (Florida))
• Original Assignee: Fairfield Manufacturing Company, Inc. (Oerlikon USA, Inc. (Florida))
• Inventors: Caron, LaVerne Andrew
• Primary Examiner(s): BUTLER, RODNEY ALLEN
• Application Number:
  US14/929,390
• Publication Number:
  US 20160052383A1
• Time in Patent Office: 821 Days
• CPC Class Codes: B60K 23/08 for changing number of driven wheels , for switching from driving one axle to driving two or more axles B60K17/3515 takes precedence
• CPC Class Codes: B60K 6/22 characterised by apparatus, components or means specially adapted for HEVs
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 50/13 using AC generators and AC motors
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60W 10/00 Conjoint control of vehicle sub-units of different type or different function for propulsion of purely electrically-propelled vehicles with power supplied within the vehicle B60L50/00 - B60L58/00
• 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 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/15 Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 2556/00 Input parameters relating to data
• CPC Class Codes: B60Y 2200/40 Special vehicles
• CPC Class Codes: B60Y 2200/92 Hybrid vehicles
• CPC Class Codes: H02J 1/082 Plural DC voltage, e.g. DC supply voltage with at least two different DC voltage levels
• CPC Class Codes: H02P 25/08 Reluctance motors
• CPC Class Codes: H02P 9/00 Arrangements for controlling electric generators for the purpose of obtaining a desired output Ward-Leonard arrangements H02P7/34; vector control H02P21/00; feeding a network by two or more generators H02J; for charging batteries H02J7/14
• 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 10/7072 : 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 903/93 : Conjoint control of different elements

Abstract

A hybrid electric vehicle includes a high voltage DC bus and an internal combustion engine. The internal combustion engine is mechanically coupled to a non self-excited generator/motor which is preferably a switched reluctance machine. A power inverter electrically and bidirectionally couples the high voltage DC bus to the non self-excited switched reluctance generator/motor. Front and rear axle dual DC-AC inverters electrically and bidirectionally couple two traction AC non self-excited switched reluctance motors/gear reducers to the high voltage DC bus for moving the vehicle and for regenerating power. An ultracapacitor coupled to the high voltage DC bus. A bidirectional DC-DC converter interposed between a low voltage battery and the high voltage DC bus transfers energy to the high voltage DC bus and ultracapacitor to ensure that the non self-excited switched reluctance generator/motor operating in the motor mode is able to start the engine.

Claims

1. A series-electric hybrid vehicle, comprising:

a non self-excited generator/motor for providing power to said vehicle for propulsion and operation thereof;

a high voltage DC bus;

a plurality of wheels which propel said vehicle;

one or more non self-excited AC traction motors/generators;

one or more compact dual inverters convey power bi-directionally between said high voltage DC bus and said one or more non self-excited AC traction motors/generators which are affixed, respectively, to one or more of said plurality of wheels;

said compact dual inverters associated with said non self-excited AC traction motors/generators are configured to operate in a generator mode or in a motor mode;

said non self-excited AC traction motors/generators are configured in combination with said wheels to provide propulsion and regenerative braking;

an internal combustion engine;

said internal combustion engine coupled to said non self-excited generator/motor for providing power to said vehicle for propulsion and operation thereof;

said non self-exciting generator/motor coupled to an inverter;

said inverter supplies power bidirectionally to and from said high voltage DC bus, said inverter supplies power to said high voltage DC bus when said non self-excited generator/motor operates in said generator mode, and, said inverter supplies power to said non self-excited generator/motor when said non self-excited generator/motor operates in said motor mode;

an ultracapacitor bank, said ultracapacitor bank electrically coupled to said high voltage DC bus;

said ultracapacitor bank stores regenerative energy from said non self-excited AC traction motors when operating in said motor mode; and

,

said ultracapacitor bank supplies energy to said inverter coupled to said non self-excited generator/motor operating in said motor mode for starting said internal combustion engine;

a conventional low voltage system with at least one 12 or 24 volt DC battery;

a bidirectional DC-DC converter to convey power between said 12 or 24 volt DC battery and said ultracapacitor bank for purposes of pre-charging said ultracapacitor bank to start said internal combustion engine and to maintain the state of charge of said 12 or 24 volt battery after said internal combustion engine is started.

2. A series-electric hybrid vehicle as claimed in claim 1, further comprising:

a resistor bank, said resistor bank dissipates excess regenerative energy from said non self-excited AC traction generators/motors operating in said generator mode.

3. A series-electric hybrid vehicle as claimed in claim 1 in which said non self-excited generator/motor operating in said motor mode is used to dissipate excess kinetic energy from said vehicle by back driving said internal combustion engine while operating an engine compression brake.

4. A hybrid electric vehicle, comprising:

a high voltage DC bus;

an internal combustion engine;

said internal combustion engine driving a non self-excited generator/motor supplying energy to said high voltage DC bus;

a rear axle compact bidirectional dual DC-AC inverter driving two AC motors/generators/gear reducers for moving said vehicle and for recapturing energy from regenerative braking;

a front axle compact bidirectional dual DC-AC inverter driving two AC motors/generators/gear reducers for moving said vehicle and for recapturing energy from regenerative braking;

at least one 12-volt or 24-volt DC battery;

an ultracapacitor, said ultracapacitor electrically coupled to said high voltage DC bus;

a bidirectional DC-DC converter interposed between said 12 or 24-volt battery and said high voltage DC bus, said DC-DC converter transfers energy between said 12 or 24-volt DC battery and said high voltage DC bus and said ultracapacitor;

said non self-exciting generator/motor coupled to said engine for starting said internal combustion engine;

and, said ultracapacitor supplying energy to said inverter coupled to said generator for starting said internal combustion engine.

5. A hybrid electric vehicle as claimed in claim 4, further comprising:

a resistor bank; and

,

said compact dual bidirectional DC-AC inverters include rectification means for regenerating energy and storing said energy in said at least one battery and/or said ultracapacitor.

6. A series-electric hybrid vehicle as claimed in claim 1 wherein said non self-exciting generator/motor is a switched reluctance machine.

7. A series-electric hybrid vehicle as claimed in claim 1 wherein said non self-exciting generator/motor is the primary source of electrical energy for the vehicle.

8. A hybrid electric system, comprising:

an internal combustion engine;

a non self-exciting AC generator/motor;

said non self-exciting AC generator/motor operates in either a generator mode or a motor mode;

a high voltage DC bus;

an ultracapacitor bank, said ultracapacitor bank connected full time across said high voltage DC bus;

an AC-DC inverter for converting the AC power from said non self-exciting AC generator/motor to DC power for supply to said high voltage DC bus and said ultracapacitor bank;

a low voltage DC battery;

means for charging said ultracapacitor bank from said conventional low-voltage vehicle DC battery to provide initial excitation energy to said non self-exciting generator/motor operating in said motor mode to start said internal combustion engine.

9. A hybrid electric system as claimed in claim 8, further comprising:

dual compact inverters;

a plurality of wheels;

a plurality of non self-excited traction generators/motors each interconnected with a respective one of said plurality of wheels;

said dual compact inverters are connected across said ultracapacitor bank;

said dual compact inverters are bidirectional DC-AC inverters; and

,

said dual compact inverters transfer energy to and from said ultracapacitor bank and to and from said non self-excited traction generators/motors.

10. A hybrid electric system as claimed in claim 8, wherein said non self-excited generator/motor is operated in said motor mode to back drive said internal combustion engine and an associated engine brake in order to dissipate excessive regenerative braking energy.

11. A hybrid electric system as claimed in claim 8 wherein said ultracapacitor bank is driven to a predetermined maximum state of charge prior to engine shutdown in order to provide for rapid engine starting without need to rely on pre-charging from said vehicle low-voltage DC battery under normal operating conditions.

12. A hybrid electric system as claimed in claim 8 wherein said means for charging said ultracapacitor bank from said conventional low voltage vehicle DC battery to provide initial excitation energy to said non self-exciting generator/motor operating in said motor mode to start said internal combustion engine.

13. A hybrid electric system as claimed in claim in claim 9 in which one or more of said dual compact inverters discharge some energy in said ultracapacitor bank into the windings of said non self-excited traction generators/motors without motion either by operating at sufficiently low enough power to avoid motion or by operating said non self-excited traction generators/motors with opposing torques to enable safe operation of said system.

14. A hybrid electric system, comprising:

a non self-excited generator/motor coupled to an internal combustion engine;

said non self-excited generator/motor is operable in a generator mode or a motor mode;

a power inverter;

a high voltage DC bus;

an ultracapacitor interconnected with said high voltage DC bus;

a low voltage battery;

a DC-DC bidirectional converter;

said ultracapacitor bank is charged to a usable operating voltage by transferring energy from said low voltage battery by use of said DC-DC converter;

said non self-excited generator/motor is driven by said power inverter to start said internal combustion engine when said ultracapacitor is charged to a usable voltage and when said non self excited generator/motor is in said motor mode.

15. A hybrid electric system as claimed in claim 14 wherein said DC-DC converter charges said low voltage battery once said internal combustion engine is operational.

16. A hybrid electric system as claimed in claim 14 further comprising a traction motor.

17. A hybrid electric system as claimed in claim 15 further comprising a plurality of traction motors.

18. A hybrid electric system as claimed in claim 16 wherein said traction motors may be selected from the group of self-exciting interior permanent magnet motors, non-self-exciting, AC or DC motors.

19. A hybrid electric system as claimed in claim 17 wherein said traction motors may be selected from the group of self-exciting interior permanent magnet motors, non-self-exciting, AC or DC motors.

20. A hybrid electric vehicle, comprising:

a controller;

a non self-excited generator/motor mechanically interconnected with said internal combustion engine;

a power inverter;

said non self-excited generator/motor in electrical communication with said power inverter;

said non self-excited generator/motor is operable in a generator mode or a motor mode;

a high voltage DC bus;

an ultracapacitor interconnected with said high voltage DC bus;

said controller in electrical communication with said power inverter controlling said power inverter;

a low voltage battery;

a DC-DC bidirectional converter;

said ultracapacitor bank is charged to a usable operating voltage by transferring energy from said low voltage battery by use of said DC-DC converter; and

,

said non self-excited generator/motor is controlled by said controller and driven in said motor mode by said power inverter when said ultracapacitor is charged to a usable voltage to start said internal combustion engine.

21. A hybrid electric vehicle as claimed in claim 20, further comprising:

a first dual compact inverter and a second dual compact inverter;

a plurality of non self-excited traction generators/motors driven by said first and second dual compact inverters;

said first and second compact inverters controlled by said controller.

22. A hybrid electric vehicle as claimed in claim 21 wherein said first and second dual compact inverters may bidirectionally supply power.

23. A hybrid electric vehicle as claimed in claim 21 wherein said power inverter may bidirectionally supply power.

24. A hybrid electric vehicle as claimed in claim 21 wherein said first and second dual compact inverters may bidirectionally supply power and wherein said power inverter may bidirectionally supply power.

25. A series-electric hybrid vehicle comprising:

an internal combustion engine that converts chemical energy into mechanical energy;

a non-self-excited generator/motor coupled to said internal combustion engine to convert mechanical power to electric power and provide said electric power to said vehicle for propulsion;

a high-voltage DC bus;

an inverter to transfer power bi-directionally between said non-self-excited generator/motor and said high-voltage DC bus;

a traction motor/generator that provides propulsion power;

an inverter to transfer electric power bi-directionally between said traction motor/generator and said high-voltage DC bus;

a conventional low-voltage system with at least one 12 or 24 volt battery;

an ultracapacitor bank, said ultracapacitor bank electrically coupled to said high-voltage DC bus;

a bidirectional DC-DC converter to convey power between said 12 or 24 volt battery and said ultracapacitor bank for purposes of pre-charging said ultracapacitor bank when necessary to provide sufficient energy to excite said generator and start said internal combustion engine using said non self excited generator/motor operating in said motor mode and thereafter to maintain the state of charge of said low-voltage battery once said internal combustion engine is operating; and

,

control logic, said control logic manages the state of charge of said ultracapacitor bank and the propulsive operation of said vehicle and other related functions.

26. A hybrid electric system, as claimed in claim 8, further comprising a DC-AC inverter for powering an AC traction motor for powering said vehicle.

27. A hybrid electric system as claimed in claim 26, wherein said AC traction motor operates as a generator regenerating energy to said DC-AC inverter for storage in said ultracapacitor.

28. A hybrid electric vehicle as claimed in claim 20, further comprising:

a first inverter;

a traction generator/motor driven by said first inverter; and

,

said first inverter controlled by said controller.