Front end motor-generator system and hybrid electric vehicle operating method

• US 10,532,647 B2
• Filed: 08/10/2018
• Issued: 01/14/2020
• Est. Priority Date: 12/14/2016
• Status: Active Grant

• Current Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Original Assignee: Bendix Commercial Vehicle Systems LLC (Estate of Heinz Hermann Thiele)
• Inventors: Colavincenzo, David, Venegas Diaz, Fernando
• Primary Examiner(s): Holmes, Justin
• Application Number:
  US16/100,797
• Publication Number:
  US 20190001805A1
• Time in Patent Office: 522 Days
• Field of Search: None
• CPC Class Codes: B60K 2006/4833 Step up or reduction gearing driving generator, e.g. to operate generator in most efficient speed range
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/40 characterised by the assembly or relative disposition of components
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60L 2200/36 Vehicles designed to transport cargo, e.g. trucks
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 50/12 using AC generators and DC motors
• CPC Class Codes: B60W 10/02 including control of driveline clutches
• 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 10/30 including control of auxiliary equipment, e.g. air-conditioning compressors or oil pumps
• CPC Class Codes: B60W 20/15 Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 2300/125 Heavy duty trucks
• CPC Class Codes: B60W 2300/185 Off-road vehicles
• CPC Class Codes: B60W 2510/244 Charge state
• CPC Class Codes: B60W 2710/081 Speed
• CPC Class Codes: F02B 67/06 driven by means of chains, belts, or like endless members
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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

Abstract

A system and method are provided for hybrid electric internal combustion engine applications in which a motor-generator, a narrow switchable coupling and a torque transfer unit therebetween are arranged and positioned in the constrained environment at the front of an engine in applications such as commercial vehicles, off-road vehicles and stationary engine installations. The motor-generator is preferably positioned laterally offset from the switchable coupling, which is co-axially-arranged with the front end of the engine crankshaft. The switchable coupling is an integrated unit in which a crankshaft vibration damper, an engine accessory drive pulley and a disengageable clutch overlap such that the axial depth of the clutch-pulley-damper unit is nearly the same as a conventional belt drive pulley and engine damper. The front end motor-generator system includes an electrical energy store that receives electrical energy generated by the motor-generator when the coupling is engaged. When the coupling is disengaged, the motor-generator may drive the pulley portion of the clutch-pulley-damper to drive the engine accessories using energy returned from the energy store, independent of the engine crankshaft.

Claims

1. A method of operating a motor-generator accessory drive system of a vehicle, the motor-generator accessory drive system having

a motor-generator,

a torque transfer segment having a motor-generator end configured to receive the motor-generator and to transfer torque between the motor-generator end and an accessory drive end of the torque transfer segment,

an accessory drive coupled to the accessory drive end of the torque transfer segment and arranged to be driven by the motor-generator via the torque transfer and to drive a plurality of accessories,

an energy store configured to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the torque transfer segment, and

a motor-generator system controller configured to control at least one of an operating speed and a torque received by the plurality of accessories from the accessory drive by controlling a torque output of the motor-generator, the method comprising the acts of:

determining with the motor-generator system controller an operating state of the vehicle based on operating state information received from at least one of a vehicle sensor and another controller of the vehicle;

determining with the motor-generator system controller from the determined operating state a current operating priority, wherein the current operating priority is one of;

meeting a safety requirement, the safety requirement including at least a requirement to maintain a vehicle system within a system operating limit,

meeting an energy store requirement, the energy store requirement including at least a requirement to maintain a state of charge of an energy store above first state of charge level,

meeting a requirement for operating at least one accessory of the plurality of accessories at an accessory speed corresponding to a peak energy efficiency of the at least one accessory, and

meeting a driver comfort requirement, the driver comfort requirement including at least a requirement to maintain a climate condition of a passenger compartment of the vehicle in a desired temperature range;

determining an operating speed of each of the plurality of accessories needed to meet the current operating priority;

selecting the highest operating speed of the operating speeds of the plurality of accessories needed to meet the current operating priority when the accessory drive is operated by the motor-generator;

determining from the highest operating speed a corresponding motor-generator speed needed to produce the highest operating speed;

determining, from the corresponding motor-generator speed, operating speeds of the remaining accessories of the plurality of accessories when operated at the corresponding motor-generator speed, the remaining accessories not including the accessory to be operated at the highest operating speed;

determining which of the remaining accessories is capable of meeting a respective accessory demand at a lower speed than the respective accessory'"'"'s operating speed resulting at the corresponding motor-generator speed;

determining which of the remaining accessories is equipped with an individual clutch between the accessory drive and the individual clutch-equipped accessories; and

controlling operation of the motor-generator and the individual accessory clutches of the remaining accessories in response to commands from the motor-generator system controller to

control the motor-generator to the corresponding motor-generator speed, and

modulate the respective individual accessory clutches to modulate the operating speeds of the respective remaining accessories to the lower speeds at which the respective remaining accessories are capable of meeting the respective remaining accessory demands.

2. The method of claim 1, wherein

the act of controlling operation of the motor-generator includes supplying electrical energy from the energy store to the motor-generator.

3. The method of claim 2, wherein

the motor-generator is operated in an accessory drive mode when

a charge state of the energy store is above a third charge state between a first charge state and a second charge state,

the first charge state is a predetermined low state of charge,

the second charge state is a predetermined high state of charge, and

the third charge state is a predetermined intermediate state of charge.

4. The method of claim 3, wherein

the motor-generator is operated in an idle mode when there is no torque demand on the motor-generator from the plurality of accessory.

5. The method of claim 3, wherein

the first charge state is a dynamically determined low state of charge,

the second charge state is a dynamically determined high state of charge,

the third charge state is a dynamically determined intermediate state of charge, and

the dynamically determined low state of charge, the dynamically determined high state of charge and the dynamically determined intermediate state of charge are each determined based on at least one of a health state of the energy store and an energy store environmental condition.

6. A method of operating a motor-generator accessory drive system of a vehicle, the motor-generator accessory drive system having

a motor-generator,

a torque transfer segment having a motor-generator end configured to receive the motor-generator and to transfer torque between the motor-generator end and an accessory drive end of the torque transfer segment,

an accessory drive coupled to the accessory drive end of the torque transfer segment and arranged to be driven by the motor-generator via the torque transfer and to drive a plurality of accessories,

an energy store configured to store electrical energy generated by the motor-generator and to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the torque transfer segment, and

a motor-generator system controller configured to control at least one of an operating speed and a torque received by the plurality of accessories from the accessory drive by controlling at least one of an operating speed and a torque output of the motor-generator,

the method comprising the acts of:

determining with the motor-generator system controller an operating state of the vehicle based on operating state information received from at least one of a vehicle sensor and another controller of the vehicle;

determining with the motor-generator system controller from the determined operating state a current operating priority, wherein the current operating priority is one of;

meeting a safety requirement, the safety requirement including at least a requirement to maintain a vehicle system within a system operating limit,

meeting an energy store requirement, the energy store requirement including at least a requirement to maintain a state of charge of an energy store above first state of charge level,

meeting a requirement for operating at least one accessory of the plurality of accessories at an accessory speed corresponding to a peak energy efficiency of the at least one accessory, and

meeting a driver comfort requirement, the driver comfort requirement including at least a requirement to maintain a climate condition of a passenger compartment of the vehicle in a desired temperature range;

determining a highest operating speed of the plurality of accessories when the accessory drive is operated by the motor-generator at a motor-generator speed sufficient to meet the current operating priority;

determining operating speeds of the remaining accessories of the plurality of the plurality of accessories when operated at the motor-generator speed sufficient to meet the current operating priority, the remaining accessories not including the accessory to be operated at the highest operating speed;

determining which of the remaining accessories is capable of meeting a respective accessory demand at a lower speed than the respective accessory'"'"'s operating speed resulting at the corresponding motor-generator speed;

determining which of the remaining accessories is equipped with an individual clutch between the accessory drive and the individual clutch-equipped accessories; and

controlling operation of the motor-generator and the individual accessory clutches of the remaining accessories in response to commands from the motor-generator system controller to

control the motor-generator to the motor-generator speed sufficient to meet the current operating priority, and

modulate the respective individual accessory clutches to modulate the operating speeds of the remaining accessories to the lower speeds at which the remaining accessories are capable of meeting the respective remaining accessory demands.

7. The method of claim 6, wherein

the act of controlling operation of the motor-generator includes supplying electrical energy from the energy store to the motor-generator.

8. The method of claim 7, wherein

the motor-generator is operated in an accessory drive mode when

a charge state of the energy store is above a third charge state between a first charge state and a second charge state,

the first charge state is a predetermined low state of charge,

the second charge state is a predetermined high state of charge, and

the third charge state is a predetermined intermediate state of charge.

9. The method of claim 8, wherein

the motor-generator is operated in an idle mode when there is no torque demand on the motor-generator from the at least one accessory.

10. The method of claim 8, wherein

the first charge state is a dynamically determined low state of charge,

the second charge state is a dynamically determined high state of charge,

the third charge state is a dynamically determined intermediate state of charge, and

the dynamically determined low state of charge, the dynamically determined high state of charge and the dynamically determined intermediate state of charge are each determined based on at least one of a health state of the energy store and an energy store environmental condition.

11. A method of operating a motor-generator accessory drive system of a vehicle, the motor-generator accessory drive system having

a motor-generator,

a torque transfer segment having a motor-generator end configured to receive the motor-generator and to transfer torque between the motor-generator end and an accessory drive end of the torque transfer segment,

an accessory drive coupled to the accessory drive end of the torque transfer segment and arranged to be driven by the motor-generator via the torque transfer and to drive a plurality of accessories,

an energy store configured to store electrical energy generated by the motor-generator and to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the torque transfer segment,

a motor-generator system controller configured to control at least one of an operating speed and a torque received by the plurality of accessories from the accessory drive by controlling a torque output of the motor-generator,

the method comprising the acts of:

determining for each of the plurality of accessories an operating speed needed to meet the vehicle'"'"'s demand on the accessory;

determining for each of the plurality of accessories an operating speed of the motor-generator to drive the accessory drive to generate the accessory operating speed needed to meet the vehicle'"'"'s demand on the accessory, taking into account a drive ratio of each of the plurality of accessories;

identifying one or more of the plurality of accessories needed to be operated to meet a critical safety requirement;

determining whether the one or more of the plurality of accessories needed to be operated to meet the critical safety requirement has the highest of the determined motor-generator operating speeds;

if the one or more of the plurality of accessories needed to be operated to meet the critical safety requirement has the highest of the determined motor-generator operating speeds, then

select the highest of the determined motor-generator speeds as the current motor-generator operating speed,

determine from the current motor-generator speed operating speeds of the remaining accessories when operated at the current motor-generator speed, the remaining accessories not including the accessory requiring the highest of the determined motor-generator operating speeds,

determine which of the remaining accessories is capable of meeting a respective accessory demand at a lower speed than the respective accessory'"'"'s operating speed at the current motor-generator speed, and

determine which of the remaining accessories is equipped with an individual clutch between the accessory drive and the individual clutch-equipped accessories,

if the one or more of the plurality of accessories needed to be operated to meet the critical safety requirement does not have the highest of the determined motor-generator operating speeds, then

determine with the motor-generator system controller from the determined operating state a second operating priority, wherein the second operating priority is one of

meeting a safety requirement, the safety requirement including at least a requirement to maintain a vehicle system within a system operating limit,

meeting an energy store requirement, the energy store requirement including at least a requirement to maintain a state of charge of an energy store above first state of charge level,

meeting a requirement for operating the at least one accessory at an accessory speed corresponding to a peak energy efficiency of the at least one accessory, and

meeting a driver comfort requirement, the driver comfort requirement including at least a requirement to maintain a climate condition of a passenger compartment of the vehicle in a desired temperature range,

set the current motor-generator operating speed to a speed at which the second operating priority is met while still meeting the critical safety requirement,

determine which of the plurality of accessories is equipped with an individual clutch between the accessory drive and the individual clutch-equipped accessories, and

determine which of the plurality of accessories is capable of meeting a respective accessory demand at a lower speed than the respective accessory'"'"'s operating speed at the current motor-generator speed while still meeting the critical safety requirement and the second operating priority,

controlling operation of the motor-generator and the individual accessory clutches of the remaining accessories not including the one of the plurality of accessories being operated at the current motor-generator speed to meet the second operating priority, in response to commands from the motor-generator system controller to

control the motor-generator to the corresponding motor-generator speed, and

modulate the respective individual accessory clutches to modulate the operating speeds of the remaining accessories equipped with individual clutches to the lower speeds at which the accessories are capable of meeting the respective accessory demands.

12. The method of claim 11, wherein

the act of controlling operation of the motor-generator includes supplying electrical energy from the energy store to the motor-generator.

13. The method of claim 12, wherein:

the motor-generator is operated in an accessory drive mode when

a charge state of the energy store is above a third charge state between a first charge state and a second charge state,

the first charge state is a predetermined low state of charge,

the second charge state is a predetermined high state of charge, and

the third charge state is a predetermined intermediate state of charge.

14. The method of claim 13, wherein

the motor-generator is operated in an idle mode when there is no torque demand on the motor-generator from the at least one accessory.

15. The method of claim 13, wherein

the first charge state is a dynamically determined low state of charge,

the second charge state is a dynamically determined high state of charge,

the third charge state is a dynamically determined intermediate state of charge, and

the dynamically determined low state of charge, the dynamically determined high state of charge and the dynamically determined intermediate state of charge are each determined based on at least one of a health state of the energy store and an energy store environmental condition.

16. A method of operating a motor-generator accessory drive system of a vehicle, the motor-generator accessory drive system having

a motor-generator,

an accessory drive arranged to be driven by the motor-generator and to drive a plurality of accessories,

an energy store configured to deliver stored electrical energy to the motor-generator to generate torque output from the motor-generator to the torque transfer segment, and

a motor-generator system controller configured to control at least one of an operating speed and a torque received by the plurality of accessories from the accessory drive by controlling a torque output of the motor-generator,

the method comprising the acts of:

determining with the motor-generator system controller an operating state of the vehicle based on operating state information received from at least one of a vehicle sensor and another controller of the vehicle;

determining with the motor-generator system controller from the determined operating state a current operating priority, wherein the current operating priority is one of;

meeting a safety requirement, the safety requirement including at least a requirement to maintain a vehicle system within a system operating limit,

meeting an energy store requirement, the energy store requirement including at least a requirement to maintain a state of charge of an energy store above first state of charge level,

meeting a requirement for operating at least one accessory of the plurality of accessories at an accessory speed corresponding to a peak energy efficiency of the at least one accessory, and

meeting a driver comfort requirement, the driver comfort requirement including at least a requirement to maintain a climate condition of a passenger compartment of the vehicle in a desired temperature range;

determining an operating speed of each of the plurality of accessories needed to meet the current operating priority;

selecting the highest operating speed of the operating speeds of the plurality of accessories needed to meet the current operating priority when the accessory drive is operated by the motor-generator;

determining from the highest operating speed a corresponding motor-generator speed needed to produce the highest operating speed;

determining, from the corresponding motor-generator speed, operating speeds of the remaining accessories of the plurality of accessories when operated at the corresponding motor-generator speed, the remaining accessories not including the accessory to be operated at the highest operating speed;

determining which of the remaining accessories is capable of meeting a respective accessory demand at a lower speed than the respective accessory'"'"'s operating speed resulting at the corresponding motor-generator speed;

determining which of the remaining accessories is equipped with an individual clutch between the accessory drive and the individual clutch-equipped accessories; and

controlling operation of the motor-generator and the individual accessory clutches of the remaining accessories in response to commands from the motor-generator system controller to

control the motor-generator to the corresponding motor-generator speed, and

modulate the respective individual accessory clutches to modulate the operating speeds of the respective remaining accessories to the lower speeds at which the respective remaining accessories are capable of meeting the respective remaining accessory demands.