Flywheel assisted electro-mechanical drive system

• US 4,423,794 A
• Filed: 03/12/1981
• Issued: 01/03/1984
• Est. Priority Date: 03/12/1981
• Status: Expired due to Fees

• Current Assignee: The Garrett Corporation
• Original Assignee: The Garrett Corporation
• Inventors: Beck, William H.
• Primary Examiner(s): Peters, Jr., Joseph F.
• Assistant Examiner(s): Rice, Kenneth R.
• Application Number:
  US06/243,134
• Time in Patent Office: 1,027 Days
• Field of Search: 180/165, 180/65 R, 180/65 A, 180/65 C, 74/674, 74/675, 74/679, 74/686, 74/720.5, 318/139
• US Class Current: 180/165
• CPC Class Codes: B60K 1/04 of the electric storage means for propulsion exchanging batteries for electric propulsion of vehicles B60L53/80; for auxiliary purposes only B60R16/04; supplying batteries to, or removing batteries from, vehicles B60S5/06
• CPC Class Codes: B60K 6/105 the accumulator being a flywheel
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: Y02T 10/62 Hybrid vehicles

Abstract

A vehicle propulsion system combines an electric motor-generator and battery with a flywheel as regenerative power sources. A planetary differential gear train couples together the shafts from the flywheel and the motor-generator. A controller connected between the battery and the motor-generator serves to maintain the current level to or from the battery with a range which develops optimum efficiency of battery energy utilization while causing the flywheel to absorb the relatively large peaks in battery power requirements.

In one embodiment, the controller is made up of a transistorized chopper, a free-wheeling diode, a regenerative diode, a current sensor, and a switch to change the controller between the motor and generator modes of operation. The motor-generator is a separately excited, DC machine.

Claims

1. An electro-mechanical drive system for vehicles comprising:

a planetary differential gear transmission having three separate shafts coupled respectively to a sun gear, planet gears and a ring gear;

a propulsion drive shaft coupled to a first one of said shafts;

a flywheel coupled to a second one of said shafts;

a motor-generator coupled to a third one of said shafts and having the capability of operating as a motor to drive the third shaft and as a generator to develop an output current when driven by the third shaft, the motor-generator and the flywheel being the only sources of propulsion in said drive system;

electrical storage means for supplying electrical energy to the motor-generator when operated as a motor and for receiving electrical energy from the motor-generator when operated as a generator; and

electrical control means for selectively controlling the motor-generator to cause the flywheel to deliver driving power to the drive shaft.

2. The system of claim 1 wherein the control means further includes means for causing the planetary transmission to deliver power from the drive shaft to the flywheel during a regenerative braking mode.

3. The system of claim 1 or claim 2 wherein the control means includes means for limiting current flowing between the battery and the motor-generator to a level within a preselected range.

4. The system of claim 1 wherein the control means includes means for operating the motor-generator to cause the drive shaft to be driven in the reverse direction in response to operator command.

5. The system of claim 1 wherein the control means includes mode switching means for operating the motor-generator selectively in either a motoring or a generator mode.

6. The system of claim 1 wherein the first shaft is coupled to the planet gears, the second shaft is coupled to the sun gear, and the third shaft is coupled to the ring gear.

7. An electro-mechanical drive system for vehicles comprising:

a planetary differential gear transmission having three separate shafts coupled respectively to a sun gear, planet gears and a ring gear;

a propulsion drive shaft coupled to a first one of said shafts;

a flywheel coupled to a second one of said shafts;

a motor-generator coupled to a third one of said shafts and having the capability of operating as a motor to drive the third shaft and as a generator to develop an output current when driven by the third shaft;

electrical storage means for supplying electrical energy to the motor-generator when operated as a motor and for receiving electrical energy from the motor-generator when operated as a generator; and

electrical control means for selectively controlling the motor-generator to cause the flywheel to deliver driving power to the drive shaft;

wherein the motor-generator is a separately excited DC machine having means for separately controlling the polarity and direction of current to a field winding thereof, and further comprising a mode switch connected between one side of the motor-generator armature and the battery with a current interrupting means connected between the other side of the motor-generator armature and the other side of the battery.

8. The system of claim 7 wherein the control means further comprises a driving stage coupled to the current interrupting means for selectively controlling the current interrupting means between on and off positions.

9. The system of claim 8 further including current sensing means connected in series with the armature, and a comparison stage coupled to receive input signals from the current sensing means and from a current control means for making a comparison between said two input signals and applying an output signal to control the driving stage.

10. The system of claim 9 wherein the control means further includes a first diode coupled between one pole of the armature and a corresponding terminal of the battery for conducting charging current to the battery when the current interrupting means is in the off condition and the motor-generator is being operated in a generating mode.

11. The system of claim 10 wherein the control means further comprises a free-wheeling diode connected in a circuit path across the armature to conduct armature current when the current interrupting means is in the off condition and the motor-generator is being operated as a motor.

12. The system of claim 7 further including reversible power supply means coupled to control the magnitude and direction of current in the motor-generator field winding in response to applied field current command signals.

13. The system of claim 12 further including means for controlling the mode switch between motoring and generating mode positions in response to applied command signals.

14. The system of claim 7 wherein the control means further includes selector means operable for selectively controlling armature current and field current in accordance with the conditions of associated accelerator, brake and forward/reverse switch devices.

15. The system of claim 14 wherein the selector means further includes means for monitoring speeds of the drive shaft, the flywheel and the motor-generator.

16. The method of controlling a battery powered motor-generator intercoupled with a flywheel and a vehicle drive shaft through a planetary differential gear transmission comprising the steps of:

selecting between motor and generator modes of operation for the motor-generator;

establishing a motor-generator field in accordance with a predetermined field current command signal; and

controlling the armature current of the motor-generator within preselected levels to develop a torque at the planetary transmission which controls the proportion of power flow contributed by the flywheel to level out peak curent loads applied to the battery,

the step of controlling the armature current including sensing the level of armature current, comparing the sensed level with a preselected command signal, and variably controlling the armature current in accordance with the difference between the sensed level and the command signal.

17. The method of claim 16 wherein the mode selecting step includes selecting the motor mode of operation, and further including periodically interrupting the current from the battery while permitting armature current to flow through a unidirectional bypass path and continuing to sense the level of armature current.

18. The method of claim 16 wherein the mode selecting step includes selecting the generator mode of operation, and further including permitting generated armature current to build up to a first preselected level, then interrupting one armature current path to divert induced current to the battery until the current drops to a second preselected level, and repeating the cycle in order to build up charge in the battery.

19. The method of controlling a battery powered motor-generator intercoupled with a flywheel and a vehicle drive shaft through a planetary differential gear transmission comprising the steps of:

selecting between motor and generator modes of operation for the motor-generator;

establishing a motor-generator field in accordance with a predetermined field current command signal; and

controlling the armature current of the motor-generator within preselected levels to develop a torque at the planetary transmission which controls the proportion of power flow contributed by the flywheel to level out peak current loads applied to the battery;

wherein the step of establishing the motor-generator field includes establishing a polarity of field effective to induce an armature potential polarity opposing the polarity of the battery while selecting the generator mode of operation.

20. The method of controlling a battery powered motor-generator intercoupled with a flywheel and a vehicle drive shaft through a planetary differential gear transmission comprising the steps of:

selecting between motor and generator modes of operation for the motor-generator;

establishing a motor-generator field in accordance with a predetermined field current command signal; and

controlling the armature current of the motor-generator within preselected levels to develop a torque at the planetary transmission which controls the proportion of power flow contributed by the flywheel to level out peak current loads applied to the battery;

wherein the step of establishing the motor-generator field includes establishing a polarity of field effective to establish an armature potential polarity such as to draw current from the battery while operating as a motor and concurrently selecting the motor mode of operation.