Hybrid electric vehicle with electric motor providing strategic power assist to load balance internal combustion engine

• US 6,367,570 B1
• Filed: 05/09/2000
• Issued: 04/09/2002
• Est. Priority Date: 10/17/1997
• Status: Expired due to Term

• Current Assignee: Electromotive Incorporated
• Original Assignee: Electromotive Incorporated
• Inventors: Long, James B., Long, Alexander J. III, Samstag, Frank J.
• Primary Examiner(s): MAR, MICHAEL Y
• Application Number:
  US09/566,725
• Time in Patent Office: 700 Days
• Field of Search: 318/139, 318/811, 318/376, 607/04, 607/05, 180/65.2, 180/65.3, 180/65.4, 180/65.8, 180/65.1, 701/22
• US Class Current: 180/65.26
• CPC Class Codes: B60K 6/485 Motor-assist type
• CPC Class Codes: B60L 50/15 with additional electric power supply with capacitors charged by engine-driven generators B60L50/40; with batteries charged by engine-driven generators B60L50/61
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 2540/10 Accelerator pedal position
• 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

Abstract

A parallel hybrid electric vehicle design delivers smooth, high power performance while decreasing harmful exhaust emissions and maximizing fuel economy. An electric motor strategically assists the internal combustion engine. This arrangement can increase driveability and make for a very smooth driving vehicle. Decreased emissions are realized by helping the engine to run in a fashion which inherently minimizes emissions. Fuel economy is significantly enhanced by efficiently producing power needed to make the car meet the demands of the driver while leveling the load demands placed on the internal combustion engine. When the internal combustion engine is operating very efficiently under light loading or deceleration, the power source is charged as the motor turns into a generator.

Claims

1. A hybrid motor vehicle power plant arrangement comprising:

an internal combustion engine having an internal combustion engine output shaft;

an electric motor having an electric motor output shaft;

a coupling arrangement that couples the electric motor output shaft to the internal combustion engine output shaft; and

an electronic controller connected to electronically control the internal combustion engine and the electric motor,

wherein the electric controller controls the electric motor to provide a positive or negative loading to the internal combustion engine output shaft, and at least sometimes operates the electric motor in a mode that allows the electric motor to remain mechanically coupled to the internal combustion engine through the coupling arrangement while minimizing loading of the internal combustion engine output shaft by the electric motor, by controlling electric current to the electric motor so that the electric motor output shaft rotates at substantially the same speed as the internal combustion engine output shaft.

2. An arrangement as in claim 1 wherein the electric motor is coupled in parallel with the internal combustion engine.

3. An arrangement as in claim 1 wherein the electronic controller monitors parameters relating to the operation of at least the internal combustion engine, and provides an electric motor control signal to control the electric motor.

4. An arrangement as in claim 3 wherein the electronic controller is connected in a closed loop configuration.

5. An arrangement as in claim 1 wherein the internal combustion engine output shaft comprises a crankshaft, and the electric motor output shaft comprises a rotor.

6. An arrangement as in claim 5 wherein the coupling arrangement includes a serpentine belt.

7. An arrangement as in claim 1 wherein the internal combustion engine output shaft comprises a crankshaft, and the electric motor output shaft comprises a disk mounted to the internal combustion engine, the disk being coupled to the crankshaft.

8. An arrangement as in claim 1 further including an electric power storage device coupled to the electric motor, the electric motor sometimes operating in a charging mode to charge the electric power storage device.

9. An arrangement as in claim 8 wherein the electric motor charges the electric power storage device by converting torque generated by the internal combustion engine to electric energy during times when loading on the internal combustion engine is light.

10. An arrangement as in claim 8 wherein the electric motor charges the electric power storage device through regenerative braking.

11. An arrangement as in claim 8 wherein the electric power storage device comprises a battery.

12. An arrangement as in claim 8 wherein the electric power storage device includes a large capacitor.

13. An arrangement as in claim 1 wherein the electronic controller effectively lowers the rate of change of internal combustion engine loading so maximum and minimum internal combustion engine loads are closer to average internal combustion engine load.

14. An arrangement as in claim 1 wherein the electric motor provides a maximum torque output less than half the internal combustion engine maximum torque output.

15. An arrangement as in claim 14 wherein the electric motor provides a maximum torque output that is in the range of ⅙

to ½

the internal combustion engine maximum torque output.

16. An arrangement as in claim 1 wherein the electronic controller allows the internal combustion engine to run with a leaner air-fuel ratio while maintaining acceptable driveability.

17. An arrangement as in claim 1 wherein the electronic controller pulse width modulates the electric motor at specific events associated with the internal combustion engine, the electronic controller changing the advance or retard timing of the pulse width modulation to achieve a desired load leveling effect of the internal combustion engine.

18. A hybrid power source including an internal combustion engine having an internal combustion engine output shaft and an electric motor having an electric motor output shaft, the internal combustion engine output shaft and the electric motor output shaft being connected in parallel via a coupling arrangement, the hybrid power source further including an electric controller connected to electronically control the internal combustion engine and the electric motor, wherein the electric controller monitors a load imposed upon the internal combustion engine output shaft and controls the electric motor to level an effective loading of the internal combustion engine output shaft and provide better fuel efficiency and reduce harmful emissions from the internal combustion engine, and wherein the electric controller at least sometimes operates the electric motor in a mode that allows the electric motor to remain mechanically coupled to the internal combustion engine through the coupling arrangement while minimizing loading of the internal combustion engine output shaft by the electric motor, by controlling electric current to the electric motor so that the electric motor output shaft rotates at substantially the same speed as the internal combustion engine output shaft.

19. A hybrid power source as in claim 18 wherein the electric controller pulse width modulates the electric motor at specific events associated with the internal combustion engine, the electric controller changing the advance or retard timing of the pulse width modulation to achieve a desired load leveling effect of the internal combustion engine.

20. A method of operating a hybrid power plant including an electric motor providing a torque output coupled to a torque output of an internal combustion engine, the method including the steps of electronically controlling the electric motor to provide a positive or negative loading to an output shaft of the electric motor, and at least sometimes operating the electric motor in a mode that allows the electric motor to remain mechanically coupled to an output shaft of the internal combustion engine through a coupling mechanism while minimizing loading of the output shaft of the internal combustion engine by the electric motor, by controlling electric current to the electric motor so that the electric motor output shaft rotates at substantially the same speed as the internal combustion engine output shaft.

21. A method as in claim 20 further including the steps of pulse width modulating the electric motor at specific events associated with the internal combustion engine, and changing the advance or retard timing of the pulse width modulation to achieve a desired load leveling effect of the internal combustion engine.

22. A method as in claim 20 further including the step of coupling the electric motor torque output in parallel with the internal combustion engine torque output.

24. A method as in claim 20 further including the step of controlling using closed loop feedback to control the electric motor.

25. A method as in claim 20 wherein the internal combustion engine has a crankshaft, the electric motor has a rotor, and the method further includes the step of coupling the crankshaft and the rotor so that they turn together.

26. A method as in claim 20 further including the step of sometimes operating the electric motor in a charging mode to charge the electric power storage device.

27. A method as in claim 26 wherein the charging mode operating step includes sensing when loading on the internal combustion engine is light, and using the electric motor to convert torque generated by the internal combustion engine to electric energy during times when the sensing step senses that the loading on the internal combustion engine is light.

28. A method as in claim 26 wherein the charging mode operating step includes using the electric motor as a regenerative brake.

29. A method as in claim 20 further including the step of storing electric power in a large capacitor.

30. A method as in claim 20 further including the step of electronically controlling the electric motor to effectively lower the rate of change of internal combustion engine loading so maximum and minimum internal combustion engine loads are closer to average internal combustion engine load.

31. A method as in claim 20 including the step of outputting, from the electric motor, a maximum torque less than half the internal combustion engine maximum torque output.

32. A method as in claim 31 including the step of outputting, from the electric motor, a maximum torque output that is in the range of ⅙

to ½

the internal combustion engine maximum torque output.

33. A method as in claim 20 including the step of operating the internal combustion engine with a lean air-fuel ratio and supplementing the internal combustion engine power output and thereby maintain acceptable driveability.

23. A method as in claim 23 further including the step of continually electronically monitoring parameters relating to the operation of at least the internal combustion engine, and providing a responsive electric motor control signal to control the electric motor.