Hybrid vehicles

• US 7,597,164 B2
• Filed: 05/08/2006
• Issued: 10/06/2009
• Est. Priority Date: 09/14/1998
• Status: Expired due to Fees

• Current Assignee: Abell Foundation Incorporated
• Original Assignee: Paice LLC
• Inventors: Louckes, Theodore, Severinsky, Alex J.
• Primary Examiner(s): VANAMAN, FRANK BENNETT
• Application Number:
  US11/429,460
• Publication Number:
  US 20060237246A1
• Time in Patent Office: 1,247 Days
• Field of Search: 180/65.2, 180/65.3, 180/65.4, 180/242, 180/243, 903/930, 903/941
• US Class Current: 180/65.27
• CPC Class Codes: B60H 1/004 for vehicles having a combustion engine and electric drive means, e.g. hybrid electric vehicles
• CPC Class Codes: B60H 1/3222 characterised by the compressor driving arrangements, e.g. clutches, transmissions or multiple drives B60H1/3208, B60H1/3226 take precedence
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 2006/268 Electric drive motor starts the engine, i.e. used as starter motor
• CPC Class Codes: B60K 6/22 characterised by apparatus, components or means specially adapted for HEVs
• CPC Class Codes: B60K 6/365 with the gears having orbital motion
• CPC Class Codes: B60K 6/442 Series-parallel switching type
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 6/48 Parallel type
• CPC Class Codes: B60K 6/485 Motor-assist type
• CPC Class Codes: B60K 6/547 the transmission being a stepped gearing
• CPC Class Codes: B60L 15/2045 for optimising the use of energy
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/12 Induction machines
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/16 DC brushless machines
• CPC Class Codes: B60L 2240/34 Cabin temperature
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/443 : Torque
• CPC Class Codes: B60L 2240/445 : Temperature
• CPC Class Codes: B60L 2260/28 : Four wheel or all wheel drive
• CPC Class Codes: B60L 2270/145 : Structure borne vibrations
• CPC Class Codes: B60L 50/16 : with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/61 : by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 53/00 : Methods of charging batteries, specially adapted for electric vehicles; Charging stations or on-board charging equipment therefor; Exchange of energy storage elements in electric vehicles
• CPC Class Codes: B60L 53/20 : characterised by converters located in the vehicle
• CPC Class Codes: B60L 58/10 : for monitoring or controlling batteries
• CPC Class Codes: B60L 58/12 : responding to state of charge [SoC]
• CPC Class Codes: B60L 7/18 : Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B60L 7/26 : Controlling the braking effect
• CPC Class Codes: B60T 11/18 : Connection thereof to initiating means
• CPC Class Codes: B60T 13/586 : the retarders being of the electric type
• CPC Class Codes: B60T 2270/60 : Regenerative braking
• CPC Class Codes: B60T 2270/604 : Merging friction therewith; Adjusting their repartition
• CPC Class Codes: B60T 7/06 : Disposition of pedal
• CPC Class Codes: B60T 8/17 : Using electrical or electronic regulation means to control braking detecting or indicating faulty operation B60T8/885
• CPC Class Codes: B60T 8/172 : Determining control parameters used in the regulation, e.g. by calculations involving measured or detected parameters B60T8/17551 takes precedence
• 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 10/18 : including control of braking systems
• CPC Class Codes: B60W 10/26 : for electrical energy, e.g. batteries or capacitors
• 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 20/10 : Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60W 20/14 : in conjunction with braking regeneration
• CPC Class Codes: B60W 20/15 : Control strategies specially adapted for achieving a particular effect
• CPC Class Codes: B60W 20/30 : Control strategies involving selection of transmission gear ratio control of change speed gearings, together with other vehicle sub-units B60W10/10; HEV transmission gearing B60K6/36; gearings and control thereof F16H
• CPC Class Codes: B60W 2510/0633 : Turbocharger state
• CPC Class Codes: B60W 2510/0657 : Engine torque
• CPC Class Codes: B60W 2510/244 : Charge state
• CPC Class Codes: B60W 2530/16 : Driving resistance
• CPC Class Codes: B60W 2540/12 : Brake pedal position
• CPC Class Codes: B60W 2710/08 : Electric propulsion units
• CPC Class Codes: B60W 2710/18 : Braking system
• CPC Class Codes: B60W 2710/244 : Charge state
• CPC Class Codes: B60W 30/18127 : Regenerative braking
• CPC Class Codes: B60Y 2200/91 : Electric vehicles
• CPC Class Codes: B60Y 2200/92 : Hybrid vehicles
• CPC Class Codes: B60Y 2300/18125 : Regenerative braking
• CPC Class Codes: B60Y 2300/91 : Battery charging
• CPC Class Codes: B60Y 2400/112 : Batteries
• CPC Class Codes: B60Y 2400/435 : Supercharger or turbochargers
• CPC Class Codes: B60Y 2400/81 : Braking systems
• CPC Class Codes: F01N 3/2013 : using electric or magnetic heating means
• CPC Class Codes: F02B 37/00 : Engines characterised by provision of pumps driven at least for part of the time by exhaust
• CPC Class Codes: F02B 37/16 : by bypassing charging air
• CPC Class Codes: F02B 37/18 : by bypassing exhaust from the inlet to the outlet of turbine or to the atmosphere
• CPC Class Codes: F02D 2250/18 : Control of the engine output torque
• CPC Class Codes: F02D 41/0007 : for control of turbo-charged or super-charged engines control of the pumps per se F02B37/12
• CPC Class Codes: F02M 35/10157 : Supercharged engines
• CPC Class Codes: F02M 35/10163 : having air intakes specially adapted to selectively deliver naturally aspirated fluid or supercharged fluid
• CPC Class Codes: F02N 11/0818 : Conditions for starting or stopping the engine or for deactivating the idle-start-stop mode
• CPC Class Codes: F02N 2200/061 : Battery state of charge [SOC]
• CPC Class Codes: H01M 10/4207 : for several batteries or cells simultaneously or sequentially
• CPC Class Codes: H01M 2220/20 : Batteries in motive systems, e.g. vehicle, ship, plane
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• CPC Class Codes: Y02T 10/12 : Improving ICE efficiencies
• 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: Y02T 90/14 : Plug-in electric vehicles
• CPC Class Codes: Y10S 903/903 : having energy storing means, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/904 : Component specially adapted for hev
• CPC Class Codes: Y10S 903/907 : Electricity storage, e.g. battery, capacitor
• CPC Class Codes: Y10S 903/93 : Conjoint control of different elements
• CPC Class Codes: Y10S 903/946 : Characterized by control of driveline clutch
• CPC Class Codes: Y10S 903/947 : Characterized by control of braking, e.g. blending of regeneration, friction braking

Abstract

A hybrid vehicle comprises an internal combustion engine, a traction motor, a starter motor, and a battery bank, all controlled by a microprocessor in accordance with the vehicle'"'"'s instantaneous torque demands so that the engine is run only under conditions of high efficiency, typically only when the load is at least equal to 30% of the engine'"'"'s maximum torque output. In some embodiments, a turbocharger may be provided, activated only when the load exceeds the engine'"'"'s maximum torque output for an extended period; a two-speed transmission may further be provided, to further broaden the vehicle'"'"'s load range. A hybrid brake system provides regenerative braking, with mechanical braking available in the event the battery bank is fully charged, in emergencies, or at rest; a control mechanism is provided to control the brake system to provide linear brake feel under varying circumstances.

Claims

1. A method of operating a hybrid vehicle, said vehicle comprising:

at least two wheels, operable to receive power to propel said hybrid vehicle;

a first alternating current (AC) electric motor, operable to provide power to said at least two wheels to propel said hybrid vehicle;

a second AC electric motor;

an engine coupled to said second electric motor, operable to provide power to said at least two wheels to propel the hybrid vehicle, and/or to said second electric motor to drive the second electric motor to generate electric power, said engine being fitted with a turbocharger operable in response to a control signal to increase the maximum torque output by said engine;

a first alternating current-direct current (AC-DC) converter having an AC side coupled to said first electric motor, operable to accept AC or DC and convert the current to DC or AC respectively;

a second AC-DC converter coupled to said second electric motor, at least operable to accept AC and convert the AC to DC;

an electrical storage device operable to store energy converted to DC by said AC-DC converters and to provide energy to be converted to AC by at least said first AC-DC converter to power at least said first electric motor; and

a controller, operable to disable or operate the engine;

said method comprising the steps of monitoring a load signal responsive to at least road load, disabling the engine from operating when said load signal corresponds to a value less than a predetermined value, operating the engine when said load signal corresponds to a value at least equal to said predetermined value, disabling said turbocharger when said load signal corresponds to a value less than the maximum normally-aspirated power output of said engine and operating said turbocharger to increase the torque output by said engine when said load signal corresponds to a value exceeding the maximum normally-aspirated power output of said engine for at least a predetermined period of time.

2. The method of claim 1, comprising the further step of varying said predetermined period of time in accordance with the state of said electrical storage device.

3. The method of claim 1, wherein said steps of disabling and of operating said turbocharger are performed by control of a waste gate providing a path outside of said turbocharger for engine exhaust.

4. The method of claim 3, wherein said waste gate is controlled responsive to atmospheric pressure.

5. The method of claim 1, wherein said controller is further operable to:

start and stop said engine at any speed of said hybrid vehicle;

disable engine operation when said load signal corresponds to a value less than 20% of a maximum torque output (MTO) of said engine; and

enable engine operation at any required combination of its speed and its torque, except said condition of disabling operation.

6. The method of claim 5, wherein said controller is operable to stop said engine when said vehicle load on said engine results in torque lower than 30% of the MTO of the engine.

7. The method of claim 1, wherein said controller is operable to start and operate said engine when said load signal corresponds to a value sufficient to require said engine to produce torque at least equal to a setpoint (SP), and wherein said SP is substantially less than the MTO of said engine.

8. The method of claim 7, wherein said SP is at least 20% of the MTO of the engine.

9. The method of claim 7, wherein said SP is at least 30% of the MTO of the engine.

10. The method of claim 7, wherein said controller is operable to disable engine operation when said load signal corresponds to a value below a second setpoint (SP2), wherein said SP2 is less than said SP.

11. The method of claim 7, wherein said SP varies over said engine speed range.

12. A method for controlling a hybrid vehicle, comprising:

operating a first alternating current (AC) electric motor comprised in the hybrid vehicle to propel the hybrid vehicle, comprising;

providing direct current (DC) from an electrical storage device to be converted to AC by a first alternating current-direct current (AC-DC) converter;

providing the AC to the first AC electric motor to drive the first AC electric motor, said first AC electric motor providing power to a first pair of wheels of the hybrid vehicle;

starting and operating an engine comprised in the hybrid vehicle to propel the vehicle and/or drive a second AC electric motor comprised in the hybrid vehicle to generate electric power, comprising providing power to the at least two wheels and/or the second AC electric motor respectively, when the torque required of said engine to thus propel the vehicle and/or drive said second AC electric motor is at least equal to a setpoint value (SP) that is substantially less than the engine'"'"'s normally-aspirated maximum torque output (MTO);

converting the generated electric power from AC to DC using a second AC-DC converter;

storing the converted electric power in the electrical storage device; and

operating a turbocharger coupled to the engine of the hybrid vehicle to increase the power produced by the engine when torque required of the engine to thus propel the vehicle and/or drive said second AC electric motor exceeds MTO for at least a predetermined period of time, and disabling said turbocharger when torque required of the engine to thus propel the vehicle and/or drive said second AC electric motor is less than MTO.

13. A method of operating a hybrid vehicle, said vehicle comprising:

at least two wheels, operable to receive power to propel said hybrid vehicle;

a first alternating current (AC) electric motor, operable to provide power to said at least two wheels to propel said hybrid vehicle;

a second AC electric motor;

an engine coupled to said second electric motor, operable to provide power to said at least two wheels to propel the hybrid vehicle, and/or to said second electric motor to drive the second electric motor to generate electric power, said engine being fitted with a turbocharger operable in response to a control signal to increase the maximum torque output by said engine;

a first alternating current-direct current (AC-DC) converter having an AC side coupled to said first electric motor, operable to accept AC or DC current and convert the current to DC or AC current respectively;

a second AC-DC converter coupled to said second electric motor, at least operable to accept AC current and convert the current to DC;

an electrical storage device operable to store energy converted to DC by said AC-DC converters and to provide energy to be converted to AC by at least said first AC-DC converter to power at least said first electric motor; and

a controller, operable to disable or operate the engine;

said method comprising the steps of monitoring a load signal at least responsive to road load, disabling said turbocharger when said load signal corresponds to a value less than the maximum normally-aspirated power output of said engine and operating said turbocharger to increase the torque output by said engine when said load signal corresponds to a value exceeding the maximum normally-aspirated power output of said engine for at least a predetermined period of time.

14. The method of claim 13, comprising the further step of varying said predetermined period of time in accordance with the state of said electrical storage device.

15. The method of claim 13, wherein said steps of disabling and of operating said turbocharger are performed by control of a waste gate providing a path outside of said turbocharger for engine exhaust.

16. The method of claim 15, wherein said waste gate is controlled responsive to atmospheric pressure.

17. The method of claim 13, wherein said controller is further operable to:

start and stop said engine at any speed of said hybrid vehicle;

disable engine operation when said load signal corresponds to a value less than 20% of a maximum torque output (MTO) of said engine; and

enable engine operation at any required combination of its speed and its torque, except said condition of disabling operation.

18. The method of claim 13, wherein said controller is operable to stop said engine when said load signal corresponds to a value lower than 30% of the MTO of the engine.

19. The method of claim 13, wherein said controller is operable to start and operate said engine when said load signal corresponds to a value at least equal to a setpoint (SP), and wherein SP is substantially less than the MTO of said engine.

20. The method of claim 19, wherein SP is at least 20% of the MTO of the engine.

21. The method of claim 19, wherein SP is at least 30% of the MTO of the engine.

22. The method of claim 19, wherein said controller is operable to disable engine operation when said signal corresponds to a value below a second setpoint (SP2) wherein SP2 is less than SP.

23. The method of claim 19, wherein SP varies with respect to the speed of the engine.

24. A method for controlling a hybrid vehicle, comprising the steps of:

operating a first alternating current (AC) electric motor comprised in the hybrid vehicle to propel the hybrid vehicle, comprising;

providing direct current (DC) from an electrical storage device to be converted to AC by a first alternating current-direct current (AC-DC) converter;

providing the AC to the first AC electric motor to drive the AC electric motor; and

providing power to a first pair of wheels of the hybrid vehicle;

employing a second AC electric motor driven by an engine of the hybrid vehicle to generate AC electric power;

converting the generated electric power from AC to DC using a second AC-DC converter;

storing the converted electric power in the electrical storage device; and

operating a turbocharger coupled to the engine to increase the power produced by the engine when torque required of the engine to propel the vehicle and/or drive said second AC electric motor exceeds the engine'"'"'s normally-aspirated maximum torque output (MTO) for at least a predetermined period of time, and disabling said turbocharger when torque required of the engine to thus propel the vehicle and/or drive said second AC electric motor is less than MTO.

25. The method of claim 24, comprising the further steps of starting and operating the engine of the hybrid vehicle to propel the vehicle and/or drive said second AC electric motor comprised in the hybrid vehicle to generate electric power when the torque required of said engine to thus propel the vehicle and/or drive said second AC electric motor is at least equal to a setpoint value (SP) that is substantially less than MTO.