U.S. patent application number 09/728473 was filed with the patent office on 2002-05-30 for method and arrangement in hybrid vehicle for maintaining a catalyst in an effective state.
Invention is credited to Lennevi, Jerker.
Application Number | 20020063001 09/728473 |
Document ID | / |
Family ID | 26936986 |
Filed Date | 2002-05-30 |
United States Patent
Application |
20020063001 |
Kind Code |
A1 |
Lennevi, Jerker |
May 30, 2002 |
METHOD AND ARRANGEMENT IN HYBRID VEHICLE FOR MAINTAINING A CATALYST
IN AN EFFECTIVE STATE
Abstract
Method for maintaining a catalyst of an emissions system in a
hybrid electric vehicle in an operative condition is disclosed. The
method includes sensing that an engine of a hybrid electric vehicle
has stopped operating. A time period is predicted after which a
catalyst of an emissions system associated with the engine will
cool to a light-off temperature below which the catalyst becomes
ineffective. The predicting step is based on known qualities of the
catalyst and ambient conditions in which the vehicle is being
operated. The engine is restarted when the predicted time period
has expired thereby maintaining the catalyst at temperatures in
excess of the light-off temperature.
Inventors: |
Lennevi, Jerker; (Lerum,
SE) |
Correspondence
Address: |
TRACY W. DRUCE
KILPATRICK STOCKTON LLP
11130 SUNRISE VALLEY DRIVE
SUITE 300
RESTON
VA
20191-4329
US
|
Family ID: |
26936986 |
Appl. No.: |
09/728473 |
Filed: |
November 30, 2000 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60245090 |
Oct 31, 2000 |
|
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|
Current U.S.
Class: |
180/65.235 ;
180/68.5; 903/910; 903/913; 903/945 |
Current CPC
Class: |
B60W 50/0097 20130101;
B60K 6/383 20130101; B60K 2001/005 20130101; F02D 2250/18 20130101;
B60L 2240/421 20130101; B60K 1/04 20130101; B60K 6/365 20130101;
B60L 50/61 20190201; B60L 2240/445 20130101; B60W 2510/081
20130101; Y02T 10/62 20130101; Y10S 903/91 20130101; B60W 10/10
20130101; B60K 6/445 20130101; B60W 2710/105 20130101; B60W 10/06
20130101; B60W 2710/0622 20130101; Y02T 10/72 20130101; B60L
2240/443 20130101; Y10S 903/913 20130101; B60L 3/0046 20130101;
B60L 58/18 20190201; Y02T 10/64 20130101; B60L 58/12 20190201; B60L
2240/423 20130101; B60W 20/00 20130101; B60W 2510/083 20130101;
F02N 11/0814 20130101; B60W 2050/0012 20130101; Y02T 10/40
20130101; B60L 15/2045 20130101; B60L 2260/42 20130101; F02D 41/021
20130101; Y02T 10/84 20130101; B60L 2240/441 20130101; F02N
2300/2006 20130101; F02N 11/0829 20130101; Y02T 10/7072 20130101;
B60L 50/16 20190201; B60W 10/08 20130101; B60W 2520/10 20130101;
B60W 2710/0616 20130101; B60W 2710/0666 20130101; F02N 2200/026
20130101; B60L 2260/26 20130101; B60L 50/64 20190201; B60L 58/26
20190201; B60L 2210/40 20130101; B60W 10/26 20130101; B60W 2510/244
20130101; Y02T 10/70 20130101; B60L 2240/486 20130101; Y10S 903/945
20130101; B60W 2540/10 20130101; B60W 2710/065 20130101; B60L
2270/20 20130101; B60W 20/15 20160101; B60W 30/18027 20130101; B60W
2050/0022 20130101; B60K 1/02 20130101; B60L 2240/80 20130101; B60W
2510/068 20130101; B60W 2510/0638 20130101; B60W 2510/0657
20130101 |
Class at
Publication: |
180/65.2 ;
180/68.5 |
International
Class: |
B60K 001/00 |
Claims
What is claimed and desired to be secured by Letters Patent is as
follows:
1. A method for maintaining a catalyst of an emissions system in a
hybrid electric vehicle in an operative condition, said method
comprising: sensing that an engine of a hybrid electric vehicle has
stopped operating; predicting a time period after which a catalyst
of an emissions system associated with said engine will cool to a
light-off temperature below which said catalyst becomes
ineffective; basing said predicting step on known qualities of said
catalyst and ambient conditions in which the vehicle is being
operated; and restarting the engine when the predicted time period
has expired thereby maintaining the catalyst at temperatures in
excess of the light-off temperature.
2. The method as recited in claim 1 further comprising: sensing a
temperature of said catalyst and initiating stopping of operation
of the engine when a predetermined temperature is detected.
3. The method as recited in claim 1 further comprising: running the
engine at idle speed; and charging batteries of the hybrid electric
vehicle utilizing power produced from the idling engine.
4. The method as recited in claim 1 further comprising: heating
said catalyst to a predetermined temperature differential above
said light-off temperature; and stopping operation of the engine
when the predetermined temperature differential is achieved.
5. The method as recited in claim 4 further comprising: sensing a
temperature of said catalyst and initiating the stopping of
operation of the engine when the predetermined temperature
differential is detected.
6. The method as recited in claim 5 further comprising: sensing
said temperature of said catalyst utilizing a physical sensor
located proximate said catalyst.
7. The method as recited in claim 5 further comprising: sensing
said temperature of said catalyst utilizing a catalyst modeling
process; said modeling process being dependent upon catalyst,
engine and ambient conditions.
Description
RELATED APPLICATION(S)
[0001] This patent application claims priority to U.S. Provisional
Application No. 60/245,090 filed Oct. 31, 2000 and entitled HYBRID
ELECTRIC VEHICLE. Said application in its entirety is hereby
expressly incorporated by reference into the present
application.
INDUSTRIAL APPLICABILITY
[0002] The present invention finds applicability in the
transportation industries, and more specifically private and
commercial vehicles. Of particular importance is the invention's
incorporation into hybrid electric vehicles.
BACKGROUND ART
[0003] Generally, a hybrid electric vehicle combines electric
propulsion with traditional internal combustion engine propulsion
to achieve enhanced fuel economy and/or lower exhaust emissions.
Electric propulsion has typically been generated through the use of
batteries and electric motors. Such an electric propulsion system
provides the desirable characteristics of high torque at low
speeds, high efficiency, and the opportunity to regeneratively
capture otherwise lost braking energy. Propulsion from an internal
combustion engine provides high energy density, and enjoys an
existing infrastructure and lower costs due to economies of scale.
By combining the two propulsive systems with a proper control
strategy, the result is a reduction in the use of each device in
its less efficient range. Furthermore, and as shown in FIG. 1
regarding a parallel hybrid configuration, the combination of a
downsized engine with an electric propulsion system into a minimal
hybrid electric vehicle results in a better utilization of the
engine, which improves fuel consumption. Furthermore, the electric
motor and battery can compensate for reduction in the engine
size.
[0004] In typical configurations, the combination of the two types
of propulsion systems (internal combustion and electric) is usually
characterized as either series or parallel hybrid systems. In a
pure series hybrid propulsion system, only the electric motor(s)
are in direct connection with the drive train and the engine is
used to generate electricity which is fed to the electric motor(s).
The advantage of this type of system is that the engine can be
controlled independently of driving conditions and can therefore be
consistently run in its optimum efficiency and low emission ranges.
A key disadvantage to the series arrangement is the loss in energy
experienced because of the inefficiencies associated with full
conversion of the engine output to electricity.
[0005] In a pure parallel hybrid propulsion system, both the engine
and the electric motor(s) are directly connected to the drive train
and either one may independently drive the vehicle. Because there
is a direct mechanical connection between the engine and the drive
train in a parallel hybrid propulsion system, less energy is lost
through conversion to electricity compared to a series hybrid
propulsion system. The operating point for the engine, however, can
not always be chosen with full freedom.
[0006] The two hybrid propulsion systems can be combined into
either a switching hybrid propulsion system or a power-split hybrid
propulsion system. A switching hybrid propulsion system typically
includes an engine, a generator, a motor and a clutch. The engine
is typically connected to the generator. The generator is connected
through a clutch to the drive train. The motor is connected to the
drive train between the clutch and the drive train. The clutch can
be operated to allow series or parallel hybrid propulsion.
[0007] A power-split hybrid system, as is exemplarily employed with
respect to the present invention, includes an engine, a generator
and a motor. The engine output is "split" by a planetary gear set
into a series path from the engine to the generator and a parallel
path from the engine directly to the power train. In a power-split
hybrid system, the engine speed can be controlled by varying the
power split to the generator by way of the series path, while
maintaining the mechanical connection between the engine and drive
train through the parallel path. The motor augments the engine on
the parallel path in a similar manner as a traction motor in a pure
parallel hybrid propulsion system, and provides an opportunity to
use energy directly through the series path, thereby reducing the
losses associated with converting the electrical energy into, and
out of chemical energy at the battery.
[0008] In a typical power-split hybrid system, the generator is
usually connected to the sun gear of the planetary gear set. The
engine is connected to the planetary carrier and the output gears
(usually including an output shaft and gears for interconnection
with the motor and the wheel-powering, final drive train) are
connected to the ring gear. In such a configuration, the
power-split hybrid system can generally be operated in four
different modes; one electric mode and three hybrid modes.
[0009] In the electric mode, the power-split hybrid system propels
the vehicle utilizing only stored electrical energy and the engine
is turned off. The tractive torque is supplied from the motor, the
generator, or a combination of both. This is the preferred mode
when the desired power is low enough that it can be produced more
efficiently by the electrical system than by the engine and when
the battery is sufficiently charged. This is also a preferred mode
for reverse driving because the engine cannot provide reverse
torque to the power train in this configuration.
[0010] In the parallel hybrid mode, the engine is operating and the
generator is locked. By doing this, a fixed relationship between
the speed of the engine and the vehicle speed is established. The
motor operates as either a motor to provide tractive torque to
supplement the engine's power, or can be operated to produce
electricity as a generator. This is a preferred mode whenever the
required power demand requires engine operation and the required
driving power is approximately equal to an optimized operating
condition of the engine. This mode is especially suitable for
cruising speeds exclusively maintainable by the small internal
combustion engine fitted to the hybrid electric vehicle.
[0011] In a positive split hybrid mode, the engine is on and its
power is split between a direct mechanical path to the drive train
and an electrical path through the generator. The engine speed in
this mode is typically higher than the engine speed in the parallel
mode, thus deriving higher engine power. The electrical energy
produced by the generator can flow to the battery for storage or to
the motor for immediate utilization. In the positive split mode,
the motor can be operated as either a motor to provide tractive
torque to supplement the engine's power or to produce electricity
supplementally with the generator. This is the preferred mode
whenever high engine power is required for tractive powering of the
vehicle, such as when high magnitude acceleration is called for, as
in passing or uphill ascents. This is also a preferred mode when
the battery is charging.
[0012] In a negative split hybrid mode, the engine is in operation
and the generator is being used as a motor against the engine to
reduce its speed. Consequently, engine speed, and therefore engine
power, are lower than in parallel mode. If needed, the motor can
also be operated to provide tractive torque to the drive train or
to generate electricity therefrom. This mode is typically never
preferred due to increased losses at the generator and planetary
gear system, but will be utilized when engine power is required to
be decreased below that which would otherwise be produced in
parallel mode. This situation will typically be brought about
because the battery is in a well charged condition and/or there is
low tractive power demand. In this regard, whether operating as a
generator or motor, the toque output of the generator is always of
the same sense (+/-); that is, having a torque that is always
directionally opposed to that of the engine. The sign of the speed
of the generator, however, alternates between negative and positive
values depending upon the direction of rotation of its rotary
shaft, which corresponds with generator vs. motor modes. Because
power is dependent upon the sense of the speed (torque remains of
the same sense), the power will be considered to be positive when
the generator is acting as a generator and negative when the
generator is acting as a motor.
[0013] When desiring to slow the speed of the engine, the current
being supplied to the generator is changed causing the speed of the
generator to slow. Through the planetary gear set, this in turn
slows the engine. This effect is accomplished because the resistive
force acting against the torque of the generator is less at the
engine than at the drive shaft which is connected to the wheels and
is being influenced by the entire mass of the vehicle. It should be
appreciated that the change in speed of the generator is not equal,
but instead proportional to that of the engine because of gearing
ratios involved within the connection therebetween.
[0014] In electric and hybrid electric vehicles, large capacity
electricity storage device(s), usually in the form of battery
packs, are required. By conventional design, these batteries
include a plurality of cylindrical battery cells that are
collectively utilized to obtain sufficient performance and range in
the vehicle. Typically, batteries are positioned within the vehicle
in a compartment configured to protect against damage and to
prevent the cells, and mostly their acidic contents, from causing
injury or damage, especially in the event of a crash. When stored
in these typically confined compartment(s), heat buildup generated
from use and/or charging affects the endurance of the batteries,
and in some circumstances can destroy individual battery cells.
Traditional cooling of the batteries and the battery compartment
requires increasing the volume of the compartment for air cooling
and/or running cooling hoses to external radiators.
[0015] Typically, to achieve a smooth engine start in a hybrid
electric vehicle in which the engine is mechanically interconnected
with the drive wheels, the start of engine fuel injection and
ignition are made at revolutionary speeds above any mechanical
resonance speeds of the drive train. Additionally, at full take-off
acceleration, any delay in the engine's production of power
typically decreases engine performance. Still further, to achieve
smooth driving characteristics and obtain low fuel consumption, the
engine torque and speed change rates must be limited. At full
take-off, this usually results in an increased time period for the
engine to reach maximum power, and all of these conditions
deteriorate acceleration performance of the vehicle.
[0016] As can be appreciated, the engine is not always running
during vehicle operation. If the engine is stopped for a
sufficiently long period during the operation of the vehicle, the
exhaust system catalyst may cool down too much, and to such a
degree that a temporary, but significant increase in exhaust
emissions occur upon restart and until the catalyst once again
warms to its effective temperature.
[0017] In another aspect, the battery state-of-charge (SOC) in a
hybrid electric vehicle is typically controlled using SOC feedback
control. When applying SOC feedback control, however, and when the
vehicle is operating in a low velocity region, the SOC feedback
control tends to grow unstable as velocity increases. Instability
also occurs when the vehicle is operating at high velocity and the
velocity of the vehicle then decreases. The same instability or
weakness can still occur even when using "feed-forward" type
estimating of required tractive force; the same being a typical
complement to SOC feedback control. This is particularly true at
low vehicle velocities with velocity increases and at high vehicle
velocities with velocity decreases. Even when properly designed,
the SOC feedback control can also be weak at full take-off.
[0018] In a typical power-split hybrid electric propulsion
arrangement, the control strategy advantageously involves operating
the engine along optimum efficiency torque vs. speed curves. A
trade-off exists between traction force performance and fuel
economy which, for optimization, typically requires selection of a
particular gear ratio between the engine and the wheels that causes
the engine to deliver more power than is needed for vehicle
propulsion. This generally occurs at cruising in parallel mode, or
near constant vehicle velocity conditions. Operation under these
conditions can, sometimes, cause the battery and charging system to
reject energy being presented thereto from the engine. This problem
is generally solved by decreasing or limiting the engine output
power by entering negative split mode which entails using the
generator as a motor to control the engine to a decreased speed.
Such control allows the engine to follow an optimum curve at
reduced engine output power.
[0019] Use of the generator as a motor gives rise to a power
circulation in the power-train which leads to undesirable energy
losses at the generator, motor, inverters and/or planetary gear
set. These energy losses may be manifest as heat generation which
indicates that most efficient use is not being made of the
installed drive train.
[0020] In a power-split hybrid propulsion system having planetary
gear set(s) and utilizing a generator lock-up device, a harshness
in ride occurs when the generator lock-up device is engaged or
released. This is due primarily to the difference in how engine
torque is estimated when the vehicle is in different operating
modes. Typically, when the generator is locked up, engine torque is
estimated from the combustion control process of the engine. When
the generator is free, as in split mode, however, engine torque is
estimated from the generator torque control process. The difference
in values of these two estimating techniques gives rise to what
usually amounts to a variation in operating torque between the
engine and generator when the lock-up device is engaged or
disengaged, thereby creating harshness in the vehicle's operation,
usually manifest as abrupt changes or jerkiness in the vehicle's
ride.
[0021] As earlier indicated, the generator is typically used to
control the engine in power-split hybrid mode. This is usually
accomplished by employing a generator having maximum torque
capabilities substantially greater than the engine's maximum torque
that is transmittable to the planetary gear system. Failure to have
such a control margin can result in generator over-speed and
possible damage to the propulsion system. Such a control margin
means, however, that the engine and generator are not fully
exploited at full capacity acceleration.
[0022] Several deficiencies associated with the use of known hybrid
electric vehicle designs and methods of operating the same have
been described hereinabove. Several inventive arrangements and
methods for operating hybrid electric vehicles are described
hereinbelow that minimize, or remedy these deficient aspects of
known designs, and/or provide benefits, in and of themselves, to
the user. These new, improved and otherwise potentiated solutions
are described in greater detail hereinbelow with respect to several
alternative embodiments of the present invention.
DISCLOSURE OF THE INVENTION
[0023] In a first aspect, an arrangement for a compact battery and
cooling system therefore is disclosed. The arrangement includes a
plurality of elongate battery cells, each battery cell having a
longitudinal axis and a hexagonal cross-sectional shape in a plane
oriented substantially perpendicular to the longitudinal axis. The
cells are parallelly oriented, each to the others, within a battery
housing. Preferably, the cells are arranged in a honeycomb
configuration with opposed faces of adjacent battery cells
proximately located one to the other in face-to-face relationship.
At least one substantially hexagonally shaped cooling channel is
provided at an interior location within the plurality of battery
cells.
[0024] In a second aspect, a method for potentiating an engine's
power contribution to a hybrid electric vehicle's performance in a
take-off operating condition is disclosed. Normally, fuel injection
to, and ignition at the engine are only commenced when the engine
is operating at a speed exceeding the resonance speed of the drive
train to reduce engine start harshness; such resonance speeds of
the drive train being dictated, at least in part, by transmission
backlash, softness and the like. During high driver acceleration
demands, however, ignition and the injection of fuel is desirably
started as early as possible to potentiate output power and
acceleration.
[0025] In a third aspect, a method for maintaining a catalyst of an
emissions system in a hybrid electric vehicle in an operative
condition is disclosed. The method includes sensing that an engine
of a hybrid electric vehicle has stopped operating. A time period
is predicted after which a catalyst of an emissions system
associated with the engine will cool to a light-off temperature
below which the catalyst becomes ineffective. The predicting step
is based on known qualities of the catalyst and ambient conditions
in which the vehicle is being operated. The engine is restarted
when the predicted time period has expired thereby maintaining the
catalyst at temperatures in excess of the light-off
temperature.
[0026] In a fourth aspect, a method for minimizing driver
perceptible drive train disturbances during take-off in a hybrid
electric vehicle when maximized power is often desired is
disclosed. The method includes sensing an actual state-of-charge
(SOC) value of a battery in a hybrid electric vehicle and a
traveling velocity of the vehicle during take-off operation. The
sensed actual SOC value is compared with a SOC reference value and
computing a delta SOC value as a difference therebetween. A
velocity-based SOC calibration factor is looked up that corresponds
to the traveling velocity of the vehicle. A combination is utilized
of the delta SOC value and the SOC calibration factor as a SOC
feedback engine speed control instruction to an engine controller
of the hybrid electric vehicle. A driver's desired vehicular
acceleration is sensed based on accelerator position. Maximum
possible engine power generatable at the sensed vehicle speed is
determined, as is a required power value from the power train of
the vehicle to meet the driver's desired vehicular acceleration.
The maximum possible engine power generatable at the sensed vehicle
speed is compared with the required power value and computing a
delta power train requirement value as a difference therebetween. A
velocity-based and accelerator position-based power calibration
factor is looked-up that corresponds to the traveling velocity of
the vehicle and the accelerator position. A combination of the
delta power train requirement value and the power calibration
factor is utilized as a power requirement feed-forward engine speed
control instruction to an engine controller of the hybrid electric
vehicle.
[0027] In a fifth aspect, a method for optimizing the operational
efficiency of a hybrid electric vehicle is disclosed. The method
comprises operating an engine of a hybrid electric vehicle
preferentially on an optimized power curve of the engine for
maximizing the efficiency of the engine and sensing a
state-of-charge (SOC) condition of a battery of the hybrid electric
vehicle being at a preferential value indicative of no additional
charging being desired. The running torque of the engine is reduced
below the optimized torque curve to a point that the power produced
by the engine is substantially equal to the power demanded for
driving the hybrid electric vehicle.
[0028] In a sixth aspect, a method for calibrating and
synchronizing sensed operating torques of an engine and a generator
in a planetary gear based hybrid electric vehicle is disclosed. The
method includes providing a sensor that detects the operational
torque of an engine of a hybrid electric vehicle at the engine's
interface with a planetary gear system of the hybrid electric
vehicle. A sensor is provided that detects the operational torque
of a generator of a hybrid electric vehicle at the motor's
interface with the planetary gear system of the hybrid electric
vehicle. The planetary gear system of the hybrid electric vehicle
is operated in a split mode so that the generator is directly
linked to the engine and a reading of the sensor that detects the
operational torque of the generator may be used to compute the
operating torque of the engine. Paired values of sensed operational
torques of the engine and the generator at like times are recorded.
Each pair of recorded values are arithmetically processed and a
calibrating value is computed therebetween. The sensing and
recording of paired values is repeated at the same sensed generator
and engine speeds and torques thereby enabling the calculation of
computed average calibrating values at each of the particular
sensed generator speeds suitable for subsequent utilization in
computing corresponding engine torques in the future. The engine
and the generator are controlled utilizing the average calibrating
value at future times of transition between power-split mode and
parallel mode of the planetary gear system so that the engine is
substantially synchronized with the generator at the time of direct
linkage across the planetary gear arrangement thereby avoiding
driver detectible irregularities in the performance of the power
train of the hybrid electric vehicle.
[0029] In a seventh aspect, a method for potentiating the
utilizable torque output capacity of a hybrid electric vehicle is
disclosed. The method includes controlling operation of an engine
of a hybrid electric vehicle using a generator, the engine and
generator being interconnected through a planetary gear system, the
generator having approximately equal torque output capacity as the
engine based on connective gear ratio selection. An engine
controller is utilized for managing the engine's operation thereby
permitting the engine to be operated at a torque output level
substantially equal to the maximum torque output of the generator
without a significant margin of excess control capacity of the
generator over the engine. An overpower condition is detected in
which the torque output of the engine is surpassing the maximum
torque output of the generator. The engine is controlled to a
torque output that is less than the maximum torque output of the
generator.
[0030] The general beneficial effects described above apply
generally to the exemplary descriptions and characterizations of
the devices, mechanisms and methods disclosed herein. The specific
structures and steps through which these benefits are delivered
will be described in detail hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the following, the invention will be described in greater
detail by way of examples and with reference to the attached
drawings, in which:
[0032] FIG. 1 is a graphical comparison of torque generated by a
parallel hybrid and systems that have either an engine or
motor.
[0033] FIG. 2 is a perspective of a hybrid electric vehicle showing
exemplarily system component locations on the vehicle.
[0034] FIG. 3 is a schematic depicting the architecture of a
power-split hybrid electric vehicle.
[0035] FIG. 4 is a cross-sectional schematic representation of a
planetary gear set.
[0036] FIG. 5 is a simplified schematic view of a one-way clutch
shown in FIG. 2.
[0037] FIG. 6 is a schematic depicting control relationships
between the various systems of a hybrid electric vehicle as
coordinated utilizing the CAN.
[0038] FIG. 7 is a functional schematic depicting the processes,
tasks and controls of the various systems of the exemplary hybrid
electric vehicle.
[0039] FIG. 8a is a schematic horizontal cross-sectional view of a
battery for a hybrid electric vehicle according to one aspect of
the present invention(s).
[0040] FIG. 8b is a schematic horizontal cross-sectional view of a
traditional battery having cylindrically-shaped cells.
[0041] FIG. 8c is a schematic vertical cross-sectional view of a
battery cooling system as depicted in FIG. 8a.
[0042] FIGS. 9 and 10 schematically illustrate a method for
minimizing driver perceptible drive train disturbances during
take-off in a hybrid electric vehicle.
[0043] FIGS. 11 through 15 schematically illustrate a method for
potentiating the utilizable torque output of a particularly sized
engine in a hybrid electric vehicle.
MODE(S) FOR CARRYING OUT THE INVENTION
[0044] As required, detailed embodiments of the present invention
are disclosed herein; however, it is to be understood that the
disclosed embodiments are merely exemplary of the invention(s) that
may be embodied in various and alternative forms. The figures are
not necessarily to scale; some features may be exaggerated or
minimized to show details of particular components. Therefore,
specific structural and functional details disclosed herein are not
to be interpreted as limiting, but merely as a basis for the claims
and as a representative basis for teaching one skilled in the art
to variously employ the present invention.
[0045] As depicted in FIGS. 1 and 2, a hybrid electric transporting
vehicle 10 has a power train system (having components generally
designated with reference numbers from the 500's series) included
therein for providing propulsion, as well as serving supplemental
functions which are described in greater detail herein.
Predominantly, the power train system is positioned in an engine
room 11 located near a passenger compartment 12 of the vehicle 10.
A battery compartment or housing 14, also positioned near the
passenger compartment 12 holds one or more batteries 410. As will
be appreciated by those skilled in the art, the positioning of both
the engine room 11 and battery housing 14 is not limited to the
locations set forth in FIG. 2. For example, either may be
positioned in front of, or behind the passenger compartment 12.
[0046] As depicted in FIG. 2, the overall systems architecture of
the electric hybrid vehicle 10 comprises an engine system 510,
including an internal combustion engine 511 (petrol, diesel or the
like), that is mechanically connected by an output shaft system 520
to a transaxle system 530. The transaxle system 530 is further
connected to a drive shaft system 540 utilized to rotate one or
more drive wheels 20 that propel the hybrid electric transporting
vehicle 10. In a preferred embodiment, the combustion engine 511 is
controlled by an engine control module (ECM) or unit 220 which is
capable of adjusting, among possible parameters, airflow to, fuel
flow to and/or ignition at the engine 511. The engine 511 is
mechanically connected via an output shaft 522 to the transaxle
system 530. A planetary gear set 535 establishes interconnection
between the engine 511 (via the output shaft 522), a generator 532,
and the drive shaft system 540 (via the transaxle system 530). A
motor 531 is also coupled to the drive shaft system 540, also
possibly via the transaxle system 530.
[0047] In one embodiment, and which is illustrated in at least
FIGS. 3 and 5, a one way clutch 521 is engageable with the output
shaft 522, which in turn is connect to the engine 511 and to the
planetary gear set 535. The function of the one-way clutch 521 is
to limit the engine to being only a power/torque input to the
planetary gear set 535, and with only one direction of rotation.
Consequently, the one-way clutch 521 prevents power or torque from
being transmitted from the planetary gear set 535 back to the
engine 511.
[0048] In another aspect, and as shown in FIG. 4, the planetary
gear set 535 comprises a plurality of concentrically positioned
planet gears 539 mechanically engaged between a perimeter region of
a centrally located sun gear 538 and an interior surface of a ring
gear 537. The individual gears that make up the plurality or set of
planet gears 539 are fixed in positions relative to each other by a
planetary carrier 536.
[0049] The generator 532 is mechanically connected to the sun gear
538 and is configured to convey rotational power and torque to and
from the planetary gear set 535. In a preferred embodiment, the
generator 532 is capable of being locked to prevent rotation of the
sun gear 538 by a generator brake or lock-up device 533. As further
contemplated by the present invention, the motor 531 is
mechanically connected to the ring gear 537 and is configured to
convey rotational power and torque to and from the planetary gear
set 535. In a preferred embodiment, and as schematically shown in
FIG. 3, the drive shaft system 540 is engagable with the motor 531
and effectively terminates at the drive wheel 20, via what can be a
conventionally configured transmission/differential arrangement
542.
[0050] Based on the above disclosed system architecture,
implementation of an energy management strategy, which is a focus
of the hybrid electric vehicle 10, starts at a high level within a
vehicle control unit or vehicle systems controller (VCU) 100 as
schematically shown in FIGS. 6 and 7. The vehicle systems
controller 100 is programmed with control strategies for the drive
train system and battery system, as well as others. The vehicle
systems controller 100 is responsible for interpreting driver
inputs, coordinating the component controllers, and determining
vehicle system operating states. The VCU 100 also generates
commands to appropriate component sub-sytems based on defined
vehicle systems controller 100 functions, and sends those commands
to the component controllers that, based thereon, take appropriate
actions. The vehicle systems controller 100 also acts as a
reference signal generator for the sub-system controllers. The
vehicle systems controller 100 may take the form of a single,
integrated microprocessor, or comprise multiple microprocessors
that are suitably interconnected and coordinated.
[0051] A primary function of the vehicle systems controller 100 is
to carry out vehicle mode processes and tasks (also known as the
sequential control process), as well as make torque determinations,
set reference values and perform energy management processes.
Certain systems of the vehicle 10 are managed or monitored by a
vehicle management (VM) unit or controller 105 which carries out
sequential control processes, including ascertaining the position
of the vehicle key and gear selector positioning, among others. It
is at this level that certain inputs from the driver and conditions
of the vehicle are synthesized for utilization as command inputs
for sub-system controllers.
[0052] At the lower level of the VCU 100, three sub-component
controllers are illustrated in FIG. 7. The first is a high voltage
DC controller (HVDC) 115; the second is a battery management unit
or controller 110 (bbb); and the third is a drive train controller
120 (DTC). As indicated above, certain inputs and processes are
taken from the driver and the vehicle's systems at the vehicle
management unit 105. Conversely, certain outputs relevant to the
driver will be transmitted and displayed at the dashboard display
unit 107 from the VCU 100 or the VM 105.
[0053] The HVDC 115 is responsible for coordinating operation of
the high voltage components. The positioning of this controller is
schematically shown in FIG. 6. The HVDC contains contactors or
breakers which are normally positioned to an open configuration
that prevents electricity from flowing thereacross. But when called
on to take action and engage the battery 410, for instance when
starting of the engine 511 is required, these contractors (usually
a pair) close completing an appropriate connective circuit.
[0054] As shown in FIG. 6, the HVDC serves as a shield or buffer
between the high voltage battery 410, and the inverters 534, as
well as other auxiliary loads run off of the electric power of the
battery 410. An example of such a high voltage auxiliary load may
include an electrically run air-conditioning compressor system. In
order to act as such a buffer, the high voltage output from the
battery 410 must be relatively slowly "brought-up" to operating
levels at the inverter 534 and/or auxiliary loads. In order to
accept this "run-up" of the voltage, relatively small capacity
contactors are initially closed that cause voltage from the battery
to pass to a capacitor in either the inverter 534 or the
appropriate auxiliary load, across a resistive circuit (a circuit
containing buffering resistors). Once an appropriate pre-charge is
built-up in the capacitor, primary contractors are then closed
which complete the high voltage circuit between the batteries 410
and the capacitor contained within the receiving component which
may be exemplified by the DC to AC inverter(s) 534, or an auxiliary
load such as an electric air-conditioning system as indicated
hereinabove. In this manner, a potentially damaging high voltage is
prevented from being introduced too quickly to the receiving
components.
[0055] The HVDC 115 also carries out certain diagnostic functions
regarding the components of the HVDC 115, such as the contactors
within the HVDC 115 itself, and also possibly the several systems
interconnected through the HVDC, such as the battery 410, the
inverters 534, or an electrically driven air-conditioning
compressor which has not been illustrated in the Figures. Among
other parameters, these diagnostics may be performed based on
measurements of voltage and/or current.
[0056] The HVDC 115 also provides interconnection between an
exterior charger connection (see ext. charger in FIG. 6), thereby
allowing the battery 410 to be "plugged-in" for charging from an
external power source.
[0057] The battery management controller (BMU) 110 handles control
tasks relative to the battery system 410. Among other
characteristics, the BMU 110 can estimate and measure
state-of-charge (SOC) levels, and voltage and current parameters.
It can also sense/determine and maintain maximum and minimum
voltage and current levels with respect to the battery 410. Based
on these determinations or sensed quantities/qualities, the VM 105,
via such control modules as the DTC 120, can direct certain
operations for affecting changes in the SOC of the battery 410.
Other characteristics which may be monitored include operating
temperature(s) of the battery 410, and voltages at the individual
battery cells 412. Similarly, pressure within the cells 412 can
also be monitored. Failures may be detected and reported, at least
back to the VCU; but there is also the possibility of the
information being passed to the operator via the dashboard display
unit 107.
[0058] The DTC 120 makes the mode selection under which the several
powering components will cooperate. That includes choices between
parallel and split modes, as well as positive and negative split
modes. The operational points for the several components of the
drive train are also specified by the DTC 120. Still further,
reference values are provided by the DTC 120 for the several
sub-sytems, including the transaxle management control modules or
unit (TMU) 230 and the engine control module or unit (ECM) 220.
From among the possible settings established by the DTC 120,
battery charging/discharging mode is a possibility, as well as
specifying whether the generator 532 and/or motor 531 should be
used in their powering capacity as a motor, or their generating
capacity as a generator. Torque references for the generator and
motor are also issued from the TMU 230.
[0059] As a sub-component under the TMU 230, the transaxle control
unit TCU 232 handles the transaxle 530 with respect to torque
compensation when starting and stopping the engine 511. The TCU 232
uses and controls two slave processors characterized as a generator
control unit GCU 236 and a motor control unit MCU 234. The GCU 236
handles the current and torque control of the generator 532;
typically, via the inverter 534. The GCU 236 receives its torque
and speed reference information from the TCU 232 as its immediate
controller. The TCU 232 receives a total torque reference for the
transaxle 530 and the speed reference value for the engine 511,
together with mode reference information regarding cooperation
between the engine 511 and generator 532; such as, whether
parallel-, positive-split, or negative-split mode configurations
will be assumed. The TCU 232 generates the torque reference
parameters for the generator 532 and motor 531, each of which are
implemented under the control of the GCU 236 and MCU 234,
respectively. The specified torque settings are accomplished by
controlling the current provided to the respective generator/motor
controllers 236,234.
[0060] Based on a map of optimal engine torque vs. speed curves,
engine speed and torque are selected by the DTC 120 so that the
engine system 510 can deliver the desired engine power and
simultaneously lie on one of the engine's optimized efficient
curves. If the DTC 120 determines that the speed of the engine 511
is too low for efficient operation, then the engine 511 is turned
(or left) off by the engine control unit 220. If the power train
control module 120 determines that the speed of the engine 511 is
too high to be controlled by the generator 532 (based on SOC and
generator limitations), the engine 511 is set to a slowed
operational speed by the ECM 220.
[0061] Once the speed, torque and power of the engine 511 are
determined by the vehicle systems controller 100, particularly at
the DTC 120 of the controller 100, then the DTC 120 further
determines the required speed and torque of the generator 532 to
control the engine 511. The DTC 120, using this information, then
determines the required speed and torque of the motor 531 to meet
the difference, if any, between driver power (torque) demand and
the engine power (torque).
[0062] Torque determination and monitoring is also carried out at
the VCU 100. This function further ensures that torque delivered to
the drive wheel(s) 20 is substantially equal to the torque
(acceleration) demanded by the driver. The VCU 100 also monitors
and controls the torque from the engine 511 and transaxle system
530 by comparing a sensed torque against the torque demanded by the
driver. Torque management by the VCU 100 interprets driver inputs
and speed control demands to determine regenerative brake torque
and desired output shaft torque.
[0063] From the VCU 100, commands and references are distributed
over a controller area network (CAN) 300 to component controllers
generally referenced herein utilizing reference numbers in the
200's series. As indicated above, these controllers include the ECM
220 and the TMU 230 that together control the power train system to
achieve efficient energy management, partition torque, determine
engine 511 operating point(s), and decide on, and coordinate engine
511 start/stops. Commands and references from the VCU 100 to a
series regenerative brake controller determine regeneration torque
limitations, desired regenerative torque and zero vehicle speed
control.
[0064] Finally, if and/or when individual system components are
rendered inoperative, such as the motor 531 becomes disabled, the
VCU 100 is configured to provide limited operating control over the
power train system to allow the hybrid engine vehicle 10 to "limp"
home.
[0065] As shown in FIG. 8a, a compact battery system 400 is made up
of a number of elongate battery cells 412, each cell 412 having a
longitudinal axis and a hexagonal cross-section shape in a plane
oriented substantially perpendicular to the longitudinal axis. Each
cell 412 is parallelly oriented to each other within a battery
housing 14. As shown in FIG. 8a, the plurality of cells 412 are
arranged in a honeycomb configuration with opposed faces of
adjacent cells 412 proximately located one to the other in
face-to-face relationship. One or more hexagonally shaped cooling
channels 442 are located at an interior location(s) amongst the
plurality of battery cells 412. As appreciated by those skilled in
the art, a significant amount of volume is unused and wasted in
battery compartments configured to hold traditional cylindrical
battery cells as is exemplarily depicted in FIG. 8b. Furthermore,
the traditional cooling system often requires the use of a system
of fluid filled pipes to cool a fraction of the cylindrically
shaped battery cells' curved exterior surface. In contrast, the
battery cooling system 440 for the hexagonal battery cells 412, as
depicted in FIG. 8a, presents a greater surface area for heat
exchange to take place.
[0066] In another aspect of the system 440, and as is shown in FIG.
8c, a thermally radiative cap 443 is in fluid communication with
one or more of the cooling channels 442 which is filled with a
cooling fluid 445 that circulates between the cap 443 and the
channels 442 to cool the battery cells 412. The cooling fluid 445
may consist of water maintained under a vacuum so that it boils at
approximately 40.degree. centigrade. Circulation of the fluid, as
well as transformation between the gaseous and liquid states,
occurs because of the temperature differential between the warmer
lower area among the battery cells 412 and the cooler upper area
with the cap 443. Exemplarily, this temperature of vaporization or
boiling advantageously falls between these warmer and cooler
temperatures.
[0067] An air circulation system cools the battery arrangement by
drawing air through an air inlet exposed to the passenger
compartment 12 and directs the air along a circulation path that
crosses the radiative cap 443. The temperature of the air drawn
from the passenger compartment 12 is normally in a range suited for
passenger comfort, a temperature normally well below 40.degree.
centigrade. The intake may also pull air from outside the vehicle
if ambient conditions are favorable. Air source selection may be
easily accomplished using a flap-style valve common in other air
duct environments.
[0068] After traversing the circulation path, the cooling air is
most preferably discharged away from the passenger compartment 12
to avoid circulation and the introduction of heat and potentially
airborne contaminants into the passenger compartment 12 that may
have been picked up from the battery system 400. The risk of this
occurrence, however, is reduced significantly through this
battery's 410 configuration in which the circulated air passes over
the closed system of the battery and its housing, and not through
or near the more hazardous chemical cells 412.
[0069] To further promote cooling, the radiative cap 443 may be
configured with a plurality of fin-type members 444 that extend
from an exteriorly exposed surface thereof for enhancing thermal
discharge of heat from the cap 443 to air circulated across the
fins 444.
[0070] In another aspect, the disclosed invention(s) include a
method for potentiating an engine's 511 power contribution to a
hybrid electric vehicle's 10 performance in a take-off operating
condition. Normally, fuel injection to, and ignition at the engine
511 are only commenced when the engine 511 is operating at a speed
exceeding the resonance speed of the drive train to reduce engine
start harshness; such resonance speeds of the drive train being
dictated, at least in part, by transmission backlash, softness and
the like. During high driver acceleration demands, however,
ignition and the injection of fuel is desirably started as early as
possible to potentiate output power and acceleration. The present
method amends this typical operation and includes initiating
take-off acceleration of the vehicle 10 exclusively using the motor
531, predicting the future demand for an engine's 511 power
contribution to the vehicle's 10 immediate future power demand
during the take-off acceleration, and starting the engine 511 at
the time that the determination is made of future demand for the
engine's 511 power contribution during the take-off acceleration.
This full take-off control method or process further includes
making the prediction of future demand at the initiation of
take-off acceleration and/or increasing the speed of engine 511
operation as rapidly as predetermined operating efficiency
parameters permit. The full take-off control method which increases
the speed of engine 511 operation as rapidly as predetermined
operating efficiency parameters permit may also include a step of
allowing the increase in speed of engine operation to progress to a
predetermined peak efficiency rate and diverting excess power from
the engine 511 to the generator 532 that generates electricity with
the diverted power. This full take-off control method which
increases the speed of the engine 511 operation as rapidly as
predetermined operating efficiency parameters permit, may also
include a step of allowing the increase in speed of engine 511
operation to progress to a predetermined peak efficiency rate which
enables exclusive utilization of the engine 511 to meet the
entirety of the vehicle's 10 future power demand and reducing the
motor's 531 contribution to the power supplied to the vehicle 10 so
that no excess power above demand is supplied by the engine
511.
[0071] In still a further aspect, the present invention provides a
process or method for maintaining a catalyst 702 of an emissions
system 700 in a hybrid electric propulsive system in an operative
state. The method calls for sensing that the engine 511 has stopped
operating. A time period is then predicted after which the catalyst
702 will cool down below a temperature (also known as a light-off
temperature) at which the catalyst becomes ineffective. Pursuant
thereto, the engine 511 is restarted when the time period has
expired or lapsed, thereby maintaining the catalyst 702 at
temperatures in excess of the light-off temperature, regardless of
whether power is need from the engine 511 at that time. Predicting
the time period after which the catalyst 702 will cool down takes
into consideration known qualities of the catalyst 702 and ambient
conditions in which the hybrid electric vehicle 10 is being
operated. Such known qualities of the catalyst 702 include, but are
not limited to, heating and cooling characteristics of the catalyst
702, life expectancy of the catalyst 702, and age of the catalyst
702. Relevant ambient conditions in which the vehicle 10 is being
operated include, but are not limited to, weather and environmental
conditions such as temperature, humidity and contaminant loads, as
well as traffic conditions and road conditions. As an example, if
driving is occurring in hilly terrain, this can be sensed as a
cyclical demand for engine power for recurring uphill climbs. If
this is quantified, it may be considered in the control parameter
as a predictable occurrence. Additionally, the system may take into
account sensed or "learned" driver habits or performance for
predicting purposes which can include the a particular driver's
demand for power is cyclical or otherwise patterned. This may be
typified by some drivers' bad habit of repeatedly accelerating to a
speed, and then subsequently slowing therefrom. When the decrease
in speed is realized by the driver, rapid acceleration is then
demanded for again setting the desired travel speed. If the control
system "learns" such a pattern, it may be utilized in the
predicting or calculating process for maximum elapse time before
the catalyst excessively cools.
[0072] This method for maintaining the exhaust catalyst 702 in an
operative condition may also include sensing the catalyst's 702
temperature and initiating operation or stopping of the engine 511
when a predetermined temperature is detected. Because of the
hybrid's 10 characteristics, the catalyst maintenance process may
further include running the engine 511 at idle speed when
temperature elevation is required and charging the batteries 410
with the power produced from the idling engine 511. An alternative
aspect to this process calls for heating the catalyst 702 to a
predetermined temperature differential above the light-off
temperature and then stopping operation of the engine 511 when the
predetermined temperature differential is achieved. Engine
operation is stopped when the predetermined temperature
differential is detected by a temperature sensor 704 monitoring the
temperature of the catalyst 702 or is predicted by a catalyst
temperature model.
[0073] A method for minimizing driver perceptible drive train
disturbances during take-off driving in a hybrid electric vehicle
10 when maximized power is often desired is also described herein.
The concepts of this method are illustrated in FIGS. 9 and 10. The
method includes sensing an actual state-of-charge (SOC) value of
the battery 410 in a hybrid electric vehicle 10 and a traveling
velocity of the vehicle 10 during take-off operation. The sensed
actual SOC value is compared with a SOC reference value and a delta
SOC value is computed as a difference therebetween. A
velocity-based SOC calibration factor corresponding to the
traveling velocity of the vehicle 10 is obtained from a look-up
table maintained in the control system. A combination of the delta
SOC value and the SOC calibration factor are utilized as a SOC
feedback engine speed control instruction to the engine control
unit (ECM) 220 of the hybrid electric vehicle 10. A driver's
desired vehicular acceleration based on accelerator position is
also sensed. A maximum possible engine power generatable at the
sensed vehicle speed is determined, as is a required power value
from the power train of the vehicle to meet the driver's desired
vehicular acceleration. The maximum possible engine power
generatable at the sensed vehicle speed is compared with the
required power value and a delta power train requirement value is
computed as a difference therebetween. A velocity-based and
accelerator position-based power calibration factor corresponding
to the traveling velocity of the vehicle and the accelerator
position is determined from a second look-up table. A combination
of the delta power train requirement value and the power
calibration factor is utilized as a power requirement feed-forward
engine speed control instruction to the engine controller 220 of
the hybrid electric vehicle 10.
[0074] The combination of the delta SOC value and the SOC
calibration factor is by multiplication, as is the combination of
the delta power train requirement value and the power calibration
factor is by multiplication.
[0075] In a separate or enhancing aspect of the method outlined
immediately above, a takeoff vehicle operating condition is
detected in which maximized power is likely to be demanded from the
drive train of the hybrid electric vehicle 10. A sensed SOC
discharge condition during the take-off operation due to motor
utilization of battery power is prevented from triggering a battery
charging condition which would reduce engine torque available to
power the drive train of the vehicle 10. Alternatively, and/or
additionally, immediate acceleration of the engine's 511 operation
beyond an optimized operational speed in anticipation of an actual
maximized power demand is initiated. Still further, a command may
be issued from a generator controller (GCU) 236, responsive to a
sensed SOC discharge condition, instructing immediate acceleration
of the engine's 511 operation beyond an optimized operational speed
thereby minimizing discharge of the battery 410 or commencing
recharge of the battery 410.
[0076] A preferred SOC reference value, of exemplarily, but not
necessarily, fifty percent of battery 410 total charge capacity, is
utilized in at least one embodiment of the invention; on others, a
more lenient range of forty to sixty percent of battery total
charge capacity may be observed.
[0077] In another aspect, the invention takes the form of a method
for optimizing the operational efficiency of a hybrid electric
vehicle 10. The method includes operating an engine 511 of a hybrid
electric vehicle 10 preferentially on an optimized power curve of
the engine 511 for maximizing the efficiency of the engine 511. A
state-of-charge (SOC) condition of a battery 410 of the hybrid
electric vehicle 10 is sensed and constitutes a preferential value
indicative of no additional charging being desired. At cruising,
however, the engine power output in parallel mode is too large
along the engine's 511 optimized power curve, particularly in view
of gear ratios set by acceleration requirements. Instead of using
negative-split mode and suffering the inherent losses of that
configuration, the running torque of the engine 511 in parallel
mode is reduced to a level below the optimized torque curve to a
point that the power produced by the engine 511 is substantially
equal to the power demanded for driving the hybrid electric vehicle
10.
[0078] The reduction in engine torque is affected by adjusting
airflow to, fuel flow to and/or ignition parameters of the engine
511.
[0079] The drive train of the hybrid electric vehicle 10 is thus
reconfigured from a negative power-split mode in which engine power
is split through a planetary gear arrangement 535 between the drive
wheels 20 and the generator 532 to a parallel mode in which the
generator 532 is locked and all engine power is output to the drive
wheels 20 of the hybrid electric vehicle 10 through the planetary
gear arrangement 535. This parallel mode, but with reduced and
non-optimized engine operation, is used when efficiency is higher
in this mode than if using negative split mode for the same torque
output.
[0080] As a goal, the time spent in negative power-split mode is
minimized and time spent in parallel mode is maximized. Utilization
of the generator to motor the engine 511 to a slowed operational
speed is avoided using this process thereby avoiding sequential
charge and discharge cycles through the drive train components of
the hybrid vehicle. Energy losses in the power train of the hybrid
electric vehicle 10 are therefore reduced by avoiding charge and
discharge of the hybrid electric vehicle's battery system 400.
Cooling requirements for the hybrid electric vehicle's battery 410
are also reduced since battery losses are decreased.
[0081] In yet another aspect, the present invention takes the form
of a method for calibrating and synchronizing sensed operating
torques of the engine 511 and the generator 532 in a planetary gear
based hybrid electric vehicle 10. The method includes providing a
sensor that detects the operational torque of the engine 511 at the
engine's interface with the planetary gear system 535 (power-split
hybrid drive train) of the hybrid electric vehicle 10. A sensor is
provided that detects the operational torque of the generator 532
at its interface with the planetary gear system 535 of the hybrid
electric vehicle 10. The planetary gear system 535 of the hybrid
electric vehicle 10 is operated in the split mode so that the
generator 532 is directly linked to the engine 511 and a reading of
the sensor that detects the operational torque of the generator 532
may also be used to compute the operating torque of the engine 511.
Paired values of sensed operational speeds of the engine 511 and
the generator 532 at like times are recorded. Each pair of recorded
values is arithmetically processed and a calibrating value
therebetween is computed. The sensing and recording of paired
values at the same sensed generator and engine operation points is
repeated thereby enabling the calculation of computed average
calibrating values at each of the particular sensed generator and
engine speeds and torques suitable for subsequent utilization in
computing correlating engine torques in the future. The engine 511
and the generator 532 are controlled utilizing the average
calibrating value at future times of transition between power-split
mode and parallel mode of the planetary gear system 535 so that the
engine torque is substantially matched with the generator torque at
the time of direct linkage across the planetary gear arrangement
(i.e., when releasing generator lock-up), thereby avoiding driver
detectible irregularities or harshness in the performance of the
power train of the hybrid electric vehicle 10.
[0082] The predictability of the relationship between the engine
511 and generator 532 in the parallel mode is based on gear ratios
that remain substantially unchanging.
[0083] Contemporaneously measured values of complementary operating
parameters of the hybrid electric vehicle 10 may also be recorded
for each pair of recorded values of sensed operational torques of
the engine 511 and the generator 532 to be used supplementally in
the torque matching process.
[0084] To maintain trueness, the average calibration value is
permitted to be varied by a limited maximum value with respect to
time so that anomalous disturbances do not significantly impact the
computed average calibration value. The updating of the computed
average calibration value for a particular generator sensed speed
is ongoing, and continuous thereby continually improving the
quality of the average calibration value for that particular
generator sensed speed.
[0085] The irregularities to be avoided are manifest as jerking
motions induced in the hybrid electric vehicle 10 by the planetary
gear system 535. Customization of the computed average calibration
value to an individual vehicle is enabled via the invention in the
presently disclosed embodiment since histories are taken,
maintained, and considered in the matching process.
[0086] Referring to FIGS. 11-15, yet another aspect of the present
invention is disclosed. This aspect takes the form of a method for
potentiating the utilizable torque output capacity of a hybrid
electric vehicle 10. The method includes controlling operation of
the engine 511 of the hybrid electric vehicle 10 using the
generator 532, the engine 511 and generator 532 being
interconnected through the planetary gear system 535. The generator
532 has approximately equal torque output capacity as the engine
511 when connecting gear ratios are considered. An engine
controller 220 is utilized for managing the engine's 511 operation
thereby permitting the engine 511 to be operated at a torque output
level substantially equal to the maximum torque output of the
generator 532 without a significant margin of excess control
capacity of the generator 532 over the engine 511. An overpower
condition is detected in which the torque output of the engine 511
is surpassing the maximum torque output of the generator 532.
Responsively, the engine 511 is controlled to a torque output that
is less than the maximum torque output of the generator 532.
[0087] The method continues by rechecking for a continuation of the
engine overpower condition and shutting the engine 511 down if the
control actions are not sufficient and a continuing overpower
condition is detected. In this manner, generator and engine
over-speed is avoided.
[0088] By this process, total utilizable capacity of the hybrid
electric vehicle's power plant is optimized by enabling running the
engine 511 at substantially maximum capacity where greatest torque
is produced therefrom.
[0089] Available take-off torque in the hybrid electric vehicle 10
is optimized by running the engine 511 at substantially maximum
torque capacity together with a commensurately sized, but not
oversized, generator 532 with respect to relative torque
capacities. Torque output of the engine 511 and the generator 532
are calculated based on detected operational speeds of the engine
511 and the generator 532, respectively. Speed error may be
calculated utilizing one or two sensors.
[0090] In a supplemental embodiment of this general control
concept, a command is issued to increase the torque output of the
generator 532 responsively to detection of an engine 511 over power
condition. A check for the continuation of the engine overpower
condition is repeated. Then again, a continuing overpower condition
may be detected in which the torque output of the engine 511
continues to surpass the torque output of the generator 532 and a
supplemental command is issued to again increase the torque output
of the generator 532. Again, the check for a continuation of the
engine overpower condition is repeated. Ultimately, the engine
torque is reduced back to a torque output that is less than the
torque output of the generator 532 when repeated checks, of a
predetermined number, each detects an overpower condition in which
the torque output of the engine 511 surpasses the torque output of
the generator 532.
[0091] In yet another embodiment of this same basic concept, the
method includes detecting an overpower condition in which the
torque output of the engine 511 is surpassing the maximum torque
output of the generator 532; the engine 511 is responsively
controlled to a maximum torque output set at a value less than the
maximum torque output of the generator 532.
[0092] Referring now with greater specificity to the drawings,
FIGS. 11 and 12 comparatively illustrate the present method of
control which enables the elimination of a thirty percent (30%)
"buffer" that has been conventionally provided between the torque
capacities of the engine 511 and the generator 532; the necessity
of this buffer resulting in the use of generators 532 significantly
larger, or engines 511 significantly smaller than would otherwise
be optimal since thirty percent of one of their capacities must be
sacrificed to maintain the buffer margin for control, just in case
it is needed. By otherwise controlling the engine 511 so that it
can be assured that the capacity of the torque capacity of the
generator 532 will not be exceeded, the approximately thirty
percent of lost capacity can be exploited. Graphically this is
shown in FIG. 12 where the speed (.omega.), plotted on the x-axis,
is equalized at the right side of the graph where the maximum
torque of the generator (T.sub.gen.sub..sub.--.sub.max) is equal to
the torque of the engine 511 when the constant (K) representing the
gearing ratio is considered (T.sub.eng/K). The increase in useable
speed, and in turn useable power (P=T.multidot..omega.), from both
the engine 511 and generator 532 is represented by the distance
moved to the right along the x-axis from the buffered position
(K.multidot..DELTA..omega..sub.eng.sub..sub.--.sub.max) to the
"virtualized" position (K.multidot..DELTA..omega.eng.sup.--.sub.ma-
x.sub..sub.--.sub.virt) where the buffer is virtual, and not
actual, because of the control strategy exercised.
[0093] Referring now to FIGS. 13-15, the VCU 100 calculates an
engine reference value (.omega..sub.eng.sub..sub.--.sub.ref) and
the TMU 230 receives that value and, together with a sensed speed
of the motor (.omega..sub.motor), taking into account the gearing
ratio consequence, a generator reference speed
(.omega..sub.gen.sub..sub.--.sub.ref) is calculated and passed
forward for comparison, by summation, with the actual generator
speed (.omega..sub.gen). The result of that comparison is then
processed through a proportional integral controller (PI) for,
among other things, amplifying the error value and "learning" error
patterns that continue over periods of time based on historical
values. The learning process is enabled by performing repetitive
calculations. From the PI controller, a generator torque reference
(T.sub.gen.sub..sub.--.sub.ref) is derived. This reference is
passed to the generator torque controller 236 for operational
control purposes; i.e., by adjusting current, by adjusting voltage
with is accomplished using pulse width modulation using transistors
in the inverter (see FIG. 6). The same reference
(T.sub.gen.sub..sub.--.sub.ref) is further processed by subtracting
therefrom the maximum torque capacity of the generator
(T.sub.gen.sub..sub.--.sub.max(.omega..sub.gen)). The sense,
whether positive or negative, of this outcome is then determined;
if negative, the maximum torque capacity of the generator has not
been exceeded; if positive, the maximum torque capacity of the
generator has been exceeded. If positive, the capacity of the
generator is being exceeded. This positive value is then multiplied
by the constant K to take into account the effect of the gearing
ratio and thereby calculating a modification torque
(T.sub.modifictation).
[0094] To the ECM 220, an engine torque reference
(T.sub.eng.sub..sub.--.s- ub.ref) is supplied from the VCM 100. At
the ECM 220, the engine torque reference
(T.sub.eng.sub..sub.--.sub.ref) is compared to the maximum torque
of the engine (T.sub.eng.sub..sub.--.sub.max). The smaller (min) of
these two values is further processed by comparison with the
modification torque (T.sub.modifictation) which is subtracted
therefrom producing a modified engine torque reference
(T.sub.eng.sub..sub.--.sub.r- ef.sub..sub.--.sub.mod). This
reference (T.sub.eng.sub..sub.--.sub.ref.sub- ..sub.--.sub.mod) is
fed forward to the engine torque controller 220 for operational
control purposes over the engine 511; i.e., for adjusting, among
possible parameters, airflow to, fuel flow to and/or ignition at
the engine 511. In practice, if the generator 532 has not been
determined to be in a condition overpowering the engine 511 at the
TMU 230, then the engine torque reference
(T.sub.eng.sub..sub.--.sub.ref) from the VCU 100 will be processed
through to the engine 511. If, however, there is a torque
modification value (T.sub.modifictation) from the TMU 230 that is
not zero, the engine 511 will be controlled to eliminate the
condition in which the engine torque exceeds that of the generator
532.
[0095] A primary benefit of the above described arrangement is that
a single controller, the TMU 230, provides both the
(.omega..sub.gen.sub..s- ub.--.sub.ref) and the (.omega..sub.gen)
This avoids the possibility of introducing errors that are
attributable to mis-calibrations that can otherwise occur when
multiple controllers are employed for similar purposes. Still
further, a maximum engine torque limit
(T.sub.eng.sub..sub.--.sub.max.sub..sub.--.sub.lim) may be derived
at the TMU 230 to provide dc over-voltage protection, but which is
affected at the engine torque control unit 220.
[0096] In the embodiment illustrated in FIG. 14, two Pi controllers
are incorporated. In the embodiment of FIG. 15, the modified engine
torque reference
(T.sub.eng.sub..sub.--.sub.ref.sub..sub.--.sub.mod) and the maximum
engine torque limit (T.sub.eng.sub..sub.--.sub.max.sub..sub.--.su-
b.lim) are rationalized to produce the maximum engine torque limit
(T.sub.eng.sub..sub.--.sub.max.sub..sub.--.sub.lim) that will be
utilized by the engine torque controller 220.
[0097] Although the present invention has been described and
illustrated in detail, it is to be clearly understood that the same
is by way of illustration and example only, and is not to be taken
as a limitation. The spirit and scope of the present invention are
to be limited only by the terms of any claims presented
hereafter.
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