U.S. patent application number 10/413544 was filed with the patent office on 2004-10-21 for method and apparatus for adaptive control of vehicle regenerative braking.
This patent application is currently assigned to Transportation Techniques, LLC. Invention is credited to Anderson, Joshua J., Schmitz, Robert W., Wilton, Thomas F..
Application Number | 20040207350 10/413544 |
Document ID | / |
Family ID | 25008375 |
Filed Date | 2004-10-21 |
United States Patent
Application |
20040207350 |
Kind Code |
A1 |
Wilton, Thomas F. ; et
al. |
October 21, 2004 |
Method and apparatus for adaptive control of vehicle regenerative
braking
Abstract
A hybrid electric vehicle having an energy generation system, an
energy storage system and at least one electric motor includes a
controller for controlling operation of vehicle systems. The
controller monitors the status of vehicle systems and system
parameters and determines the regenerative braking mode of the
vehicle and the appropriate level of regenerative braking for
proper vehicle operation. The controller generates commands based
upon these determinations to produce regenerative braking, monitors
the status to determine the effects of the regenerative braking
command generated, and adaptively changes the regenerative braking
command generated in response to the measured effects. A method for
adaptively controlling a hybrid electric vehicle is also
provided.
Inventors: |
Wilton, Thomas F.; (Aurora,
CO) ; Anderson, Joshua J.; (Edgewater, CO) ;
Schmitz, Robert W.; (Littleton, CO) |
Correspondence
Address: |
OLIFF & BERRIDGE, PLC
P.O. BOX 19928
ALEXANDRIA
VA
22320
US
|
Assignee: |
Transportation Techniques,
LLC
Denver
CO
80205
|
Family ID: |
25008375 |
Appl. No.: |
10/413544 |
Filed: |
April 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10413544 |
Apr 15, 2003 |
|
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|
09748182 |
Dec 27, 2000 |
|
|
|
6573675 |
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Current U.S.
Class: |
318/376 |
Current CPC
Class: |
B60L 3/0061 20130101;
B60L 2250/10 20130101; B60L 2210/30 20130101; Y02T 10/62 20130101;
B60L 2220/16 20130101; B60L 58/15 20190201; B60L 2240/425 20130101;
Y02T 10/72 20130101; B60L 3/102 20130101; Y02T 10/7072 20130101;
Y02T 10/64 20130101; Y02T 10/70 20130101; B60L 2240/36 20130101;
B60L 3/0046 20130101; B60L 2210/40 20130101; B60L 2240/423
20130101; B60L 3/0092 20130101; B60L 50/61 20190201; B60L 2220/14
20130101 |
Class at
Publication: |
318/376 |
International
Class: |
H02P 003/14 |
Claims
What is claimed is:
1. A method for adaptively controlling a hybrid electric vehicle
including an energy generation system, an energy storage system
receiving electric current at least from the energy generation
system, and at least one electric drive motor receiving current
from the energy storage system, comprising: monitoring the status
of various vehicle systems; monitoring user inputs for removal of
acceleration command inputs and application of braking inputs;
determining if the vehicle is in one of a plurality of regenerative
braking modes, including determining which regenerative braking
mode the vehicle is in; determining an appropriate level of
regenerative braking to be applied in a braking event, given the
monitored status of vehicle systems and the determination of the
regenerative braking mode; generating a command signal to the
electric drive motor to generate the determined level of
regenerative braking; determining the effect of the regenerative
braking command on the status of the vehicle systems; and
adaptively generating further command signals to the electric drive
motor altering the level of regenerative braking applied.
2. The method of claim 1, wherein a state of charge of the energy
storage system is monitored and the step of determining an
appropriate level of regenerative braking to be applied is
determined based on the monitored state of charge and the
determined regenerative braking mode.
3. The method of claim 1, further comprising: monitoring for the
signal of one or more vehicle fault states; determining if a fault
state is related to energy storage or drive motor systems; and
reducing or eliminating regenerative braking commands if the fault
is related to energy storage or drive motor systems.
4. The method of claim 1, further comprising: monitoring the
temperature of energy storage, electric drive motor, and/or cooling
systems temperatures; reducing or eliminating regenerative braking
commands if one or more monitored temperatures are above a
predetermined level; and increasing regenerative braking commands
if one or more monitored temperatures are below a predetermined
level.
5. The method of claim 1, further comprising: monitoring for a
signal indicating that vehicle anti-lock braking or traction
control systems are actively affecting vehicle braking or
propulsion; and reducing or eliminating regenerative braking
commands if one or more of the monitored systems are active.
6. The method of claim 1, further comprising: monitoring the
rotational speeds or one or more driving wheels; determining if
monitored wheel rotation velocity exceeds an expected velocity
range relative to other monitored wheels or to a predicted
velocity; generating a greater regenerative braking command to
reduce wheel rotation velocity if the monitored velocity is greater
than an expected upper velocity limit; and generating a reduced
regenerative braking command to reduce de-acceleration of wheel
rotational velocity if the monitored velocity is less than an
expected lower velocity limit.
7. The method of claim 1, wherein the vehicle further includes an
electrical load bank for dissipation of electrical energy to heat
or mechanical work, and the method further comprises: monitoring a
state of charge of the energy storage system; monitoring when
regenerative braking commands are active; determining when the
state of charge of the energy storage system meets or exceeds an
upper limit and regenerative braking is active; generating a
command to allow electrical energy created by regenerative braking
to be diverted to the electrical load bank; and reducing or
eliminating the command allowing electrical energy to be diverted
to the electrical load bank upon reduction or elimination of the
regenerative braking command.
8. The method of claim 1, further comprising: determining if the
vehicle is in at least one of a first regenerative braking mode, a
second regenerative braking mode and a third regenerative braking
mode; decreasing regenerative braking, if the vehicle is in the
first regenerative braking mode; decreasing regenerative braking if
a battery state of charge is approaching an upper control limit and
the vehicle is in the second regenerative braking mode; increasing
regenerative braking if the battery state of charge is approaching
a lower control limit and the vehicle is in the second regenerative
braking mode; and increasing regenerative braking, if the vehicle
is in the third regenerative braking mode.
9. A hybrid electric vehicle, comprising: an energy generation
system; an energy storage system receiving electric current at
least from the generation system; at least one electric motor
receiving current from the energy storage system; and a vehicle
controller that: monitors a status of various vehicle systems;
monitors user inputs for removal of acceleration command inputs and
application of braking inputs; determines if the vehicle is in one
of a plurality of regenerative braking modes, including determining
which regenerative braking mode the vehicle is in; determines an
appropriate level of regenerative braking to be applied in a
braking event, given the monitored status of vehicle systems and
the determination of the regenerative braking mode; generates a
command signal to the electric drive motor to generate the
determined level of regenerative braking; determines an effect of
the regenerative braking command on the status of the vehicle
systems; and adaptively generates further command signals to the
electric drive motor altering the level of regenerative braking
applied.
10. The hybrid electric vehicle of claim 9, wherein the controller:
monitors a state of charge of the energy storage system and
determines the appropriate level of regenerative braking to be
applied based on the monitored state of charge and determined
regenerative braking mode.
11. The hybrid electric vehicle of claim 9, wherein the controller:
monitors for the signal of one or more vehicle fault states:
determines if the fault state is related to energy storage or drive
motor systems; and reduces or eliminates regenerative braking
commands if the fault is related to energy storage or drive motor
systems.
12. The hybrid electric vehicle of claim 9, wherein the controller:
monitors the temperature of energy storage, electric drive motor,
and/or cooling systems temperatures; reduces or eliminates
regenerative braking commands if one or more monitored temperatures
are above a predetermined level; and increases regenerative braking
commands if one or more monitored temperatures are below a
predetermined level.
13. The hybrid electric vehicle of claim 9, wherein the controller:
monitors for a signal indicating that vehicle anti-lock braking or
traction control systems are actively affecting vehicle braking or
propulsion; and reduces or eliminates regenerative braking commands
if one or more monitored systems are active.
14. The hybrid electric vehicle of claim 9, wherein the controller:
monitors rotational speeds or one or more driving wheels;
determines if the monitored wheel rotation velocity exceeds an
expected velocity range relative to other monitored wheels or to a
predicted velocity; generates a greater regenerative braking
command to reduce wheel rotation velocity if the monitored velocity
is greater than an expected upper velocity limit; and generates a
reduced regenerative braking command to reduce de-acceleration of
wheel rotational velocity if the monitored velocity is less than an
expected lower velocity limit.
15. The hybrid electric vehicle of claim 9, wherein an electrical
load bank is available for dissipation of electrical energy to heat
or mechanical work and wherein the controller: monitors a state of
charge of the energy storage system; monitors when regenerative
braking commands are active; determines when the state of charge of
the energy storage system meets or exceeds an upper limit and
regenerative braking is active; generates a command to allow
electrical energy created by regenerative braking to be diverted to
the electrical load bank; and reduces or eliminates the command
allowing electrical energy to be diverted to the electrical load
bank upon reduction or elimination of the regenerative braking
command.
16. The hybrid electric vehicle of claim 9, wherein the controller:
determines if the vehicle is in at least one of a first
regenerative braking mode, a second regenerative braking mode and a
third regenerative braking mode; decreases regenerative braking, if
the vehicle is in the first regenerative braking mode; decreases
regenerative braking if a battery state of charge is approaching an
upper control limit and the vehicle is in the second regenerative
braking mode; increasing regenerative braking if the battery state
of charge is approaching a lower control limit and the vehicle is
in the second regenerative braking mode; and increases regenerative
braking, if the vehicle is in the third regenerative braking
mode.
17. A method for adaptively controlling propulsion of a hybrid
electric vehicle including an energy generation system, an energy
storage system receiving electric current at least from the energy
generation system, and at least one electric drive motor receiving
current from the energy storage system, comprising: generating a
first signal having a value indicative of an accelerator command to
a controller; generating a second signal having a value
proportional to the first signal and indicative of a demand of the
at least one electric drive motor from the controller to a motor
controller; determining if the value of the first signal is smaller
than the value of the second signal; increasing the value of a
command signal to the at least one electric motor, if the value of
the first signal is not smaller than the value of the second
signal; and decreasing the value of the command signal, if the
value of the first signal is smaller than the value of the second
signal.
18. A hybrid electric vehicle, comprising: an energy generation
system; an energy storage system receiving current at least from
the energy generation system; at least one electric drive motor
receiving current from the energy storage system; at least one
motor controller that controls the at least one electric drive
motor; a sensor that generates a first signal having a value
indicative of an accelerator command; and a controller that:
receives the first signal from the sensor; generates a second
signal having a value proportional to the first signal and
indicative of a demand of the at least one electric drive motor and
sends the second signal to the motor controller; determines if the
value of the first signal is smaller than the value of the second
signal; increases the value of a command signal to operate the at
least one electric motor, if the value of the first signal is not
smaller than the value of the second signal; and decreases the
value of the command signal, if the value of the first signal is
smaller than the value of the second signal.
19. The hybrid electric vehicle of claim 18, wherein the energy
generation system includes an internal combustion engine connected
to a generator.
20. The hybrid electric vehicle according to claim 19, wherein the
energy storage system includes a battery array.
21. The hybrid electric vehicle according to claim 19, wherein the
vehicle is a series type hybrid.
Description
[0001] This is a Continuation-in-Part of application Ser. No.
09/748,182 filed Dec. 27, 2000. The entire disclosure of the prior
application is hereby incorporated by reference herein in its
entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] This invention relates to methods and apparatus for
adaptively controlling operation of regenerative braking in an
electric or hybrid electric vehicle.
[0004] 2. Description of Related Art
[0005] The desire for cleaner air has caused various federal,
state, and local governments to adopt or change regulations
requiring lower vehicle emissions. Increasing urban traffic
congestion has prompted a need for increases in public mass transit
services. All mass transit systems utilizes buses, at least in
part, to transport people into, out of, and within traffic
congested urban areas. Conventional buses use diesel powered
internal combustion engines. Diesel engines produce emissions,
including carbon monoxide, that contribute to air pollution. It is
possible to refine cleaner diesel fuel. However, cleaner diesel
fuel is more costly to refine and causes a corresponding increase
in the cost of bus service.
[0006] Alternative fuels have been used to reduce emissions and
conserve oil resources. Compressed natural gas has been used as an
alternative fuel. Compressed natural gas does not produce as much
power in conventional internal combustion engines as gasoline and
diesel and has not been widely developed or accepted as an
alternative to gasoline and diesel.
[0007] Additives have also been developed for mixing with gasoline
to reduce emissions. Ethanol and MTBE have been added to gasoline
to oxygenate the combustion of gasoline and reduce emissions of
carbon monoxide. These additives, however, are believed to cause
decreased gas mileage and, in the case of MTBE, to be a potential
public health threat.
[0008] Electric vehicles have been developed that produce zero
emissions. Electric vehicles are propelled by an electric motor
that is powered by a battery array on board the vehicle. The range
of electric vehicles is limited as the size of the battery array
which can be installed on the vehicle is limited. Recharging of the
batteries can only be done by connecting the battery array to a
power source. Electric vehicles are not truly zero emitters when
the electricity to charge the battery array is produced by a power
plant that burns, for example, coal.
[0009] Hybrid electric vehicles have also been developed to reduce
emissions. Hybrid electric vehicles include an internal combustion
engine and at least one electric motor powered by a battery array.
In a parallel type hybrid electric vehicle, both the internal
combustion engine and the electric motor are coupled to the drive
train via mechanical means. The electric motor may be used to
propel the vehicle at low speeds and to assist the internal
combustion engine at higher speeds. The electric motor may also be
driven, in part, by the internal combustion engine and be operated
as a generator to recharge the battery array.
[0010] In a series type hybrid electric vehicle, the internal
combustion engine is used only to run a generator that charges the
battery array. There is no mechanical connection of the internal
combustion engine to the vehicle drive train. The electric traction
drive motor is powered by the battery array and is mechanically
connected to the vehicle drive train.
[0011] Conventional internal combustion engine vehicles control
propulsion by increasing and decreasing the flow of fuel to the
cylinders of the engine in response to the position of an
accelerator pedal. Electric and hybrid electric vehicles also
control propulsion by increasing or decreasing the rotation of the
electric motor or motors in response to the position of an
accelerator pedal. Electric and series type hybrid electric
vehicles may be unable to accelerate properly if the power
available from the battery or batteries and/or genset is
insufficient.
[0012] Conventional internal combustion engine vehicles may also
include systems to monitor the slip of a wheel or wheels to thereby
control the engine and/or the brakes of the vehicle to reduce the
slip of the wheel or wheels. In hybrid electric vehicles, however,
it is necessary to control the speed and torque of the electric
motor or motors to control the slip of wheels.
[0013] Conventional internal combustion engine vehicles may also
include systems to modify effects of vehicle braking in certain
situations, including loss of traction, wheel slippage, and load
shifting. In electric and hybrid electric vehicles, however,
regenerative braking operation must interface with these and other
propulsion system conditions to prevent unexpected or unsafe
operation. Additionally, this system must interface with the energy
storage and generation systems because it is electrically based.
Furthermore, in electric and hybrid electric vehicles, an operator
input may be used to manually indicate the level and types of
regenerative braking to be applied.
SUMMARY OF THE INVENTION
[0014] The invention provides methods and apparatus for adaptively
controlling the regenerative braking operation of electric and
hybrid electric vehicles.
[0015] An exemplary embodiment of a hybrid electric vehicle
according to the invention, including an energy generation system,
an energy storage system that receives energy at least from the
energy generation system, and at least one electric motor receiving
current from the energy storage system, is adaptively controlled so
that a command signal to the at least one electric motor follows
and is proportional to a signal having a value indicative of a user
demand. The vehicle propulsion is also adaptively controlled based
on a state of charge and temperature of a battery array of the
vehicle, an emission mode of the vehicle, a regenerative braking
mode of the vehicle, and a nominal operating state of the at least
one electric motor.
[0016] According to an exemplary embodiment, a method according to
the invention for adaptively controlling propulsion of a hybrid
electric vehicle including an energy generation system, an energy
storage system that receives energy from at least the energy
generation system, and at least one electric motor receiving
current from the energy storage system, includes generating a first
signal having a value indicative of a user demand, generating a
second signal having a value proportional to the first signal and
indicative of a demand of the at least one electric motor,
determining if the value of the first signal is larger than the
value of the second signal, increasing the value of a command
signal to the at least one electric motor, if the value of the
first signal is not larger than the value of the second signal and
decreasing the value of the command signal, if the value of the
first signal is larger than the value of the second signal.
[0017] According to an exemplary embodiment, a method according to
the invention for adaptively controlling the regenerative braking
system of a hybrid electric vehicle including an energy generation
system, an energy storage system receiving electric current at
least from the energy generation system, and at least one electric
motor receiving current from the energy storage system, includes
monitoring a user input or other selector to determine one of a
multiplicity of regenerative braking modes, monitoring a number of
vehicle states and conditions, including energy storage system
state of charge, ABS events, loss of traction, operator inputs and
others, and creating a regenerative braking command based upon
these factors.
[0018] According to another exemplary embodiment, a hybrid electric
vehicle according to the invention includes an energy generation
system, an energy storage system receiving current at least from
the energy generation system, at least one electric motor receiving
current from the energy storage system, a component that indicates
a signal in the event of a failure, a controller that monitors
failure signals and determines the failure of the component based
upon the signal, generates a corresponding signal to reset or
correct the failure signal, determines if the failure was
corrected, disables or isolates the failed component, and generates
signals to alter the control of other components.
[0019] Other features of the invention will become apparent as the
following description proceeds and upon reference to the
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Various exemplary embodiments of this invention will be
described in detail with reference to the following figures,
wherein like numerals reference like elements, and wherein:
[0021] FIG. 1 is schematic view of an exemplary embodiment of a
series type hybrid electric vehicle according to the invention;
[0022] FIG. 2 is a schematic diagram illustrating an exemplary
embodiment of a circuit for controlling charging of the battery
array by the generator;
[0023] FIG. 3 is a diagram illustrating an exemplary embodiment of
a circuit for controlling the electric motors;
[0024] FIG. 4 is a diagram illustrating an exemplary embodiment of
a circuit of the motor controllers;
[0025] FIG. 5 is a diagram illustrating the relationship between
the power created, the power stored, and the power consumed by the
series hybrid electric vehicle according to the invention;
[0026] FIG. 6 is a diagram illustrating an exemplary embodiment of
a master control switch;
[0027] FIG. 7 is a diagram illustrating an exemplary embodiment of
a driver's input control panel for determining a driving mode;
[0028] FIG. 8 is a diagram illustrating an exemplary embodiment of
a driver's input control panel for determining a regenerative
braking mode;
[0029] FIG. 9 is a diagram schematically illustrating an exemplary
embodiment of the relationship between an accelerator pedal and the
electric motors; and
[0030] FIGS. 10-18 are flowcharts illustrating an exemplary
adaptive control of the propulsion of the series type hybrid
electric vehicle.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] Referring to FIG. 1, an exemplary embodiment of a hybrid
electric vehicle 10 which embodies the invention includes a
plurality of wheels 11, 12, 13, and 14 and a vehicle chassis 15.
The wheels 13 and 14 are coupled to electric motors 50 and 60,
respectively, through gear boxes 52 and 62, respectively. The
wheels 13 and 14 are independently mounted to respective suspension
components, such as swing arms. In this embodiment, the wheels 13
and 14 are not coupled together by an axle. In other embodiments,
the wheels 13 and 14 may be coupled together, for example, by an
axle.
[0032] The wheels 13 and 14 may be either the front wheels or the
rear wheels of the vehicle 10. In this embodiment, the wheels 11
and 12 are not driven and may be coupled together by an axle. In
other embodiments, the wheels 11 and 12 may be driven.
[0033] Four wheel speed sensors 11'-14' are provided for sensing
the rotational speed of each wheel 11-14, respectively.
[0034] In an exemplary embodiment of a vehicle which embodies this
invention, the vehicle 10 is a bus having an occupancy capacity in
excess of 100. However, it should be appreciated that the vehicle
may be a bus of a smaller capacity or that the vehicle may be a
smaller passenger vehicle, such as a sedan. Further, the invention
is not limited to passenger vehicles, the invention can be used in
any type of motor vehicle, including trucks, boats, etc. In various
exemplary embodiments, the vehicle may be any size and form
currently used or later developed.
[0035] The electric motors 50 and 60 are powered by an energy
storage system, such as a battery array 30, and are controlled by
motor controllers 51 and 61, respectively. An energy storage system
temperature sensor 30' detects the temperature of the battery array
30. While exemplary embodiments use a battery array, the invention
is not limited to this. Other known or subsequently developed
energy storage systems can be adapted for use with this invention,
such as capacitors, ultra capacitors, flywheels or other inertia
storing systems, or hydraulic accumulators.
[0036] According to an exemplary embodiment of the vehicle 10, the
electric motors 50 and 60 are synchronous, permanent magnet DC
brushless motors. Each electric motor 50 and 60 is rated for 220 Hp
and 0-11,000 rpm. The maximum combined power output of the electric
motors 50 and 60 is thus 440 Hp. The permanent magnet DC brushless
motors include permanent magnets, such as rare earth magnets, for
providing a magnetic field as opposed to AC induction motors which
create or induce a magnetic field on the rotating portion of the
motor. The DC brushless motors are thus inherently more efficient
than AC induction motors as no losses occur from inducing the
magnetic field. The DC brushless motors also have a more useful
torque profile, a smaller form factor, and lower weight than AC
induction motors. The DC brushless motors also require less energy
input for an equivalent power output than AC induction motors.
However, this invention is not limited to permanent magnet DC
brushless motors, and other types of electric motors, such as AC
induction motors, can be used.
[0037] The hybrid electric vehicle 10 is preferably a series type
hybrid electric vehicle that includes an energy generation system,
such as a generator set (genset) 300, 310 including an internal
combustion engine 300 and a generator 310 that is driven by the
internal combustion engine 300. The internal combustion engine 300
may be powered by gasoline, diesel, or compressed natural gas. It
should be appreciated, however, that the internal combustion engine
300 may be replaced by a fuel cell, turbine or any other number of
alternatives for creating usable electric power.
[0038] According to an exemplary embodiment of the invention, the
internal combustion engine 300 may be a 2.5 liter Ford LRG-425
engine powered by compressed natural gas. The 2.5 liter Ford
LRG-425 engine produces 70 Hp. It should be appreciated that the
power output of such an engine may be increased by increasing the
RPM of the engine and decreased by decreasing the RPM of the
engine. In this embodiment with two 220 Hp electric motors 50 and
60 and an internal combustion engine 300 operating at 70 Hp, the
performance enhancement factor of the vehicle 10 is 440/70, or at
least 6.2. Other internal combustion engines can of course be
utilized.
[0039] In this embodiment, the generator 310 is a DC brushless
generator that produces, for example, 240-400 V.sub.AC. Other types
of generators may be employed. In an exemplary embodiment of the
vehicle 10, the generator is operated to produce 345 V.sub.AC
during certain drive modes.
[0040] An output shaft of the internal combustion engine 300 is
connected to the generator 310 to power the generator 310 and the
AC voltage output by the generator 310 is converted to a DC voltage
by a generator controller 320. The converted DC voltage charges the
battery array 30. The battery array 30 may include, for example, 26
deep cycle, lead-acid batteries of 12 volts each connected in
series. It should be appreciated, however, that other batteries,
such as nickel cadmium, metal hydride or lithium ion, may be used
and that any number of batteries can be employed, as space permits.
In this embodiment, depending upon the load on the vehicle 10, the
battery array voltage ranges between 240 and 400 V.sub.DC.
[0041] An electronic control unit (ECU) 200 includes a programmable
logic controller (PLC) 210 and a master control panel (MCP) 220.
The MCP 220 receives information from various sensors, such as the
wheel speed sensors 11'-14' and the battery array temperature
sensor 30', and provides this information to gauges or other
outputs in the vehicle 10, as desired. The PLC 210 executes various
programs to control various components of the vehicle 10, for
example, the internal combustion engine 300, the generator 310, the
generator controller 320, the electric motors 50 and 60, and the
motor controllers 51 and 61.
[0042] Although not shown in the drawings, the vehicle 10 may
include a cooling system or cooling systems for the internal
combustion engine 300, the generator controller 320, the battery
array 30, the motor controllers 51 and 61, and the motors 50 and
60. The cooling system may be a single system which includes a
coolant reservoir, a pump for pumping the coolant through a heat
exchanger such as a radiator and a fan for moving air across the
heat exchanger or a plurality of cooling systems similarly
constructed. The ECU 200 controls the cooling systems, including
the pumps and the fans, to perform a heat shedding operation in
which the heat generated by the engine 300, the controllers 320,
51, and 61, the battery array 30, the motors 50 and 60, and various
other systems is released to the atmosphere. Any acceptable means
and methods for cooling the vehicle components may be utilized.
[0043] As shown in FIG. 2, the coils of the generator 310 are
connected to the generator controller 320 by leads 311, 312, and
313. The generator controller 320 includes two switching insulated
or isolated gate bipolar transistors (IGBT) 330 per phase of the
generator 310 and their corresponding diodes. In an exemplary
embodiment including a three phase generator 310, the generator
controller 320 includes 6 IGBT 330 and six corresponding
diodes.
[0044] The PLC 210 controls each IGBT 330 of the generator
controller 320 to control the conversion of the AC voltage of the
generator 310 to the DC voltage for charging the battery array 30.
The PLC 210 may switch one or more of the IGBT 330's off when the
SOC of the battery array 30 reaches an upper control limit, to stop
the conversion of the AC voltage to DC voltage and prevent
overcharging of the battery array 30.
[0045] According to an exemplary embodiment of the invention, the
engine 300 runs continuously during operation of the vehicle 10 and
continuously turns the shaft 315 of the generator 310. The PLC 210
switches each IGBT 330 on and off via high speed pulse width
modulation (PWM) to control charging of the battery array 30. It
should be appreciated however that the PLC 210 may control the
charging of the battery array 30 by turning the engine 300 on and
off, or in the alternative, by changing the RPM's of the engine
300.
[0046] A possible control circuit for the electric motors 50 and 60
is illustrated in FIG. 3, and includes the motor controllers 51 and
61. The motor controllers 51 and 61 receive power from the battery
array 30 and distribute the power to the electric motors 50 and 60
by switches B1-B6 of pulse width modulation (PWM) inverters 54 and
64. The PWM inverters 54 and 64 generate AC current from the DC
current received from the battery array 30. The battery current
I.sub.B is distributed by the switches B1-B6, for example IGBT, of
the PWM inverters 54 and 64 into motor currents I.sub.1, I.sub.2,
and I.sub.3 for driving the motors 50 and 60.
[0047] The motor controllers 51 and 61 distribute the battery
current I.sub.B via the switches B1-B6 by factoring feedback from
position sensors 53 and 63 and encoders 56 and 66 that determine
the timing or pulsing of electromagnets of the motors 50 and 60.
The pole position sensors 53 and 63 determine the pole positions of
the permanent magnets of the motors 50 and 60 and the encoders 56
and 66 determine the phase angle. It should be appreciated that
each pair of pole position sensors 53 and 63 and encoders 56 and
66, respectively, may be replaced by a phase position sensor and
the phase change frequency may be read to determine the speed of
rotation of the electric motors 50 and 60.
[0048] The motor controllers 51 and 61 calculate the motor
connector voltages U.sub.12, U.sub.31, and U.sub.23 based on the
rotary velocity and the known flux value of the motors 50 and 60
between the motor connectors. The operating voltage of the
inverters 54 and 64 is then determined by the rectified voltages of
the diodes of the switches B1-B6 or by the voltage Ui of an
intermediate circuit including a capacitor C. If the voltage Ui
becomes larger than the battery voltage U.sub.B, uncontrolled
current may flow to the battery array 30. Voltage sensors 55 and 65
determine the voltage Ui and the motor controllers 51 and 61
compare the voltage Ui to the battery voltage U.sub.B. The motor
controllers 51 and 61 activate the switches B1-B6 to cause
magnetizing current to flow directly to the motors 50 and 60 to
avoid unnecessary recharging of the battery array 30.
[0049] As shown in FIG. 3, each motor controller 51 and 61 receives
control data from the ECU 200 through a controller area network
(CAN). The ECU 200 can communicate with the various sensors and the
motor controllers 51 and 61 by, for example, DeviceNet.TM., an
open, global industry standard communication network.
[0050] Referring to FIG. 4, each motor controller 51 and 61
includes a control unit 101 including a field axis current and
torque axis current detector 102. The detector 102 calculates the
torque axis current I.sub.t and the field axis current I.sub.f of
each motor 50 and 60 by executing a 3-phase, 2-phase coordinate
transfer from the input of the current detectors 57 and 67 that
measure the 3-phase AC current of the motors 50 and 60 and the
phase calculator 108 that received input from the pole position
sensors 53 and 63 and the encoders 56 and 66. The torque axis
current I.sub.t and the field axis current I.sub.f calculated by
the detector 102 are input to a field axis current and torque axis
current control unit 103. The current control unit 103 receives a
field axis current reference value I.sub.fref from a field axis
current reference control unit 104 and receives a torque axis
current reference value I.sub.tref from a torque axis current
reference control unit 105.
[0051] The reference control units 104 and 105 determine the
current reference values I.sub.fref and I.sub.tref by comparing a
torque reference value T.sub.ref (which is determined by the
position of an accelerator pedal of the vehicle) with the actual
rotational velocity determined by an rpm calculator 106 that
receives input from the encoders 56 and 66. A 2/3 phase changer 107
receives input from a phase calculator 108 and calculates the
3-phase AC reference values by performing a 2-phase/3-phase
coordinate transformation. A PWM control unit 109 generates a PWM
signal by comparing the 3-phase reference values with a triangular
wave signal which is input to the PWM inverters 54 and 64.
[0052] Referring to FIG. 5, the relationship between the power
generated, the power stored, and the power consumed over time, by
the series hybrid electric vehicle 10 according to the invention
will be explained.
[0053] Power is consumed from the battery array 30 by the electric
motors 50 and 60 during acceleration of the vehicle 10 to a
cruising speed. As shown in FIG. 5, the vehicle 10 reaches cruising
speed at time t.sub.1 which corresponds to a peak power P.sub.peak
of the electric motors 50 and 60. The peak power P.sub.peak the
electric motors 50 and 60 is dependent on the driving mode
(discussed below) of the vehicle 10 selected by the operator. In
the exemplary embodiment of the invention in which the electric
motors 50 and 60 are each 220 Hp, the peak power P.sub.peak
consumed by the electric motors 50 and 60 is 440 Hp.
[0054] The power consumption (traction effort) of the electric
motors 50 and 60 during acceleration is represented by the curve
below the horizontal axis and the area defined by the curve below
the horizontal axis between the times t.sub.0 and t.sub.2
represents the total power consumption of the vehicle 10 during
acceleration. In the event that the SOC of the battery array 30 is
insufficient to achieve the cruising speed, the ECU 200 controls
the motor controllers 51 and 61 to limit the peak power P.sub.peak
the electric motors 50 and 60 may draw from the battery array 30.
After the vehicle 10 has accelerated to cruising speed, the
traction effort of the electric motors 50 and 60 may be reduced
between the time t.sub.1 and the time t.sub.2, and the power
consumption by the electric motors 50 and 60 may also be
reduced.
[0055] The cruising speed of the vehicle 10 is maintained between
the time t.sub.2 and the time t.sub.3. In this embodiment, during
the time between t.sub.2 and t.sub.3, the genset 300, 310 is
operated to produce power P.sub.gen higher than the power
consumption (traction effort) of the electric motors 50 and 60
necessary to maintain the vehicle's cruising speed. The
differential in power between the traction effort and the power
generated P.sub.gen is stored in the battery array 30.
[0056] The power P.sub.gen generated by the genset 300, 310, in
this embodiment, is dependent on the rpm of the engine 300 and a
user demand signal sent to the genset 300, 310 that is controlled
by the ECU 200. The ECU 200 controls the engine 300 to generally
maintain the rpm of the engine 300, and the power generated
P.sub.gen, constant. However, it should be appreciated that the ECU
200 may control the engine 300 to reduce or increase the rpm of the
engine 300, and thus the reduce or increase, respectively, the
power generated P.sub.gen.
[0057] The power generated P.sub.gen by the genset 300, 310 may be
reduced if the SOC of the battery array 30 approaches an upper
control limit at which the battery array 30 may become overcharged.
The power generated P.sub.gen by the genset 300, 310 may be
increased if the SOC of the battery array 30 approaches a lower
control limit at which the battery array 30 would be unable to
drive the electric motors 50 and 60 with enough torque to propel
the vehicle 10. In an exemplary embodiment of the vehicle 10 in
which the engine 300 is a 2.5 liter Ford LRG-425 engine powered by
compressed natural gas, the power generated P.sub.gen is 70 Hp.
[0058] Regenerative braking occurs between the times t.sub.3 and
t.sub.4 when the vehicle 10 decelerates after release of the
accelerator pedal or when the vehicle 10 travels on a downhill
slope at a constant speed. During regenerative braking, the
electric motors 50 and 60 function as generators and current is
supplied to the battery array 30 by the electric motors 50 and 60.
The power generated P.sub.braking during regenerative braking is
stored in the battery array 30.
[0059] The power generated by the genset 300, 310 during
maintenance of the cruising speed and the power generated by
regenerative braking P.sub.braking is represented by the curve
above the horizontal axis and the area A.sub.2 defined by the curve
above the horizontal axis represents the total energy creation and
storage of the vehicle 10 during maintenance of the cruising speed
and regenerative braking.
[0060] The power P.sub.gen of the genset 300, 310 and the
regenerative braking power P.sub.braking are controlled by the ECU
200 to substantially equal the energy consumption (traction effort)
of the electric motors 50 and 60 during acceleration. In other
words, the area A.sub.1 defined by the curve below the horizontal
axis is equal to the area A.sub.2 defined by the curve above the
horizontal axis. The ECU 200 controls the traction effort of the
electric motors 50 and 60 (including the peak power P.sub.peak) and
the power generated P.sub.gen so that the power generated and the
power stored do not exceed the power consumed, and vice versa, so
as to maintain the SOC of the battery array 30 within a range of
control limits. The ECU 200 controls the power generated P.sub.gen
and the traction effort of the electric motors 50 and 60 so that
the ampere hours during energy consumption do not exceed the
thermal capacity of the battery array during power creation and
storage.
[0061] An exemplary method for adaptively controlling the state of
charge SOC of the battery array 30 is disclosed in U.S. patent
application Ser. No. 09/663,118, filed Sep. 15, 2000, now U.S. Pat.
No. 6,333,620, the entire contents of which are herein incorporated
by reference.
[0062] This embodiment includes a master control switch. Referring
to FIG. 6, a master control switch 20 positioned, for example, in
an operator area of the vehicle 10, includes an OFF position, a
DRIVE ENABLE position and an ENGINE RUN position. Any acceptable
switch mechanism can be employed. The rotary switch 20 in FIG. 6 is
merely an example of an acceptable switch. The position of the
switch 20 is input to the MCP 220. When the switch 20 is moved to
the DRIVE ENABLE position, the PLC 210 controls the electric motors
50 and 60 to run the vehicle in a driver selected zero emissions
mode by drawing power from the battery array 30. The engine 300 is
not operated during the zero emissions mode, i.e., when the switch
20 is in the DRIVE ENABLE position. The range of the vehicle 10 in
zero emissions mode is limited as the SOC of the battery array 30
will eventually be lowered below a level sufficient to drive the
electric motors 50 and 60 to propel the vehicle.
[0063] When the switch 20 is moved to the ENGINE RUN position, the
ECU 200 instructs the generator 310 to operate as a motor for
starting the engine 300. During the starting of the engine 300, the
generator 310 receives current from the battery array 30. The
current is supplied until the engine 300 reaches a predetermined
idling speed and then the current supply is stopped. The engine 300
then drives the generator 310 to charge the battery array 30, as
necessary.
[0064] The ECU 200 controls the engine 300 by monitoring the engine
speed (rpm) as sensed by a tachometer (not shown) and the fuel
mixture as sensed by an oxygen sensor (not shown). The ECU 200 may,
for example, control the amount of fuel injected into the engine
300 and/or the position of a throttle valve of the engine 300. The
ECU 200 may also monitor engine conditions such as the oil pressure
and the coolant temperature as detected by sensors (not shown). An
automatic zero emission mode is provided by the ECU 200 when the
switch 20 is in the ENGINE RUN position when the SOC of the battery
array 30 is sufficient or when the sensors of the vehicle 10 sense
areas and routes where the zero emission mode is required. The ECU
200 will turn the engine 300 off, even though the switch 20 is in
the ENGINE RUN position, when it determines that the zero emission
mode is required. As discussed above, the zero emissions mode may
be initiated when the SOC of the battery array 30 is sufficient or
when designated areas or routes are entered. For example, the
vehicle 10 may be equipped with sensors (not shown) responsive to
signals from the global positioning system (GPS) or other signal
emitting devices that indicate that the vehicle has entered an area
or route where the zero emission mode is required.
[0065] This embodiment also includes a control panel that controls
the driving mode of the vehicle. Referring to FIG. 7, a control
panel 25 positioned, for example, in the operator area of the
vehicle 10, includes a plurality of switches 26-29. After starting
the vehicle 10 by moving the master switch 20 to the engine run
position, one of the switches 26-29 is selected to establish a
driving mode of the vehicle 10. A first driving mode F1 is
established by selecting switch 26. In this embodiment, the first
driving mode F1 is established for driving the vehicle at lower
speeds and under conditions in which the vehicle 10 will start and
stop frequently. A second driving mode F2 is established by
selecting switch 27. The second driving mode F2 is established for
driving the vehicle at higher speeds and under conditions in which
the vehicle is started and stopped less frequently. The ECU 200
controls the electric motors 50 and 60 depending on which driving
mode is established. The maximum power output and rpm of the
electric motors 50 and 60 in the second driving mode F2 are higher
than the maximum power output and rpm of the motors 50 and 60 in
the first driving mode F1.
[0066] While two driving modes are shown in FIG. 7 and discussed
above, any number of modes can be provided. These modes can be
directed to different driving conditions, road conditions, weather
conditions, and the like.
[0067] The control panel 25 also includes a switch 28 to establish
a neutral mode N. In the neutral mode N, the electric motors 50 and
60 are disengaged by the ECU 200 and the vehicle 10 is not
propelled by the electric motors 50 and 60, even if an accelerator
pedal (discussed below) is pressed by the operator.
[0068] A reverse mode R is established by selecting a switch 29. In
the reverse mode R, the electric motors 50 and 60 are controlled to
rotate in the opposite direction of the first and second driving
modes F1 and F2 to propel the vehicle 10 in a reverse
direction.
[0069] This embodiment may also include a second control panel for
controlling the regenerative braking of the vehicle 10. Referring
to FIG. 8, a second control panel 75 positioned, for example, in
the operator area of the vehicle 10, includes a plurality of
switches 76-78. After starting the vehicle 10 by moving the master
switch 20 to the engine run position, one of the switches 76-78 is
selected to establish a regenerative braking mode of the vehicle
10. A first regenerative braking mode R1 is established by
selecting switch 76. In the first regenerative braking mode R1, the
regenerative braking function is turned off. The first regenerative
braking mode R1 may be selected during icy road conditions.
[0070] A second regenerative braking mode R2 may be selected by
switch 77. The second braking mode R2 is selected when the
regenerative braking effort should be minimal, such as wet road
conditions or when the state of charge SOC of the battery array
approaches an upper control limit UCL.
[0071] A third regenerative braking mode R3 may be selected by
switch 78. The third braking mode R3 is selected when the
regenerative braking efforts should be at a maximum, such as during
dry road conditions or when the state of charge SOC of the battery
array 30 approaches a lower control limit LCL.
[0072] Although the regenerative braking mode has been shown as
selected by the operator, it should be appreciated that the ECU 200
may change the regenerative braking mode when certain conditions,
such as slipping of any of the wheels 11-14, are detected.
Moreover, while three modes are illustrated in this embodiment, any
number of modes could be employed as desired, directed to any types
of environmental conditions and/or operating parameters.
[0073] Referring to FIG. 9, the position of an accelerator pedal 40
is detected by a sensor 45. The sensor 45 sends a demand signal DEM
indicative of the accelerator pedal 40 position, i.e., the user
demand, to the MCP 220. The demand signal DEM has a value of zero
when the accelerator pedal 40 is not depressed and a maximum value
when the accelerator pedal 40 is fully depressed.
[0074] The ECU 200 sends a drive demand signal DRVDEM to the motor
controllers 51 and 61. The drive demand signal DRVDEM follows and
is proportional to the demand signal DEM of the sensor 45. However,
due to a lag in the processing by the ECU 200, the instantaneous
value of the demand signal DEM from the sensor 45 may be greater
than or less than the drive demand signal DRVDEM produced by the
ECU 200 and sent to the motor controllers 51 and 61. Accordingly,
there is a difference in the signals equal to the difference
between the instantaneous value of the demand signal DEM and the
value of the drive demand signal DRVDEM. The motor controllers 51
and 61 send a drive command signal DRVCMD to the motors 50 and 60
to create torque and speed. The drive command signal DRVCMD follows
and is proportional to the drive demand signal DRVDEM. The
relationship between the value of the drive command signal DRVCMD
and the instantaneous value of the drive demand signal DRVDEM is
similar to the relationship between the drive demand signal DRVDEM
and the instantaneous value of the demand signal DEM.
[0075] The ECU 200 uses a proportional-integral-derivative (PID)
control mode to adaptively control the propulsion of the vehicle
10. The control mode may be stored as a program in a memory of the
ECU 200 and executed by the PLC 210. The proportional mode produces
an output proportional to the difference between the instantaneous
value of the demand signal DEM and the drive demand signal DRVDEM.
The integral mode produces an output proportional to the amount of
the difference and the length of time the difference is present.
The derivative mode produces an output proportional to the rate of
change of the difference. The PID control mode may be applied to
other systems of the vehicle 10 in addition to the control of the
motors 50 and 60 for controlling the propulsion of the vehicle 10
and may be applied to systems that have transient differences and
to systems that have steady-state differences. All three
components, proportional, integral, and derivative, of the PID
control mode are summed and can be adjusted in real time to create
a controlled output, thus changing the system responsiveness.
[0076] The PID control mode is provided with parameters within
which the signals necessary to control the electric motors 50 and
60, including the drive command signal DRVCMD, are adaptively
adjusted and controlled. For example, the drive demand signal
DRVDEM generated by the ECU 200 is proportional to the demand
signal DEM sent by the accelerator pedal position sensor 45.
Generally, the value of the drive demand signal DRVDEM is equal to
100% of the value of the demand signal DEM. However, within the PID
control mode, the value of the drive demand signal DRVDEM may be
set equal to 110% of the value of the demand signal DEM in order to
increase the responsiveness of the vehicle 10. Conversely, the
value of the drive demand signal DRVDEM may be set equal to 90% of
the value of the demand signal DEM in order to decrease the
responsiveness of the vehicle 10, for example when the state of
charge SOC of the battery array 30 is insufficient to meet a sudden
increase in user demand.
[0077] Additionally, a drive command upper control limit DRVCMDUCL
and a drive command lower control limit DRVCMDLCL of the drive
command signal DRVCMD are adaptively adjusted by the PID control
mode in response to vehicle conditions, such as the driving mode
and/or an emission mode of the vehicle 10. The drive command upper
control limit DRVCMDUCL and drive command lower control limit
DRVCMDLCL may be empirically determined and dependent on service
conditions, such as terrain and weather conditions, that the
vehicle 10 will likely be operated under. It should also be
appreciated that the PID parameters are also empirically determined
and may be any value. For example, the PID parameters may be
determined so that the value of the drive demand signal DRVDEM may
be as low as 80% of the value of the demand signal DEM and as high
as 120% of the value of the signal DEM.
[0078] An exemplary embodiment of a method for adaptively
controlling the propulsion of the series hybrid electric vehicle
will be explained with reference to FIGS. 10-15. The control
subroutines illustrated in FIGS. 10-15 are executed concurrently at
predetermined time intervals during operation of the vehicle.
[0079] Referring to FIG. 10, a throttle control subroutine begins
in step S100 and proceeds to step S110 where it is determined if
the demand signal DEM is smaller than the drive demand signal
DRVDEM. If the demand signal DEM is not smaller than the drive
demand signal DRVDEM (S110: NO), the control proceeds to step S120
where the drive command signal DRVCMD to the motors 50 and 60 is
increased within the PID parameters. The control then returns to
the beginning in step S140. If the demand signal DEM is smaller
than the drive demand signal DRVDEM (S110: Yes), the control
proceeds to step S130 where the drive command signal DRVCMD to the
motors 50 and 60 is decreased within the PID parameters. The
control then returns to the beginning in step S140.
[0080] Referring to FIG. 11, a battery array state of charge
subroutine begins in step S200 and proceeds to step S210 where it
is determined if the battery array state of charge SOC is
sufficient to sustain a state of charge upper control limit UCL. If
the state of charge SOC is not sufficient (S210: No), the control
proceeds to step S220 where the drive command upper control limit
DRVCMDUCL parameters are lowered. The control then returns to the
beginning in step S280. If the state of charge SOC is sufficient to
sustain the state of charge upper control limit UCL (S210: Yes),
the control proceeds to step S230 where it is determined if the
battery array temperature is sufficient to sustain the state of
charge upper control limit UCL.
[0081] If the battery array temperature is not sufficient to
sustain the state of charge upper control limit UCL (S230: No), the
control proceeds to step S220 where the drive command upper control
limit DRVCMDUCL parameters are lowered. The control then returns to
the beginning in step S280. If the battery array temperature is
sufficient to sustain the state of charge upper control limit UCL
(S230: Yes), the control proceeds to step S240 where it is
determined if the vehicle 10 is in the first driving mode F1. If it
is determined that the vehicle 10 is not in the first driving mode
F1 (S240: No), the control proceeds to step S250 where it is
determined if the drive command upper control limit DRVCMDUCL is
less than a drive command upper control limit DRVCMDUCL2 associated
with the second driving mode F2.
[0082] If it is determined that the drive command upper control
limit DRVCMDUCL is not less than the drive command upper control
limit DRVCMDUCL2 associated with the second driving mode F2 (S250:
No), the control proceeds to step S220 where the drive command
upper control limit DRVCMDUCL parameters are lowered. The control
then returns to the beginning in step S280. If it is determined
that the drive command upper control value DRVCMDUCL is less than
the drive command upper control limit DRVCMDUCL2 associated with
the second driving mode F2 (S250: Yes), the control proceeds to
step S270 where the drive command upper control limit DRVCMDUCL
parameters are raised. The control then returns to the beginning in
step S280.
[0083] If it is determined that the vehicle 10 is in the first
driving mode F1 (S240: Yes), the control proceeds to step S260
where it is determined whether the drive command upper control
limit DRVCMDUCL is less than a drive command upper control limit
DRVCMDUCL1 associated with the first driving mode F1. If the drive
command upper control limit DRVCMDUCL is not less than the drive
command upper control limit DRVCMDUCL1 associated with the first
driving mode F1 (S260: No), the control proceeds to step S220 where
the drive command upper control limit DRVCMDUCL parameters are
lowered. The control then returns to the beginning in step
S280.
[0084] If the drive command upper control limit DRVCMDUCL is less
than the drive command upper control limit DRVCMDUCL1 associated
with the first driving mode F1 (S260: Yes), the control proceeds to
step S270 where the drive command upper control limit DRVCMDUCL
parameters are raised. The control then returns to the beginning in
step S280.
[0085] Referring to FIG. 12, an emission mode subroutine begins in
step S300 and proceeds to step S310 where it is determined if the
vehicle 10 is in a first emission mode. The first emission mode is
a mode in which the engine 300 is at full output or where full
output is allowed. If it is determined that the vehicle 10 is in
the first emission mode (S310: Yes), the control proceeds to step
S320 where the drive command upper control limit DRVCMDUCL and the
drive command lower control limit DRVCMDLCL are raised. The control
then returns to the beginning in step S370.
[0086] If it determined that the vehicle 10 is not in the first
emission mode (S310: No), the control proceeds to step S330 where
it is determined if the vehicle 10 is in a second emission mode.
The second emission mode is a mode in which the engine 300 is at a
minimum output. If it is determined that the vehicle 10 is in the
second emission mode (S330: Yes), the control proceeds to step S340
where the drive command upper control limit DRVCMDUCL and the drive
command lower control limit DRVCMDLCL are modified. If the vehicle
10 was previously in the first emission mode, the drive command
upper control limit DRVCMDUCL and the drive command lower control
limit DRVCMDLCL are lowered. If the vehicle 10 was previously in a
third emission mode, the drive command upper control limit
DRVCMDUCL and the drive command lower control limit DRVCMDLCL are
raised. The control then returns to the beginning in step S370.
[0087] If it is determined that the vehicle 10 is not in the second
emission mode (S330: No), the control proceeds to step S350 where
it is determined if the vehicle 10 is in the third emission mode.
The third emission mode is a mode in which the engine 300 is turned
off. In other words, the third emission mode is a zero emission
mode.
[0088] If it is determined that the vehicle 10 is in the third
emission mode (S350: Yes), the control proceeds to step S360 where
the drive command upper control limit DRVCMDUCL and the drive
command lower control limit DRVCMDLCL are lowered. The control then
returns to the beginning in step S370. If it is determined that the
vehicle 10 is not in the third emission mode (S350: No), the
control returns to the beginning in step S370.
[0089] Referring to FIG. 13, a regenerative braking mode subroutine
begins in step S400 and proceeds to step S410 where it is
determined if the vehicle is in the first regenerative braking mode
R1. If it is determined that the vehicle 10 is in the first
regenerative braking mode R1 (S410: Yes), the control proceeds to
step S420 where feedforward regeneration mode settings associated
with the first regeneration mode R1 are lowered. The feedforward
regeneration mode settings are used to raise the PID parameters to
quicken the response of the system. The control then returns to the
beginning in step S 470.
[0090] If it is determined that the vehicle 10 is not in the first
regenerative braking mode R1 (S410: No), the control proceeds to
step S430 where it is determined if the vehicle is in the second
regenerative braking mode R2. If the vehicle is in the second
regenerative braking mode R2 (S430: Yes), the control proceeds to
step S440 where the feedforward regeneration mode settings
associated with the second regenerative braking mode R2 are
modified. If the state of charge SOC is approaching the upper
control limit UCL, the feedforward regeneration mode settings
associated with the second regenerative braking mode R2 are
lowered. Conversely, if the state of charge SOC is approaching the
lower control limit LCL, the feedforward regeneration mode settings
associated with the second regenerative braking mode R2 are raised.
The control then returns to the beginning in step S470.
[0091] If is determined that the vehicle 10 is not in the second
regenerative braking mode R2 (S430: No), the control proceeds to
step S450 where it is determined if the vehicle 10 is in the third
regenerative braking mode R3. If the vehicle 10 is in the third
regenerative braking mode R3 (S450: Yes), the control proceeds to
step S460 where the feedforward regeneration mode settings
associated with the third regenerative braking mode R3 are raised.
The control then returns to the beginning in step S470. If it is
determined that the vehicle 10 is not in the third regenerative
braking mode R3 (S450: No), the control returns to the beginning in
step S470.
[0092] Referring to FIG. 14, a left traction control subroutine for
the electric motor 50 (left drive), in an exemplary embodiment in
which the vehicle 10 is rear wheel drive, begins in step S500 and
proceeds to step S510 where it is determined if the electric motor
50 is operating nominally. According to an exemplary embodiment of
the invention, the electric motor 50 is determined to be operating
nominally if the voltage and temperature of the electric motor 50
are within predetermined parameters. If the electric motor 50 is
not operating nominally (S510: No), the control proceeds to step
S520 where a drive warning and/or faults are reset. The faults are
error codes generated by the ECU 200 upon detection of
abnormalities, such as a short circuit in an IGBT 330 or failure of
an encoder 56 or 66. The control then proceeds to step S530 where
it is determined if the electric motor 50 is operating nominally.
If the electric motor is still not operating nominally (S530: No),
the control proceeds to step S540 where the electric motor 50 is
shut down if required and torque is shifted to the right side by
increasing the torque drive command to the electric motor 60. The
control then returns to the beginning in step S595.
[0093] If after resetting the drive warning and/or faults, it is
determined that the electric motor 50 is operating nominally (S530:
Yes), the control proceeds to step S550 where it is determined if
the electric motor 60 (right drive in the exemplary rear wheel
drive vehicle 10) is operating nominally. The electric motor 60 is
determined to be operating nominally if the voltage and temperature
of the electric motor 60 are within predetermined parameters. If
the electric motor 60 is not operating nominally (S550: No), the
control proceeds to step S560 where torque is shifted to the left
drive by increasing the drive to the electric motor 50 and
increasing upper control limits of the torque and velocity of the
electric motor 50. The control then proceeds to step S570. If it is
determined that the electric motor 60 is operating nominally (S550:
Yes), the control proceeds directly to step S570.
[0094] In step S570, it is determined if adequate traction is
maintained. Adequate traction is not maintained if excessive
slippage is detected between a rear wheel 13 or 14 and a speed
reference which is a value slightly higher than the speed of the
front wheels 11 and 12. If adequate traction is not maintained
(S570: No), the control proceeds to step S580 where the drive to
motors 50 and 60 is decreased until the speed of the wheels 13 and
14 matches the speed reference. The control then returns to the
beginning in step S595. If adequate traction is maintained (S570:
Yes), the drives to the motors 50 and 60 are maintained in step
S590. The control then returns to the beginning in step S595.
[0095] Referring to FIG. 15, a right traction control subroutine
including steps S600-S695 for the electric motor 60 (right drive)
corresponds to the steps S500-S595 of the left traction control
subroutine shown in FIG. 14. The right drive is checked in steps
S610 and S630 to determine if the electric motor 60 is operating
nominally and the left drive is checked in step S650 to determine
if the electric motor 50 is operating nominally.
[0096] Referring to FIG. 16, a regenerative braking control
subroutine includes steps S700-S765 for determining when to operate
regenerative braking and to what power levels. An exemplary
embodiment of a regenerative braking arrangement implemented on the
vehicle 10 includes battery array 30 and battery array temperature
probe 30', drive motors 50 and 60 capable of producing regenerative
braking, drive motor controllers 51 and 61, throttle input sensor
45, wheels 13 and 14, and wheel speed sensors 13' and 14'. It will
be appreciated that other implementations may exist, with a
multiplicity of energy storage, drive motors and other systems
alternately employed.
[0097] In the exemplary embodiment described herein, the control
begins at step S700, where it proceeds to step S705. In step S705
it is determined if a drive motor is rotating. In the exemplary
embodiment, this is accomplished by using the wheel speed sensors
13' and 14' to characterize the rotation of the wheels 13 and 14.
It will be appreciated that other methods may be employed to
determine if a drive motor is rotating. If it is determined that a
drive motor is rotating (S705: Yes), the control proceeds to step
S710, where it is determined if the throttle input 45 is inactive.
This is used to determine if the operator is commanding the
throttle to accelerate the vehicle. Regenerative braking should
only be activated if the driver is not commanding the throttle.
[0098] If the throttle input is inactive (S710: Yes), the control
proceeds to step S715, where it is determined if the battery array
30 is operating nominally. In the exemplary embodiment, the battery
array is operating nominally if the battery temperature sensed at
the probe 30' is within a predefined range of temperature, and the
battery array state of charge is below an upper state of charge
limit. If the battery array is operating nominally (S715: Yes), the
control proceeds to step S720, where it is determined if the
braking input is active. In the embodiment, the braking input is
used to determine if the operator is commanding a braking event. If
it is determined that there is a braking input active (S720: Yes),
the control proceeds to step S725, where it is determined if the
anti-lock braking system (ABS), traction control system, or other
wheel spin control device or algorithm is inactive. In the
embodiment, this determines if there are other vehicle systems or
controls that have the potential to interfere with the regenerative
braking. If it is determined that there is one or more wheel spin
control devices active (S725: No) the control proceeds to step
S730, where regenerative braking is disabled. The control then
proceeds to step S760, where it returns to the beginning.
[0099] If it is determined that all wheel spin control devices are
inactive (S725: Yes), the control proceeds to step S735. In step
S735 in the exemplary embodiment, signals are generated to allow
regenerative braking corresponding to the levels indicated by the
selected mode of regenerative braking. The control then proceeds to
step S740, where it is determined if traction is maintained. In the
exemplary embodiment, this is determined by using the wheel speed
sensors 13' and 14' to measure the speed of wheels 13 and 14 and
make a comparison. A difference in rotational wheel speed of more
than a critical percentage, for example 5%, would indicate a
slipping wheel. It will be appreciated that other methods of
determining wheel slippage may be used, and the control method
herein is not limited to this embodiment.
[0100] If in step S740 it is determined that wheel traction is not
maintained (S740: No), the control proceeds to step S745, where the
regenerative braking command is reduced. In the exemplary
embodiment, wheel traction loss may be indicative of a regenerative
braking command that causes the wheel to lose traction on a surface
of reduced coefficient of friction, such as ice. The control then
proceeds to step S760, where it returns to the beginning. If in
step S740 it is determined that wheel traction is maintained (S740:
Yes), the control proceeds to step S750, where it is determined if
the battery array is operating nominally. In the exemplary
embodiment, a high battery array state of charge indicates
reduction of regenerative braking is necessary to reduce the amount
of energy being transferred from regenerative braking into the
battery array. If it is determined in step S750 that the battery
array is not operating nominally (S750: No), the control proceeds
to step S755 where regenerative braking is reduced. The control
then proceeds to step S760, where it returns to the beginning. If
it is determined that the battery array is operating nominally
(S750: Yes) the control proceeds to step S760, where it returns to
the beginning.
[0101] Referring to FIG. 17, a regenerative braking fault control
includes steps S800-S870 for determining if vehicle components are
faulted, and controlling the regenerative braking based upon the
fault status. An exemplary embodiment of a regenerative braking
arrangement implemented on the vehicle 10 includes battery array 30
and battery array temperature probe 30', drive motors 50 and 60
capable of producing regenerative braking, drive motor controllers
51 and 61. It will be appreciated that other implementations may
exist, with a multiplicity of energy storage, drive motors and
other systems alternately employed.
[0102] In the exemplary embodiment described herein, the control
begins at step S800, where it proceeds to step S810. In step S810,
it is determined if the battery array 30 is in a warning state or
faulted. If the battery array is faulted (S810: Yes), the control
proceeds to step S820 where it is determined if the battery array
is depleted. In an exemplary embodiment, the battery array may
generate warnings or faults if the state of charge of the battery
array falls below a predetermined lower state of charge limit. It
will be appreciated that other systems for determining battery
array warnings or faults may also be used, and other conditions or
states may also cause battery array warnings or faults. If the
battery array is depleted (S820: Yes), the control proceeds to step
S830, where the regenerative braking command is increased. The
control then proceeds to step S870, where it returns to the
beginning. If the battery array is not depleted (S820: No), the
control proceeds to step S840, where the regenerative braking is
disabled. The control then proceeds to step S870, where it returns
to the beginning.
[0103] If it is determined that the battery array 30 is not in a
warning or fault state (S810: No), the control proceeds to step
S850 where it is determined if the drive motor is in a warning
state or faulted. In an exemplary embodiment, the drive motor may
generate warnings or faults if the drive motor temperature exceeds
a predetermined limit. It will be appreciated that other conditions
or states may also cause drive motor warnings or faults. If the
drive motor is in a warning or fault state (S850: Yes) the control
proceeds to step S860 where the regenerative braking is disabled.
The control then proceeds to step S870, where it returns to the
beginning. If the drive motor is not in a warning or fault state
(S850: No), the control proceeds to step S870, where it returns to
the beginning.
[0104] Referring to FIG. 18, a regenerative braking temperature
control includes steps S900-S965 for determining the appropriate
level of regenerative braking to be provided in response to system
component temperatures. An exemplary embodiment of a regenerative
braking arrangement implemented on the vehicle 10 includes battery
array 30 and battery array temperature probe 30', drive motors 50
and 60 capable of producing regenerative braking, drive motor
controllers 51 and 61, internal combustion engine 300, generator
310, and generator controller 320. It will be appreciated that
other implementations may exist, with a multiplicity of energy
storage, drive motors and other systems alternately employed.
[0105] In the exemplary embodiment described herein, the control
begins at step S900, where it proceeds to step S905. In step S905,
it is determined if the battery array 30 temperature is nominal. If
it is not (S905: No), the control proceeds to step S910, where it
is determined if the battery array temperature above a
predetermined limit. If it is determined the battery array
temperature is not above a predetermined limit (S910: No), the
control proceeds to step S915, where the regenerative braking
command is increased. The control then proceeds to step S965, where
it returns to the beginning. If the battery array temperature is
above a predetermined limit (S910: Yes), the control proceeds to
step S920, where the regenerative braking command is reduced. The
control then proceeds to step S965, where it returns to the
beginning.
[0106] If in step S905 it is determined that the battery array
temperature is nominal (S905: Yes), the control proceeds to step
S925 where it is determined if the cooling system temperature is
nominal. If it is not (S925: No), the control proceeds to step
S930, where it is determined if the cooling system temperature is
above a predetermined limit. If it is determined the cooling system
temperature is not above a predetermined limit (S930: No), the
control proceeds to step S935, where the regenerative braking
command is increased. The control then proceeds to step S965, where
it returns to the beginning. If the cooling system temperature is
above a predetermined limit (S930: Yes), the control proceeds to
step S940, where the regenerative braking command is reduced. The
control then proceeds to step S965, where it returns to the
beginning.
[0107] If in step S925 it is determined that the cooling system
temperature is nominal (S925: Yes), the control proceeds to step
S945 where it is determined if the drive motor temperature is
nominal. If it is not (S945: No), the control proceeds to step
S950, where it is determined if the drive motor temperature is
above a predetermined limit. If it is determined the drive motor
temperature is not above a predetermined limit (S950: No), the
control proceeds to step S955, where the regenerative braking
command is increased. The control then proceeds to step S965, where
it returns to the beginning. If the drive motor temperature is
above a predetermined limit (S950: Yes), the control proceeds to
step S960, where the regenerative braking command is reduced. The
control then proceeds to step S965, where it returns to the
beginning.
[0108] It will be appreciated by those skilled in the art that the
ECU can be implemented using a single special purpose integrated
circuit (e.g., ASIC) having a main or central processor section for
overall, system-level control, and separate sections dedicated to
performing various different specific computations, functions and
other processes under control of the PLC. The ECU also can be a
plurality of separate dedicated or programmable integrated or other
electronic circuits or devices (e.g., hardwired electronic or logic
circuits such as discrete element circuits, or programmable logic
devices such as PLDs, PLAs, PALs, DSPs or the like). The ECU can be
implemented using a suitably programmed general purpose computer,
e.g., a microprocessor, microcontroller or other processor device
(CPU or MPU), either alone or in conjunction with one or more
peripheral (e.g., integrated circuit) data and signal processing
devices. In general, any device or assembly of devices on which a
finite state machine capable of implementing the flowcharts shown
in FIGS. 8-12 and described herein can be used as the ECU. A
distributed processing architecture can be used for maximum
data/signal processing capability and speed.
[0109] While the invention has been described with reference to
various exemplary embodiments thereof, it is to be understood that
the invention is not limited to the disclosed embodiments or
constructions. To the contrary, the invention is intended to cover
various modifications and equivalent arrangements. In addition,
while the various elements of the disclosed invention are shown in
various combinations and configurations, which are exemplary, other
combinations and configurations, including more, less or only a
single element, are also within the spirit and scope of the
invention.
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