U.S. patent application number 10/648079 was filed with the patent office on 2006-05-25 for method and apparatus for power flow management in electro-mechanical transmissions.
Invention is credited to Xiaolan Ai, Scott Anderson.
Application Number | 20060111212 10/648079 |
Document ID | / |
Family ID | 34216670 |
Filed Date | 2006-05-25 |
United States Patent
Application |
20060111212 |
Kind Code |
A9 |
Ai; Xiaolan ; et
al. |
May 25, 2006 |
METHOD AND APPARATUS FOR POWER FLOW MANAGEMENT IN
ELECTRO-MECHANICAL TRANSMISSIONS
Abstract
A method for power management in an electro-mechanical
power-split infinitely variable transmission (eVT) designed to
operated within a designated speed ratio range for vehicular
applications. The eVT is comprised of an input shaft coupled to the
output shaft of a drive engine to receive power, a drive shaft, two
electric machines, and a pair of planetary trains each having a sun
member, a ring member, a set of planetary members, and a planet
carrier. The eVT further contains one or more torque transfer
devices to connect or disconnect members of the planetary trains
for transferring torque. The drive shaft is coupled with a final
drive of a vehicle for delivering or recapturing power to or from
the vehicle drive wheels. The two electric machines are
interconnected electronically via a power control unit and are
coupled respectively with members of the planetary train. The
method of power management in the eVT is selected based on the
current speed and torque of the input and drive shafts, and upon
the desired operating parameters.
Inventors: |
Ai; Xiaolan; (Massillon,
OH) ; Anderson; Scott; (Palos Hills, IL) |
Correspondence
Address: |
POLSTER, LIEDER, WOODRUFF & LUCCHESI
12412 POWERSCOURT DRIVE SUITE 200
ST. LOUIS
MO
63131-3615
US
|
Prior
Publication: |
|
Document Identifier |
Publication Date |
|
US 20050049100 A1 |
March 3, 2005 |
|
|
Family ID: |
34216670 |
Appl. No.: |
10/648079 |
Filed: |
August 26, 2003 |
Current U.S.
Class: |
475/5 |
Current CPC
Class: |
B60K 6/445 20130101;
Y02T 10/6239 20130101; B60W 20/10 20130101; F16H 3/728 20130101;
B60K 6/543 20130101; F16H 2200/2007 20130101; Y10T 477/337
20150115; B60W 10/10 20130101; B60K 6/365 20130101; B60W 20/00
20130101; B60K 1/02 20130101; B60W 10/08 20130101; Y02T 10/62
20130101; F16H 2037/102 20130101; F16H 3/727 20130101 |
Class at
Publication: |
475/005 |
International
Class: |
F16H 3/72 20060101
F16H003/72 |
Claims
1. A power transmission system for regulating the delivery of power
to a drive shaft, said power transmission system comprising: an
engine having an output shaft; a pair of planetary trains
operatively coupled between said output shaft and said drive shaft
for transmitting power output from said engine to said drive shaft,
each of said planetary trains including a sun member, a ring
member, a set of planet members, and a planet carrier; a first
electric machine linked with at least said one member of a first
planetary train in said pair of planetary trains for receiving and
transmitting power to and from said drive shaft; a second electric
machine linked with said one member of a second planetary train in
said pair of planetary trains for receiving and transmitting power
to and from said drive shaft; a set of torque transfer components
operatively coupled to said pair of planetary trains, said set of
torque transfer components including a clutch for selectively
coupling a member of said first planetary train to a member of said
second planetary train, and a brake for selectively coupling said a
member of said second planetary train to a fixed member of the
power transmission system; an engine control unit configured to
provide an engine torque responsive to a target torque level
established based on a performance objective; a power control unit
operatively coupled to said first and second electric machines,
said power control unit configured to control a flow of electric
power to and from each of said electric machines to regulate a
magnitude of delivered power to the drive shaft, and said power
control unit further configured to control of said at least one set
of torque transfer components.
2. The power transmission system of claim 1 wherein said first and
second electric machines each have a power rating P.sub.v of: P v
.gtoreq. ( SR 2 SR 1 .times. ( 1 + .psi. ) - 1 ) 2 SR 2 SR 1 - 1
.times. P in ##EQU17## where P.sub.in is power delivered to the
input of said power transmission system; where SR.sub.1 is the
output-to-input speed ratio at which said first electric machine
has a zero rotational speed; where SR.sub.2 is the output-to-input
speed ratio at which said second electric machine has a zero
rotational speed; and where .psi. is a ratio of electric input
power to said first and second electric machines to mechanical
input power at said engine output shaft.
3. The power transmission system of claim 1 wherein said power
control unit is configured to select a control structure for said
first and second electric machines responsive to a speed ratio
between said drive shaft and said engine output shaft.
4. The power transmission system of claim 3 wherein said power
control unit is configured to control one of said first and second
electric machines to provide torque to regulate said speed
ratio.
5. The power transmission system of claim 3 wherein said power
control unit is configured to control one of said first and second
electric machines to provide torque to balance power in said pair
of planetary trains.
6. The power transmission system of claim 1 wherein said power
control unit is configured to selectively control said at least one
set of torque transfer components responsive to a speed ratio
between said drive shaft and said engine output shaft.
7. The power transmission system of claim 6 wherein said power
control unit is configured to control said at least one set of
torque transfer components to selectively couple two or more
components of said pair of planetary trains in an output
power-split configuration.
8. The power transmission system of claim 6 wherein said power
control unit is configured to control said at least one set of
torque transfer components to selectively couple two or more
components of said pair of planetary trains in an compound
power-split configuration.
9. The power transmission system of claim 6 wherein said power
control unit is configured to control said at least one set of
torque transfer components to alter one or more couplings between
said pair of planetary trains between an output power-split
configuration and a compound power-split configuration at a node
point where a rotational speed of at least one of said first and
second electric machines is substantially zero.
10. The power transmission system of claim 1 further including an
energy storage device operatively coupled to said first and second
electric machines; and wherein said power control unit is
operatively coupled to said energy storage device to regulate a
flow of electric energy between said energy storage device, said
first electric machine, and said second electric machine.
11. The power transmission system of claim 10 wherein said engine
control unit is configured to shut off said engine responsive to a
predetermined set of operating conditions; and wherein said power
control unit is further configured to control said torque transfer
components to decouple said first and second planetary trains
responsive to said predetermined set of operating conditions; and
to regulate a flow of electric power from said energy storage
device to at least one of said first and second electric machines,
wherein said electric machine provides power to said drive shaft
through said second planetary train.
12. The power transmission system of claim 3 wherein said power
control unit is configured responsive to said speed ratio: (a) at
or below a first node point to regulate torque from said first
electric machine and said second electric machine utilizing a first
control regime; and (b) greater than said first node point to
regulate torque from said first electric machine and said second
electric machine utilizing a second control regime.
13. The power transmission system of claim 12 wherein said power
control unit is further configured responsive to said speed ratio
greater than a switch point to regulate torque from said second
electric machine and said first electric machine utilizing a third
control regime.
14. The power transmission system of claim 13 wherein said power
control unit is further configured to optionally utilize said third
control regime in place of said second control regime when said
speed ratio is greater than said first node point to regulate
torque from said first electric machine and said second electric
machine.
15. The power transmission system of claim 12 wherein said power
control unit is configured responsive to said speed ratio at or
below said first node point to regulate torque from said first
electric machine to: T E1 = T R1 K 1 + .phi. SGI .function. (
.omega. e * - .omega. e ) ##EQU18## and the power from said second
electric machine to: P.sub.E2=-P.sub.E1+P.sub.pto.sub.--.sub.e
where T.sub.R1 is the input torque to the ring member of the first
planetary train; K.sub.1 is the planetary ratio of the first
planetary train; .phi..sub.SGI(.omega..sub.e*-.omega..sub.e) is a
feedback function of engine speed error; P.sub.E1 is the electrical
power from the first electric machine; and P.sub.pto.sub.--.sub.e
is the electrical power taken off from said engine and said pair of
planetary trains.
16. The power transmission system of claim 12 wherein said power
control unit is configured responsive to said speed ratio greater
than said first node point to regulate torque from said first
electric machine to: T E1 = ( K 1 .times. K 2 K 2 + 1 1 SR o - i +
1 - K 1 .times. K 2 K 2 + 1 ) .times. T R1 K 1 - K 2 K 2 + 1 P
pto_e .omega. d + .phi. SGii .function. ( .omega. e * - .omega. e )
##EQU19## and the power from said second electric machine to:
P.sub.E2=-P.sub.E1+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.O-I is the speed ratio; .phi..sub.SGII
(.omega..sub.e*-.omega..sub.e) is a feedback function of engine
speed error; P.sub.E1 is the electrical power from the first
electric machine; and P.sub.pto.sub.--.sub.e is the electrical
power taken off from said engine and said pair of planetary
trains.
17. The power transmission system of claim 12 wherein said power
control unit is configured responsive to said speed ratio greater
than said first node point to regulate torque from said second
electric machine to: T E2 = ( K 1 K 2 + 1 1 SR o - i - K 1 + 1 K 2
+ 1 ) .times. T R1 K 1 - 1 K 2 + 1 P pto_e .omega. d + .phi. SGiIi
.function. ( .omega. e * - .omega. e ) ##EQU20## and the power from
said first electric machine to:
P.sub.E1=-P.sub.E2+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.O-I is the speed ratio; .omega..sub.d is the drive shaft
speed; .phi..sub.SGIII (.omega..sub.e*-.omega..sub.e) is a feedback
function of engine speed error; P.sub.E2 is the electrical power
from the second electric machine; and P.sub.pto.sub.--.sub.e is the
electrical power taken off from said engine and said pair of
planetary trains.
18. The power transmission system of claim 12 wherein said power
control unit is configured responsive to said speed ratio: (a)
greater than said first node point and below a switch point less
than a second said node point to regulate torque from said first
electric machine to T E1 = ( K 1 .times. K 2 K 2 + 1 1 SR o - i + 1
- K 1 .times. K 2 K 2 + 1 ) .times. T R1 K 1 - K 2 K 2 + 1 P pto_e
.omega. d + .phi. SGii .function. ( .omega. e * - .omega. e )
##EQU21## and to regulate power from said second electric machine
to: P.sub.E2-P.sub.E1+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.O-I is the speed ratio; .phi..sub.SGII
(.omega..sub.e*-.omega..sub.e) is a feedback function of engine
speed error; P.sub.E1 is the electrical power from said first
electric machine; and P.sub.pto.sub.--.sub.e is the electrical
power taken off from said engine and said pair of planetary trains;
(b) at or greater than said switch point to regulate torque from
said second electric machine to T E2 = ( K 1 K 2 + 1 1 SR o - i - K
1 + 1 K 2 + 1 ) .times. T R1 K 1 - 1 K 2 + 1 P pto_e .omega. d +
.phi. SGiIi .function. ( .omega. e * - .omega. e ) ##EQU22## and
the power from said first electric machine to:
P.sub.E1=-P.sub.E2+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.o-I is the speed ratio; .omega..sub.d is the drive shaft
speed; .phi..sub.SGIII (.omega..sub.e*-.omega..sub.e) is a feedback
function of engine speed error; P.sub.E2 is the electrical power
from said second electric machine; and P.sub.pto.sub.--.sub.e is
the electrical power taken off from said engine and said pair of
planetary trains.
19. The power transmission system of claim 1 wherein said power
control unit is further configured to control said at least one set
of torque transfer components to decouple said first and second
planetary trains, to drive said first electric machine from said
engine through said first planetary train to generate electric
power, and to drive said drive shaft in reverse operation from said
second electric machine through said second planetary train; and
wherein said power control unit is further configured to regulate a
flow of electric power from said first electric machine to said
second electric machine.
20. The power transmission system of claim 19 wherein said first
planetary train is configured to amplify a rotational speed between
said output shaft of said engine and said first electric machine;
and wherein said second planetary train is configured to reduce a
rotational speed between said second electric machine and said
drive shaft.
21. The power transmission system of claim 1 wherein said engine
control unit and power control unit are configured for hybrid mode
operation.
22. The power transmission system of claim 1 wherein said engine
control unit and power control unit are configured for non-hybrid
mode operation.
23. The power transmission system of claim 1 wherein said engine
control unit and power control unit are configured for
electric-only operation.
24. The power transmission system of claim 1 wherein said engine
control unit and power control unit are configured for series
hybrid mode operation.
25. A method for series hybrid operation in a power transmission
system including an engine having an output shaft, a pair of
planetary units between the engine output shaft and an output drive
shaft, each planetary unit having ring member located around a sun
member, planet members located between the sun and ring members,
and a carrier member coupled with the planets and providing axes
about which the planet members rotate, one of the members of the
first planetary unit engageable with one of the members of the
second planetary unit to form a first compound member branch,
another of the members of the first unit engageable with another of
the members of the second planetary unit to form a second compound
branch, a first electric machine coupled to the sun member of the
first planetary unit, and a second electric machine coupled to the
sun member of the second planetary unit, a power control unit
coupled to the first and second electric machines, the method
comprising: decoupling said first and second planetary trains from
each other; configuring said first planetary train as a speed
increaser; driving said first electric machine from said engine
output shaft through said first planetary train to generate
electrical power; configuring said second planetary train as a
speed reducer; delivering said electrical power from said first
electric machine to said second electric machine; driving said
output drive shaft from said second electric machine through said
secondary planetary train; and regulating said generation and
delivery of electrical power from said first electric machine to
said second electric machine to control said output drive shaft
rotational speed.
26. A method for power regulation in a power transmission system
including an engine having an output shaft, a pair of planetary
units between the engine output shaft and an output drive shaft,
each planetary unit having ring member located around a sun member,
planet members located between the sun and ring members, and a
carrier member coupled with the planets and providing axes about
which the planet members rotate, at least one of the members of the
first planetary unit engagable with one of the members of the
second planetary unit to form a compound member branch, a first
electric machine coupled to one member of the first planetary unit,
and a second electric machine coupled to one member of the second
planetary unit, a power control unit coupled to the first and
second electric machines, the method comprising: identifying the
output drive shaft rotational speed and driver inputs; calculating
engine output utilizing said output drive shaft rotational speed
and at least one driver input; determining a engine operating point
based on a selected performance objective; calculating a speed
ratio between said output drive shaft and said engine output shaft;
selecting an operating regime for said power transmission system
based upon said calculated speed ratio; selecting a control routine
for each of said first and second electric machines based upon said
calculated speed ratio; controlling one of said electric machines
to provide torque to regulate said engine rotational speed based
upon said operating regime and control routines; controlling a
second of said electric machines to provide torque to balance power
in said first and second planetary units based upon said operating
regime and control routines; and regulating the engine to achieve a
desired engine output torque based on a selected performance
objective.
27. The method for power regulation of claim 26 wherein the step of
selecting a control routine for each of said electric machines is
responsive to said speed ratio being: (a) at or below a first node
point, to select a first set of control routines; (b) greater than
said first node to select a second set of control routines; and (c)
greater than a switch point to select a third set of control
routines.
28. The method for power regulation of claim 27 wherein said first
set of control routines regulates torque from said first electric
machine to: T E1 = T R1 K 1 + .phi. SGI .function. ( .omega. e * -
.omega. e ) ##EQU23## and power from said second electric machine
to: P.sub.E2=-P.sub.E1+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
.phi..sub.SGI (.omega..sub.e*-.omega..sub.e) is a feedback function
of engine speed error; P.sub.E1 is the electrical power from the
first electric machine; and P.sub.pto.sub.--.sub.e is the
electrical power taken off from said engine and said pair of
planetary trains.
29. The method for power regulation of claim 27 wherein said second
set of control routines regulates torque from said first electric
machine to: T E1 = ( K 1 .times. K 2 K 2 + 1 1 SR o - i + 1 - K 1
.times. K 2 K 2 + 1 ) .times. T R1 K 1 - K 2 K 2 + 1 P pto_e
.omega. d + .phi. SGII .function. ( .omega. e * - .omega. e )
##EQU24## and power from said second electric machine to:
P.sub.E2=-P.sub.E1+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.O-I is the speed ratio; .phi..sub.SGII
(.omega..sub.e*-.omega..sub.e) is a feedback function of engine
speed error; P.sub.E1 is the electrical power from the first
electric machine; and P.sub.pto.sub.--.sub.e is the electrical
power taken off from said engine and said pair of planetary
trains.
30. The method for power regulation of claim 27 wherein said third
set of control routines regulates torque from said first electric
machine to: T E2 = ( K 1 K 2 + 1 1 SR o - i - K 1 + 1 K 2 + 1 )
.times. T R1 K 1 - 1 K 2 + 1 P pto_e .omega. d + .phi. SGIII
.function. ( .omega. e * - .omega. e ) ##EQU25## and power from
said first electric machine to:
P.sub.E1=-P.sub.E2+P.sub.pto.sub.--.sub.e where T.sub.R1 is the
input torque to the ring member of the first planetary train;
K.sub.1 is the planetary ratio of the first planetary train;
K.sub.2 is the planetary ratio of the second planetary train;
SR.sub.O-I, is the speed ratio; .omega..sub.d is the drive shaft
speed; .phi..sub.SGIII (.omega..sub.e*-.omega..sub.e) is a feedback
function of engine speed error; P.sub.E2 is the electrical power
from the second electric machine; and P.sub.pto.sub.--.sub.e is the
electrical power taken off from said engine and said pair of
planetary trains.
31. The method for power regulation of claim 26 wherein the step of
selecting an operating regime for said power transmission system is
responsive to said calculated speed ratio being: (a) at or below a
first node point, to select an output-power split operating regime
and to disengage the second compound branch members; and (b)
greater than said first node point to select a compound power-split
operating regime and to engage the second compound branch
members.
32. The method of claim 26 for power regulation in a power
transmission system wherein a low-speed hybrid operating regime is
selected further including the steps of: decoupling said first and
second planetary units; regulating said engine output torque to
zero; delivering electrical power to said second electric machine
from an energy storage device; and controlling said second electric
machine to provide torque to said output drive shaft through said
second planetary unit.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH
[0002] Not Applicable.
BACKGROUND OF THE INVENTION
[0003] This invention relates in general to transmissions for
transmitting rotary motion and, more particularly, to a method for
power flow management in an electro-mechanical output power-split
and compound power-split infinitely variable transmission.
[0004] The primary function of a transmission in an automotive
vehicle is to convert the output speed and torque of an engine or
prime mover into the speed and torque of a drive shaft to meet the
specific requirements of the vehicle. In general it is desirable
for this power transmission to occur with minimal power loss; that
is, at high transmission efficiency. To optimize the overall power
train performance, specifically the engine and transmission
combination, it is also desirable to minimize engine transients and
operate the engine at a power state that yields the best tradeoff
between good fuel economy, low emissions and power.
[0005] Transmissions can be broadly categorized as "step-less" or
"stepwise", according to the way that the final desired speed ratio
is achieved. A stepwise transmission has a fixed number of speed
ratios that are sequentially selected to achieve the final desired
ratio. Therefore, it is not always possible to use the maximum
available engine power, because engine speed and load vary as the
transmission moves through its limited number of fixed ratios.
Moving from one ratio to another is sometimes termed "shifting" in
transmission design descriptions, and is often associated with
unfavorable torque interruptions. Such interruptions offset overall
drive-line efficiency and detract from driving comfort. Moreover,
for some applications, such as agricultural and construction
vehicles, an output torque interruption is extremely undesirable,
more so than a momentary loss of efficiency. Such inherent
shortcomings, associated with shifting, are minimized to some
extent in more recent designs that incorporate pre-shifting and
clutching to reduce torque interruptions. To reduce engine speed
and torque variations, modern transmissions use a greater number of
selectable ratios.
[0006] In principle, a stepwise transmission cannot achieve the
overall vehicle efficiency of a step-less transmission which offers
an infinite number of speed ratios. With a step-less transmission,
there is the option to operate the engine at its optimum efficiency
or lowest emission point at all times while the vehicle is moving
to its desired speed at a desired power level.
[0007] Step-less transmissions can be further classified into
continuously variable transmissions (CVTs) and infinitely variable
transmissions (IVTs). A continuously variable transmissions,
usually mechanical, provides continuously variable speed ratios
over the designed speed range of the vehicle. A launch-clutch and
engine-disconnect device is often required in this type of
transmission for vehicle start-up, as well as a separate gear for
reverse operation. In addition, most of the CVT designs transmit
torque through contacting friction surfaces and are not suitable
for high-torque and high-power applications.
[0008] The infinitely variable transmission, by definition, is
capable of providing infinitely selectable (output-to-input) speed
ratios from reverse, thru zero, to a wide range of forward speeds.
No launching device is required for an IVT. In theory, the engine
can be directly connected to the transmission at all times, because
a zero output-to-input speed ratio or an infinite input-to-output
speed ratio exists. An IVT transmission is based on a power-split
concept that provides multiple, often hybrid, power paths. Among
the multiple power paths, there exists at least one power path that
regulates the power flow and thus provides the input-to-output
speed ratio controlling path. The actual devices that effect the
speed ratio change within the regulating path is called a variator.
A well designed power-split transmission is able to transmit power
from the input to the output in at least two parallel power paths,
one path being the regulating or variator path, and one path being
a mechanical path. While the speed ratio is controlled in the
variator path, it is most desirable to have the majority of the
power pass through the mechanical path were the efficiency is the
highest.
[0009] The speed ratio change is made by the variators by
regulating the power that is transmitted through the variator path.
There are moments where the power that passes through the variator
path is literally zero. That is, all power is transmitted through
the mechanical path. At these moments, the transmission yields the
highest efficiency. The transmission output-to-input speed ratios
or the output speeds at these points are often referred to as node
points or nodes. The node point corresponding to the lowest
output-to-input speed ratio or the lowest output speed is called
the first node point. The node point corresponding to the next
higher output-to-input speed ratio or the next higher output speed
is the second node point, etc.
[0010] In an electro-mechanical infinitely variable transmission
(eVT), the variators are electric machines, namely motors and
generators. The advantages of using electric motors and generators
include system design flexibility, controllability, and improved
performance in terms of a wider range of speed, better efficiency,
and reduced operating noise. The electro-mechanical transmission
may also be used in conjunction with energy storage devices to
supplement the output power, allowing the engine to be downsized
and/or to operate at an optimum efficiency point for a greater
period of time. These so-called hybrid electro-mechanical
power-split transmissions have been recently designed for use in
both cars and in heavy trucks.
[0011] There are three basic power-split configurations, the "input
power-split", the "output power-split", and the "compound
power-split". These three configurations define different
relationships between the power within the variator path and the
speed ratio of the transmission. Input power-split and output
power-split configurations are often devices with single planetary
transmissions, and are capable of providing at least a single node
point. Compound power-split configurations are associated primarily
with compound planetary transmission, and are capable of providing
at least two node points.
[0012] Within power-split transmissions, there are moments when the
speed ratio goes beyond a certain range and the power in the
electric path can actually exceed several times the power that is
transmitted through the mechanical path in the transmission. This
phenomenon is known as internal power circulation. It consumes
power and decreases transmission efficiency by generating unwanted
heat within the transmission.
[0013] For input power-split transmissions, internal power
circulation occurs when output-to-input speed ratio is somewhere
below the node point. When the transmission is operated in the slow
speed regime, power in the variator path can actually exceed
several times the power that is transmitted through the
transmission. Likewise, internal power circulation can occur with
output power-split transmissions when operated at high
output-to-input speed ratios (overdrive), somewhere above the node
point, or in reverse operation. Compound power-split transmissions
have very high efficiency when operated between the two node
points. Internal power circulation occurs at speed ratios somewhere
below the first node point or above the second node point.
[0014] To restrict power circulation through the electric machines
and to control the magnitude of the electric power in the electric
power path, various control systems are known, for example, as
shown in European Patent No. 0 867 323 A2 and in U.S. Pat. Nos.
5,907,191, 5,914,575, and 5,991,683 for an output power-split
configuration and an input-power-split configuration. These control
systems employ a torque control routine to monitor the electric
motor torque and to shift the engine's operating point to a higher
engine speed when the torque limit of the electric motor is
reached. However, in doing so, the engine is operated at a point
which is less than optimal.
[0015] An alternate control system is shown in U.S. Pat. No.
6,478,705 B1 to Holmes, et al., the '705 patent. This '705 patent
discloses an eVT having two differential gearsets coupled to an
engine and first and second electric machines, wherein the gearsets
are configurable in input-split and compound-split modes. The
control system disclosed in the '705 patent provides for shifting
between the input-split and compound-split modes of operation only
at a zero speed point of one of the electric machines, thereby
permitting smooth synchronous clutch engagement. However, since the
mode shift in the control system of the '705 patent occurs
independently of the state of the second electric machine, the
problem of internal power circulation remains when the transmission
is operated in reverse, and when the second electric machine
continues to provide torque to the system during a mode shift.
[0016] Accordingly, it would be advantageous to develop an eVT
which does not suffer from the above-mentioned internal power
circulation problem when operated within the designed speed ration
ranges specified by a vehicle application.
BRIEF SUMMARY OF THE INVENTION
[0017] Briefly stated, the present invention provides a method for
power management in an electro-mechanical power-split infinitely
variable transmission (eVT) designed to operate- within a
designated speed ratio range for vehicular applications. The eVT is
comprised of an input shaft coupled to the output shaft of a drive
engine to receive power, a drive shaft, two electric machines, and
a pair of planetary trains each having a sun member, a ring member,
a set of planetary members, and a planet carrier. The eVT further
contains one or more torque transfer devices to connect or
disconnect members of the planetary trains for transferring torque.
The drive shaft is coupled with a final drive of a vehicle for
delivering or recapturing power to or from the vehicle drive
wheels. The two electric machines are interconnected electronically
via a power control unit and are coupled respectively with members
of the planetary train. The method of power management in the eVT
is selected based on the current speed and torque of the input and
drive shafts, and upon the desired operating parameters.
[0018] The foregoing and other objects, features, and advantages of
the invention as well as presently preferred embodiments thereof
will become more apparent from the reading of the following
description in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] In the accompanying drawings which form part of the
specification:
[0020] FIG. 1 is a schematic diagram of the components associated
with a vehicle drive system;
[0021] FIG. 2 is a schematic view of an electro-mechanical
power-split infinitely-variable transmission constructed in
accordance with and embodying the present invention;
[0022] FIG. 3 is a schematic view of a modified electromechanical
power-split infinitely-variable transmission similar to the
transmission of FIG. 2, but further including components for park
and reverse;
[0023] FIG. 4 is a flow chart which describes the high level power
flow and electric machine control decisions employed in the control
of the transmission;
[0024] FIG. 5 is a schematic of the constant power and brake
specific fuel consumption lines for a typical engine used to
illustrate the determination of the engine target curve;
[0025] FIG. 6 is a block diagram of the control loop used to
control the engine speed though operation of an electric machine in
the transmission.
[0026] Corresponding reference numerals indicate corresponding
parts throughout the several figures of the drawings.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0027] The following detailed description illustrates the invention
by way of example and not by way of limitation. The description
clearly enables one skilled in the art to make and use the
invention, describes several embodiments, adaptations, variations,
alternatives, and uses of the invention, including what is
presently believed to be the best mode of carrying out the
invention.
[0028] Turning first to FIG. 1, a vehicle drive system for use with
the current invention is shown generally at 10. The system 10
includes an engine 100, an electro-mechanical power-split
infinitely-variable transmission 102 having an input shaft 103 from
the engine and a drive shaft 104 coupled to drive wheels 105 via a
final drive 106. The system 10 further includes an engine control
unit 110 for controlling the operation of the engine 100 and a
power-train control unit 120 for communicating with the engine
control unit 110 and for controlling the operation of the
transmission 102 and the engine 100 based upon information provided
by an accelerator pedal 122, a brake pedal 124, a gear-shift
selector 126, a drive mode selector 128, and other sensors of the
vehicle. The system may further include a storage battery 140 for
supplying power to, or receiving power from, the transmission 102
based upon the operating conditions and the state of the battery
charge (SOC).
[0029] Turning to FIG. 2, a first exemplary embodiment of the
electro-mechanical power-split infinitely variable transmission 102
is shown. The transmission 102 is comprised of a mechanical portion
and an variator portion, where the variators are electric machines
E1 and E2, working either as motors or generators. The transmission
102 has infinite speed ratios and operates in at least two
modes--namely, an output-split mode and a compound-split
mode--depending on several factors including transmission speed
ratio, output speed, and power demands. To this end, the
transmission 102 in each of its modes transfers power through two
paths--specifically, through a purely mechanical path and through a
variator path. The mechanical path provides no basis for varying
the speed ratio of the transmission 102. The variator path does
that for both modes of operation. Thus, the transmission 102
operates on a power-split principle. The transmission may also
operate in a series hybrid mode as will be discussed later.
[0030] When in the output-split mode, the transmission 102 has its
greatest input-to-output ratio, that is to say its lowest output
speeds. While the transfer of power occurs generally through both
the mechanical path and the variator path, as the output speed
increases, the transfer of power comes to a point or node during
which all of the transfer occurs in the mechanical path. When in
the compound power-split mode the transfer of power occurs through
a somewhat different mechanical path and the variator path, except
at two points or nodes when the transfer occurs purely through the
mechanical path--one a low speed node and the other a high speed
node. The low speed node for compound-split mode corresponds with
the single node for the output-split mode. The transition between
modes occurs at the low speed mode without interruption in torque
and is otherwise imperceptible. Thus, the transmission 102 offers
the advantages of both a compound-split transmission, which
provides high efficiency between its node points, and an
output-split transmission, which provides high efficiency at high
input-to-output speed ratios and at vehicle launch.
[0031] While the electro-mechanical power-split, infinite variable
transmission 102 can assume any one of several configurations, each
configuration has the following components: [0032] 1. two planetary
units U1 and U2 [0033] 2. two electric machine variators E1 and E2
[0034] 3. a torque transfer-device L [0035] 4. an input I [0036] 5.
an output O [0037] 6. a control unit K [0038] 7. a housing H
[0039] It may also have an energy storage device E.
[0040] Each planetary unit U1, U2 includes a sun member S, a ring
member R located around the sun member, at least one and more
likely more planets P located between the sun members and the ring
member R, and a carrier member C coupled with the planets P and
providing axes about which the planets P rotate. Thus, each
planetary unit U1 and U2 has three concentric members, namely its
sun member S, its ring member R, and its carrier member C.
Typically, the sun member S, the ring member R and the planets P
are gears which mesh, although there may be traction rollers which
transfer power purely through friction contacts without any
mechanical interlock as in gear systems. The two planetary units U1
and U2 are contained within the housing where they are organized
about a common axis X. Eccentric arrangements are also possible.
The unit U1 has a sun member S1, a ring member R1, planets P1, and
a carrier member C1. Likewise, the unit U2 has sun member S2, a
ring member R2, planets P2, and a carrier member C2. Preferably,
the first sun member S1 is operatively connected to the first
electric machine E1, and the second sun member S2 is operatively
connected to the second electric machine E2.
[0041] When the transmission 102 operates in its compound-split
mode, the two planetary units U1 and U2 are compounded. In
particular, one of the three concentric members of the unit U1 is
connected to the one of the three concentric members of the unit
U2, and another of the three members of the unit U1 is connected to
another of the three members of the unit U2, thus forming two
compound member branches and leaving two single member branches.
Preferably, the two carrier members C1 and C2 are joined to form
one compound member branch, operatively connected to the output O.
The ring member R2 may be selectively joined to the sun member S1
through a clutch 130 to or from another compound member branch or
to a fixed member F of the transmission 102 through a brake 131.
This leaves the ring member R1 and the sun member S2 as the single
member branches. One of the compound member branches is connected
to one of the variators E1, E2 and the other to the output O.
[0042] In the example, the compound member branch formed by the sun
member S1 and ring member R2 is connected to the variator E1,
whereas the other compound member branch formed by the coupled
carrier members C1 and C2 is connected to the output O. One of the
single member branches is connected to the input I and the other to
the other variator E2. In the example, the ring member R1 is
connected to the input I and the sun member S2 is connected to the
variator E2.
[0043] Turning now to the variators E1, E2, each has the capacity
to deliver (generate) power and receive (consume) power. They are
connected together by an electric conduit 132 through a control
unit K so that when the variator E1 generates power, the variator
E2 may consume the power so generated, and conversely, when the
variator E2 generates power, the variator E1 may consume the power
generated. Typically and preferably each variator E1, E2 is an
electrical machine capable of serving both as a generator and a
motor. When so constructed, each variator E1, E2 includes a stator
133 that is mounted on the housing H and a rotor 134 that revolves
in the housing H. The two variators E1 and E2 are optionally
connected to the energy storage unit E through the control unit
K.
[0044] The transition device L includes a clutch 130 and a brake
131. The clutch 130 has the capacity to sever or interrupt one of
the compound member branches, thus disconnecting the member of the
unit U1 that is in that branch from the member of the unit U2 that
is in the branch. The brake 131 retards rotation of one of the
disconnected members by preferably clamping it to the housing H, or
in other words, "grounding" that disconnected member. When the
clutch 130 is disengaged and the brake 131 applied, the
transmission 102 operates in its output power-split mode, and
conversely when the transmission 102 operates in its compound
power-split mode the clutch 130 is engaged and the brake 131 is
released.
[0045] The input I may be a simple shaft, a gear, a pulley, a
sprocket, or some other type of coupling. The same holds true for
the output O. Optionally, there may be a damping device between the
engine 100 and input I of the transmission.
[0046] The control unit K controls the power transferred between
the variators E1 and E2. It may transfer all of the power or
modulate it. It may also transfer power to the energy storage
device E, when the device E is present. The energy storage device E
may take the form of an accumulator, a capacitor, a battery pack or
a mechanical device such as a flywheel. It can release power to the
control device K for transfer to one of the variators E1, E2.
[0047] For slow speed operation, from zero vehicle speed to the
first node speed, the transmission 102 operates in the output-split
mode. The clutch 130 disengages the first sun member S1 and the
electric machine E1 from the second ring member R2.
Correspondingly, the brake 131 engages, fixing the second ring
member R2 to the ground or fixed member F.
[0048] At zero vehicle speed, the electric machine E2 is
stationary, and provides the sole source of torque reaction to
allow acceleration of the vehicle. The electric machine E1 is in a
free wheeling state. At zero speed, this torque reaction consumes
no mechanical power and only very small electrical power, hence,
neither electric machine provides or consumes any substantial
electric power.
[0049] As the vehicle moves forward, the electric machine E2
increases a rotational speed, and the torque load on the electric
machine E2 decreases. The torque required for vehicle acceleration
is shared between the engine 100 and the electric machine E2, which
operates as a motor to provide torque assistance to the output O.
Concurrently, electric machine E1 serves as a generator, providing
resistant torque to the sun member S1, thus balancing the engine
torque applied to the ring member R1. The electric power generated
by the electric machine E1 is regulated through the control unit K
and sent to drive the electric machine E2.
[0050] As the vehicle speed further increases, the speed of the
electric machine E2 continues to increase and the torque
correspondingly continues to decrease. The speed and torque of the
electric machine E2 are in the opposite rotational directions until
the transmission encounters the first node point, where the torque
of the electric machine E2 momentarily drops to zero. Concurrently,
the speed of the electric machine E1 becomes zero. At this first
node point, no power is passing through the variator path. Rather,
all power is being transmitted through the mechanical power
path.
[0051] The first node point marks the end of the output-split mode
and the beginning of a compound power-split mode of operation for
the transmission 102. At the first node point, the clutch 130
engages, connecting the second ring member R2 to the first sun
member S1 and to the first electric machine E1. The brake 131
disengages, releasing the second ring member R2 from the fixed
member F.
[0052] As the vehicle speed continues to increase, the speed of the
electric machine E2 starts to decrease, and the torque starts to
increase in an opposite direction. Electric machine E2 operates as
a generator, converting mechanical energy into electrical energy.
Concurrently, electric machine E1 reverses direction, and increases
rotational speed, serving as a motor to reconvert electrical energy
into mechanical energy. Eventually, the transmission 102 encounters
the second node point, where the speed of the electric machine E2
drops momentarily to zero, and the torque of the electric machine
E1 becomes zero.
[0053] Beyond the second node point, the direction of rotation for
the electric machine E2 reverses, and the torque of the electric
machine E1 begins to increase in the opposite direction. Electric
machine E2 returns to motor operation, and electric machine E1
returns to operation as a generator.
[0054] Since the mode shifting from output-split to compound-split
is continuous in speed and torque, it is a smooth power shift. The
power flow management method of the present invention, set forth
below, leverages the advantages of an output-split configuration in
slow speed operation and of a compound-split configuration during
medium to high-speed operation, eliminating internal power
circulation over the entire speed range. Consequently, the
transmission 102 is able to provide a high degree of operating
efficiency over a wide speed range.
[0055] Those of ordinary skill in the art will recognize that the
functionality of the transmission 102 may be enhanced by the
addition of other clutches, brakes, and gears, such as shown in
FIG. 3, illustrating the addition of a clutch 136 and brake 138.
The addition of the clutch 136 and brake 138 provide parking and
series hybrid mode reverse functionality. Parking functionality is
realized by engaging the clutch 136 and the brake 138.
[0056] For series electric hybrid reverse operation, the brake 138
is engaged, grounding the first carrier C1 to the fixed member F.
The clutch 136 is disengaged, disconnecting the carrier C1 from the
output shaft O. The brake 131 engages, grounding the second ring
member R2 to the fixed member F. Clutch 130 is disengaged, freeing
the second ring member R2 from the first sun member S1, and from
the electric machine E1.
[0057] During the series electric hybrid reverse operation, the
first planetary train U1 serves as a speed increaser between the
input I and the electric machine E1. The second planetary train U2
serves as a speed reducer between the electric machine E2 and
output O. The mechanical input I from the engine drives the
electric machine E1 through the first planetary train U1 to
generate electric power. The first planetary train U1 amplifies the
input speed, which in many cases is desirable for an electric
machine to generate electric power. The electric power is then used
by the electric machine E2 to power the vehicle through the second
planetary train U2 where torque is amplified.
[0058] The method of the present invention for power flow
management in the transmission 102 will be described with reference
to a single sequence of repeating steps shown in the flow chart of
FIG. 4. This single sequence is executed repeatedly during vehicle
operation at a predetermined time interval to maintain the
transmission 102 and engine in a desired operating state.
Initially, as shown in step S100, sensor outputs are obtained.
Included in these, the speed of the drive shaft O, identified as
.omega..sub.d is determined. The speed information for the drive
shaft O can be provided by one or more speed sensors mounted to
detect the drive shaft speed directly, or may be determined
indirectly through the speed of the driven wheels 105. Other sensor
information would typically include engine speed, accelerator pedal
position, brake pedal position, battery state of charge, gear shift
selector and drive mode selector.
[0059] Next, a determination of the desired drive shaft torque
T.sub.d and power P.sub.d is made, as shown in Step S110 of FIG. 4.
The torque required to propel the vehicle to achieve a driver's
desired performance is set by the position of the acceleration
pedal, PA, and the position of the brake pedal, PB:
T.sub.d=C.sub.K1PA-C.sub.K2-C.sub.K3PB Equation (1)
[0060] where C.sub.K1, C.sub.K2 and C.sub.K3 are constants. For
non-hybrid operation, C.sub.K2 and C.sub.K3 would normally be zero.
For hybrid operation, C.sub.K2 and C.sub.K3 may both be nonzero,
allowing a negative output torque command. A negative output torque
command will slow the vehicle and allow the vehicle's kinetic
energy to be recaptured for recharging of the battery or other
energy storage device. Operation in this mode is commonly referred
to as regenerative braking. The desired output power to the drive
shaft is then calculated as: P.sub.d=.omega..sub.dT.sub.d Equation
(2)
[0061] When the vehicle is operated at high speeds, the maximum
output torque to the drive shaft O may be limited by the maximum
available power. In this case, the desired output power to the
drive shaft is determined by the position of the acceleration pedal
PA and brake pedal PB: P.sub.d=C.sub.K4PA-C.sub.K5-C.sub.K6PB
Equation (3)
[0062] where C.sub.K4, C.sub.K5 and C.sub.K6 are constants.
C.sub.K5 and C.sub.K6 are normally zero in non-hybrid operation.
The desired output torque to the drive shaft is then calculated as:
T d = P d .omega. d Equation .times. .times. ( 4 ) ##EQU1##
[0063] A map representing the relationships established by Equation
(1) through Equation (4) for each and every drive shaft speed and
pedal position can be stored prior to use in a ROM or other
suitable storage component associated with the control unit K.
Alternately, the equations may be calculated on-line in control
unit K directly from Equations (1) through Equation (4).
[0064] With hybrid operation in the low speed mode, it may be
desirable to drive the vehicle over short distances with the engine
shut off if the required transmission output power P.sub.d is
small. This would prevent operation of the engine at low power
operating points, where the thermal efficiency of the engine is
typically poor. Herein, this condition is referred to as
"electric-only operation". In electric-only operation, the electric
machine E2 provides power to propel the vehicle through the speed
reduction obtained through planetary train U2. No torque is applied
to electric machine E1. The battery or other energy storage device
is used to provide the power to electric machine E2.
[0065] Step S120 in FIG. 4 illustrates the decision to operate in
electric-only mode. Electric-only operation would normally be
prohibited at high vehicle speeds, when the commanded output power
P.sub.d is high, when commanded output torque T.sub.d is high or if
the energy stored in the battery or other energy storage device was
low. In this electric-only mode, the electric machine E2 can be
used to propel the vehicle, indicated in step S125 in FIG. 4. When
a requirement arises to restart the engine due to high speed, for
example, the engine can be restarted using electric machine E1.
[0066] The next step, represented as S130 in FIG. 4, is to
determine the desired engine output power P.sub.e. The desired
engine output power P.sub.e is determined by the required drive
shaft power P.sub.d plus any mechanical power
P.sub.pto.sub.--.sub.m and electrical power P.sub.pto.sub.--.sub.e
taken off from the engine and transmission. In desired engine
output power calculations, the powertrain efficiency .eta. is taken
into consideration, as shown for example, in the following
equation: P e = ( P d + P pto_m + P pto_e ) .eta. Equation .times.
.times. ( 5 ) ##EQU2##
[0067] The mechanical power take off P.sub.pto.sub.--.sub.m
includes all mechanical power required to drive various auxiliary
machine devices such as a compressor of an air-conditioner and a
water-cooling pump. The electric power take off
P.sub.pto.sub.--.sub.e includes the electrical power used to charge
the vehicle batteries, and electrical power consumed by various
electronic devices on the vehicle, such as a radio, lights, etc. In
cases where the transmission 102 is dedicated to regulating the
speed ratio only, no electrical power is taken off the transmission
102, and P.sub.pto.sub.--.sub.e is zero.
[0068] In hybrid operation, during regenerative braking, the
electric power P.sub.pto.sub.--.sub.e would normally be equal in
magnitude and opposite in sign to P.sub.d. In this way, the engine
power required, as calculated from Equation (5), would balance the
mechanical power for the auxiliary machines and the braking energy
contributed from the transmission output would be used to recharge
the battery or other energy storage device.
[0069] The next step, S140, shown in FIG. 4 requires a
determination of the desired engine operating point for a selected
performance objective. The method of the present invention permits
output power from the engine to be transmitted to the drive shaft
to achieve various desired performance objectives, such as
maximization of fuel economy.
[0070] A maximization of engine fuel economy can be achieved with
the use of a brake specific fuel consumption (BSFC) map of the
engine. A BSFC map, such as shown in FIG. 5, may be obtained
experimentally. As seen in FIG. 5, the ordinate indicates engine
speed, and the abscissa indicates the engine output torque. For a
given constant engine power line, such as A-A, which corresponds to
engine output power P.sub.e.sub.--.sub.a, there exists a point A1
which provides the lowest BSFC or best fuel economy. The speed
.omega..sub.e.sub.--.sub.a and torque T.sub.e.sub.--.sub.a of the
engine at the point A1 establish an optimal fuel economy power
state P.sub.e.sub.--.sub.a(.omega..sub.e.sub.--.sub.a,
T.sub.e.sub.--.sub.a). On an adjacent constant power line B-B, a
similar fuel economy power state
P.sub.e.sub.--.sub.b(.omega..sub.e.sub.--.sub.b,
T.sub.e.sub.--.sub.b) can be identified at B1. By repeating the
process for each and every constant power line, a series of fuel
economy power states
P.sub.e.sub.--.sub.i(.omega..sub.e.sub.--.sub.i,
T.sub.e.sub.--.sub.i) for i=(a, b, c, . . . ) can be established. A
connecting line between each of the fuel economy power states, from
low power to high power defines a working curve for the engine at
which the best fuel economy is achieved for the required engine
output power. Since the extreme point on this working curve is at
the engine's maximum power operating point, this approach
simultaneously provides the greatest vehicle acceleration when the
accelerator pedal is at its maximum. For various desired engine
output power levels P.sub.e, this working curve can be stored as
torque T.sub.e and speed .omega..sub.e lookup table(s) in a ROM or
other data storage component associated with the controller K.
[0071] In a variation of the method of the present invention, an
alternative objective is to achieve engine operation at the lowest
emissions point for various engine output power levels. Emission
maps can be obtained experimentally to yield data similar to the
BSFC maps shown in FIG. 5, from which a similar engine working
curve for the lowest emissions can be established and stored as
torque T.sub.e and speed .omega..sub.e lookup table(s) or other
regression equations in a ROM or other data storage component
associated with the controller K.
[0072] Those of ordinary skill in the art will recognize that other
calibrations are possible in which a performance objective is
established that provides a compromise between the lowest engine
BSFC and lowest emissions, since these are normally obtained at
different engine operating points. Other constraints may also be
considered in determining the performance objective, such as noise
or vibration levels in the vehicle.
[0073] Once the desired engine operating point for a selected
performance objective has been identified in step S140 of FIG. 4,
the output-to-input speed ratio is calculated, as shown in step
S150. The speed ratio of the transmission is one of the parameters
used to determine the transmission operating regime and control
structures for the electric machines E1 and E2.
[0074] At the first node point, the transmission shifts between the
output power-split and compound-split configurations. The
output-to-input speed ratio at the node point is given by: SR o - i
.function. ( 1 ) = K 1 K 1 + 1 < 1 Equation .times. .times. ( 6
) ##EQU3##
[0075] where K.sub.1 is the planetary ratio of the first planetary
train U1, defined as the pitch diameter ratio of the first ring
member R1 to the sun member S1. Similarly, the output-to-input
speed ratio at the second node point is given by: SR o - i
.function. ( 2 ) = K 1 .times. K 2 K 1 .times. K 2 - 1 > 1
Equation .times. .times. ( 7 ) ##EQU4##
[0076] where K2 is the planetary ratio of the second planetary
train U2, defined as the pitch diameter ratio of the second ring
member R2 to the sun member S2.
[0077] Below the speed ratio defined by Equation (6), the
transmission 102 is operated in the low speed regime where the
transmission 102 is in the output power-split configuration by
engaging the brake 131 and disengaging the clutch 130. Above the
speed ratio, the transmission 102 is operated in the high-speed
regime where the transmission 102 assumes a compound power-split
configuration by engaging the clutch 130 and disengaging the brake
131. This decision is shown in step S160. The shifting from the
output power-split mode to the compound-split configuration may be
further subjected to other constraints, such as a minimum engine
speed constraint and a minimum vehicle speed constraint.
[0078] When the transmission is operated in compound-split mode
between the two node points, the maximum power required at the
electric machine can be approximated by:
P.sub.elc.sub.--.sub.max.apprxeq..alpha.P.sub.in+.beta.P.sub.pto.sub.--.s-
ub.e Equation (8)
[0079] where P.sub.in is power delivered to the input of the
transmission, .alpha. = .PHI. - 1 .PHI. + 1 , .PHI. = SR o - i
.function. ( 2 ) SR o - i .function. ( 1 ) Equations .times.
.times. ( 9 , 10 ) ##EQU5##
[0080] and 0.ltoreq..beta..ltoreq.1 for all conditions, hence:
.PHI. - 1 .PHI. + 1 < P elc_max < .PHI. - 1 .PHI. + 1 P in +
P pto_e Equation .times. .times. ( 11 ) ##EQU6##
[0081] Once the desired operating point of the engine and the
operating regime of the transmission have been selected, one of the
electric machines, E1 or E2, together with the engine throttle, can
be operated to drive the engine to the desired operating point and
provide the requested output shaft power. In the current invention,
this is accomplished using feedforward and feedback control loops.
An example of the engine speed control loop is shown in FIG. 6. The
desired engine operating speed, .omega..sub.ed, was calculated in
step S140 of FIG. 4, described previously. This desired engine
operating speed is compared to the measured engine speed,
.omega..sub.e and the speed error, e, is computed. A feedback
control law, FB, operates on this error to produce the feedback
control motor torque, T.sub.m.sub.--.sub.fb, that would be applied
to the electric machine that is selected as the speed control
motor. As examples, the control law could be a proportional or
proportional-integral control law that would be familiar to those
of ordinary skill in the art.
[0082] In order to provide faster transient response or better
stability margins in the feedback control, a feedforward control
law FF may be used to compute a feedforward torque,
T.sub.m.sub.--.sub.ff, that can be added to the electric machine
torque. This feedforward torque is based on the desired engine
operating torque, T.sub.ed. The feedforward torque would ordinarily
represent the electric machine torque required to balance the
desired engine operating torque under steady state conditions.
[0083] In most operating modes and transmission output-to-input
speed ratio ranges, electric machine E1 is used for controlling
engine speed in the current invention. As used herein, the term
"speed machine" refers to the electric machine used for speed
control. Under non-hybrid mode operation at high output speeds, it
may be desirable to use electric machine E2 as the speed machine
for reasons of improved stability margin. Thus, the control
structure is switched to use E2 as the speed machine in non-hybrid
mode at high output speeds. In the current embodiment, this control
structure is switched at the direct drive ratio, i.e., at the point
where SR.sub.O-i=1. However, other values of output-to-input speed
ratio, SR.sub.s, may be selected for this switch provided that the
speed ratio satisfies Equation (12).
SR.sub.o-i(l)<SR.sub.S<SR.sub.o-i(2) Equation (12)
[0084] A constant offset torque, T.sub.os, shown in FIG. 6, is
added to the speed machine torque to provide a smooth transition
when the control structure is changed.
[0085] The electric machine that is not used as the speed machine
is adjusted to balance power requirements on the transmission. As
used herein, the term "power machine" refers to the electric
machine used for balancing power demands on the planetary
transmission.
[0086] Returning to FIG. 4, at step S170, the control structure is
determined based on the operating mode and output-to-input speed
ratio. The speed machine and power machine are also selected.
[0087] As previously described in connection with Steps S160 and
S170, there are regime changes at SR.sub.o-i=SR.sub.o-i(1) and a
control structure change at SR.sub.o-i=1. These two change points
in the speed ratio, along with other conditions, divide the entire
speed ratio range into three segments as shown below in Table (1).
Accordingly, three control regimes can be defined as will be
discussed in detail below. TABLE-US-00001 TABLE 1 Speed Power
Segment Condition Power Split Machine Machine SG-I SR.sub.o-i
.ltoreq. SR.sub.o-i(1) output E1 E2 SG-II SR.sub.o-i(1) <
SR.sub.o-i < 1 compound E1 E2 or hybrid mode SG-III SR.sub.o-i
> 1 compound E2 E1 and non-hybrid mode
[0088] Different segments preferably have different calculation
routines for each electric machine E1, E2 in which the machine
command is set.
[0089] In segment SG-I, the first electric machine E1 is used as
the "speed machine" and the second electric machine E2 is used as
the "power machine". The transmission 102 is in an output
power-split configuration. The torque command value T.sub.E1 for
the first electric machine E1 is calculated as follows: T E1 = T R1
K 1 + .phi. SGI .function. ( .omega. e * - .omega. e ) Equation
.times. .times. ( 13 ) ##EQU7##
[0090] where T.sub.R1 is the input torque to the first ring member
R1 of the transmission 102, and .phi..sub.SGI( ) is a feedback
function of speed error .omega..sub.e*-.omega..sub.e.
[0091] The input torque T.sub.R1 is related to the engine torque
command T.sub.e through the following equation: T R1 = T e - P
pto_m .eta..omega. e Equation .times. .times. ( 14 ) ##EQU8##
[0092] The feedback function of speed error .phi..sub.SGI( ) may,
for example, take the following forms shown below in Equation (15a)
or (15b):
.phi..sub.SGI(.omega..sub.e*-.omega..sub.e)=C.sub.f1(.omega..sub.e*-.ome-
ga..sub.e)+C.sub.f2.intg.(.omega..sub.e*-.omega..sub.e)dt+C.sub.offset
Equation (15a) or
.phi..sub.SGI(.omega..sub.e*-.omega..sub.e)=C.sub.f(.omega..sub.e*-.omega-
..sub.e)+C.sub.offset Equation (15b)
[0093] where C.sub.f1, C.sub.f2, and C.sub.f are constants and
C.sub.offset is an offset constant to allow smooth transitions
between structures.
[0094] In segment SG-I, the power command value P.sub.E2 for the
second electric machine E2 is calculated to balance the electrical
system power: P.sub.E2=-P.sub.E1+P.sub.pto.sub.--.sub.e Equation
(16a)
[0095] Alternatively, the torque command value T.sub.E2 for the
second electric machine E2 may be set to balance the system power:
T E2 = [ K 1 K 2 + 1 1 SR o - i - K 1 + 1 K 2 + 1 ] T E1 - P pto_e
( K 2 + 1 ) .times. .omega. d Equation .times. .times. ( 16 .times.
b ) ##EQU9##
[0096] In segment SG-II, the first electric machine E1 remains as
the "speed machine", providing torque to control the drive line
speed, while the second electric machine E2 remains as the "power
machine", providing the power balance requirements on the planetary
trains U1 and U2. The key difference between segment SG-I and
segment SG-II is that in segment SG-II, the transmission 102 is
operating in the compound power-split configuration.
[0097] For segment SG-II, the new torque command value T.sub.E1 for
the first electric machine E1 is defined by Equation (17) as
follows: T E1 = ( K 1 .times. K 2 K 2 + 1 1 SR o - i + 1 - K 1
.times. K 2 K 2 + 1 ) .times. T R1 K 1 - K 2 K 2 + 1 P pto_e
.omega. d + .phi. SGii .function. ( .omega. e * - .omega. e )
Equation .times. .times. ( 17 ) ##EQU10##
[0098] where .phi..sub.SGII( ) is a feedback function of speed
error which may take the same forms as .phi..sub.SGI( ), shown in
Equations (15a) and (15b) above.
[0099] The power command value P.sub.E2 for the second electric
machine E2 in segment SG-II is defined by Equation (16a).
Similarly, one can set the torque command value T.sub.E2 for the
second electric machine: T E2 = T E1 K 2 - T R1 K 1 .times. K 2
Equation .times. .times. ( 18 ) ##EQU11##
[0100] In the third operating segment, SG-III, the transmission 102
continuously operates in the compound power-split configuration,
but the control structure is preferably altered. The first electric
machine E1 is now utilized as the "power machine" and the second
electric machine E2 becomes the "speed machine". The torque command
values for the speed machine T.sub.E2 are computed from Equation
(19) as follows T E2 = ( K 1 K 2 + 1 1 SR o - i - K 1 + 1 K 2 + 1 )
.times. T R1 K 1 - 1 K 2 + 1 P pto_e .omega. d + .phi. SGiIi
.function. ( .omega. e * - .omega. e ) Equation .times. .times. (
19 ) ##EQU12##
[0101] where .phi..sub.SGIII( ) is a feedback function of speed
error which may take the same forms as .phi..sub.SGI( ), shown
above in Equation (15).
[0102] The corresponding command values for the power machine (E1)
are computed from: P.sub.E1=-P.sub.E2+P.sub.pto.sub.--.sub.e
Equation (20a)
[0103] Alternatively, the torque command T.sub.E1 for the first
electric machine E1 can be calculated as: T E1 = T R2 K 1 + K 2 T
E2 Equation .times. .times. ( 20 .times. b ) ##EQU13##
[0104] Those of ordinary skill in the art will readily recognize
that in addition to the equations set forth above for determining
command values for electric machines E1 and E2 in each operating
segment of the transmission 102 that the torque and power command
values may be limited to maximum values based upon the size of the
electric machines E1 and E2.
[0105] Once the operating regime, i.e., SG-I, SG-II, or SG-III and
associated control structure has been selected for the transmission
102, as shown in Steps S160 and S170 of FIG. 4, control of the
speed machine, power machine, and engine is carried out in parallel
as shown by Steps S180A, S180B, and S180C of FIG. 4.
[0106] Control of the speed machine, as shown in step S180A,
depends largely upon the type of electric machine utilized in the
transmission 102. For synchronous, permanent magnet electric
machines, voltages applied to the winding coils may be controlled
in accordance with the set torque command value to achieve the
target value of torque through a fixed procedure. The voltage
control is accomplished through conventional electronic circuits.
Alternatively, currents flowing through the winding coils may be
controlled in a conventional manner in accordance with the set
torque command values to achieve the target torque value.
[0107] Control of the power machine, as shown in step S180B, also
depends largely upon the type of electric machine utilized in the
transmission 102. The power command is normally converted to an
electrical command to the electric machine such as a current
command that depends on the voltage applied. The voltage and
currents may be controlled in a conventional manner as for the
speed machine.
[0108] Finally, control of the engine, as shown in Step 180C is
dependent upon the control of the speed machine. The engine control
thus implies engine torque control through control of the engine
fueling, injection or spark timing and/or throttle position, for
example. The present invention can be embodied in-part in the form
of computer-implemented processes and apparatuses for practicing
those processes. The present invention can also be embodied in-part
in the form of computer program code containing instructions
embodied in tangible media, such as floppy diskettes, CD-ROMs, hard
drives, or an other computer readable storage medium, wherein, when
the computer program code is loaded into, and executed by, an
electronic device such as a computer, micro-processor or logic
circuit, the device becomes an apparatus for practicing the
invention.
[0109] Those of ordinary skill in the art will recognize that the
electric machines E1 and E2, i.e. the variators, must have a
minimum power rating for operation as described above. The
following equations describe the power relationship between the
transmission mechanical input power P.sub.in (at the input shaft),
transmission electric input power (at electric power take off)
P.sub.pto-e and maximum variator power P.sub.vmax. These
relationship can used to establish a minimum power rating for each
of the variators or electric machines E1, E2.
[0110] Assume SR.sub.1 to be the transmission output-to-input speed
ratio at which the first variator is at a zero rotation speed, and
SR.sub.2 to be the transmission output-to-input speed ratio at
which the second variator is at zero rotation speed. The maximum
power of one of the variator is achieved at the speed ratio defined
by SR.sub.max= {square root over (SR.sub.1 SR.sub.2(1+.psi.))}
Equation (21a)
[0111] where .psi. = P pto - e P in ( Equation .times. .times. 21
.times. b ) ##EQU14## is the ratio of electric input power in the
variator power path to the mechanical input power at the input
shaft. Assuming SR.sub.2.gtoreq.SR.sub.1, the maximum power ratio
of the variator power to the transmission mechanical input power is
given by: ( P v P in ) max = ( SR 2 SR 1 .times. ( 1 + .psi. ) - 1
) 2 SR 2 SR 1 - 1 Equation .times. .times. ( 22 ) ##EQU15##
[0112] Thus for a design specified input power P.sub.in at the
transmission input shaft and for a designed hybrid power ratio
.psi., the minimum power rating for the variators is established
as: P v .gtoreq. ( SR 2 SR 1 .times. ( 1 + .psi. ) - 1 ) 2 SR 2 SR
1 - 1 .times. P in Equation .times. .times. ( 23 ) ##EQU16##
[0113] In general, .psi. is considered as the hybrid power ratio.
That is, the ratio of power taken off from the variator path
compared to the mechanical power input to the transmission at the
input shaft. The hybrid power is usually in form of electric power,
but can be hydraulic power or other form of power.
[0114] The present invention can also be embodied in-part in the
form of computer program code, for example, whether stored in a
storage medium, loaded into and/or executed by a computer, or
transmitted over some transmission medium, such as over electrical
wiring or cabling, through fiber optics, or via electromagnetic
radiation, wherein, when the computer program code is loaded into
and executed by a computer, the computer becomes an apparatus for
practicing the invention. When implemented in a general-purpose
microprocessor, the computer program code segments configure the
microprocessor to create specific logic circuits.
[0115] In view of the above, it will be seen that the several
objects of the invention are achieved and other advantageous
results are obtained. As various changes could be made in the above
constructions without departing from the scope of the invention, it
is intended that all matter contained in the above description or
shown in the accompanying drawings shall be interpreted as
illustrative and not in a limiting sense.
* * * * *