Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60W—CONJOINT CONTROL OF VEHICLE SUB-UNITS OF DIFFERENT TYPE OR DIFFERENT FUNCTION; CONTROL SYSTEMS SPECIALLY ADAPTED FOR HYBRID VEHICLES; ROAD VEHICLE DRIVE CONTROL SYSTEMS FOR PURPOSES NOT RELATED TO THE CONTROL OF A PARTICULAR SUB-UNIT
  • B60W10/00—Conjoint control of vehicle sub-units of different type or different function
  • B60W10/04—Conjoint control of vehicle sub-units of different type or different function including control of propulsion units
  • B60W10/08—Conjoint control of vehicle sub-units of different type or different function including control of propulsion units including control of electric propulsion units, e.g. motors or generators
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
  • B60K6/00—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00
  • B60K6/20—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs
  • B60K6/42—Arrangement or mounting of plural diverse prime-movers for mutual or common propulsion, e.g. hybrid propulsion systems comprising electric motors and internal combustion engines ; Control systems therefor, i.e. systems controlling two or more prime movers, or controlling one of these prime movers and any of the transmission, drive or drive units Informative references: mechanical gearings with secondary electric drive F16H3/72; arrangements for handling mechanical energy structurally associated with the dynamo-electric machine H02K7/00; machines comprising structurally interrelated motor and generator parts H02K51/00; dynamo-electric machines not otherwise provided for in H02K see H02K99/00 the prime-movers consisting of electric motors and internal combustion engines, e.g. HEVs characterised by the architecture of the hybrid electric vehicle
  • B60K6/48—Parallel type
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
  • Y02T10/00—Road transport of goods or passengers
  • Y02T10/60—Other road transportation technologies with climate change mitigation effect
  • Y02T10/62—Hybrid vehicles

Definitions

• This invention relates to motor vehicle power plants, and more particularly, to "hybrid" motor vehicles powered by both electrical and fossil fuel power plants. Still more particularly, the present invention relates to a parallel hybrid electric/fossil fuel power plant for a motor vehicle such as a passenger car, in which the electric motor shaft is connected in parallel with an internal combustion engine shaft, and the electric motor is controlled to balance the load of the internal combustion engine.
• the gasoline or diesel powered internal combustion engine has been extremely successful in powering motor vehicles throughout the world.
• the internal combustion engine efficiently delivers high power outputs by converting fossil fuels such as gasoline into mechanical power.
• the fossil-fuel powered internal combustion engine has some significant drawbacks:
• the all-electric vehicle is one possible alternative.
• an electric motor and a source of electric power would replace the internal combustion engine.
• the electric motor would provide power to drive the wheels, and the electric power source would deliver electricity to drive the motor.
• An all-electric vehicle has zero exhaust gas emissions and requires no fossil fuels. Widespread use of all-electric vehicles would decrease the economic dependency of major industrialized nations on foreign oil producing countries, and could help us provide cleaner air.
• a motor vehicle moves, it must be self-contained and store its own power. Ideally, the power storage should be small, lightweight, and deliver a lot of power.
• Today's motor vehicles carry two different power storage devices: an electric battery and a gasoline tank. Most of the vehicle's power comes from the gas tank —with the electric battery contributing only enough power to turn a starter motor that gets the internal combustion engine started. Why?
• gasoline stores on the order of fifty times the power versus a battery of the same weight. You would need about a ton of electric batteries to store the same amount of power provided by the gasoline held by the average passenger car fuel tank. Such a large quantity of electric batteries would cost on the order of several thousand dollars, would be very bulky, and may need to be replaced every few years as they wear out.
• the batteries also have to be recharged somehow once they become “dead.”
• an alternator converts power from the internal combustion engine into electricity for recharging the battery. If there were no internal combustion engine, the recharging power would have to come from some other source. While some recharging power could come from the force of gravity (for example, the momentum from going down a hill could be converted into electricity), most of the recharging power would have to come from somewhere else — such as an electric wall socket the car owner plugs his car into every night.
• This battery recharging process could take many hours or even overnight — as compared with the essentially instant refilling of a passenger car gas tank at a filling station.
• the idea that electric power is clean and non-polluting is a fiction. Although some electric power plants (for example, nuclear and hydroelectric power plants) do not pollute the air, the vast majority of electric power plants in the United States burn coal or other combustible materials — and therefore are major polluters. Some people say that an all-electric vehicle would simply move air pollution from individual car exhausts to electric power plant smokestacks.
• hybrid electric vehicle may provide many of the advantages of both electric and fossil fuel power storage while eliminating at least some of the 7494 _.
• This "series” hybrid design has the advantage of reducing the number and weight of the electric batteries required to power the vehicle. Because the vehicle generates electrical power as it goes, it does not need as many electric batteries and also avoids a long battery recharge time. In addition, the gasoline engine can be operated under essentially constant conditions that can provide low exhaust emissions and low fuel consumption. But this "series" hybrid electric vehicle has some significant drawbacks. Its main drawback is that it is very inefficient in its use of gasoline. The process of converting the mechanical power produced by the gasoline engine into electrical power using a generator for powering the electric traction motor is relatively inefficient. This inefficient process wastes power.
• the present invention provides a new parallel hybrid electric vehicle- design that delivers smooth, high power performance while decreasing harmful exhaust emissions and maximizing fuel economy.
• a battery- powered electric motor assists the internal combustion engine.
• the electric motor is controlled to output power under certain operating conditions to assist the internal combustion engine.
• the electric motor provides a "load leveling" function that improves performance and driveability while maximizing fuel economy and reducing harmful emissions.
• a controller can control the electric motor to assist the internal combustion engine during times when the engine is called upon to produce a rapid speed RPM change (for example, upon acceleration from low to high speed). It is during such rapidly changing conditions that the internal combustion engine runs least efficiently and produces a lot of harmful exhaust emissions. By controlling the electric motor to "load balance" the internal combustion engine during these rapidly changing conditions, it is possible for the controller to control the internal combustion engine to operate in ways that might otherwise be unacceptable from a performance or other standpoint.
• the controller can supply the internal combustion engine with less fuel so it runs "leaner” during times when the electric motor is assisting the engine-increasing fuel economy and dramatically reducing harmful exhaust emissions.
• the internal combustion engine operates very “lean”
• overall vehicle performance doesn't suffer (and can actually be improved) because the electric motor provides power assist to make up for decreased internal combustion engine torque output.
• the resulting power train operation is exceptionally smooth and powerful.
• the acceleration curve is rapid and continuous. Depending on the particular system characteristics and system design and operating criteria, acceleration performance can be improved dramatically relative to a non-hybrid system while improving fuel economy and lowering harmful exhaust gas emissions.
• the controller may operate the electric motor as an electrical generator during times when the internal combustion engine produces (or the vehicle drive train otherwise has) more power than the vehicle needs. For example, during vehicle deceleration or regenerative braking and vehicle idle, the internal combustion engine produces excess power that can be used to recharge the batteries powering the electric motor. During such excess power conditions, the controller controls the electric motor to act as a generator to convert excess mechanical energy from the internal combustion engine to electrical energy. This electrical energy is used to recharge the electric battery.
• the electrical assist computer gives appropriate commands to
• the electrical motor is used for charging or producing power.
• Battery/motor weight and size can be selected to be about the
• weight e.g., no more than a few pounds weight gain — 75 lbs.
• the electric motor can replace an alternator, generator, and, at
• the electric motor's output shaft can be directly coupled to the internal combustion engine's crankshaft.
• a real-time computer-based electronic controller can be used to optimally control both the internal combustion engine and. the electric motor.
• the controller can monitor vehicle operating parameters in real time, and optimizes the electric motor's operation (and, if desired, also the operation of the internal combustion engine) to achieve desired operation characteristics including, but not limited to, maximal efficiency, best fuel economy, desired vehicle range, highest performance and/or lowest exhaust emissions.
• the controller can provide very rapid real time response — making possible closed loop real time feedback control of the overall parallel hybrid motor/engine system.
• the electric motor controller can phase the internal combustion engine and electric motor together so that pulse width pockets of power are applied at specific angled engine events even with a rapid speed and load change - providing a net effect of a smoother, cleaner and more efficient internal combustion engine.
• the controller can operate the electric motor in neutral or
• Figure 1 shows an example parallel hybrid system 100 in which an electric motor and an internal combustion engine crankshaft are connected together in parallel using a serpentine drive belt;
• Figure 1 A shows an alternate embodiment using a pancake style electric motor directly coupled to the internal combustion engine crankshaft
• FIG. 2 is a simplified block diagram of system 100
• Figure 2A is a more detailed schematic illustration of system 100
• Figure 3 shows an example connection diagram for system 100
• Figures 4 and 4A show flowcharts of example steps performed by the an example electronic controller
• Figure 5 shows an example three-dimensional control "map"
• Figures 6 A and 6B are graphs illustrating example comparative emissions test results.
• FIG. 1 shows an example parallel hybrid vehicle power train arrangement 100.
• a motor vehicle such as, for example, a passenger car is powered by both a gasoline internal combustion engine 150 and an electric motor 200.
• Internal combustion engine 150 is a fossil fuel burning engine that produces noxious emissions.
• Electric motor 200 is a "clean" power plant that converts electric power stored in an electric motor power source 400 (e.g., a battery) to mechanical power.
• an electric motor power source 400 e.g., a battery
• System 100 provides an overall complementary system that matches the complementary strengths and weaknesses of electrical propulsion and fossil fuel propulsion to provide an overall power plant that performs significantly better than either an electric motor or an internal combustion engine alone.
• both the internal combustion engine 150 and the electric motor 200 are used as drive and load sensing devices to produce torque.
• Electric motor 200 is used to assist the internal combustion engine 150 at varying loads.
• the output of electric motor 200 reduces the load on the internal combustion engine and/or is used to augment the power of the internal combustion engine 150.
• the preferred embodiment example system 100 uses the electric motor 200 to provide a load leveling function that lowers the rate of change and the peaks and/or dips of the load on the internal combustion engine 150 so that the internal combustion engine loading is very close to the average of that load.
• This load leveling function increases the efficiency of internal combustion engine 150 - providing better fuel economy and reducing emissions.
• An electrical assist computer 406 can be used to monitor engine sensors and battery information to perform calculations to determine the amount of assist or charge rate (see below).
• electric motor 200 may be a relatively small electric motor (for example, 15-17 horsepower) used to "load level" a substantially larger internal combustion engine 150 (e.g., a 90 horsepower engine). Electric motor 200 is controlled to provide "power assist" at strategic points during the vehicle's operation so that the internal combustion engine 150 need not operate within high fuel consumption and/or high noxious exhaust gas output conditions.
• a relatively small electric motor for example, 15-17 horsepower
• Electric motor 200 is controlled to provide "power assist" at strategic points during the vehicle's operation so that the internal combustion engine 150 need not operate within high fuel consumption and/or high noxious exhaust gas output conditions.
• Electric motor 200 uses power from the battery 400 when it is assisting internal combustion engine 150. Electric motor 200 could no longer assist engine 150 if the battery was allowed to completely discharge. In this preferred example, electric motor 200 charges the battery 400 during periods of light (or negative) loading of system 100. More specifically, during light or negative overall loading of system 100, electric motor 200 loads the internal combustion engine 150 and provides a light load charging function.
• Light load charging can be regarded as being the "opposite" of electrical assist.
• the electric motor 200 When there is little load on the internal combustion engine 150, the electric motor 200 will load the internal combustion engine and produce a charging voltage back to the electric motor power source 400.
• the battery 400 or other electric motor power source sustains a state of charge within a few percent of the starting state of charge and can maintain that state of charge over many cycles.
• a load applied to the drive system by electric motor produces a regenerative braking function.
• the regenerative braking function provides a charge voltage back to the electric motor power source, and reduces the need for friction braking to slow or stop the vehicle.
• the force of gravity acting on the vehicle e.g., as the vehicle goes down a hill
• electric motor 200 acting as a generator
• This mode of operation has the advantage of not using up fossil fuel (e.g., gasoline) to recharge battery 400.
• Figure 1 shows a belt 250 that connects the internal combustion engine crankshaft 152 and the electric motor output shaft 202 in parallel.
• electric motor shaft 202 may terminate in a pulley 204
• the internal combustion engine crankshaft 152 may terminate in a harmonic balancer 152a.
• a serpentine belt 250 may directly couple the electric motor pulley 204 to the engine harmonic balancer 152a in a substantially non-slip 17494 ⁇
• the vehicle differential, transmission, and associated vehicle drive wheels are coupled to the engine crankshaft 152 through conventional means such as a drive shaft or other linkage (not shown). Rotation of engine crankshaft 152 is delivered to vehicle wheels. Rotation of electric motor shaft 202 causes (further) rotation of engine crankshaft 152 — which, in turn, causes vehicles wheels to rotate. Thus, in this example, the internal combustion engine crankshaft 152 transmits torque from motor shaft 202 to the vehicle wheels.
• Figure 1 A shows an alternative example in which motor 200' is a "pancake" design that is directly coupled to the internal combustion engine crankshaft 152 without requiring a belt.
• the internal combustion engine crankshaft 152 is coupled to a rotor 280 of electric motor 200'.
• Mounting structures 282 are used to mount the motor stator 284 to engine 150.
• the Fjgure 1A example has the advantage of providing an overall more compact design.
• FIG. 2 shows an example simplified block diagram of system 100.
• internal combustion engine 150 interacts with electric motor 200 as described above.
• Battery 400 powers electric motor 200, and electrical assist computer 406 controls the electric motor based on internal combustion engine sensor 408 outputs and battery sensor 462 outputs.
• FIG. 2A shows a more detailed example schematic diagram of system 100.
• internal combustion engine 150 delivers torque to vehicle wheels 302, 304 via a conventional transmission/drive train/differential 300.
• Electric motor 200 has an output shaft 202 that is coupled in parallel with the internal combustion engine output shaft 152 via a serpentine belt 250 or other suitable arrangement as described above.
• Electric motor 200 is powered by electric batteries 400.
• An electric motor power controller 402 selectively couples electrical current from batteries 400 to electric motor 200.
• Electric motor power controller 402 provides power conductors and signal (control) conductors to electric motor 200.
• a capacitor bank 404 connected in parallel with electric batteries 400 is used to load balance the battery to provide higher transient currents for both charging and recharging.
• Batteries 400 and capacitor 404 together provide an energy storage means.
• This energy storage means uses both light weight high storage density batteries and existing industrial capacitors that reduce peak instant power draws the motor 200 required for acceleration, and reduce the high instant charge power that results when the motor 200 operates as a generator in a regenerative braking mode.
• the capacitors 404 increase the effective battery power and energy density, protect the batteries 400 from high power spikes, reduce the high currents as described above, and protect the batteries 400 from damage that can result from overheating — thus extending battery life.
• a computer 406 controls and manages electric motor 200 and may also manage internal combustion engine 150 if desired.
• Computer 406 provides an electric motor control signal to power controller 402 via an output board 452.
• Power controller 402 in turn, provides drive current and voltage to electric motor 200.
• Electrical assist computer 406 pulse width modulates the electric motor controller 402 and electric motor 200 at specific engine events. The pulse width of the electric motor control signal can be advanced or retarded to best achieve the desired load leveling of the internal combustion engine 150.
• Computer 406 receives engine sensor inputs 408 (e.g., manifold absolute pressure, engine crankshaft 152 speed, coolant temperature, exhaust gas parameters, vehicle speed, etc.) via an input board 454.
• computer 406 may monitor the voltage and charging current of battery 400 via voltage divider 456 and differential amplifier 458 respectively (the differential amplifier monitoring the voltage drop across shunt resistor 459 to indirectly measure charging current).
• Computer 406 may also receive a battery temperature signal from a temperature sensor 462 mounted in, on or near battery 400.
• Computer 406 may also monitor, directly or indirectly, the state of an ignition switch 412 and the position of an accelerator pedal 414. 22
• computer 406 uses 3-D MAP tables based on its sensor and control inputs to generate the electric motor control signal.
• computer 406 may use similar 3-D MAP tables to determine spark advance and air/fuel ratio for internal combustion 5 engine 150 — and these tables can be compensated empirically for the effects of electric motor 200, the particular values within the electric motor tables, and the effects of the interaction between the motor and the engine.
• Computer 406 pulse width modulates the electric motor controller (and thus the electric motor) at specific engine events; the 10 pulse width then can be advanced or retarded to best achieve the desired load leveling of the internal combustion engine 150.
• electric motor 200 is a "brushless", switched magnet motor that uses switched pulse control to provide over one horsepower per pound of weight.
• Motor controller 402 controls
• System 100 could be manufactured by an automobile manufacturer, or it can be retrofitted onto existing vehicles. For 25 example, it is possible to provide a kit including motor 200, controller 402, batteries 400, capacitor 404 and computer 406. These components can be retro-fit installed on an already-manufactured vehicle at relatively low cost to provide increased performance, fuel economy and/or lower tailpipe emissions.
• Figure 3 is a more detailed connection diagram for connecting motor 200 and power controller 402 to overall system 100.
• battery 400 is connected to power controller 402 through a power switch 850, a fuse 852, and shunt 459.
• Controller 402 may provide an outboard display 856 indicating the presence of power, current limiting, regenerative braking, and direction of rotation status.
• the Figure 3 example shows how discrete control inputs such as, for example, a throttle/accelerator pedal 414 voltage, a braking voltage from a braking control 858, a logic on/off switching control 860, and a hall effect clock input signal 862 may be used to control controller 402.
• these various control inputs could be provided by a three-switch, two-potentiometer control box — but in the preferred embodiment most or all of these control signals are provided by computer 406.
• Example Vehicle Operation To operate system 100, a user may close an ignition switch 412
• computer 406 may control power controller 402 to deliver an appropriate amount of starting drive current to electric motor 200 — operating the electric motor as a starting motor to start internal combustion engine 150.
• belt 250 transmits the rotational energy to internal combustion engine crankshaft 152 — causing the engine crankshaft to turn and the engine's pistons to move.
• the computer 406 may control power controller 402 to stop driving electric motor 200 — and to instead begin operating the electric motor as a dc power generator. Rotational energy that would normally be wasted by the engine 150 during idling can be converted by electric motor 200 into electrical energy for recharging battery 400. Once the battery is fully charged (as computer 406 can sense by monitoring the battery current and voltage), the computer can begin operating electric motor 200 in a neutral mode — delivering just enough current to the electric motor so it appears to be a "zero load" to internal combustion engine 150.
• Computer 406 senses an acceleration request when the vehicle driver puts his foot on accelerator pedal 414. In response, computer 406 may control electric motor 200 to immediately respond to the acceleration request by delivering output torque to its output shaft 202. Computer 406 thus controls electric motor 200 to assist internal combustion engine 150 during periods of rapidly changing power demands.
• batteries 400 supply electric motor 200 with power during times when computer 406 controls the electric motor to produce power output.
• Capacitor 404 in parallel with batteries 400 provides short term, low-impedance charge storage to meet high instantaneous current demands of electric motor 200.
• Capacitor 404 "load balances" batteries 400 — providing high peak current delivery and absorption rates at a much lower internal resistance than batteries 400 provide.
• Computer 406 continually monitors the state of batteries 400 during vehicle operation. If computer 406 determines that batteries 400 need to be charged, the computer controls electric motor 200 to begin operating in the generator mode. Since electric motor 200 is capable of charging batteries 400, there is no need for an additional alternator or generator. To prevent overcharging of batteries 400, computer 406 can operate electric motor in the neutral mode. In this neutral mode, computer 406 controls power controller 402 to deliver just enough current to electric motor 200 so that the electric motor shaft 202 rotates at exactly the same speed as the internal combustion engine 152. Because computer 406 exactly matches the electric motor 200 speed with the engine 150 rpm, the electric motor neither drains mechanical power from nor outputs mechanical power to the engine crankshaft 152.
• This neutral mode effectively disappears, from a load standpoint, with respect to the internal combustion engine 150.
• This neutral mode is useful during times when no power assist is desired (e.g., because of internal combustion engine 150 operating conditions and/or battery 400 charge state) and when it is undesirable to charge the battery (e.g., because battery charging would unduly load internal combustion engine 150, or because batteries 400 are already fully charged).
• Figures 4 and 4A are flowcharts of example control steps performed by computer 406 during vehicle operation.
• the hybrid control program shown in Figure 4 is a loop which controls both the internal combustion engine 150 and the electric motor 200 simultaneously by continuously interpreting sensor data 408 about internal combustion operation and the amount of power available to the electric motor.
• the example hybrid control program has available to it (e.g., in a memory that is part of computer 406) programmable constants which define for the electric motor 200:
• computer 406 reads sensor inputs 408 and control inputs 414 as well as battery status inputs to determine the overall state of system 100 — including battery charge state and the state of internal combustion engine 150 as described above ( Figure 4, block 502). Based on the control inputs, computer 406 determines whether system 100 should be operated in a special state (e.g., acceleration/deceleration or idle), or whether it should be operated in the normal 3-D control state (decision block 504, Figure 4).
• a special state e.g., acceleration/deceleration or idle
• Figure 4A is a more detailed view of the "select mode" decision 504.
• the computer 406 reads the sensor inputs from internal combustion engine 150 and determines whether the engine is accelerating or decelerating (decision block 504a), at idle (decision block 504b), or in a "normal" operating range (decision block 504c). If the engine 150 is operating in its normal operating range, control proceeds to "select table" block 506 ( Figure 4). If the engine is not operating in its normal range, computer 406 determines whether the engine is at idle ( Figure 4A, decision block 504b); if so, control proceeds to "idle” block 522 (see Figure 4).
• normal 3-D control exit to decision block 504, Figure 4
• computer 406 selects an appropriate 3- D control table from storage based on the charge state of batteries 400.
• computer 406 selects an overcharge table biased toward providing active assist from motor 200 (decision block 506, block 508, Figure 4) to use up some battery power.
• computer 406 selects a control table biased toward regeneration (decision block 506, block 510, Figure 4) to help charge the batteries.
• computer 406 first attempts to correct the problem by full-time generation and, if no improvement is noted within a specific time period, the computer puts electric motor 200 into neutral and activates a trouble indicator.
• computer 406 determines the state of the charge of batteries 400 by reading the battery voltage while measuring the instantaneous battery current — resulting in the value of the battery charge which is empirically plotted on a look up table to obtain the state of the charge of the battery. If batteries 400 are not over charged or under charged, computer 406 selects a "normal" table from which to look up control parameters (decision block 506, block 512).
• Each of the over charge, under charge and normal look up tables is comprised of a three-dimensional map.
• These 3-D control tables accept engine speed and engine load as control inputs and provide motor 200 current as a control output.
• the tables may each contain sixty-four constants (in one example) representing internal combustion engine load, internal combustion engine rpm, and electric motor 200 control values. All electric motor 200 current control values stored in these tables are derived empirically in this example. They can be set to meet the energy needs throughout the engine operating range to achieve lower emissions, more fuel economy and/or special performance.
• the resulting electric motor control value is obtained by a dynamic interpolation of the apposite three constants.
• Figure 5 shows an example 3-D charge mapping provided by the example look up tables.
• the example look up table maps the amount of electric motor 200 current in three dimensions — making motor current (a positive value for assist, a negative value for charging) a function of both manifold absolute pressure (MAP) and internal combustion engine crankshaft 152 rotational speed (rpm). Because internal combustion engine 150 is providing most of the output power most of the time to drive vehicle wheels 302, 304, the internal combustion engine manifold absolute pressure (MAP) is a relatively accurate indication of the overall load on the hybrid power plant 100.
• MAP manifold absolute pressure
• Figure 5 shows that motor current can be positive (in the case of using motor 200 to power assist) or it can be negative (in the case ofusing the motor regeneratively to charge batteries 400).
• the Figure 5 graph shows that when MAP (load) is high and engine speed (rpm) is high, electric motor 200 uses the reserves in batteries 400 to assist in propulsion. When load is low, electric motor 200 may begin operating regeneratively to recharge batteries 400.
• computer 406 determines motor 200 current by looking this parameter up in one of the tables based on engine speed and load ( Figure 4, blocks 508, 512, 510).
• Computer 406 may interpolate between values if desired, and/or it may scale the values it obtains from the lookup process so the amounts can be made to vary as the battery charge level changes.
• the resulting value obtained from the lookup process may be outputted as a pre-programmed value of electric current for controlling electric motor 200 optimally throughout the entire operating range of internal combustion engine 150 ( Figure 4, block 516).
• each change in the electric motor 200 control value causes a change in the operation of internal combustion engine 150 —which may in turn be sensed by computer 406 to provide modified control over the electric motor.
• the closed loop feedback control properly managed, balances changes in electric motor 200 output against thermodynamic changes to the internal combustion engine 150, minimizes over correction and provides smooth and imperceptible transition from electric motor 200 neutral to "assist” or "regeneration” throughout the operating range of internal combustion engine 150.
• capacitors 404, electric motor 200 and power controller 402 work together to provide very rapid reaction times. This high speed reaction makes control smooth and sure.
• 3-D tables could be used for deceleration, acceleration, and idle conditions, they are not necessary in this example since control of electric motor 200 is more straightforward under those conditions.
• computer 406 may control motor 200 to operate regeneratively in a charge mode (or in a neutral mode if the batteries 400 are fully charged) ( Figure 4, block 516).
• an acceleration condition Figure 4, block 520
• computer 406 provides current to electric motor 200 to provide power assist ( Figure 4, block 516).
• idle conditions Figure 4, block 522
• computer 406 may control electric motor 200 to operate regeneratively or neutrally, depending on the charge state of batteries 400 ( Figure 4, block 516) and the leanness of the air/fuel ratio being delivered to internal combustion engine 150.
• the smoothness of power control is such that no roughness is detectable by the driver. All this contributes to smooth driveability and adds to the vehicle's power from the combination of internal combustion engine 150 and electric motor 200.
• the combination of the power from the internal combustion engine 150 and electric motor 200 provides a means to propel the vehicle which is superior to either power source acting alone.
• the load on the internal combustion engine 150 is reduced. This reduces the power the internal combustion engine 150 must produce — saving fuel and making it easier to reduce tailpipe emissions — and also increasing driveability of the vehicle.
• Computer 406 can apply a small amount of electrical power to motor 200 to assist the internal combustion engine 150 — allowing the internal combustion engine to resist stalling or erratic turning when the engine is running in an extremely lean condition.
• internal combustion engine 150 could be a high power (e.g., 200 horsepower) engine, and a high power (e.g., 52 horsepower) electric motor could be used for motor 200. This high performance configuration would provide very fast, smooth acceleration while still allowing the motor to act as a generator to recharge the battery.
• Experimental results of systems embodying the present invention provide excellent driveability.
• the feedback control allows electric motor 200 to load level the internal combustion engine 150 and provides smooth and imperceptible operation of vehicle.
• the system increased driveability and provided a very smooth driving vehicle.
• the "power assist" provided by electric motor 150 during acceleration was smooth, strong and peppy without providing any unexpected surges or other erratic results. Decreased emissions were realized by helping the engine run in a fashion which inherently minimizes emissions. By enhancing the production of power needed to make the car meet the demands of the driver, fuel economy was significantly enhanced.
• the batteries were charged when the internal combustion engine reached its sweet spot (where it is much more efficient) and the motor began operating as a generator.
• Figures 6A and 6B show one example comparison of internal combustion engine THC emissions (in milligrams per second) without electrical assist (Figure 6A) and with electrical assist (Figure 6B). These experimental results were measured in September 1997 by the EPA test lab in Springfield Virginia. The measurements were conducted on a 1993 Honda Civic modified to incorporate the present invention with the following characteristics:
• Internal combustion engine 150 Honda® 1.5 liter "lean burn” four-cylinder, fuel injected distributorless 90 horsepower engine.
• Electric motor model DRl 27 brushless 15-17 horsepower "switched magnet” manufactured by Unique Mobility, Inc., Englewood, Colorado.
• Power controller 402 Model CRlO-100 manufactured by Unique Mobility, Inc.
• Batteries 400 YUSA (not liquid) lead-acid type connected to provide ninety-six volts (lithium ion type may be preferred for reduced weight),
• Computer 406 TEC total engine management/control system manufactured by Electromotive, Inc., Manassas, Virginia modified to provide additional memory and further control inputs for dc current and voltage.
• Capacitor 404 1.5 Farads (while high voltages up to 100 VDC may be used efficiently, safety reasons dictate that relatively low voltages are used to prevent dangerous shocks to humans).
• the measurements were made on a "hot" system - i.e., one in which the internal combustion engine is at operating temperature at the beginning of the test.
• each chart shows THC emissions in milligrams per second. While the THC emission profile in the Figure 6A example without electrical assist appears somewhat similar to the THC emission profile in the Figure 6B example using electrical assist, the THC emissions scales on the right-hand side of the two Figures are different.
• the Figure 6A THC emissions scale is from 0-8 milligrams per second, while the Figure 6B emissions scale is 4.5 times greater (0-36 milligrams per second).

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• Electric Propulsion And Braking For Vehicles (AREA)

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• 1997
  • 1997-10-17 WO PCT/US1997/018182 patent/WO1998017494A1/en not_active Application Discontinuation
  • 1997-10-17 EP EP97912677A patent/EP0930982A1/de not_active Withdrawn
  • 1997-10-17 AU AU49792/97A patent/AU4979297A/en not_active Abandoned

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