Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K16/00—Machines with more than one rotor or stator
• • 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
  • B60K6/22—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 apparatus, components or means specially adapted for HEVs
  • B60K6/38—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 apparatus, components or means specially adapted for HEVs characterised by the driveline clutches
  • B60K6/383—One-way clutches or freewheel devices
• • 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
  • B60K6/44—Series-parallel type
  • B60K6/442—Series-parallel switching type
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63H—MARINE PROPULSION OR STEERING
  • B63H21/00—Use of propulsion power plant or units on vessels
  • B63H21/20—Use of propulsion power plant or units on vessels the vessels being powered by combinations of different types of propulsion units
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63H—MARINE PROPULSION OR STEERING
  • B63H23/00—Transmitting power from propulsion power plant to propulsive elements
  • B63H23/02—Transmitting power from propulsion power plant to propulsive elements with mechanical gearing
  • B63H23/10—Transmitting power from propulsion power plant to propulsive elements with mechanical gearing for transmitting drive from more than one propulsion power unit
  • B63H23/12—Transmitting power from propulsion power plant to propulsive elements with mechanical gearing for transmitting drive from more than one propulsion power unit allowing combined use of the propulsion power units
  • B63H23/14—Transmitting power from propulsion power plant to propulsive elements with mechanical gearing for transmitting drive from more than one propulsion power unit allowing combined use of the propulsion power units with unidirectional drive or where reversal is immaterial
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63H—MARINE PROPULSION OR STEERING
  • B63H23/00—Transmitting power from propulsion power plant to propulsive elements
  • B63H23/22—Transmitting power from propulsion power plant to propulsive elements with non-mechanical gearing
  • B63H23/24—Transmitting power from propulsion power plant to propulsive elements with non-mechanical gearing electric
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63J—AUXILIARIES ON VESSELS
  • B63J3/00—Driving of auxiliaries
  • B63J3/02—Driving of auxiliaries from propulsion power plant
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K11/00—Structural association of dynamo-electric machines with electric components or with devices for shielding, monitoring or protection
  • H02K11/30—Structural association with control circuits or drive circuits
  • H02K11/33—Drive circuits, e.g. power electronics
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
  • H02K7/10—Structural association with clutches, brakes, gears, pulleys or mechanical starters
  • H02K7/108—Structural association with clutches, brakes, gears, pulleys or mechanical starters with friction clutches
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60L—PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES; SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL; MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES
  • B60L2220/00—Electrical machine types; Structures or applications thereof
  • B60L2220/50—Structural details of electrical machines
  • B60L2220/52—Clutch motors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63H—MARINE PROPULSION OR STEERING
  • B63H21/00—Use of propulsion power plant or units on vessels
  • B63H21/20—Use of propulsion power plant or units on vessels the vessels being powered by combinations of different types of propulsion units
  • B63H2021/202—Use of propulsion power plant or units on vessels the vessels being powered by combinations of different types of propulsion units of hybrid electric type
  • B63H2021/205—Use of propulsion power plant or units on vessels the vessels being powered by combinations of different types of propulsion units of hybrid electric type the second power unit being of the internal combustion engine type, or the like, e.g. a Diesel engine
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63H—MARINE PROPULSION OR STEERING
  • B63H23/00—Transmitting power from propulsion power plant to propulsive elements
  • B63H23/22—Transmitting power from propulsion power plant to propulsive elements with non-mechanical gearing
  • B63H23/24—Transmitting power from propulsion power plant to propulsive elements with non-mechanical gearing electric
  • B63H2023/245—Transmitting power from propulsion power plant to propulsive elements with non-mechanical gearing electric with two or more electric motors directly acting on a single drive shaft, e.g. plurality of electric rotors mounted on one common shaft, or plurality of electric motors arranged coaxially one behind the other with rotor shafts coupled together
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63J—AUXILIARIES ON VESSELS
  • B63J3/00—Driving of auxiliaries
  • B63J2003/001—Driving of auxiliaries characterised by type of power supply, or power transmission, e.g. by using electric power or steam
  • B63J2003/002—Driving of auxiliaries characterised by type of power supply, or power transmission, e.g. by using electric power or steam by using electric power
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
  • H02K7/14—Structural association with mechanical loads, e.g. with hand-held machine tools or fans
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K7/00—Arrangements for handling mechanical energy structurally associated with dynamo-electric machines, e.g. structural association with mechanical driving motors or auxiliary dynamo-electric machines
  • H02K7/18—Structural association of electric generators with mechanical driving motors, e.g. with turbines
  • H02K7/1807—Rotary generators
  • H02K7/1815—Rotary generators structurally associated with reciprocating piston engines

Definitions

• the present invention refers to an electric power module for a hybridization system for thermal engines, in particular usable in the marine sector in pleasure boats or fishing boats.
• the invention refers to a hybridization system for internal combustion engines that can operate both in "hybrid series coaxial” mode and in "hybrid parallel” mode.
• the invention also refers to an electric power module that can be used for the hybridization of thermal engines, both for installation in a propulsion system and inserted in a retrofitting kit that can be installed to make a propulsion system hybrid, in particular a thermal engine of a boat or installed on vehicles or generic operating machines, integrating into pre-existing architectures .
• Hybridization systems for thermal engines are known, in particular for diesel internal combustion engines for the naval sector, in which an automatic joint interposed between the thermal engine and the electric one is used as over speed. The joint allows the passage from electric-only to thermal- only or mixed operation, during which the electric motor alone can function as a motor or as a generator for recharging a battery.
• a problem of known hybridization systems is that they do not guarantee the possibility of having numerous operating modes and, at the same time, of ensuring high efficiency in the battery recharging steps with the heat engine running, not being able to simultaneously perform the generation and propulsion function, with only one machine.
• Object of the present invention is providing an electric power module for a hybridization system for heat engines that is fully integrated with the heat engine, which allows all the advantages of internal combustion engines to be maintained
• Another object of the present invention is providing a hybridization system including this electric power module that is able to obtain a reduction in consumption and therefore an increase in autonomy compared to the equivalent non-hybrid configuration.
• Another object of the invention is allowing the hybridization of a heat engine of reduced power and size, in order to reduce the weight, costs and consumption of this component and to ensure high flexibility of use.
• FIG. 1 shows a diagram of a DC bus and its connections with other components of the hybridization system for heat engines according to the invention
• FIG. 2 shows a diagram of the main electrical connections of the electrical power module according to the invention and its interfacing with the existing architectures and other components of the hybridization system for heat engines according to the invention.
• the electric power module 11 for a hybridization system 10 for heat engines comprises: a first electric motor 1 comprising an input shaft 21 connectable to a heat engine 3 to be hybridized, a second electric motor 2 comprising an output shaft 22 connectable to a motion transmission system 4, unidirectional motion transmission means 5, preferably a free wheel 5 used as a speed override, interposed between the two shafts 21, 22 of the electric motors 1, 2 in order to guarantee the transmission of the torque in one direction only, from the first electric motor 1 to the second electric motor 2.
• the input shafts 21 and output shafts 22, preferably splined shafts, are inserted in the rotors 31, 32 of the first electric motor 1 and of the second electric motor 2, respectively, so as to rotate with said rotors 31, 32; preferably, the stators 41, 42 are integrated into a single stator structure, which allows the structural function of connection between the heat engine 3 to be hybridized and the motion transmission system 4.
• the electric power module 11 further comprises: means 6, 7 for the electric motors 1 , 2 comprising two inverters 6, configured to convert a direct current into alternating current and each connected to a respective electric motor 1, 2, and at least one battery pack 7, preferably two battery packs 7 for load distribution and redundancy reasons, for powering a direct current bus 9 electrically connected to the inverters, hereinafter referred to as DC bus; DC/DC and DC/AC voltage converter means 8 connected to DC bus 9 for powering on-board systems 12 (hotel load) ; a control system comprising means for controlling an organ located at the output of the motion transmission system 4, for example comprising a throttle for controlling the speed of the propeller 14 of a boat and a control unit comprising a microcontroller and memory means on which the necessary software is installed to perform the optimal management of the hybridization system 10 according to the invention, in a transparent manner by an operator through suitable operating logics and adequate control algorithms .
• DC bus electrically connected to the inverters
• DC/DC and DC/AC voltage converter means 8 connected to
• the electrical power module 11 of the invention comprises two sealing rings installed on the input shafts 21 and output 22 to avoid external contamination, and also comprises two radial bearings supporting the shafts 21, 22 to compensate for radial and axial stresses.
• the hybridization system 10 for heat engines comprises a heat engine 3 to be hybridized connected to the input shaft 21 and a motion transmission system 4 connected to the output shaft 22 of the electric power module 11, in which the free wheel 5 interposed between the two electric motors 1, 2 and used as over speed in order to guarantee the transmission of the torque in a single direction allows different operating modes of the system, which will be explained in more detail below.
• the hybridization system 10 for heat engines of the invention preferably comprises, installed in the electric power module 11 or outside it, the means for powering the electric motors 6, 7 of the electric motors 1, 2, the voltage converting means
• DC/DC and DC/AC 8 for powering the on-board systems 12 (hotel load) and the control system to perform the optimal management of the hybridization system
• the hybridization system 10 for heat engines further comprises first connection means, for example a known vibration damper or disk damper, for connecting the input shaft 21 with the heat engine 3 to be hybridized and second connection means, for example an elastomeric joint, to connect the output shaft 22 to a transmission shaft 24 which transmits motion to a member, for example the propeller 14 of a boat, an inverter or stern drive, located at the output of the motion transmission 4.
• first connection means for example a known vibration damper or disk damper
• second connection means for example an elastomeric joint
• the operator acts directly on the throttle by controlling the speed of the propeller 14 without having to manually operate the electric motors 1, 2.
• Starting and stopping the heat engine requested by the control system when necessary, it is activated with the consent of the operator for safety reasons.
• the control system allows to simultaneously obtain, thanks to the presence of two electric machines, an automatic management of the propulsion and the energy balance of the storage, ensuring the improvement of the overall autonomy of the boat with minimal operator intervention.
• the control logic adapts the rotation speed of the heat engine 3 according to its optimal performance, depending on the operating mode, ensuring the achievement of the propeller speed 14 required by the operator through the throttle.
• the hybridization system 10 for thermal engines of the invention can be used with different operating modes and is able to create a complex plug-in hybrid system, in particular but not exclusively for pleasure boats.
• the transition from one operating mode to another takes place transparently, with the minimum request for supervision and intervention by the operator thanks to the presence of appropriate hardware/software and control and safety systems.
• Electric-only operating mode in this mode the heat engine 3 and the first electric motor/generator 1 are off, while the second electric motor 2 is active; the battery 7 is discharging, the freewheel 5 is not triggered and runs in neutral without transmitting torque; in this operating mode the torque available to the propeller 14 can reach the maximum torque value of the second electric motor 2; this operating mode can be used as an aid to sailing;
• Direct drive operating mode in this mode the heat engine 3 is active, the first electric motor 1 works as a generator to recharge the battery 7 while the second electric motor 2 is not active. This mode allows the heat engine 3 to work at full load while the battery 7 is charging and the freewheel 5 is activated; the torque transmitted to the propeller 14 reaches the maximum torque value of the heat engine 3;
• Overboost operating mode in this mode all the electric motors 1, 2 and thermal 3 are active. This mode allows the heat engine 3 to work at full load up to the value of its maximum speed.
• the battery 7 is discharging and the freewheel 5 is activated; the torque transmitted to the propeller 14 reaches the value of the sum of the maximum torques of all the electric motors 1, 2 and thermal 3; this operating mode can be useful for navigation against rough seas.
• the system also offers the possibility to avoid stalling and cavitation of the propeller 14 in rough seas, allowing to increase the torque on the propeller 14 without increasing the rotation speed of the same;
• Battery charging operating mode via heat engine in this mode only the heat engine 3 is active, while the first electric motor 1 works as a generator. This mode allows you to use the heat engine to recharge battery 7.
• the battery 7 is charging and the freewheel 5 is activated; during navigation, torque is transmitted to the propeller 14, while at anchor and sailing the inverter is in neutral and the electric motor 2 is off;
• Battery recharging operating mode in port in this mode all the electric motors 1, 2 and thermal 3 are off. Battery 7 is recharged thanks to bidirectional network inverters. In this operating mode the battery 7 is charging and no torque is transferred to the transmission 4;
• Battery recharge operation mode via propeller 14 in this mode the second electric motor 2 works as a generator during sailing, driven by the propeller 14. This mode allows the second electric motor 2 to be used to recharge the battery 7 Battery 7 is charging and freewheel 5 is not triggered.
• the electric power module 11 has extremely reduced dimensions in order to allow simple installation even on existing architectures (retrofit).
• the two electric motors 1, 2 are designed in such a way as to each supply (in continuous operation) up to 80% of the maximum torque of the internal combustion engine 3.
• the freewheel 5 which is installed between the two electric motors allows a transfer of maximum torque (in activated wheel condition) equal to more than 150% of the nominal value of the assembly (thermal engine + electric) and an overrun speed (in neutral operation) equal to more than 140% of the maximum speed in solo operation electric.
• the electric power module 11 can be completely installed and integrated with traditional traction systems, and is designed to be completely accessible from the outside, in order to be able to carry out maintenance and/or replacements of the module without the need for disassembly, of the entire heat engine 3 and of the transmission 4.
• the presence of appropriate redundancies and design precautions guarantees the operation of the hybridization system 10 for thermal engines of the invention in safety in any condition.
• the thermal engine 3 it is possible to operate the boat in electric only mode.
• the throttle allows to directly control the operation of the heat engine 3 only in case of need.
• the DC bus 9 is powered by two identical battery packs 7 which ensure redundancy and power supply to the system 10 even in the event of a failure of one of them.

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• Engineering & Computer Science (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Mechanical Engineering (AREA)
• Ocean & Marine Engineering (AREA)
• Power Engineering (AREA)
• Transportation (AREA)
• Microelectronics & Electronic Packaging (AREA)
• Electric Propulsion And Braking For Vehicles (AREA)

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• 2021
  • 2021-04-06 EP EP21725605.6A patent/EP4320717A1/de active Pending
  • 2021-04-06 WO PCT/IT2021/000019 patent/WO2022215097A1/en active Application Filing

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