US6209672B1 — Hybrid vehicle

Claim 1

Independent Claim 305 words

A hybrid vehicle, comprising: a controller capable of accepting inputs indicative of vehicle operating parameters and providing control signals in response to a control program; a battery bank; an internal combustion engine; a first electric starting motor electrically coupled to said battery bank for (a) accepting electrical energy from said battery bank and (b) providing electrical energy to said battery bank, and said first motor being mechanically coupled to said internal combustion engine, the combination of said internal combustion engine and said first electric motor being mechanically coupled to a clutch controlled by said controller for controllable torque-transmitting connection between said combination and road wheels of said vehicle, said first motor being responsive to commands from said controller, such that said first electric motor can be controlled to (1) accept torque from said engine to charge said battery bank, (2) accept energy from said battery bank to apply torque to said engine for starting said engine, (3) accept energy from said battery bank to apply torque to said road wheels to propel said vehicle, and (4) accept torque from said road wheels to charge said battery bank; and a second electric traction motor, electrically coupled to said battery bank, such that said second electric motor can be controlled for (a) accepting electrical energy from said battery bank and (b) providing electrical energy to said battery bank, said second motor being directly coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said second motor is permanently connected to said road wheels for torque transmission therebetween, and said second motor being responsive to commands from said controller in order to (1) accept energy from said battery bank to apply torque to said road wheels to propel said vehicle, and (2) accept torque from said road wheels to charge said battery bank.

Claim 2

Dependent Claim 305 words

A hybrid vehicle, comprising: a controller capable of accepting inputs indicative of vehicle operating parameters and providing control signals in response to a control program; a battery bank; an internal combustion engine; a first electric starting motor electrically coupled to said battery bank for (a) accepting electrical energy from said battery bank and (b) providing electrical energy to said battery bank, and said first motor being mechanically coupled to said internal combustion engine, the combination of said internal combustion engine and said first electric motor being mechanically coupled to a clutch controlled by said controller for controllable torque-transmitting connection between said combination and road wheels of said vehicle, said first motor being responsive to commands from said controller, such that said first electric motor can be controlled to (1) accept torque from said engine to charge said battery bank, (2) accept energy from said battery bank to apply torque to said engine for starting said engine, (3) accept energy from said battery bank to apply torque to said road wheels to propel said vehicle, and (4) accept torque from said road wheels to charge said battery bank; and a second electric traction motor, electrically coupled to said battery bank, such that said second electric motor can be controlled for (a) accepting electrical energy from said battery bank and (b) providing electrical energy to said battery bank, said second motor being directly coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said second motor is permanently connected to said road wheels for torque transmission therebetween, and said second motor being responsive to commands from said controller in order to (1) accept energy from said battery bank to apply torque to said road wheels to propel said vehicle, and (2) accept torque from said road wheels to charge said battery bank.

Claim 3

Dependent Claim 64 words

The hybrid vehicle of claim 1 , wherein said controller is provided with signals indicative of the instantaneous road load experienced by said vehicle and of the state of charge of said battery bank, and controls operation of said engine, said clutch, and said first and second motors so that said vehicle is operated in a plurality of operating modes responsive to said signals.

Claim 4

Dependent Claim 36 words

The hybrid vehicle of claim 2 wherein said signal indicative of the instantaneous road load experienced by said vehicle is determined by said controller at least in part by monitoring commands provided by the vehicle operator.

Claim 5

Dependent Claim 140 words

The hybrid vehicle of claim 2 , wherein road load (RL) is expressed as a percentage of the maximum torque output of the engine (MTO), and said operating modes include: a low-speed mode I, wherein said vehicle is propelled by torque provided by said traction motor in response to energy supplied from said battery bank, while RL<SP, wherein SP is a setpoint expressed as a predetermined percentage of MTO, a highway cruising mode IV, wherein said vehicle is propelled by torque provided by said engine in response to supply of combustible fuel, while SP<RL<100% of MTO, and an acceleration mode V, wherein said vehicle is propelled by torque provided by said engine in response to supply of combustible fuel and by torque provided by said traction motor in response to energy supplied from said battery bank, while RL>100% of MTO.

Claim 6

Dependent Claim 26 words

The hybrid vehicle of claim 4 , wherein said clutch is disengaged during operation in mode I and engaged during operation in modes IV and V.

Claim 7

Dependent Claim 98 words

The hybrid vehicle of claim 4 , wherein said operating modes further include a low-speed battery charging mode II, entered while RL<SP and the state of charge of the battery bank is below a predetermined level, and wherein said vehicle is propelled by torque provided by said traction motor in response to energy supplied from said battery bank, and wherein said battery bank is simultaneously charged by supply of electrical energy from said starting motor, being driven by torque by said engine in response to supply of combustible fuel, said clutch being disengaged during operation in mode II.

Claim 8

Dependent Claim 27 words

The hybrid vehicle of claim 4 , wherein said setpoint SP may be varied by said controller in response to monitoring patterns of vehicle operation over time.

Claim 9

Dependent Claim 46 words

The hybrid vehicle of claim 4 , wherein the transition between operation in modes I and IV is controlled to occur only when RL>SP for at least a predetermined time, or when RL>SP 2 , wherein SP 2 is a larger percentage of MTO than SP.

Claim 10

Dependent Claim 30 words

The hybrid vehicle of claim 4 , wherein the transition between operation in modes IV and I is controlled to occur only when RL<SP for at least a predetermined time.

Claim 11

Dependent Claim 36 words

The hybrid vehicle of claim 4 , wherein the controller may control transition of the operating mode from operation in mode I directly to operation in mode V where a rapid increase in RL is detected.

Claim 12

Dependent Claim 67 words

The hybrid vehicle of claim 4 , wherein the controller may accept operator input of a desired cruising speed, and thereafter controls the instantaneous engine torque output in accordance with variation in RL so as to maintain vehicle speed substantially constant, and does not permit transition to mode I operation until the operator provides a further signal indicating that the desired cruising speed is no longer desired.

Claim 13

Dependent Claim 35 words

The hybrid vehicle of claim 4 , wherein regenerative charging of the battery bank is performed when the engine's instantaneous torque output >RL, when RL is negative, or when braking is initiated by the operator.

Claim 14

Dependent Claim 34 words

The hybrid vehicle of claim 1 , wherein the total torque available at the road wheels from said engine is no greater than the total torque available from said first and second motors combined.

Claim 15

Dependent Claim 27 words

The hybrid vehicle of claim 1 , wherein the maximum speed of at least said traction motor is least 150% of the maximum speed of said engine.

Claim 16

Independent Claim 181 words

A method for controlling the operation of a hybrid vehicle operable in a plurality of differing modes, comprising the steps of: providing a hybrid vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO), said engine being controllably coupled to road wheels of said vehicle by a clutch, a traction motor being coupled to road wheels of said vehicle, a starting motor coupled to said engine, both said motors being operable as generators, a battery bank for providing electrical energy to and accepting energy from said motors, and a controller for controlling operation of said engine, clutch, and first and second motors, and controlling flow of electrical energy between said motors and said battery bank, and operating said controller to control selection of the operational mode of said vehicle between a low-speed mode I, a cruising mode IV, and an acceleration mode V, wherein torque to propel said vehicle is provided by said traction motor, said engine, and both, respectively, in response to monitoring the instantaneous torque requirements required for propulsion of the vehicle (RL).

Claim 17

Independent Claim 181 words

A method for controlling the operation of a hybrid vehicle operable in a plurality of differing modes, comprising the steps of: providing a hybrid vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO), said engine being controllably coupled to road wheels of said vehicle by a clutch, a traction motor being coupled to road wheels of said vehicle, a starting motor coupled to said engine, both said motors being operable as generators, a battery bank for providing electrical energy to and accepting energy from said motors, and a controller for controlling operation of said engine, clutch, and first and second motors, and controlling flow of electrical energy between said motors and said battery bank, and operating said controller to control selection of the operational mode of said vehicle between a low-speed mode I, a cruising mode IV, and an acceleration mode V, wherein torque to propel said vehicle is provided by said traction motor, said engine, and both, respectively, in response to monitoring the instantaneous torque requirements required for propulsion of the vehicle (RL).

Claim 18

Dependent Claim 52 words

The method of claim 15 , wherein said controller controls said vehicle to operate in said low speed mode I while RL<SP, wherein SP is a setpoint expressed as a predetermined percentage of MTO, said highway cruising mode IV while SP<RL<100% of MTO, and said acceleration mode V while RL>100% of MTO.

Claim 19

Dependent Claim 30 words

The method of claim 16 , comprising the further step of disengaging said clutch during operation in mode I and engaging said clutch during operation in modes IV and V.

Claim 20

Dependent Claim 101 words

The method of claim 16 , wherein said controller further controls said vehicle to operate in a low-speed battery charging mode II, entered while RL<SP and the state of charge of the battery bank is below a predetermined level, during which said vehicle is propelled by torque provided by said traction motor in response to energy supplied from said battery bank, and wherein said battery bank is simultaneously charged by supply of electrical energy from said starting motor, being driven by torque by said engine in response to supply of combustible fuel, said clutch being disengaged during operation in mode II.

Claim 21

Dependent Claim 28 words

The method of claim 16 , comprising the further step of employing said controller to monitor patterns of vehicle operation over time and vary said setpoint SP accordingly.

Claim 22

Dependent Claim 61 words

The method of claim 16 , comprising the further step of employing said controller to monitor RL over time, and to control transition between operation in modes I and IV accordingly, such that said transition occurs only when RL>SP for at least a predetermined time, or when RL>SP 2 , wherein SP 2 is a larger percentage of MTO than SP.

Claim 23

Dependent Claim 45 words

The method of claim 16 , comprising the further step of employing said controller to monitor RL over time, and to control transition between operation in modes I and IV accordingly, such that said transition occurs only when RL<SP for at least a predetermined time.

Claim 24

Dependent Claim 48 words

The method of claim 16 , comprising the further step of operating said controller to a monitor RL over time, and to control the operating mode to change from from operation in mode I directly to operation in mode V where a rapid increase in RL is detected.

Claim 25

Dependent Claim 71 words

The method of claim 16 , comprising the further step of operating said controller to accept operator input of a desired cruising speed, said controller thereafter controlling the instantaneous engine torque output in accordance with variation in RL so as to maintain vehicle speed substantially constant, and to prevent transition to mode I operation until the operator provides a further signal indicative that the desired cruising speed is no longer desired.

Claim 26

Dependent Claim 39 words

The method of claim 16 , comprising the further step of performing regenerative charge of the battery bank under controller control when the engine's instantaneous torque output>RL, when RL is negative, or when braking is initiated by the operator.

Claim 27

Dependent Claim 26 words

The method of claim 16 , wherein said motors are controlled together to provide maximum torque at least equal to the maximum torque of said engine.

Claim 28

Dependent Claim 30 words

The method of claim 16 , wherein the maximum speed of at least said traction motor is controlled to be at least 150% of the maximum speed of said engine.

Claim 29

Independent Claim 256 words

A method for controlling the operation of a hybrid vehicle operable in a plurality of differing modes, comprising the steps of: providing a hybrid vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO), said engine being controllably coupled to road wheels of said vehicle by a clutch, a traction motor being coupled to road wheels of said vehicle, a starting motor coupled to said engine, both said motors being operable as generators, a battery bank for providing electrical energy to and accepting energy from said motors, and a controller for controlling operation of said engine, clutch, and first and second motors, and controlling flow of electrical energy between said motors and said battery bank, and operating said controller to control selection of the operational mode of said vehicle between a low-speed mode I and a cruising mode IV, wherein torque to propel said vehicle is provided by said traction motor or said engine, respectively, in response to monitoring the instantaneous torque requirements required for propulsion of the vehicle (RL), and wherein further according to said method, when said controller determines that transition of the operating mode of said vehicle from mode I to mode IV is desirable, said controller controls said starting motor to spin said engine for starting at a minimum speed of at least 300 rpm, and said clutch is not engaged for supply of torque from said engine to said road wheels until said engine is running at a speed at which it efficiently produces torque.

Claim 30

Independent Claim 256 words

A method for controlling the operation of a hybrid vehicle operable in a plurality of differing modes, comprising the steps of: providing a hybrid vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO), said engine being controllably coupled to road wheels of said vehicle by a clutch, a traction motor being coupled to road wheels of said vehicle, a starting motor coupled to said engine, both said motors being operable as generators, a battery bank for providing electrical energy to and accepting energy from said motors, and a controller for controlling operation of said engine, clutch, and first and second motors, and controlling flow of electrical energy between said motors and said battery bank, and operating said controller to control selection of the operational mode of said vehicle between a low-speed mode I and a cruising mode IV, wherein torque to propel said vehicle is provided by said traction motor or said engine, respectively, in response to monitoring the instantaneous torque requirements required for propulsion of the vehicle (RL), and wherein further according to said method, when said controller determines that transition of the operating mode of said vehicle from mode I to mode IV is desirable, said controller controls said starting motor to spin said engine for starting at a minimum speed of at least 300 rpm, and said clutch is not engaged for supply of torque from said engine to said road wheels until said engine is running at a speed at which it efficiently produces torque.

Claim 31

Dependent Claim 95 words

The method of claim 27 , wherein said vehicle further comprises a catalytic converter comprising a catalyst for reducing noxious emissions from said engine to harmless products, said catalytic converter being provided with a heater controlled by said controller for heating said catalyst to an effective working temperature, and wherein when said controller determines that transition of the operating mode of said vehicle from mode I to mode IV is desirable, said controller heats said catalyst to a minimum effective working temperature if necessary before controlling said starting motor to spin said engine for starting.

Claim 32

Dependent Claim 227 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine, and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said battery bank is configured as two separate battery sub-banks, each having positive and negative poles, the positive pole of one of said sub-banks being connected to the negative pole of the other of said sub-banks at a vehicle chassis connection, and the opposite poles of said battery sub-banks being connected across said pairs of elements of said at least one inverter/charger.

Claim 33

Dependent Claim 227 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine, and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said battery bank is configured as two separate battery sub-banks, each having positive and negative poles, the positive pole of one of said sub-banks being connected to the negative pole of the other of said sub-banks at a vehicle chassis connection, and the opposite poles of said battery sub-banks being connected across said pairs of elements of said at least one inverter/charger.

Claim 34

Dependent Claim 201 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said battery bank is configured as a number of batteries connected by normally-open switching devices, such that said batteries are electrically isolated from one another in the event power is cut off from said switching devices.

Claim 35

Dependent Claim 201 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said battery bank is configured as a number of batteries connected by normally-open switching devices, such that said batteries are electrically isolated from one another in the event power is cut off from said switching devices.

Claim 36

Dependent Claim 245 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said at least one motor is permanently connected to said road wheels for torque transmission therebetween, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said motor has at least four phases, and wherein said motor is operated by said inverter/charger in response to control signals provided by said controller so that said motor provides constant torque from zero rpm to a base speed, and provides constant power at speeds greater than said base speed and less than a maximum speed.

Claim 37

Dependent Claim 245 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said at least one motor is permanently connected to said road wheels for torque transmission therebetween, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said motor has at least four phases, and wherein said motor is operated by said inverter/charger in response to control signals provided by said controller so that said motor provides constant torque from zero rpm to a base speed, and provides constant power at speeds greater than said base speed and less than a maximum speed.

Claim 38

Dependent Claim 255 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said at least one motor is permanently connected to said road wheels for torque transmission therebetween, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said motor is operated by said inverter/charger in response to control signals provided by said controller so that said motor provides constant torque from zero rpm to a base speed, and provides constant power at speeds greater than said bass speed and less than a maximum speed, and wherein the ratio between said base speed and said maximum speed is between about 3 and about 6:1.

Claim 39

Dependent Claim 255 words

A hybrid vehicle operable in a plurality of differing modes, said vehicle comprising an internal combustion engine for providing torque up to a maximum torque output (MTO) and at least one traction motor being coupled to road wheels of said vehicle, without a controllable clutch disposed therebetween, such that said at least one motor is permanently connected to said road wheels for torque transmission therebetween, said at least one motor being operable as a generator, a battery bank for providing electrical energy to and accepting energy from said motor, a controller for controlling operation of said engine and said at least one motor, and controlling flow of electrical energy between said motor and said battery bank, and at least one controllable inverter/charger connected between said motor and said battery bank, said controllable inverter/charger comprising a plurality of pairs of elements controllably switched in response to commands from said controller for operating said motor to supply propulsive torque to said road wheels in response to energy from said battery bank, and for converting torque transmitted from said road wheels to said motor into energy for recharging said battery bank, wherein said motor is operated by said inverter/charger in response to control signals provided by said controller so that said motor provides constant torque from zero rpm to a base speed, and provides constant power at speeds greater than said bass speed and less than a maximum speed, and wherein the ratio between said base speed and said maximum speed is between about 3 and about 6:1.

Claim 40

Dependent Claim 24 words

The vehicle of claim 32 , wherein the maximum speed of said motor is at least about 150% the maximum speed of said engine.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	2004-04-02	2004-10-02	2005-04-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2008-04-02	2008-10-02	2009-04-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2012-04-02	2012-10-02	2013-04-03	$7700.00	Window Closed / Lapsed

Hybrid vehicle

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