Crankshaft controller

Abstract

A hybrid electric vehicle includes a controller and control method to control position of a crankshaft of an internal combustion engine when the engine is stopped and the vehicle is moving to balance bearing wear associated with road-surface induced vibrations or oscillations imparted to the bearings while the crankshaft is not rotating. The controller is configured to store information relating to a cumulative time stopped at a plurality of angular positions of the crankshaft while the vehicle is in operation and/or moving, and to control stopping or repositioning of the crankshaft to balance or approximately evenly distribute the stopping positions among the plurality angular stopping positions to reduce or eliminate the possibility of excessive wear at any particular position relative to the others.

Claims

1. A hybrid vehicle comprising: an internal combustion engine having a crankshaft and associated crankshaft position sensor; an electric machine coupled to the internal combustion engine; a battery coupled to the electric machine; and a controller programmed to store a cumulative stopped time over multiple engine stops for each of a plurality of stopped angular positions of the crankshaft in response to a crankshaft position sensor signal while the vehicle is in operation, and control at least one of the electric machine and the internal combustion engine to control a stopped angular position of the crankshaft responsive to the cumulative stopped time for at least one of the plurality of stopped angular positions.

2. The hybrid vehicle of claim 1 wherein the controller controls at least one of the electric machine and the internal combustion engine to position the crankshaft in response to a difference between a first angular position having a highest cumulative time and a second angular position having a lowest cumulative time exceeding an associated threshold.

3. The hybrid vehicle of claim 2 wherein the associated threshold is 15 minutes.

4. The hybrid vehicle of claim 1 wherein the controller controls at least one of the electric machine and the internal combustion engine to position the crankshaft at one of the plurality of stopped angular positions corresponding to a lowest cumulative time.

5. The hybrid vehicle of claim 1 wherein the controller controls stopping position of the crankshaft during engine shutdown based on the cumulative stopped times associated with the plurality of stopped angular positions.

6. The hybrid vehicle of claim 1 wherein the controller controls at least one of the electric machine and the internal combustion engine to reposition the crankshaft to one of the plurality of stopped angular positions after engine shutdown based on the cumulative stopped times.

7. The hybrid vehicle of claim 1 wherein the controller is further programmed to output a maintenance warning in response to a highest of the cumulative stopped times exceeding a corresponding threshold.

8. The hybrid vehicle of claim 1 wherein the plurality of angular positions comprises 60 angular positions arranged at intervals of six degrees about a circumference of the crankshaft.

9. The hybrid vehicle of claim 1 wherein the controller is further programmed to increase the cumulative stopped time for a current one of the plurality of stopped angular positions only when vehicle speed exceeds a corresponding threshold.

10. The hybrid vehicle of claim 1 wherein the controller is further programmed to increase the cumulative stopped time for a current one of the plurality of stopped angular positions when the electric machine is in operation.

11. The hybrid vehicle of claim 1 wherein the battery is configured for charging by the electric machine and from an external electric connection.

12. A method for controlling a hybrid vehicle having an internal combustion engine with a crankshaft and an associated crankshaft position sensor, an electric machine, and a battery, comprising, by a controller: controlling at least one of the internal combustion engine and the electric machine to position the crankshaft at one of a plurality of stopped positions based on cumulative stopped times over multiple engine stops at each of the plurality of stopped positions.

13. The method of claim 12 further comprising generating a maintenance alert in response to the cumulative stopped time associated with any of the plurality of stopped positions exceeding a corresponding threshold.

14. The method of claim 12 further comprising controlling at least one of the internal combustion engine and the electric machine to position the crankshaft in response to a difference between a maximum of the cumulative stopped times and a minimum of the cumulative stopped times exceeding a threshold.

15. The method of claim 12 further comprising controlling at least one of the internal combustion engine and the electric machine to position the crankshaft to one of the plurality of stopped positions corresponding to a lowest of the cumulative stopped times.

16. The method of claim 12 wherein a current one of the cumulative stopped times is increased only when vehicle speed exceeds an associated threshold.

17. A hybrid vehicle including an engine having a crankshaft, an electric machine, a battery coupled to the electric machine, and a controller, the controller programmed to: position the crankshaft during or after stopping the engine to one of a plurality of angular crankshaft stopped positions in response to cumulative vehicle operation time at each of the plurality of angular crankshaft stopped positions over multiple engine stops.

18. The hybrid vehicle of claim 17 wherein the controller is programmed to control at least one of the engine and the electric machine to position the crankshaft.

19. The hybrid vehicle of claim 17 wherein controller is programmed to position the crankshaft at one of the plurality of angular crankshaft stopped positions having a lowest of the cumulative vehicle operation times relative to other ones of the plurality of angular crankshaft stopped positions.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a schematic diagram of a hybrid electric vehicle including a controller and an internal combustion engine.

(2) FIG. 2 is a flowchart illustrating operation of a system or method for controlling crankshaft position when the internal combustion engine is stopped.

DETAILED DESCRIPTION

(3) A controller 1 in accordance with the present disclosure is shown in FIG. 1. The controller 1 comprises an evaluation unit 3, a memory 5, and a sensor 7. The controller 1 (or the evaluation unit 3 and memory 5 of the controller 1) may be integrated into a larger engine management system. Alternatively, the controller 1 may be a separate unit. To illustrate a relationship between the sensor 7 of the controller 1 and a crankshaft 9 of an internal combustion engine (ICE) 11, these components of a hybrid electric vehicle (HEV) 13 are also shown schematically in FIG. 1.

(4) In FIG. 1, the direction of rotation of the crankshaft 9 of this example system is shown using curved arrows. Four angular positions spaced around the circumference of the crankshaft 9 are also marked in FIG. 1, using the reference signs A, B, C and D. The angular positions may be defined with respect to, for example, the remainder of the ICE 11. In FIG. 1, the crankshaft 9 has stopped in position A. FIG. 1 shows four angular positions for simplicity; typically the plurality of stop positions of the crankshaft 9 would consist of a larger number of angular positions, such as 60 angular positions, for example. Selection of the number of angular positions may vary based on the particular application and implementation.

(5) The HEV 13 in FIG. 1 also includes a battery 17, which can be charged by the ICE 11 (via an electric machine or moto/generator 21) or using an external power source (such as an external battery, renewable power source or connection to mains electricity) via an external electric connection 19. As discussed above, the system is even more effective where the hybrid vehicle comprises one or more batteries 17, which may be charged using an external electric connection 19 to an external power source in addition to being charged by the internal combustion engine output, because the operational time of the ICE 11 in such systems is often a low fraction of the operational time of the HEV 13.

(6) For simplicity in the schematic of FIG. 1, only some of the potential connections between components have been illustrated. As an example of this, the potential connection between the electric motor 15 and the crankshaft 9 allowing the electric motor 15 to be used to adjust the angular position of the crankshaft 9 if desired, has not been shown. The omission of some potential connections does not imply that these connections are any more or less important than the displayed connections. Any omitted connections are simply to improve the clarity of the diagram.

(7) FIG. 2 shows a flowchart illustrating operation of a system or method for controlling a crankshaft according to various embodiments. The method illustrated by FIG. 2 is for illustrative purposes only, and some of the steps shown in FIG. 2 are optional steps. Optional steps are indicated by dashed boxes.

(8) At the start of the method illustrated in FIG. 2, the ICE 11 is operating and is being used to generate power. The power may be directed to the motor generator 21 and used to move the HEV 13, or may be directed to a battery 17 or other energy storage unit for storage. The power may also be used to move the HEV 13 directly (without passing through the motor generator 21 and the electric motor 15). In step S101, an instruction to stop the ICE 11 is sent. The instruction may be generated automatically by an engine management unit or may be manually input by a user of the HEV 13.

(9) The instruction to stop the ICE 11 is received by the controller 1 (as shown in step S201). The first condition may also include further requirements, such as determining that the electric motor 15 is operating (see step S102), in order to be satisfied. As explained above, although some wear may occur to the bearing while the vehicle is stationary (and neither of the electric motor 15 or ICE 11 is operating), the false brinelling may occur due to vibrations or oscillations imparted from the roadway when the ICE 11 is inoperative and the vehicle is in motion, being powered by the electric motor 15. Accordingly, by including a check that the electric motor 15 of the hybrid electric vehicle 13 is operating in the first condition, the accuracy with which the wear of the bearings can be estimated is increased. Similarly, by controlling the stopping position of the crankshaft, or repositioning the crankshaft after stopping, the wear associated with false brinelling can be distributed or balanced among the available plurality of stopping positions.

(10) The evaluation unit 3 may be further configured to retrieve, from the memory 5, cumulative durations corresponding to each of the plurality of angular positions (S202). The cumulative durations indicate the total time of vehicle operation and/or vehicle movement that the crankshaft 9 has spent stopped in each of the angular positions. Where the first condition requires that the electric motor 15 is operating, the cumulative durations indicate the total time that the crankshaft 9 has spent stopped in each of the angular positions while the electric motor 15 is powered on and/or rotating. If the cumulative durations have been retrieved, the evaluation unit 3 may then determine which of the plurality of angular positions has the highest cumulative duration and which of the plurality of angular positions has the lowest cumulative duration. With reference to the FIG. 1, the memory 5 may indicate (for example) that the crankshaft 9 has spent 114.00 hours in position A, 115.25 hours in position B, 112.32 hours in position C and 110.81 hours in position D.

(11) Using the highest and lowest cumulative durations, the evaluation unit 3 may then determines the difference between the highest and lowest cumulative durations, that is, how much longer the crankshaft 9 has spent stopped in the angular position corresponding to the highest cumulative duration than in the angular position corresponding to the lowest cumulative duration (see step S203). Turning again to the example discussed above, the evaluation unit 3 could then determine that the highest cumulative duration of 115.25 hours corresponded to angular position B, and the lowest cumulative duration of 110.81 hours corresponded to angular position D. Accordingly, the difference could be determined as 115.25-110.81=4.44 hours.

(12) If the difference between the highest and lowest cumulative durations has been obtained, the evaluation unit 3 may then compare the difference to a first threshold value (S204). An example of a suitable first threshold value is 15 minutes (0.25 hours), although other first threshold values may also be used depending on the specific configuration of the system and of the hybrid vehicle. If the difference is greater than the first threshold value, the controller 1 may then instruct the stopping of the crankshaft 9 in the angular position corresponding to the lowest cumulative duration. In this way, the wear on the bearings of the crankshaft 9 can be spread more equally across the plurality of angular positions to avoid excessive wear on any one angular position relative to the other angular positions and maximizing the lifetime of the crankshaft 9 prior to maintenance. Based on the specific configuration of the HEV 13, the rotation of the crankshaft 9 to the desired stop position may be caused by either the electric motor 15 or the ICE 11, and the HEV 13 may be configured such that both options are available. In the example situation, the difference is determined as 4.44 hours. Accordingly, if the example threshold of 15 minutes (0.25 hours) is used, then the difference is higher than the threshold. The crankshaft 9 can therefore be caused to rotate to the angular position corresponding to the lowest cumulative duration; position D in this example.

(13) If the cumulative durations corresponding to each of the plurality of angular positions have been retrieved (step S202 has been performed), the evaluation unit 3 may be further configured to compare the highest cumulative duration among the plurality of cumulative durations against a second threshold (step S205). The second threshold can be based on a predicted operational lifetime without maintenance of the crankshaft 9, which typically would be of the order of several thousands of hours. The specific value used for the second threshold is typically determined based on the configuration of the system. If the highest cumulative duration is found to exceed the second threshold, a maintenance warning can then be output (S206). The maintenance warning can be output in any suitable way, for example, a warning light on a dashboard, an audible warning, a display on a screen in the vehicle, a warning logged in the vehicle systems to be passed to an engineer when the HEV 13 is serviced, and so on.

(14) In addition to, or alternatively to, comparing the highest of the cumulative durations against the second threshold, further comparisons and determinations may be made using the cumulative duration values (in conjunction with the corresponding angular position values). In an example of a further comparison, a total cumulative duration may be obtained by calculating a sum of the plurality of cumulative durations corresponding to the plurality of angular positions. The total cumulative duration therefore indicates the total stationary time of the crankshaft 9 in all of the angular positions (which, as discussed above, may be the total time while the HEV is moving). This total cumulative duration can then be compared against a threshold value and, if the total cumulative duration exceeds the threshold value, a warning can then be output as discussed above. In the example discussed above, the total cumulative duration could be obtained by adding the cumulative durations for angular positions A to D, thereby obtaining a total cumulative duration of 114.00+115.25+112.32+110.81=452.38 hours.

(15) Regardless of whether or not the cumulative duration comparison and rotation process of steps S202 to S204, or the second threshold comparison process of steps S205 and S206, have been performed, the method then continues with step S301. That is, the method may proceed to step S301 immediately following step S201. In step S301, the evaluation unit 3 then uses data supplied by the position sensor 7 to determine the angular position in which the crankshaft 9 has stopped. Typically, the position sensor 7 will monitor the position of the crankshaft 9 only when the crankshaft 9 has stopped rotating, although the position sensor 7 may also monitor the position of the crankshaft 9 constantly. Where the position sensor 7 is configured to monitor the position of the crankshaft 9 only when the crankshaft 9 has stopped rotating, these measurements may be taken automatically by the sensor 7 and sent to the evaluation unit 3, or alternatively may be taken in response to a query from the evaluation unit. In the example shown in FIG. 1, the crankshaft 9 is shown stopped in angular position A (example positions A, B, C and D are marked on FIG. 1). Once the angular position has been determined, this is recorded in the memory (S401).

(16) The method does not require any further actions (with the potential exception of running a timer starting from the point at which the angular position of the crankshaft 9 is recorded in the memory) until a second condition is satisfied (S501), the second condition comprising that an instruction to start the ICE 11 is received by the controller 1. The second condition may also include other requirements.

(17) When the second condition is satisfied, the time duration during which the crankshaft 9 remained in the recorded angular position is determined (S601). This determination may use the output of a timer that started at point at which the angular position of the crankshaft 9 is recorded in the memory, or an alternative time determination means such as retrieving time information from a computing or controlling system included in the HEV 13. Once the time duration has been determined, this information is recorded in the memory 5 in conjunction with the recorded angular stop position (S701). Although the information can be recorded in any form, such as a chronological listing of the stop positions linked to the durations, typically this information is recorded by maintaining a cumulative duration that the crankshaft 9 spends in each of the angular positions. Where cumulative durations are maintained for each angular position, the time duration determined in step S601 is added to any already recorded duration corresponding to the recorded angular stop position. The contents of the memory 5 may be output to the user of the HEV 13, or to an engineer servicing the HEV 13, either periodically, in response to specific queries, or when threshold values are exceeded (for example).

(18) The present disclosure advantageously provides a controller 1 and method for controlling a crankshaft 9 of an ICE 11 and monitoring the cumulative duration that the crankshaft 9 spends stopped in each of a plurality of angular positions while the vehicle is in operation and/or moving. This allows the wear on the crankshaft 9 bearings to be accurately predicted, and the maintenance point of the bearings may be estimated and addressed by maintenance if necessary. The disclosure also relates to controllers and methods for causing the crankshaft 9 to stop in an angular position having a lowest cumulative duration if desirable, thereby allowing the wear on the bearings of the crankshaft 9 to be spread more equally across the plurality of angular positions, balancing the wear on any one angular position and maximizing the lifetime of the crankshaft 9 prior to maintenance.

(19) As such, various embodiments of the disclosure may include a controller for a crankshaft of an internal combustion engine in a hybrid electric vehicle, the hybrid electric vehicle further comprising an electric motor, the controller comprising: an evaluation unit; a memory connected to the evaluation unit and configured to store cumulative durations that the crankshaft has spent in each angular position among a plurality of angular positions; and a position sensor connected to the evaluation unit and configured to monitor an angular stop position, from among the plurality of angular positions, of the crankshaft, wherein, when a first condition is satisfied, the evaluation unit is configured to: determine the angular position of the crankshaft using data from the position sensor; and record the angular stop position of the crankshaft in the memory, and when a second condition is satisfied, the evaluation unit is configured to: determine the time duration during which the crankshaft remained in the recorded angular stop position; and record the determined time duration in conjunction with the recorded angular stop position in the memory, wherein the first condition comprises an instruction to stop the internal combustion engine being received by the controller, and the second condition comprises an instruction to start the internal combustion engine being received by the controller.

(20) The controller may be configured such that when the first condition is satisfied the evaluation unit is further configured, after determining the angular position of the crankshaft using data from the position sensor, to: retrieve from the memory the plurality of cumulative durations corresponding to the plurality of angular positions, respectively; determine the difference between the highest cumulative duration among the plurality of cumulative durations and the lowest cumulative duration among the plurality of cumulative durations; and if the difference is greater than a first threshold value, instruct the rotation of the crankshaft to the angular position corresponding to the lowest cumulative duration and record the angular position corresponding to the lowest cumulative duration in the memory as the angular stop position of the crankshaft.

(21) The first threshold value may be 15 minutes, for example. The controller may also be configured to instruct the electric motor to rotate the crankshaft to the angular position corresponding to the lowest cumulative duration and/or to instruct the internal combustion engine to rotate the crankshaft to the angular position corresponding to the lowest cumulative duration.

(22) When retrieving from the memory the plurality of cumulative durations, the evaluation unit may be further configured to determine if the highest cumulative duration exceeds a second threshold value, wherein, if the highest cumulative duration exceeds the second threshold value, a maintenance warning is output.

(23) The plurality of angular positions may include 60 angular positions, for example, arranged at generally equal intervals of 6 about the crankshaft circumference.

(24) The first condition may further comprise a determination that the electric motor of the hybrid electric vehicle is operating. The position sensor may be implemented by a bi-directional crankshaft position sensor installed on the internal combustion engine. Alternatively, or in combination, the position sensor may be implemented by a resolver or an angular position sensor installed on the electric motor.

(25) In various embodiments a hybrid electric vehicle comprises a controller as previously described, an electric machine (operating as a motor/generator), and an internal combustion engine comprising a crankshaft. The hybrid electric vehicle may further comprise a battery unit, wherein the battery unit is configured to allow charging from the internal combustion engine output and from an external electric connection.

(26) One or more embodiments provide a method for controlling a crankshaft of an internal combustion engine in a hybrid electric vehicle using a controller, the method comprising: when a first condition is satisfied: determining an angular position of the crankshaft, from among the plurality of angular positions, using data from a position sensor; and recording the angular stop position of the crankshaft in a memory, and when a second condition is satisfied: determining the time duration during which the crankshaft remained in the recorded angular stop position; and recording the determined time duration in conjunction with the recorded angular stop position in the memory, wherein the first condition comprises an instruction to stop the internal combustion engine being received by the controller, and the second condition comprises an instruction to start the internal combustion engine being received by the controller.

(27) The method may further comprise: when the first condition is satisfied, after determining the angular position of the crankshaft using data from the position sensor: retrieving from the memory the plurality of cumulative durations corresponding to the plurality of angular positions, respectively; determining the difference between the highest cumulative duration among the plurality of cumulative durations and the lowest cumulative duration among the plurality of cumulative durations; and if the difference is greater than a first threshold value, rotating the crankshaft to the angular position corresponding to the lowest cumulative duration and recording the angular position corresponding to the lowest cumulative duration in the memory as the angular stop position of the crankshaft.

(28) It will be appreciated by those skilled in the art that although representative embodiments have been described by way of example, with reference to one or more examples, the claimed subject matter is not limited to the disclosed examples and alternative examples may be constructed without departing from the scope of the appended claims.