Service disconnect interlock system and method for hybrid vehicles
09555800 ยท 2017-01-31
Assignee
Inventors
Cpc classification
B60L2250/12
PERFORMING OPERATIONS; TRANSPORTING
B60L3/04
PERFORMING OPERATIONS; TRANSPORTING
Y10S903/903
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
B60L58/12
PERFORMING OPERATIONS; TRANSPORTING
B60L3/0061
PERFORMING OPERATIONS; TRANSPORTING
B60L3/0046
PERFORMING OPERATIONS; TRANSPORTING
B60K2001/0455
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/70
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
B60L50/16
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/62
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
B60K2006/4825
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/72
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
B60L2270/40
PERFORMING OPERATIONS; TRANSPORTING
B60L1/003
PERFORMING OPERATIONS; TRANSPORTING
B60W20/50
PERFORMING OPERATIONS; TRANSPORTING
B60L50/30
PERFORMING OPERATIONS; TRANSPORTING
B60L3/12
PERFORMING OPERATIONS; TRANSPORTING
B60L2260/28
PERFORMING OPERATIONS; TRANSPORTING
B60L50/40
PERFORMING OPERATIONS; TRANSPORTING
B60W2050/043
PERFORMING OPERATIONS; TRANSPORTING
B60L50/64
PERFORMING OPERATIONS; TRANSPORTING
B60W50/04
PERFORMING OPERATIONS; TRANSPORTING
B60W50/035
PERFORMING OPERATIONS; TRANSPORTING
B60L3/0069
PERFORMING OPERATIONS; TRANSPORTING
B60W50/0205
PERFORMING OPERATIONS; TRANSPORTING
Y02T10/7072
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
International classification
B60W20/00
PERFORMING OPERATIONS; TRANSPORTING
B60L3/12
PERFORMING OPERATIONS; TRANSPORTING
B60L3/04
PERFORMING OPERATIONS; TRANSPORTING
B60W50/035
PERFORMING OPERATIONS; TRANSPORTING
B60W50/04
PERFORMING OPERATIONS; TRANSPORTING
B60W50/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method of servicing a hybrid system is disclosed wherein the hybrid system includes a detected fault. As a result of the detected fault the hybrid system has been disabled. The hybrid system includes a controller and a service detection interlock (SDI). The method steps include first powering up the controller and then assessing a special fault flag status. If a special fault flag is set, the next step is to check to see if the SDI is removed. If the SDI is removed then the special fault flag is cleared while the hybrid system remains disabled. The controller is then powered down with the key-off input and with the next key-on input, the hybrid system can be enabled.
Claims
1. A method of servicing a hybrid system with a detected fault, said hybrid system having a controller and a service detection interlock (SDI), said method comprising the following steps: a) powering up said controller; b) assessing a service action fault flag status; c) if a service action fault flag is set, checking to see if the SDI is removed; d) if the SDI is removed, clearing the service action fault flag; e) disabling said hybrid system; and f) powering down the controller with a key-off input.
2. The method of claim 1 which further includes, when a service action fault flag is not set, the step of allowing the controller to monitor for other faults.
3. The method of claim 2 which further includes, if a fault is detected by the controller, the step of disabling the hybrid system.
4. The method of claim 3 wherein, if a fault is not detected, maintaining the hybrid system in an enabled status until either a fault is detected or there is a key-off event.
5. The method of claim 1 which further includes, if a fault is detected, the step of allowing the controller to assess whether the fault is a service action fault which requires the setting of a flag.
6. The method of claim 5 which further includes, if the detected fault is not a service action fault, the step of checking a key-off status.
7. The method of claim 6 which includes the step of cyclically checking the key-off status.
8. The method of claim 5, which further includes, if the detected fault is a service action fault, the step of setting a flag for said service action fault which must be cleared to enable the disabled hybrid system.
9. The method of claim 8 which includes the step of cyclically checking the key-off status.
10. The method of claim 1 which further includes, if a fault is detected by the controller, the step of disabling the hybrid system.
11. The method of claim 1 wherein, if a fault is not detected, maintaining the hybrid system in an enabled status until either a fault is detected or there is a key-off event.
12. The method of claim 1 which further includes, if a fault is detected, the step of allowing the controller to assess whether the fault is a service action fault which requires the setting of a flag.
13. A method of servicing a disabled hybrid system which includes a controller and a service disconnect interlock (SDI) component and which has a service action fault flag set, said method comprising the following steps: a) removing said SDI; b) powering up the controller; c) clearing the service action fault flag in conjunction with servicing of the disabled hybrid system; d) replacing said SDI; and e) executing a key-off command.
14. An energy storage module for use in a hybrid electric vehicle, said energy storage module comprising: an enclosure; means for storing energy generated by said hybrid electric vehicle, said means being interior to said enclosure; a voltage junction box exterior to said enclosure; and a removable service disconnect interlock electrically connected between said means for storing energy and said voltage junction box, said removable service disconnect interlock being constructed and arranged to break a current path between said means for storing energy and said voltage junction box when removed, wherein said removable service disconnect interlock is controlled by fault detection logic which is constructed and arranged to detect a fault which requires a repair to be performed in order to protect a portion of the hybrid electric vehicle.
15. The energy storage module of claim 14 wherein when a fault is detected, the fault detection logic is constructed and arranged to require a key-on/key-off cycle to be performed before the hybrid electric vehicle can be re-enabled.
16. The energy storage module of claim 14 which further includes a low-voltage connector.
17. The energy storage module of claim 16 wherein said removable service disconnect interlock is controlled by fault detection logic.
18. An energy storage module for use in a hybrid electric vehicle, said energy storage module comprising: an enclosure; means for storing energy generated by said hybrid electric vehicle, said means being interior to said enclosure; a voltage junction box exterior to said enclosure; and a removable service disconnect interlock electrically connected between said means for storing energy and said voltage junction box, said removable service disconnect interlock being constructed and arranged to break a current path between said means for storing energy and said voltage junction box when removed, wherein said removable service disconnect interlock is controlled by fault detection logic which is constructed and arranged to distinguish a service action category of faults from other faults which are not in said service action category.
19. The energy storage module of claim 18 which further includes a low-voltage connector.
20. The energy storage module of claim 19 wherein said removable service disconnect interlock is controlled by fault detection logic.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(7) For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. One embodiment of the invention is shown in great detail, although it will be apparent to those skilled in the relevant art that some features not relevant to the present invention may not be shown for the sake of clarity.
(8) In order to help with an understanding of the exemplary embodiment, a representative hybrid system is disclosed (see
(9) With continued reference to
(10) The hybrid module 104 is designed to operate as a self-sufficient unit, that is, it is generally able to operate independently of the engine 102 and transmission 106. In particular, its hydraulics, cooling and lubrication do not directly rely upon the engine 102 and the transmission 106. The hybrid module 104 includes a sump 116 that stores and supplies fluids, such as oil, lubricants, or other fluids, to the hybrid module 104 for hydraulics, lubrication, and cooling purposes. While the terms oil or lubricant will be used interchangeably herein, these terms are used in a broader sense to include various types of lubricants, such as natural or synthetic oils, as well as lubricants having different properties. To circulate the fluid, the hybrid module 104 includes a mechanical pump 118 and an electrical (or electric) pump 120. With this combination of both the mechanical pump 118 and electrical pump 120, the overall size and, moreover, the overall expense for the pumps is reduced. The electrical pump 120 can supplement mechanical pump 118 to provide extra pumping capacity when required. In addition, it is contemplated that the flow through the electrical pump 120 can be used to detect low fluid conditions for the hybrid module 104.
(11) The hybrid system 100 further includes a cooling system 122 that is used to cool the fluid supplied to the hybrid module 104 as well as the water-ethylene-glycol (WEG) to various other components of the hybrid system 100 which will be described later in further detail. In one variation, the WEG can also be circulated through an outer jacket of the eMachine 112 in order to cool the eMachine 112. It should be noted that the hybrid system 100 will be described with respect to a WEG coolant, but other types of antifreezes and cooling fluids, such as water, alcohol solutions, etc., can be used. Looking at
(12) The eMachine 112 in the hybrid module 104, depending on the operational mode, at times acts as a generator and at other times as a motor. When acting as a motor, the eMachine 112 draws alternating current (AC). When acting as a generator, the eMachine 112 creates AC. An inverter 132 converts the AC from the eMachine 112 and supplies it to an energy storage system 134. In the illustrated example, the energy storage system 134 stores the energy and resupplies it as direct current (DC). When the eMachine 112 in the hybrid module 104 acts as a motor, the inverter 132 converts the DC power to AC, which in turn is supplied to the eMachine 112. The energy storage system 134 in the illustrated example includes three energy storage modules 136 that are daisy-chained together to supply high voltage power to the inverter 132. The energy storage modules 136 are, in essence, electrochemical batteries for storing the energy generated by the eMachine 112 and rapidly supplying the energy back to the eMachine 112. The energy storage modules 136, the inverter 132, and the eMachine 112 are operatively coupled together through high voltage wiring as is depicted by the line illustrated in
(13) High voltage wiring connects the energy storage system 134 to a high voltage tap 138. The high voltage tap 138 supplies high voltage to various components attached to the vehicle. A DC-DC converter system 140, which includes one or more DC-DC converter modules 142, converts the high voltage power supplied by the energy storage system 134 to a lower voltage, which in turn is supplied to various systems and accessories 144 that require lower voltages. As illustrated in
(14) The hybrid system 100 incorporates a number of control systems for controlling the operations of the various components. For example, the engine 102 has an engine control module 146 that controls various operational characteristics of the engine 102 such as fuel injection and the like. A transmission/hybrid control module (TCM/HCM) 148 substitutes for a traditional transmission control module and is designed to control both the operation of the transmission 106 as well as the hybrid module 104. The transmission/hybrid control module 148 and the engine control module 146 along with the inverter 132, energy storage system 134, and DC-DC converter system 140 communicate along a communication link as is depicted in
(15) To control and monitor the operation of the hybrid system 100, the hybrid system 100 includes an interface 150. The interface 150 includes a shift selector 152 for selecting whether the vehicle is in drive, neutral, reverse, etc., and an instrument panel 154 that includes various indicators 156 of the operational status of the hybrid system 100, such as check transmission, brake pressure, and air pressure indicators, to name just a few.
(16) As noted before, the hybrid system 100 is configured to be readily retrofitted to existing vehicle designs with minimal impact to the overall design. All of the systems including, but not limited to, mechanical, electrical, cooling, controls, and hydraulic systems, of the hybrid system 100 have been configured to be a generally self-contained unit such that the remaining components of the vehicle do not need significant modifications. The more components that need to be modified, the more vehicle design effort and testing is required, which in turn reduces the chance of vehicle manufacturers adopting newer hybrid designs over less efficient, preexisting vehicle designs. In other words, significant modifications to the layout of a preexisting vehicle design for a hybrid retrofit requires, then, vehicle and product line modifications and expensive testing to ensure the proper operation and safety of the vehicle, and this expenses tends to lessen or slow adoption of hybrid systems. As will be recognized, the hybrid system 100 not only incorporates a mechanical architecture that minimally impacts the mechanical systems of pre-existing vehicle designs, but the hybrid system 100 also incorporates a control/electrical architecture that minimally impacts the control and electrical systems of pre-existing vehicle designs.
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(18) In terms of general functionality, the transmission/hybrid control module 148 receives power limits, capacity available current, voltage, temperature, state of charge, status, and fan speed information from the energy storage system 134 and the various energy storage modules 136 within. The transmission/hybrid control module 148 in turn sends commands for connecting the various energy storage modules 136 so as to supply voltage to and from the inverter 132. The transmission/hybrid control module 148 also receives information about the operation of the electrical pump 120 as well as issues commands to the auxiliary electrical pump 120. From the inverter 132, the transmission/hybrid control module 148 receives a number of inputs such as the motor/generator torque that is available, the torque limits, the inverter's voltage current and actual torque speed. Based on that information, the transmission/hybrid control module 148 controls the torque speed and the pump 130 of the cooling system. From the inverter 132, it also receives a high voltage bus power and consumption information. The transmission/hybrid control module 148 also monitors the input voltage and current as well as the output voltage and current along with the operating status of the individual DC-DC converter modules 142 of the DC-DC converter system 140. The transmission/hybrid control module 148 also communicates with and receives information from the engine control module 146 and in response controls the torque and speed of the engine 102 via the engine control module 146.
(19) Turning to
(20) A plurality of mounting feet 306 are located on the bottom of lower housing 302 to assist in the mounting of the energy storage module 136 to the HEV body or frame. Additionally, a plurality of indentations 316 are provided around the periphery of lower housing 302 to also assist in the optional stacking of multiple energy storage modules.
(21) Located at one end 307 of the energy storage module 136 is a high voltage junction box 308. As will be described in more detail below, a series of high voltage cables 310 are connected to the high voltage junction box 308 to deliver high voltage power to and from energy storage module 136. The high voltage junction box 308 may be formed integral to the primary enclosure 301 or as a separate unit.
(22) Also provided on the end 307 of the energy storage module 136 are a service disconnect 312 and a low-voltage vehicle signal connector 314. The service disconnect 312 is provided to break the current path between the high voltage energy sources within the primary enclosure 301 and the electronics within the high voltage junction box 308. The service disconnect 312 ensures user safety during service operations of the energy storage module 136. The service disconnect 312 is also important from a safety perspective when servicing or repairing the hybrid system. The vehicle signal connector 314 allows for the energy storage module 136 to be in electrical and communicative connection with other components of the hybrid system, such as, but not limited to, the transmission/hybrid control module 148. In one embodiment, the vehicle signal connector 314 is a forty seven (47) way connector which includes gold terminals. According to one aspect of the present disclosure, the vehicle signal connector 314 is also designed and validated for heavy duty applications. Though the embodiment illustrated in
(23) With reference to
(24) The HEV of the exemplary embodiment includes various diagnostic controls and included as a part of these diagnostic controls is circuitry i.e. a controller or engine control module (ECM) for fault detection. As used in this context, a fault is defined broadly and which faults may be detected is generally a function of the selected circuitry configuration of the controller. The detection of a fault could be selectively configured as a warning or alert, which may not require repair or may not necessitate immediate servicing. However, in the context of the exemplary embodiment, the faults being detected and flagged are those faults which require a repair to be performed in order to protect the hybrid components and/or to control the stored energy of the hybrid system. This type or category of fault is described herein as special. One of the causes of uncontrolled energy is if the contactors are closed with the failure not fixed. Also in the context of the exemplary embodiment, it is noted that some failures can only be detected after attempting to enable the hybrid system.
(25) In the context of the exemplary embodiment, the acronyms SDI and SDIL are used as being descriptive of the type of service disconnect structure and its control function which are used. SDI refers to Service Disconnect Interlock and SDIL refers to Service Disconnect Interlock Loop. SDI will be used herein as a generic reference for both the structure and its control function. This SDI structure, as represented by device 402 in
(26) With reference to the flow diagram of
(27) From the perspective of the customer (i.e. driver), the hybrid system senses and signals a fault which requires the type of service action or procedure as described herein. A special fault of this type sets a flag which must be cleared before the disabled hybrid system can be enabled (see
(28) With continued reference to
(29) With continued reference to
(30) If a key-off event has not occurred, then the logic flow, via line 510, goes back to the fault monitoring stage 504. This cyclic decision loop continues until there is a key-off event at which point the controller is powered down at 512. So long as a fault is not detected and there is not a key-off event, the logic flow loop 504-506-508 cyclically continues. The sampling rate is settable by the controller.
(31) Continuing with the no flag set status at 502, what is the logic flow if at stage 504 a fault has occurred? If a fault has been detected by the controller at stage 504, the controller sets a fault indication 514 and the hybrid system is disabled at 516. This step is important for safety considerations so that the hybrid system will not be put at risk until such time as the nature of the fault can be assessed. If the type or nature of the fault does not require special clearing 518 (also see status at 502), then the no line leads to another key-off decision stage 520. When the key is off (i.e. yes), the controller is powered down at 512. If the key is not off, a decision loop is provided as a way to keep checking for a key-off status. Once the controller is powered down at 512, the next key-on signal powers up the controller 500 and the controller flow logic as described herein resumes.
(32) At stage 518 the controller provides the ability to distinguish a special fault from other non-special faults. If the type or category of fault requires a special fault clearing procedure, then a flag is set for the special fault clear required condition at 522. Once the flag is set, noting that the hybrid system is still disabled, the flow logic looks for the next key-off event at 520. The key-off event at 520 is tracked with a cyclic logic loop waiting on a key-off event at 520 to power down the controller at 512.
(33) With the controller powered down, the next key-on event powers up the controller 500. The controller then makes an assessment at 502 of any flags being set such that a special fault needs to be cleared. The no branch has been described. As for the yes branch from 502, the next assessment by the controller is whether or not the SDI is removed at 524. If the SDI is not removed (line 526), then the hybrid system is disabled at 528. The logic of these stages is based on the controller having detected a special fault and accordingly, setting a flag for that special fault. According to the exemplary embodiment, the SDI needs to be removed as part of the repair/service protocol. If the SDI is not removed after a flag is set for a special fault, then the hybrid system is not enabled. The hybrid system remains disabled until there is a key-off input (i.e. signal) at 520, followed by a key-on signal at 500, with the SDI removed 524.
(34) Even with the SDI removed at 524, there is still a command from the controller to disable the hybrid system 528. In this process and flow logic, the flag which was set for the special fault is cleared at 530. With the flag at 530 cleared, the next key-off event followed by a key-on event returns the control logic to the 504-506-508 loop until the next fault is detected. Until that next fault event, the hybrid system remains enabled at 506. The SDI is returned to its operable position within the hybrid system following whatever service or repair was needed to be performed. Since the hybrid system was disabled at 528, the conclusion of the service/repair still requires a key-off input in order to reset the hybrid system.
(35) While the preferred embodiment of the invention has been illustrated and described in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that all changes and modifications that come within the spirit of the invention are desired to be protected.