LEAN OPERATING HYBRID GASOLINE ENGINE
20230174047 · 2023-06-08
Inventors
- Jack JOHNSON (Coventry, Warwickshire, GB)
- Lyn MCWILLIAM (Coventry, Warwickshire, GB)
- John GEDDES (Coventry, Warwickshire, GB)
- Bryn LITTLEFAIR (Coventry, Warwickshire, GB)
- Thomas JOHNSON (Stratford-upon-Avon, Warwickshire, GB)
Cpc classification
B60W10/08
PERFORMING OPERATIONS; TRANSPORTING
B60W10/02
PERFORMING OPERATIONS; TRANSPORTING
B60K2006/4825
PERFORMING OPERATIONS; TRANSPORTING
B60W30/182
PERFORMING OPERATIONS; TRANSPORTING
B60W10/06
PERFORMING OPERATIONS; TRANSPORTING
B60W30/1882
PERFORMING OPERATIONS; TRANSPORTING
B60W20/20
PERFORMING OPERATIONS; TRANSPORTING
B60W20/16
PERFORMING OPERATIONS; TRANSPORTING
B60K6/442
PERFORMING OPERATIONS; TRANSPORTING
B60W10/26
PERFORMING OPERATIONS; TRANSPORTING
International classification
B60W20/16
PERFORMING OPERATIONS; TRANSPORTING
B60W10/06
PERFORMING OPERATIONS; TRANSPORTING
B60W10/08
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An engine control unit (400) for a full hybrid engine (100, 101) is provided. The full hybrid engine (100, 101) comprises an internal combustion engine (110) and an electric motor (120). The internal combustion engine (110) is coupled to the drivetrain via a clutch (130). The engine control unit (400) is configured to operate the internal combustion engine (110) in a lean-burn mode, to determine a current load level of the full hybrid engine (100, 101), and to compare the current load level to a lean-burn load threshold (210). The lean-burn load threshold (210) defines a load level below which stable operation of the internal combustion engine (110) in the lean-burn mode is impossible and/or undesirable. If the current load level of the full hybrid engine (100, 101) is below the lean-burn load threshold (210), the internal combustion engine (110) is decoupled from the drivetrain and the full hybrid engine (100, 101) is operated in an electric mode.
Claims
1. An engine control unit for a full hybrid engine, the full hybrid engine comprising an internal combustion engine and an electric motor, the internal combustion engine being coupled to the drivetrain via a clutch, the engine control unit being configured to: operate the internal combustion engine in a lean-burn mode, determine a current load level of the full hybrid engine, compare the current load level to a lean-burn load threshold, the lean-burn load threshold defining a load level below which stable operation of the internal combustion engine in the lean-burn mode is impossible and/or undesirable, and when the current load level of the full hybrid engine is below the lean-burn load threshold, decouple the internal combustion engine from the drivetrain and operate the full hybrid engine in an electric mode.
2. The engine control unit according to claim 1, configured to: operate the full hybrid engine in the electric mode, determine the current load level of the full hybrid engine, compare the current load level to the lean-burn load threshold, and when the current load level of the full hybrid engine is above the lean-burn load threshold, couple the internal combustion engine to the drivetrain and operate the internal combustion engine in the lean-burn mode.
3. The engine control unit according to claim 1, configured to determine a current RPM of the full hybrid engine, and to determine the lean-burn load threshold in dependence on the current RPM.
4. The engine control unit according to claim 1, configured to determine the current load level of the full hybrid engine in dependence on an electronic signal representative of a current position of an accelerator pedal.
5. The engine control unit according to claim 1, configured to determine the current load level of the full hybrid engine in dependence on an electronic signal representative of a current speed control setting of a cruise control system.
6. The engine control unit according to claim 1, configured to determine the current load level and/or a current RPM of the full hybrid engine using a torque model.
7. The engine control unit according to claim 1, configured to determine a current NO.sub.x concentration in an exhaust stream of the internal combustion engine, while the internal combustion engine is operating in the lean-burn mode.
8. The engine control unit according to claim 7, configured to compare the current NO.sub.x concentration to a NO.sub.x threshold and, when the current NO.sub.x concentration is above the NO.sub.x threshold, to decouple the internal combustion engine from the drivetrain and operate the full hybrid engine in the electric mode.
9. The engine control unit according to claim 7, configured to calibrate the lean-burn load threshold based on the current load level and the current NO.sub.x concentration.
10. An internal combustion engine comprising the engine control unit of claim 1.
11. A full hybrid engine for a drivetrain of a vehicle, the full hybrid engine comprising: an internal combustion engine, at least one electric motor, a clutch for coupling the internal combustion engine to the drivetrain, and the engine control unit according to claim 1.
12. The full hybrid engine as claimed in claim 11, the full hybrid engine further comprising a generator, mechanically coupled to the internal combustion engine and electrically coupled to the electric motor and/or a battery pack of the vehicle.
13. A powertrain for a vehicle, comprising the full hybrid engine of claim 11.
14. A vehicle comprising full hybrid engine according to claim 13.
15. A method of operating a full hybrid engine for a drivetrain of a vehicle, the full hybrid engine comprising an internal combustion engine and an electric motor, the internal combustion engine being coupled to the drivetrain via a clutch, the method comprising: operating the internal combustion engine in a lean-burn mode, determining a current load level of the full hybrid engine, comparing the current load level to a lean-burn load threshold, the lean-burn load threshold defining a load level below which stable operation of the internal combustion engine in the lean-burn mode is impossible and/or undesirable, and when the current load level of the full hybrid engine is below the lean-burn load threshold, decoupling the internal combustion engine from the drivetrain and operating the full hybrid engine in an electric mode.
16. A non-transitory computer readable medium comprising computer readable instructions that, when executed by a processor, cause performance of the method of claim 15.
17. An engine control unit for a battery electric vehicle, the battery electric vehicle comprising an internal combustion engine, an electric motor, a battery pack, and a generator, the generator being mechanically coupled to the internal combustion engine and electrically coupled to the electric motor and/or the battery pack, the engine control unit being configured to: operate the internal combustion engine, determine a current load level of the internal combustion engine, compare the current load level to a lean-burn load threshold, the lean-burn load threshold defining a load level below which stable operation of the internal combustion engine in the lean-burn mode is impossible and/or undesirable, and when the current load level of the internal combustion engine is below the lean-burn load threshold, increase the current load level for charging the battery pack.
18. An internal combustion engine comprising the engine control unit of claim 17.
19. A powertrain for a battery electric vehicle, the powertrain comprising: an internal combustion engine, an electric motor, a battery pack, a generator, mechanically coupled to the internal combustion engine and electrically coupled to the electric motor and/or the battery pack, and the engine control unit according to claim 17.
20. A battery electric vehicle comprising the powertrain according to claim 19.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] One or more embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
[0037]
[0038]
[0039]
[0040]
[0041]
[0042]
[0043]
[0044]
DETAILED DESCRIPTION
[0045] A powertrain in accordance with an embodiment of the present invention is described herein with reference to the accompanying
[0046] The hybrid engine 100 comprises an internal combustion engine 110 and an electric motor 120. The internal combustion engine 110 burns gasoline to convert heat into mechanical power. To enjoy the benefits of the current invention, the internal combustion engine 110 is configured for operating under lean conditions, i.e. burning the gasoline with an excess of air in the air-fuel mixture (also called charge). The electric motor 120 is powered by a battery pack 121 and converts electric power into mechanical power. When driven by an output shaft of the internal combustion engine 110, the electric motor 120 can be used as a generator for charging the battery pack. In addition thereto, the battery pack 121 may, for example, be chargeable via an external charger connected to the power grid or by via photovoltaic cells integrated in the bodywork of the vehicle.
[0047] The hybrid engine 100 used in this embodiment of the invention is of the P2 type, which means that the electric motor 120 is coupled to the output shaft of the internal combustion engine 110 via a clutch 130. When the clutch 130 is opened, the internal combustion engine 110 is decoupled from the drivetrain and the vehicle is propelled by the electric motor 120 only. When the clutch 130 is closed, power generated by the internal combustion engine 110 can be used for driving the vehicle. The vehicle 10 may then be driven by the combustion engine 110 only or assisted by the electric motor 120. Alternatively, the combustion engine 110 may be used to generate more power than needed for driving the vehicle and the excess power can be used to let the electric motor 120 convert mechanical power into electricity that can, for example, be used for charging the battery pack 121. Because the vehicle can be run only on the combustion engine 110, only on the electric motor 120, or on a combination of both, this type of hybrid engine 100 is also called a full hybrid engine 100.
[0048]
[0049] When the clutch 130 is opened and the engine 110 is uncoupled from the electric motor 120 and the drivetrain, it may continue to run in a lean-burn mode to drive the generator 530 and thereby charge the battery pack 121 or power the electric motor 120. When coupled to the drivetrain, a controlled increase of the total engine load, above the engine load that would be needed for driving the vehicle, may help to push the engine 110 into an operational mode wherein it can operate lean. This excess engine load is then used to drive the generator 530 and thereby charge the battery pack 121.
[0050] It is noted that, although in
[0051] An example of a P4 type hybrid engine 101 is shown in
[0052] The internal combustion engine 110 may additionally be coupled to a generator (not shown), which could, for example, be used to charge the battery pack 121 and/or power the electric motor 120. This will typically be useful when the vehicle 10 is driven at the rear axle 170 only but can also be done while in four-wheel drive or front-wheel drive mode. When in front-wheel drive mode, the generator is only used for charging the battery pack 121. In rear-wheel or four-wheel drive mode, the generator 530 can be used for powering the electric motor 120 and/or charging the battery pack 121.
[0053]
[0054]
[0055] The amount of electrical power generated by the generator 530 is controlled in dependence of the amount of mechanical power that is needed for driving the vehicle 10. It may, however, be advantageous to control the engine 110 and the generator 530 in such a way as to ensure that the engine 110 can always run in a lean-burn mode. This can be achieved by reducing the engine load and using more battery power when the demand for power becomes too high for running in an energy efficient lean-burn mode. Similarly, when low engine loads make it difficult or impossible for the engine 110 to deliver power in a lean-burn mode, the engine load may be increased and the excess electrical power can be stored in the battery pack 121. Such control strategies to ensure that the engine 110 runs exclusively in a lean-burn mode are then to be combined with common control strategies for dividing power demands between the battery pack 121 and the internal combustion engine or range extender 110. In the event that the battery pack 121 is already fully charged, the internal combustion engine 110 may be turned off when the current load level of the internal combustion engine 110 drops below a lean-burn threshold and it is no longer desirable and/or possible to run the engine in a lean-burn mode.
[0056] The efficiency and performance of an engine depend on the rotational speed of its output shaft (typically measured in rotations per minute) and the amount of work it has to deliver. Maximum efficiency and performance are typically achieved in a narrow range of engine speed and engine load combinations. By continuously adapting the relevant operational parameters of the engine in accordance with the desired speed and load, the engine’s performance and efficiency can also be optimised when working outside this narrow range. An engine control unit, which will be described in more detail below with reference to
[0057]
[0058] In region I, the clutch 130 is closed and the internal combustion engine 110 is coupled to the drivetrain. According to the invention, the internal combustion engine 110 runs in a lean-burn mode in the full space of region I, which means that gasoline will be burnt with an excess of air in the air-fuel mixture in the engine’s cylinders, i.e. lambda > 1. For example, a charge with lambda of at least 1.2 or 1.3 is used. The exact mixture of air and fuel, a timing of the fuel injection, valve operation and spark ignition may vary according to the circumstances and engine output demands. While operating in region I, the electric motor 120 is used in one of the three following modes: [0059] Idling. The rotor of the electric motor 120 rotates at the speed of the output shaft of the internal combustion engine 110 (
[0062] Efficient and effective strategies for switching between these three modes are generally known in the art and may depend on many input parameters, such as a charging status of the battery 121, fuel tank filling levels, vehicle speed, current fuel efficiency, required total torque, exhaust gas composition, etc.
[0063] When the engine load is low, and less fuel is needed for satisfying the power demand of the powertrain, stable combustion in a lean environment gets problematic. The flammability of the charge gets too low for ensuring proper burning of all the fuel. Further, when combustion takes place in smaller isolated pockets instead of in the full cylinder at once, this results in knock, leading to noise and damage to the internal combustion engine 110. To avoid such problems, the hybrid engine 100, 101 of
[0064] The transition between region I and region II is marked by a lean-burn load threshold 210, which is hereby defined as the load level below which stable operation of the internal combustion engine 110 in the lean-burn mode is impossible and/or undesirable. ‘Impossible’ may mean that reduced flammability of the charge makes lean combustion technically completely impossible, or at least too unpredictable and unstable to be suitable for effective use of the internal combustion engine 110. Lean-burn operation of the internal combustion engine 110 may be ‘undesirable’, for example, because of relatively low fuel efficiency or high NO.sub.x or CO emissions. Similarly, lean operation will be ‘undesirable’ when the exhaust gas temperatures are too low to allow such emissions to be effectively dealt with by the aftertreatment system. Other possible reasons for lean-burn operation not being desirable may, for example, be an excess of other undesirable or legislated emissions, (temporary) noise restrictions, low filling levels of the fuel tank, or a simple user preference to drive in the electric mode.
[0065] In a basic embodiment of the invention, the lean-burn load threshold may just be defined by a fixed engine load value. This fixed threshold may, for example, be defined as a percentage (e.g. 10%) of the maximum engine load or expressed in BMEP (e.g. 3 bar). If the vehicle demands an engine load below that fixed value, the engine 100, 101 runs in an electric mode (region II). If the vehicle demands more engine load, the engine 100, 101 operates in the lean-burn mode (region I). In a more advanced embodiment of the invention, as shown in
[0066] In addition to the regions I and II, engine map also comprises a region III and a region IV. In region III, the hybrid engine 100, 101 takes advantage of the well-known property of electric motors 120 to be capable of delivering high torque over its full range of available RPMs. In contrast, internal combustion engines 110 typically generate their maximum torque at or near a specific RPM and a reduced output outside that optimum range. The transmission 140 is used (switching gears) to keep close to the optimum RPM range at varying vehicle speeds. By hybrid operation of the engine 100, 101 in region III (low RPM) and region IV (high RPM), high torque can also be delivered at engine speeds for which such torque is not available in the lean-burn internal combustion engine 110. Regions II, III and IV may be operated in a hybrid mode combining lean combustion torque with electric drive, for example operating in region II may comprise operating the electric motor as a generator to move the combustion engine operating point into the lean region.
[0067]
[0068] While the full hybrid engine 100, 101 is running, its current load level is monitored in monitoring step 330. The current load level will typically be determined based on a torque model that uses one or more input parameters to determine or estimate the current engine load. Useful parameters to use as input for the torque model are, for example, an acceleration pedal position measured by an acceleration pedal position sensor, or a current speed control setting of a cruise control system. Other parameters that may be useful for estimating the current load level are vehicle speed, road inclination, and vehicle weight information (which may include the weight of any passengers and/or goods that are being transported by the vehicle).
[0069] As explained above, the engine management may be completely based on the monitored or estimated current engine load level only, but may take additional parameters into account, such as engine RPM and NO.sub.x and other emissions. Such additional parameters are also obtained in monitoring step 330 with the help of the appropriate sensors.
[0070] In mode selecting step 340, the monitored parameters obtained in monitoring step 330 are used for selecting an appropriate mode of operation for the engine 100, 101. For selecting the most appropriate mode, the engine map 200 of
[0071] If the engine control unit chooses to operate the engine 100, 101 in region II, the internal combustion engine 110 will be decoupled from the drivetrain and the hybrid engine 100, 101 is switched to a fully electric mode 320. If the engine control unit chooses to operate the engine 100, 101 in region I, III or IV, the internal combustion engine 110 will remain coupled to the drivetrain and the hybrid engine 100, 101 and the hybrid engine either stays in the full lean-burn mode 310 or switches to an assisted lean-burn mode 315, wherein the internal combustion engine 110 and the electric motor 120 together provide the demanded torque. As already discussed above, the decision to run the internal combustion engine 110 with or without electric assistance may, for example, depend on a charging status of the battery 121, fuel tank filling levels, current fuel efficiency, vehicle speed, required total torque, exhaust gas composition, etc. When operating in the full lean-burn mode 310, excess power from the internal combustion engine (e.g. produced to operate in a more fuel-efficient spot in the engine map 200) may be used for charging the battery 121. However, charging the battery 121 may be possible in a more energy-efficient manner while coasting or using regenerative braking.
[0072] According to an embodiment of the invention, also the current NO.sub.x emissions are taken into account for selecting the appropriate mode of operation. This may, for example, be done by temporarily overruling the engine map 200 and immediately switching to the fully electric mode 320 whenever a predetermined NO.sub.x threshold is exceeded. Alternatively, monitored NO.sub.x emission values may be used as an input for calibrating the lean-burn load threshold 210. If, for example, it turns out that NO.sub.x emissions can be kept relatively low when operating in areas of the engine map 200, just above the lean-burn threshold 210, the threshold 210 may be lowered. Conversely, the threshold may be raised when experiencing unexpectedly high NO.sub.x emissions. Such calibration may also alter the shape of the lean-burn threshold 210, if the threshold can be raised for some RPMs, but has to be lowered for others.
[0073] With reference to
[0074] It is to be understood that the or each controller 410 can comprise a control unit or computational device having one or more electronic processors (e.g., a microprocessor, a microcontroller, an application specific integrated circuit (ASIC), etc.), and may comprise a single control unit or computational device, or alternatively different functions of the or each controller 410 may be embodied in, or hosted in, different control units or computational devices. As used herein, the term “controller,” “control unit,” or “computational device” will be understood to include a single controller, control unit, or computational device, and a plurality of controllers, control units, or computational devices collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause the controller 410 to implement the control techniques described herein (including some or all of the functionality required for the method described herein). The set of instructions could be embedded in said one or more electronic processors of the controller 410; or alternatively, the set of instructions could be provided as software to be executed in the controller 410. A first controller or control unit may be implemented in software run on one or more processors. One or more other controllers or control units may be implemented in software run on one or more processors, optionally the same one or more processors as the first controller or control unit. Other arrangements are also useful.
[0075] In the example illustrated in
[0076] The, or each, electronic processor 420 may comprise any suitable electronic processor (e.g., a microprocessor, a microcontroller, an ASIC, etc.) that is configured to execute electronic instructions. The, or each, electronic memory device 430 may comprise any suitable memory device and may store a variety of data, information, threshold value(s), lookup tables or other data structures, and/or instructions therein or thereon. In an embodiment, the memory device 430 has information and instructions for software, firmware, programs, algorithms, scripts, applications, etc. stored therein or thereon that may govern all or part of the methodology described herein. The processor, or each, electronic processor 420 may access the memory device 430 and execute and/or use that or those instructions and information to carry out or perform some or all of the functionality and methodology describe herein.
[0077] The at least one memory device 430 may comprise a computer-readable storage medium (e.g. a non-transitory or non-transient storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors/computational devices, including, without limitation: a magnetic storage medium (e.g. floppy diskette); optical storage medium (e.g. CD-ROM); magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g. EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information/instructions.
[0078] Example controllers 410 have been described comprising at least one electronic processor 420 configured to execute electronic instructions stored within at least one memory device 430, which when executed causes the electronic processor(s) 420 to carry out the method as hereinbefore described. However, it is contemplated that the present invention is not limited to being implemented by way of programmable processing devices, and that at least some of, and in some embodiments all of, the functionality and or method steps of the present invention may equally be implemented by way of non-programmable hardware, such as by way of non-programmable ASIC, Boolean logic circuitry, etc.
[0079] It will be appreciated that various changes and modifications can be made to the present invention without departing from the scope of the present application.