Method and apparatus for adaptive control of vehicle regenerative braking

Abstract

A hybrid electric vehicle having an energy generation system, an energy storage system and at least one electric motor includes a controller for controlling operation of vehicle systems. The controller monitors the status of vehicle systems and system parameters and determines the regenerative braking mode of the vehicle and the appropriate level of regenerative braking for proper vehicle operation. The controller generates commands based upon these determinations to produce regenerative braking, monitors the status to determine the effects of the regenerative braking command generated, and adaptively changes the regenerative braking command generated in response to the measured effects. A method for adaptively controlling a hybrid electric vehicle is also provided.

Description

BACKGROUND OF THE INVENTION

[0002] 1. Field of Invention

[0003] This invention relates to methods and apparatus for adaptively controlling operation of regenerative braking in an electric or hybrid electric vehicle.

[0004] 2. Description of Related Art

[0005] The desire for cleaner air has caused various federal, state, and local governments to adopt or change regulations requiring lower vehicle emissions. Increasing urban traffic congestion has prompted a need for increases in public mass transit services. All mass transit systems utilizes buses, at least in part, to transport people into, out of, and within traffic congested urban areas. Conventional buses use diesel powered internal combustion engines. Diesel engines produce emissions, including carbon monoxide, that contribute to air pollution. It is possible to refine cleaner diesel fuel. However, cleaner diesel fuel is more costly to refine and causes a corresponding increase in the cost of bus service.

[0006] Alternative fuels have been used to reduce emissions and conserve oil resources. Compressed natural gas has been used as an alternative fuel. Compressed natural gas does not produce as much power in conventional internal combustion engines as gasoline and diesel and has not been widely developed or accepted as an alternative to gasoline and diesel.

[0007] Additives have also been developed for mixing with gasoline to reduce emissions. Ethanol and MTBE have been added to gasoline to oxygenate the combustion of gasoline and reduce emissions of carbon monoxide. These additives, however, are believed to cause decreased gas mileage and, in the case of MTBE, to be a potential public health threat.

[0008] Electric vehicles have been developed that produce zero emissions. Electric vehicles are propelled by an electric motor that is powered by a battery array on board the vehicle. The range of electric vehicles is limited as the size of the battery array which can be installed on the vehicle is limited. Recharging of the batteries can only be done by connecting the battery array to a power source. Electric vehicles are not truly zero emitters when the electricity to charge the battery array is produced by a power plant that burns, for example, coal.

[0009] Hybrid electric vehicles have also been developed to reduce emissions. Hybrid electric vehicles include an internal combustion engine and at least one electric motor powered by a battery array. In a parallel type hybrid electric vehicle, both the internal combustion engine and the electric motor are coupled to the drive train via mechanical means. The electric motor may be used to propel the vehicle at low speeds and to assist the internal combustion engine at higher speeds. The electric motor may also be driven, in part, by the internal combustion engine and be operated as a generator to recharge the battery array.

[0010] In a series type hybrid electric vehicle, the internal combustion engine is used only to run a generator that charges the battery array. There is no mechanical connection of the internal combustion engine to the vehicle drive train. The electric traction drive motor is powered by the battery array and is mechanically connected to the vehicle drive train.

[0011] Conventional internal combustion engine vehicles control propulsion by increasing and decreasing the flow of fuel to the cylinders of the engine in response to the position of an accelerator pedal. Electric and hybrid electric vehicles also control propulsion by increasing or decreasing the rotation of the electric motor or motors in response to the position of an accelerator pedal. Electric and series type hybrid electric vehicles may be unable to accelerate properly if the power available from the battery or batteries and/or genset is insufficient.

[0012] Conventional internal combustion engine vehicles may also include systems to monitor the slip of a wheel or wheels to thereby control the engine and/or the brakes of the vehicle to reduce the slip of the wheel or wheels. In hybrid electric vehicles, however, it is necessary to control the speed and torque of the electric motor or motors to control the slip of wheels.

[0013] Conventional internal combustion engine vehicles may also include systems to modify effects of vehicle braking in certain situations, including loss of traction, wheel slippage, and load shifting. In electric and hybrid electric vehicles, however, regenerative braking operation must interface with these and other propulsion system conditions to prevent unexpected or unsafe operation. Additionally, this system must interface with the energy storage and generation systems because it is electrically based. Furthermore, in electric and hybrid electric vehicles, an operator input may be used to manually indicate the level and types of regenerative braking to be applied.

SUMMARY OF THE INVENTION

[0014] The invention provides methods and apparatus for adaptively controlling the regenerative braking operation of electric and hybrid electric vehicles.

[0015] An exemplary embodiment of a hybrid electric vehicle according to the invention, including an energy generation system, an energy storage system that receives energy at least from the energy generation system, and at least one electric motor receiving current from the energy storage system, is adaptively controlled so that a command signal to the at least one electric motor follows and is proportional to a signal having a value indicative of a user demand. The vehicle propulsion is also adaptively controlled based on a state of charge and temperature of a battery array of the vehicle, an emission mode of the vehicle, a regenerative braking mode of the vehicle, and a nominal operating state of the at least one electric motor.

[0016] According to an exemplary embodiment, a method according to the invention for adaptively controlling propulsion of a hybrid electric vehicle including an energy generation system, an energy storage system that receives energy from at least the energy generation system, and at least one electric motor receiving current from the energy storage system, includes generating a first signal having a value indicative of a user demand, generating a second signal having a value proportional to the first signal and indicative of a demand of the at least one electric motor, determining if the value of the first signal is larger than the value of the second signal, increasing the value of a command signal to the at least one electric motor, if the value of the first signal is not larger than the value of the second signal and decreasing the value of the command signal, if the value of the first signal is larger than the value of the second signal.

[0017] According to an exemplary embodiment, a method according to the invention for adaptively controlling the regenerative braking system of a hybrid electric vehicle including an energy generation system, an energy storage system receiving electric current at least from the energy generation system, and at least one electric motor receiving current from the energy storage system, includes monitoring a user input or other selector to determine one of a multiplicity of regenerative braking modes, monitoring a number of vehicle states and conditions, including energy storage system state of charge, ABS events, loss of traction, operator inputs and others, and creating a regenerative braking command based upon these factors.

[0018] According to another exemplary embodiment, a hybrid electric vehicle according to the invention includes an energy generation system, an energy storage system receiving current at least from the energy generation system, at least one electric motor receiving current from the energy storage system, a component that indicates a signal in the event of a failure, a controller that monitors failure signals and determines the failure of the component based upon the signal, generates a corresponding signal to reset or correct the failure signal, determines if the failure was corrected, disables or isolates the failed component, and generates signals to alter the control of other components.

[0019] Other features of the invention will become apparent as the following description proceeds and upon reference to the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Various exemplary embodiments of this invention will be described in detail with reference to the following figures, wherein like numerals reference like elements, and wherein:

[0021] FIG. 1 is schematic view of an exemplary embodiment of a series type hybrid electric vehicle according to the invention;

[0022] FIG. 2 is a schematic diagram illustrating an exemplary embodiment of a circuit for controlling charging of the battery array by the generator;

[0023] FIG. 3 is a diagram illustrating an exemplary embodiment of a circuit for controlling the electric motors;

[0024] FIG. 4 is a diagram illustrating an exemplary embodiment of a circuit of the motor controllers;

[0025] FIG. 5 is a diagram illustrating the relationship between the power created, the power stored, and the power consumed by the series hybrid electric vehicle according to the invention;

[0026] FIG. 6 is a diagram illustrating an exemplary embodiment of a master control switch;

[0027] FIG. 7 is a diagram illustrating an exemplary embodiment of a driver's input control panel for determining a driving mode;

[0028] FIG. 8 is a diagram illustrating an exemplary embodiment of a driver's input control panel for determining a regenerative braking mode;

[0029] FIG. 9 is a diagram schematically illustrating an exemplary embodiment of the relationship between an accelerator pedal and the electric motors; and

[0030] FIGS. 10-18 are flowcharts illustrating an exemplary adaptive control of the propulsion of the series type hybrid electric vehicle.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0031] Referring to FIG. 1, an exemplary embodiment of a hybrid electric vehicle 10 which embodies the invention includes a plurality of wheels 11, 12, 13, and 14 and a vehicle chassis 15. The wheels 13 and 14 are coupled to electric motors 50 and 60, respectively, through gear boxes 52 and 62, respectively. The wheels 13 and 14 are independently mounted to respective suspension components, such as swing arms. In this embodiment, the wheels 13 and 14 are not coupled together by an axle. In other embodiments, the wheels 13 and 14 may be coupled together, for example, by an axle.

[0032] The wheels 13 and 14 may be either the front wheels or the rear wheels of the vehicle 10. In this embodiment, the wheels 11 and 12 are not driven and may be coupled together by an axle. In other embodiments, the wheels 11 and 12 may be driven.

[0033] Four wheel speed sensors 11′-14′ are provided for sensing the rotational speed of each wheel 11-14, respectively.

[0034] In an exemplary embodiment of a vehicle which embodies this invention, the vehicle 10 is a bus having an occupancy capacity in excess of 100. However, it should be appreciated that the vehicle may be a bus of a smaller capacity or that the vehicle may be a smaller passenger vehicle, such as a sedan. Further, the invention is not limited to passenger vehicles, the invention can be used in any type of motor vehicle, including trucks, boats, etc. In various exemplary embodiments, the vehicle may be any size and form currently used or later developed.

[0035] The electric motors 50 and 60 are powered by an energy storage system, such as a battery array 30, and are controlled by motor controllers 51 and 61, respectively. An energy storage system temperature sensor 30′ detects the temperature of the battery array 30. While exemplary embodiments use a battery array, the invention is not limited to this. Other known or subsequently developed energy storage systems can be adapted for use with this invention, such as capacitors, ultra capacitors, flywheels or other inertia storing systems, or hydraulic accumulators.

[0036] According to an exemplary embodiment of the vehicle 10, the electric motors 50 and 60 are synchronous, permanent magnet DC brushless motors. Each electric motor 50 and 60 is rated for 220 Hp and 0-11,000 rpm. The maximum combined power output of the electric motors 50 and 60 is thus 440 Hp. The permanent magnet DC brushless motors include permanent magnets, such as rare earth magnets, for providing a magnetic field as opposed to AC induction motors which create or induce a magnetic field on the rotating portion of the motor. The DC brushless motors are thus inherently more efficient than AC induction motors as no losses occur from inducing the magnetic field. The DC brushless motors also have a more useful torque profile, a smaller form factor, and lower weight than AC induction motors. The DC brushless motors also require less energy input for an equivalent power output than AC induction motors. However, this invention is not limited to permanent magnet DC brushless motors, and other types of electric motors, such as AC induction motors, can be used.

[0037] The hybrid electric vehicle 10 is preferably a series type hybrid electric vehicle that includes an energy generation system, such as a generator set (genset) 300, 310 including an internal combustion engine 300 and a generator 310 that is driven by the internal combustion engine 300. The internal combustion engine 300 may be powered by gasoline, diesel, or compressed natural gas. It should be appreciated, however, that the internal combustion engine 300 may be replaced by a fuel cell, turbine or any other number of alternatives for creating usable electric power.

[0038] According to an exemplary embodiment of the invention, the internal combustion engine 300 may be a 2.5 liter Ford LRG-425 engine powered by compressed natural gas. The 2.5 liter Ford LRG-425 engine produces 70 Hp. It should be appreciated that the power output of such an engine may be increased by increasing the RPM of the engine and decreased by decreasing the RPM of the engine. In this embodiment with two 220 Hp electric motors 50 and 60 and an internal combustion engine 300 operating at 70 Hp, the performance enhancement factor of the vehicle 10 is 440/70, or at least 6.2. Other internal combustion engines can of course be utilized.

[0039] In this embodiment, the generator 310 is a DC brushless generator that produces, for example, 240-400 VAC. Other types of generators may be employed. In an exemplary embodiment of the vehicle 10, the generator is operated to produce 345 VAC during certain drive modes.

[0040] An output shaft of the internal combustion engine 300 is connected to the generator 310 to power the generator 310 and the AC voltage output by the generator 310 is converted to a DC voltage by a generator controller 320. The converted DC voltage charges the battery array 30. The battery array 30 may include, for example, 26 deep cycle, lead-acid batteries of 12 volts each connected in series. It should be appreciated, however, that other batteries, such as nickel cadmium, metal hydride or lithium ion, may be used and that any number of batteries can be employed, as space permits. In this embodiment, depending upon the load on the vehicle 10, the battery array voltage ranges between 240 and 400 VDC.

[0041] An electronic control unit (ECU) 200 includes a programmable logic controller (PLC) 210 and a master control panel (MCP) 220. The MCP 220 receives information from various sensors, such as the wheel speed sensors 11′-14′ and the battery array temperature sensor 30′, and provides this information to gauges or other outputs in the vehicle 10, as desired. The PLC 210 executes various programs to control various components of the vehicle 10, for example, the internal combustion engine 300, the generator 310, the generator controller 320, the electric motors 50 and 60, and the motor controllers 51 and 61.

[0042] Although not shown in the drawings, the vehicle 10 may include a cooling system or cooling systems for the internal combustion engine 300, the generator controller 320, the battery array 30, the motor controllers 51 and 61, and the motors 50 and 60. The cooling system may be a single system which includes a coolant reservoir, a pump for pumping the coolant through a heat exchanger such as a radiator and a fan for moving air across the heat exchanger or a plurality of cooling systems similarly constructed. The ECU 200 controls the cooling systems, including the pumps and the fans, to perform a heat shedding operation in which the heat generated by the engine 300, the controllers 320, 51, and 61, the battery array 30, the motors 50 and 60, and various other systems is released to the atmosphere. Any acceptable means and methods for cooling the vehicle components may be utilized.

[0043] As shown in FIG. 2, the coils of the generator 310 are connected to the generator controller 320 by leads 311, 312, and 313. The generator controller 320 includes two switching insulated or isolated gate bipolar transistors (IGBT) 330 per phase of the generator 310 and their corresponding diodes. In an exemplary embodiment including a three phase generator 310, the generator controller 320 includes 6 IGBT 330 and six corresponding diodes.

[0044] The PLC 210 controls each IGBT 330 of the generator controller 320 to control the conversion of the AC voltage of the generator 310 to the DC voltage for charging the battery array 30. The PLC 210 may switch one or more of the IGBT 330's off when the SOC of the battery array 30 reaches an upper control limit, to stop the conversion of the AC voltage to DC voltage and prevent overcharging of the battery array 30.

[0045] According to an exemplary embodiment of the invention, the engine 300 runs continuously during operation of the vehicle 10 and continuously turns the shaft 315 of the generator 310. The PLC 210 switches each IGBT 330 on and off via high speed pulse width modulation (PWM) to control charging of the battery array 30. It should be appreciated however that the PLC 210 may control the charging of the battery array 30 by turning the engine 300 on and off, or in the alternative, by changing the RPM's of the engine 300.

[0046] A possible control circuit for the electric motors 50 and 60 is illustrated in FIG. 3, and includes the motor controllers 51 and 61. The motor controllers 51 and 61 receive power from the battery array 30 and distribute the power to the electric motors 50 and 60 by switches B1-B6 of pulse width modulation (PWM) inverters 54 and 64. The PWM inverters 54 and 64 generate AC current from the DC current received from the battery array 30. The battery current IB is distributed by the switches B1-B6, for example IGBT, of the PWM inverters 54 and 64 into motor currents I1, I2, and I3 for driving the motors 50 and 60.

[0047] The motor controllers 51 and 61 distribute the battery current IB via the switches B1-B6 by factoring feedback from position sensors 53 and 63 and encoders 56 and 66 that determine the timing or pulsing of electromagnets of the motors 50 and 60. The pole position sensors 53 and 63 determine the pole positions of the permanent magnets of the motors 50 and 60 and the encoders 56 and 66 determine the phase angle. It should be appreciated that each pair of pole position sensors 53 and 63 and encoders 56 and 66, respectively, may be replaced by a phase position sensor and the phase change frequency may be read to determine the speed of rotation of the electric motors 50 and 60.

[0048] The motor controllers 51 and 61 calculate the motor connector voltages U12, U31, and U23 based on the rotary velocity and the known flux value of the motors 50 and 60 between the motor connectors. The operating voltage of the inverters 54 and 64 is then determined by the rectified voltages of the diodes of the switches B1-B6 or by the voltage Ui of an intermediate circuit including a capacitor C. If the voltage Ui becomes larger than the battery voltage UB, uncontrolled current may flow to the battery array 30. Voltage sensors 55 and 65 determine the voltage Ui and the motor controllers 51 and 61 compare the voltage Ui to the battery voltage UB. The motor controllers 51 and 61 activate the switches B1-B6 to cause magnetizing current to flow directly to the motors 50 and 60 to avoid unnecessary recharging of the battery array 30.

[0049] As shown in FIG. 3, each motor controller 51 and 61 receives control data from the ECU 200 through a controller area network (CAN). The ECU 200 can communicate with the various sensors and the motor controllers 51 and 61 by, for example, DeviceNet™, an open, global industry standard communication network.

[0050] Referring to FIG. 4, each motor controller 51 and 61 includes a control unit 101 including a field axis current and torque axis current detector 102. The detector 102 calculates the torque axis current It and the field axis current If of each motor 50 and 60 by executing a 3-phase, 2-phase coordinate transfer from the input of the current detectors 57 and 67 that measure the 3-phase AC current of the motors 50 and 60 and the phase calculator 108 that received input from the pole position sensors 53 and 63 and the encoders 56 and 66. The torque axis current It and the field axis current If calculated by the detector 102 are input to a field axis current and torque axis current control unit 103. The current control unit 103 receives a field axis current reference value Ifref from a field axis current reference control unit 104 and receives a torque axis current reference value Itref from a torque axis current reference control unit 105.

[0051] The reference control units 104 and 105 determine the current reference values Ifref and Itref by comparing a torque reference value Tref (which is determined by the position of an accelerator pedal of the vehicle) with the actual rotational velocity determined by an rpm calculator 106 that receives input from the encoders 56 and 66. A 2/3 phase changer 107 receives input from a phase calculator 108 and calculates the 3-phase AC reference values by performing a 2-phase/3-phase coordinate transformation. A PWM control unit 109 generates a PWM signal by comparing the 3-phase reference values with a triangular wave signal which is input to the PWM inverters 54 and 64.

[0052] Referring to FIG. 5, the relationship between the power generated, the power stored, and the power consumed over time, by the series hybrid electric vehicle 10 according to the invention will be explained.

[0053] Power is consumed from the battery array 30 by the electric motors 50 and 60 during acceleration of the vehicle 10 to a cruising speed. As shown in FIG. 5, the vehicle 10 reaches cruising speed at time t1 which corresponds to a peak power Ppeak of the electric motors 50 and 60. The peak power Ppeak the electric motors 50 and 60 is dependent on the driving mode (discussed below) of the vehicle 10 selected by the operator. In the exemplary embodiment of the invention in which the electric motors 50 and 60 are each 220 Hp, the peak power Ppeak consumed by the electric motors 50 and 60 is 440 Hp.

[0054] The power consumption (traction effort) of the electric motors 50 and 60 during acceleration is represented by the curve below the horizontal axis and the area defined by the curve below the horizontal axis between the times t0 and t2 represents the total power consumption of the vehicle 10 during acceleration. In the event that the SOC of the battery array 30 is insufficient to achieve the cruising speed, the ECU 200 controls the motor controllers 51 and 61 to limit the peak power Ppeak the electric motors 50 and 60 may draw from the battery array 30. After the vehicle 10 has accelerated to cruising speed, the traction effort of the electric motors 50 and 60 may be reduced between the time t1 and the time t2, and the power consumption by the electric motors 50 and 60 may also be reduced.

[0055] The cruising speed of the vehicle 10 is maintained between the time t2 and the time t3. In this embodiment, during the time between t2 and t3, the genset 300, 310 is operated to produce power Pgen higher than the power consumption (traction effort) of the electric motors 50 and 60 necessary to maintain the vehicle's cruising speed. The differential in power between the traction effort and the power generated Pgen is stored in the battery array 30.

[0056] The power Pgen generated by the genset 300, 310, in this embodiment, is dependent on the rpm of the engine 300 and a user demand signal sent to the genset 300, 310 that is controlled by the ECU 200. The ECU 200 controls the engine 300 to generally maintain the rpm of the engine 300, and the power generated Pgen, constant. However, it should be appreciated that the ECU 200 may control the engine 300 to reduce or increase the rpm of the engine 300, and thus the reduce or increase, respectively, the power generated Pgen.

[0057] The power generated Pgen by the genset 300, 310 may be reduced if the SOC of the battery array 30 approaches an upper control limit at which the battery array 30 may become overcharged. The power generated Pgen by the genset 300, 310 may be increased if the SOC of the battery array 30 approaches a lower control limit at which the battery array 30 would be unable to drive the electric motors 50 and 60 with enough torque to propel the vehicle 10. In an exemplary embodiment of the vehicle 10 in which the engine 300 is a 2.5 liter Ford LRG-425 engine powered by compressed natural gas, the power generated Pgen is 70 Hp.

[0058] Regenerative braking occurs between the times t3 and t4 when the vehicle 10 decelerates after release of the accelerator pedal or when the vehicle 10 travels on a downhill slope at a constant speed. During regenerative braking, the electric motors 50 and 60 function as generators and current is supplied to the battery array 30 by the electric motors 50 and 60. The power generated Pbraking during regenerative braking is stored in the battery array 30.

[0059] The power generated by the genset 300, 310 during maintenance of the cruising speed and the power generated by regenerative braking Pbraking is represented by the curve above the horizontal axis and the area A2 defined by the curve above the horizontal axis represents the total energy creation and storage of the vehicle 10 during maintenance of the cruising speed and regenerative braking.

[0060] The power Pgen of the genset 300, 310 and the regenerative braking power Pbraking are controlled by the ECU 200 to substantially equal the energy consumption (traction effort) of the electric motors 50 and 60 during acceleration. In other words, the area A1 defined by the curve below the horizontal axis is equal to the area A2 defined by the curve above the horizontal axis. The ECU 200 controls the traction effort of the electric motors 50 and 60 (including the peak power Ppeak) and the power generated Pgen so that the power generated and the power stored do not exceed the power consumed, and vice versa, so as to maintain the SOC of the battery array 30 within a range of control limits. The ECU 200 controls the power generated Pgen and the traction effort of the electric motors 50 and 60 so that the ampere hours during energy consumption do not exceed the thermal capacity of the battery array during power creation and storage.

[0061] An exemplary method for adaptively controlling the state of charge SOC of the battery array 30 is disclosed in U.S. patent application Ser. No. 09/663,118, filed Sep. 15, 2000, now U.S. Pat. No. 6,333,620, the entire contents of which are herein incorporated by reference.

[0062] This embodiment includes a master control switch. Referring to FIG. 6, a master control switch 20 positioned, for example, in an operator area of the vehicle 10, includes an OFF position, a DRIVE ENABLE position and an ENGINE RUN position. Any acceptable switch mechanism can be employed. The rotary switch 20 in FIG. 6 is merely an example of an acceptable switch. The position of the switch 20 is input to the MCP 220. When the switch 20 is moved to the DRIVE ENABLE position, the PLC 210 controls the electric motors 50 and 60 to run the vehicle in a driver selected zero emissions mode by drawing power from the battery array 30. The engine 300 is not operated during the zero emissions mode, i.e., when the switch 20 is in the DRIVE ENABLE position. The range of the vehicle 10 in zero emissions mode is limited as the SOC of the battery array 30 will eventually be lowered below a level sufficient to drive the electric motors 50 and 60 to propel the vehicle.

[0063] When the switch 20 is moved to the ENGINE RUN position, the ECU 200 instructs the generator 310 to operate as a motor for starting the engine 300. During the starting of the engine 300, the generator 310 receives current from the battery array 30. The current is supplied until the engine 300 reaches a predetermined idling speed and then the current supply is stopped. The engine 300 then drives the generator 310 to charge the battery array 30, as necessary.

[0064] The ECU 200 controls the engine 300 by monitoring the engine speed (rpm) as sensed by a tachometer (not shown) and the fuel mixture as sensed by an oxygen sensor (not shown). The ECU 200 may, for example, control the amount of fuel injected into the engine 300 and/or the position of a throttle valve of the engine 300. The ECU 200 may also monitor engine conditions such as the oil pressure and the coolant temperature as detected by sensors (not shown). An automatic zero emission mode is provided by the ECU 200 when the switch 20 is in the ENGINE RUN position when the SOC of the battery array 30 is sufficient or when the sensors of the vehicle 10 sense areas and routes where the zero emission mode is required. The ECU 200 will turn the engine 300 off, even though the switch 20 is in the ENGINE RUN position, when it determines that the zero emission mode is required. As discussed above, the zero emissions mode may be initiated when the SOC of the battery array 30 is sufficient or when designated areas or routes are entered. For example, the vehicle 10 may be equipped with sensors (not shown) responsive to signals from the global positioning system (GPS) or other signal emitting devices that indicate that the vehicle has entered an area or route where the zero emission mode is required.

[0065] This embodiment also includes a control panel that controls the driving mode of the vehicle. Referring to FIG. 7, a control panel 25 positioned, for example, in the operator area of the vehicle 10, includes a plurality of switches 26-29. After starting the vehicle 10 by moving the master switch 20 to the engine run position, one of the switches 26-29 is selected to establish a driving mode of the vehicle 10. A first driving mode F1 is established by selecting switch 26. In this embodiment, the first driving mode F1 is established for driving the vehicle at lower speeds and under conditions in which the vehicle 10 will start and stop frequently. A second driving mode F2 is established by selecting switch 27. The second driving mode F2 is established for driving the vehicle at higher speeds and under conditions in which the vehicle is started and stopped less frequently. The ECU 200 controls the electric motors 50 and 60 depending on which driving mode is established. The maximum power output and rpm of the electric motors 50 and 60 in the second driving mode F2 are higher than the maximum power output and rpm of the motors 50 and 60 in the first driving mode F1.

[0066] While two driving modes are shown in FIG. 7 and discussed above, any number of modes can be provided. These modes can be directed to different driving conditions, road conditions, weather conditions, and the like.

[0067] The control panel 25 also includes a switch 28 to establish a neutral mode N. In the neutral mode N, the electric motors 50 and 60 are disengaged by the ECU 200 and the vehicle 10 is not propelled by the electric motors 50 and 60, even if an accelerator pedal (discussed below) is pressed by the operator.

[0068] A reverse mode R is established by selecting a switch 29. In the reverse mode R, the electric motors 50 and 60 are controlled to rotate in the opposite direction of the first and second driving modes F1 and F2 to propel the vehicle 10 in a reverse direction.

[0069] This embodiment may also include a second control panel for controlling the regenerative braking of the vehicle 10. Referring to FIG. 8, a second control panel 75 positioned, for example, in the operator area of the vehicle 10, includes a plurality of switches 76-78. After starting the vehicle 10 by moving the master switch 20 to the engine run position, one of the switches 76-78 is selected to establish a regenerative braking mode of the vehicle 10. A first regenerative braking mode R1 is established by selecting switch 76. In the first regenerative braking mode R1, the regenerative braking function is turned off. The first regenerative braking mode R1 may be selected during icy road conditions.

[0070] A second regenerative braking mode R2 may be selected by switch 77. The second braking mode R2 is selected when the regenerative braking effort should be minimal, such as wet road conditions or when the state of charge SOC of the battery array approaches an upper control limit UCL.

[0071] A third regenerative braking mode R3 may be selected by switch 78. The third braking mode R3 is selected when the regenerative braking efforts should be at a maximum, such as during dry road conditions or when the state of charge SOC of the battery array 30 approaches a lower control limit LCL.

[0072] Although the regenerative braking mode has been shown as selected by the operator, it should be appreciated that the ECU 200 may change the regenerative braking mode when certain conditions, such as slipping of any of the wheels 11-14, are detected. Moreover, while three modes are illustrated in this embodiment, any number of modes could be employed as desired, directed to any types of environmental conditions and/or operating parameters.

[0073] Referring to FIG. 9, the position of an accelerator pedal 40 is detected by a sensor 45. The sensor 45 sends a demand signal DEM indicative of the accelerator pedal 40 position, i.e., the user demand, to the MCP 220. The demand signal DEM has a value of zero when the accelerator pedal 40 is not depressed and a maximum value when the accelerator pedal 40 is fully depressed.

[0074] The ECU 200 sends a drive demand signal DRVDEM to the motor controllers 51 and 61. The drive demand signal DRVDEM follows and is proportional to the demand signal DEM of the sensor 45. However, due to a lag in the processing by the ECU 200, the instantaneous value of the demand signal DEM from the sensor 45 may be greater than or less than the drive demand signal DRVDEM produced by the ECU 200 and sent to the motor controllers 51 and 61. Accordingly, there is a difference in the signals equal to the difference between the instantaneous value of the demand signal DEM and the value of the drive demand signal DRVDEM. The motor controllers 51 and 61 send a drive command signal DRVCMD to the motors 50 and 60 to create torque and speed. The drive command signal DRVCMD follows and is proportional to the drive demand signal DRVDEM. The relationship between the value of the drive command signal DRVCMD and the instantaneous value of the drive demand signal DRVDEM is similar to the relationship between the drive demand signal DRVDEM and the instantaneous value of the demand signal DEM.

[0075] The ECU 200 uses a proportional-integral-derivative (PID) control mode to adaptively control the propulsion of the vehicle 10. The control mode may be stored as a program in a memory of the ECU 200 and executed by the PLC 210. The proportional mode produces an output proportional to the difference between the instantaneous value of the demand signal DEM and the drive demand signal DRVDEM. The integral mode produces an output proportional to the amount of the difference and the length of time the difference is present. The derivative mode produces an output proportional to the rate of change of the difference. The PID control mode may be applied to other systems of the vehicle 10 in addition to the control of the motors 50 and 60 for controlling the propulsion of the vehicle 10 and may be applied to systems that have transient differences and to systems that have steady-state differences. All three components, proportional, integral, and derivative, of the PID control mode are summed and can be adjusted in real time to create a controlled output, thus changing the system responsiveness.

[0076] The PID control mode is provided with parameters within which the signals necessary to control the electric motors 50 and 60, including the drive command signal DRVCMD, are adaptively adjusted and controlled. For example, the drive demand signal DRVDEM generated by the ECU 200 is proportional to the demand signal DEM sent by the accelerator pedal position sensor 45. Generally, the value of the drive demand signal DRVDEM is equal to 100% of the value of the demand signal DEM. However, within the PID control mode, the value of the drive demand signal DRVDEM may be set equal to 110% of the value of the demand signal DEM in order to increase the responsiveness of the vehicle 10. Conversely, the value of the drive demand signal DRVDEM may be set equal to 90% of the value of the demand signal DEM in order to decrease the responsiveness of the vehicle 10, for example when the state of charge SOC of the battery array 30 is insufficient to meet a sudden increase in user demand.

[0077] Additionally, a drive command upper control limit DRVCMDUCL and a drive command lower control limit DRVCMDLCL of the drive command signal DRVCMD are adaptively adjusted by the PID control mode in response to vehicle conditions, such as the driving mode and/or an emission mode of the vehicle 10. The drive command upper control limit DRVCMDUCL and drive command lower control limit DRVCMDLCL may be empirically determined and dependent on service conditions, such as terrain and weather conditions, that the vehicle 10 will likely be operated under. It should also be appreciated that the PID parameters are also empirically determined and may be any value. For example, the PID parameters may be determined so that the value of the drive demand signal DRVDEM may be as low as 80% of the value of the demand signal DEM and as high as 120% of the value of the signal DEM.

[0078] An exemplary embodiment of a method for adaptively controlling the propulsion of the series hybrid electric vehicle will be explained with reference to FIGS. 10-15. The control subroutines illustrated in FIGS. 10-15 are executed concurrently at predetermined time intervals during operation of the vehicle.

[0079] Referring to FIG. 10, a throttle control subroutine begins in step S100 and proceeds to step S110 where it is determined if the demand signal DEM is smaller than the drive demand signal DRVDEM. If the demand signal DEM is not smaller than the drive demand signal DRVDEM (S110: NO), the control proceeds to step S120 where the drive command signal DRVCMD to the motors 50 and 60 is increased within the PID parameters. The control then returns to the beginning in step S140. If the demand signal DEM is smaller than the drive demand signal DRVDEM (S110: Yes), the control proceeds to step S130 where the drive command signal DRVCMD to the motors 50 and 60 is decreased within the PID parameters. The control then returns to the beginning in step S140.

[0080] Referring to FIG. 11, a battery array state of charge subroutine begins in step S200 and proceeds to step S210 where it is determined if the battery array state of charge SOC is sufficient to sustain a state of charge upper control limit UCL. If the state of charge SOC is not sufficient (S210: No), the control proceeds to step S220 where the drive command upper control limit DRVCMDUCL parameters are lowered. The control then returns to the beginning in step S280. If the state of charge SOC is sufficient to sustain the state of charge upper control limit UCL (S210: Yes), the control proceeds to step S230 where it is determined if the battery array temperature is sufficient to sustain the state of charge upper control limit UCL.

[0081] If the battery array temperature is not sufficient to sustain the state of charge upper control limit UCL (S230: No), the control proceeds to step S220 where the drive command upper control limit DRVCMDUCL parameters are lowered. The control then returns to the beginning in step S280. If the battery array temperature is sufficient to sustain the state of charge upper control limit UCL (S230: Yes), the control proceeds to step S240 where it is determined if the vehicle 10 is in the first driving mode F1. If it is determined that the vehicle 10 is not in the first driving mode F1 (S240: No), the control proceeds to step S250 where it is determined if the drive command upper control limit DRVCMDUCL is less than a drive command upper control limit DRVCMDUCL2 associated with the second driving mode F2.

[0082] If it is determined that the drive command upper control limit DRVCMDUCL is not less than the drive command upper control limit DRVCMDUCL2 associated with the second driving mode F2 (S250: No), the control proceeds to step S220 where the drive command upper control limit DRVCMDUCL parameters are lowered. The control then returns to the beginning in step S280. If it is determined that the drive command upper control value DRVCMDUCL is less than the drive command upper control limit DRVCMDUCL2 associated with the second driving mode F2 (S250: Yes), the control proceeds to step S270 where the drive command upper control limit DRVCMDUCL parameters are raised. The control then returns to the beginning in step S280.

[0083] If it is determined that the vehicle 10 is in the first driving mode F1 (S240: Yes), the control proceeds to step S260 where it is determined whether the drive command upper control limit DRVCMDUCL is less than a drive command upper control limit DRVCMDUCL1 associated with the first driving mode F1. If the drive command upper control limit DRVCMDUCL is not less than the drive command upper control limit DRVCMDUCL1 associated with the first driving mode F1 (S260: No), the control proceeds to step S220 where the drive command upper control limit DRVCMDUCL parameters are lowered. The control then returns to the beginning in step S280.

[0084] If the drive command upper control limit DRVCMDUCL is less than the drive command upper control limit DRVCMDUCL1 associated with the first driving mode F1 (S260: Yes), the control proceeds to step S270 where the drive command upper control limit DRVCMDUCL parameters are raised. The control then returns to the beginning in step S280.

[0085] Referring to FIG. 12, an emission mode subroutine begins in step S300 and proceeds to step S310 where it is determined if the vehicle 10 is in a first emission mode. The first emission mode is a mode in which the engine 300 is at full output or where full output is allowed. If it is determined that the vehicle 10 is in the first emission mode (S310: Yes), the control proceeds to step S320 where the drive command upper control limit DRVCMDUCL and the drive command lower control limit DRVCMDLCL are raised. The control then returns to the beginning in step S370.

[0086] If it determined that the vehicle 10 is not in the first emission mode (S310: No), the control proceeds to step S330 where it is determined if the vehicle 10 is in a second emission mode. The second emission mode is a mode in which the engine 300 is at a minimum output. If it is determined that the vehicle 10 is in the second emission mode (S330: Yes), the control proceeds to step S340 where the drive command upper control limit DRVCMDUCL and the drive command lower control limit DRVCMDLCL are modified. If the vehicle 10 was previously in the first emission mode, the drive command upper control limit DRVCMDUCL and the drive command lower control limit DRVCMDLCL are lowered. If the vehicle 10 was previously in a third emission mode, the drive command upper control limit DRVCMDUCL and the drive command lower control limit DRVCMDLCL are raised. The control then returns to the beginning in step S370.

[0087] If it is determined that the vehicle 10 is not in the second emission mode (S330: No), the control proceeds to step S350 where it is determined if the vehicle 10 is in the third emission mode. The third emission mode is a mode in which the engine 300 is turned off. In other words, the third emission mode is a zero emission mode.

[0088] If it is determined that the vehicle 10 is in the third emission mode (S350: Yes), the control proceeds to step S360 where the drive command upper control limit DRVCMDUCL and the drive command lower control limit DRVCMDLCL are lowered. The control then returns to the beginning in step S370. If it is determined that the vehicle 10 is not in the third emission mode (S350: No), the control returns to the beginning in step S370.

[0089] Referring to FIG. 13, a regenerative braking mode subroutine begins in step S400 and proceeds to step S410 where it is determined if the vehicle is in the first regenerative braking mode R1. If it is determined that the vehicle 10 is in the first regenerative braking mode R1 (S410: Yes), the control proceeds to step S420 where feedforward regeneration mode settings associated with the first regeneration mode R1 are lowered. The feedforward regeneration mode settings are used to raise the PID parameters to quicken the response of the system. The control then returns to the beginning in step S 470.

[0090] If it is determined that the vehicle 10 is not in the first regenerative braking mode R1 (S410: No), the control proceeds to step S430 where it is determined if the vehicle is in the second regenerative braking mode R2. If the vehicle is in the second regenerative braking mode R2 (S430: Yes), the control proceeds to step S440 where the feedforward regeneration mode settings associated with the second regenerative braking mode R2 are modified. If the state of charge SOC is approaching the upper control limit UCL, the feedforward regeneration mode settings associated with the second regenerative braking mode R2 are lowered. Conversely, if the state of charge SOC is approaching the lower control limit LCL, the feedforward regeneration mode settings associated with the second regenerative braking mode R2 are raised. The control then returns to the beginning in step S470.

[0091] If is determined that the vehicle 10 is not in the second regenerative braking mode R2 (S430: No), the control proceeds to step S450 where it is determined if the vehicle 10 is in the third regenerative braking mode R3. If the vehicle 10 is in the third regenerative braking mode R3 (S450: Yes), the control proceeds to step S460 where the feedforward regeneration mode settings associated with the third regenerative braking mode R3 are raised. The control then returns to the beginning in step S470. If it is determined that the vehicle 10 is not in the third regenerative braking mode R3 (S450: No), the control returns to the beginning in step S470.

[0092] Referring to FIG. 14, a left traction control subroutine for the electric motor 50 (left drive), in an exemplary embodiment in which the vehicle 10 is rear wheel drive, begins in step S500 and proceeds to step S510 where it is determined if the electric motor 50 is operating nominally. According to an exemplary embodiment of the invention, the electric motor 50 is determined to be operating nominally if the voltage and temperature of the electric motor 50 are within predetermined parameters. If the electric motor 50 is not operating nominally (S510: No), the control proceeds to step S520 where a drive warning and/or faults are reset. The faults are error codes generated by the ECU 200 upon detection of abnormalities, such as a short circuit in an IGBT 330 or failure of an encoder 56 or 66. The control then proceeds to step S530 where it is determined if the electric motor 50 is operating nominally. If the electric motor is still not operating nominally (S530: No), the control proceeds to step S540 where the electric motor 50 is shut down if required and torque is shifted to the right side by increasing the torque drive command to the electric motor 60. The control then returns to the beginning in step S595.

[0093] If after resetting the drive warning and/or faults, it is determined that the electric motor 50 is operating nominally (S530: Yes), the control proceeds to step S550 where it is determined if the electric motor 60 (right drive in the exemplary rear wheel drive vehicle 10) is operating nominally. The electric motor 60 is determined to be operating nominally if the voltage and temperature of the electric motor 60 are within predetermined parameters. If the electric motor 60 is not operating nominally (S550: No), the control proceeds to step S560 where torque is shifted to the left drive by increasing the drive to the electric motor 50 and increasing upper control limits of the torque and velocity of the electric motor 50. The control then proceeds to step S570. If it is determined that the electric motor 60 is operating nominally (S550: Yes), the control proceeds directly to step S570.

[0094] In step S570, it is determined if adequate traction is maintained. Adequate traction is not maintained if excessive slippage is detected between a rear wheel 13 or 14 and a speed reference which is a value slightly higher than the speed of the front wheels 11 and 12. If adequate traction is not maintained (S570: No), the control proceeds to step S580 where the drive to motors 50 and 60 is decreased until the speed of the wheels 13 and 14 matches the speed reference. The control then returns to the beginning in step S595. If adequate traction is maintained (S570: Yes), the drives to the motors 50 and 60 are maintained in step S590. The control then returns to the beginning in step S595.

[0095] Referring to FIG. 15, a right traction control subroutine including steps S600-S695 for the electric motor 60 (right drive) corresponds to the steps S500-S595 of the left traction control subroutine shown in FIG. 14. The right drive is checked in steps S610 and S630 to determine if the electric motor 60 is operating nominally and the left drive is checked in step S650 to determine if the electric motor 50 is operating nominally.

[0096] Referring to FIG. 16, a regenerative braking control subroutine includes steps S700-S765 for determining when to operate regenerative braking and to what power levels. An exemplary embodiment of a regenerative braking arrangement implemented on the vehicle 10 includes battery array 30 and battery array temperature probe 30′, drive motors 50 and 60 capable of producing regenerative braking, drive motor controllers 51 and 61, throttle input sensor 45, wheels 13 and 14, and wheel speed sensors 13′ and 14′. It will be appreciated that other implementations may exist, with a multiplicity of energy storage, drive motors and other systems alternately employed.

[0097] In the exemplary embodiment described herein, the control begins at step S700, where it proceeds to step S705. In step S705 it is determined if a drive motor is rotating. In the exemplary embodiment, this is accomplished by using the wheel speed sensors 13′ and 14′ to characterize the rotation of the wheels 13 and 14. It will be appreciated that other methods may be employed to determine if a drive motor is rotating. If it is determined that a drive motor is rotating (S705: Yes), the control proceeds to step S710, where it is determined if the throttle input 45 is inactive. This is used to determine if the operator is commanding the throttle to accelerate the vehicle. Regenerative braking should only be activated if the driver is not commanding the throttle.

[0098] If the throttle input is inactive (S710: Yes), the control proceeds to step S715, where it is determined if the battery array 30 is operating nominally. In the exemplary embodiment, the battery array is operating nominally if the battery temperature sensed at the probe 30′ is within a predefined range of temperature, and the battery array state of charge is below an upper state of charge limit. If the battery array is operating nominally (S715: Yes), the control proceeds to step S720, where it is determined if the braking input is active. In the embodiment, the braking input is used to determine if the operator is commanding a braking event. If it is determined that there is a braking input active (S720: Yes), the control proceeds to step S725, where it is determined if the anti-lock braking system (ABS), traction control system, or other wheel spin control device or algorithm is inactive. In the embodiment, this determines if there are other vehicle systems or controls that have the potential to interfere with the regenerative braking. If it is determined that there is one or more wheel spin control devices active (S725: No) the control proceeds to step S730, where regenerative braking is disabled. The control then proceeds to step S760, where it returns to the beginning.

[0099] If it is determined that all wheel spin control devices are inactive (S725: Yes), the control proceeds to step S735. In step S735 in the exemplary embodiment, signals are generated to allow regenerative braking corresponding to the levels indicated by the selected mode of regenerative braking. The control then proceeds to step S740, where it is determined if traction is maintained. In the exemplary embodiment, this is determined by using the wheel speed sensors 13′ and 14′ to measure the speed of wheels 13 and 14 and make a comparison. A difference in rotational wheel speed of more than a critical percentage, for example 5%, would indicate a slipping wheel. It will be appreciated that other methods of determining wheel slippage may be used, and the control method herein is not limited to this embodiment.

[0100] If in step S740 it is determined that wheel traction is not maintained (S740: No), the control proceeds to step S745, where the regenerative braking command is reduced. In the exemplary embodiment, wheel traction loss may be indicative of a regenerative braking command that causes the wheel to lose traction on a surface of reduced coefficient of friction, such as ice. The control then proceeds to step S760, where it returns to the beginning. If in step S740 it is determined that wheel traction is maintained (S740: Yes), the control proceeds to step S750, where it is determined if the battery array is operating nominally. In the exemplary embodiment, a high battery array state of charge indicates reduction of regenerative braking is necessary to reduce the amount of energy being transferred from regenerative braking into the battery array. If it is determined in step S750 that the battery array is not operating nominally (S750: No), the control proceeds to step S755 where regenerative braking is reduced. The control then proceeds to step S760, where it returns to the beginning. If it is determined that the battery array is operating nominally (S750: Yes) the control proceeds to step S760, where it returns to the beginning.

[0101] Referring to FIG. 17, a regenerative braking fault control includes steps S800-S870 for determining if vehicle components are faulted, and controlling the regenerative braking based upon the fault status. An exemplary embodiment of a regenerative braking arrangement implemented on the vehicle 10 includes battery array 30 and battery array temperature probe 30′, drive motors 50 and 60 capable of producing regenerative braking, drive motor controllers 51 and 61. It will be appreciated that other implementations may exist, with a multiplicity of energy storage, drive motors and other systems alternately employed.

[0102] In the exemplary embodiment described herein, the control begins at step S800, where it proceeds to step S810. In step S810, it is determined if the battery array 30 is in a warning state or faulted. If the battery array is faulted (S810: Yes), the control proceeds to step S820 where it is determined if the battery array is depleted. In an exemplary embodiment, the battery array may generate warnings or faults if the state of charge of the battery array falls below a predetermined lower state of charge limit. It will be appreciated that other systems for determining battery array warnings or faults may also be used, and other conditions or states may also cause battery array warnings or faults. If the battery array is depleted (S820: Yes), the control proceeds to step S830, where the regenerative braking command is increased. The control then proceeds to step S870, where it returns to the beginning. If the battery array is not depleted (S820: No), the control proceeds to step S840, where the regenerative braking is disabled. The control then proceeds to step S870, where it returns to the beginning.

[0103] If it is determined that the battery array 30 is not in a warning or fault state (S810: No), the control proceeds to step S850 where it is determined if the drive motor is in a warning state or faulted. In an exemplary embodiment, the drive motor may generate warnings or faults if the drive motor temperature exceeds a predetermined limit. It will be appreciated that other conditions or states may also cause drive motor warnings or faults. If the drive motor is in a warning or fault state (S850: Yes) the control proceeds to step S860 where the regenerative braking is disabled. The control then proceeds to step S870, where it returns to the beginning. If the drive motor is not in a warning or fault state (S850: No), the control proceeds to step S870, where it returns to the beginning.

[0104] Referring to FIG. 18, a regenerative braking temperature control includes steps S900-S965 for determining the appropriate level of regenerative braking to be provided in response to system component temperatures. An exemplary embodiment of a regenerative braking arrangement implemented on the vehicle 10 includes battery array 30 and battery array temperature probe 30′, drive motors 50 and 60 capable of producing regenerative braking, drive motor controllers 51 and 61, internal combustion engine 300, generator 310, and generator controller 320. It will be appreciated that other implementations may exist, with a multiplicity of energy storage, drive motors and other systems alternately employed.

[0105] In the exemplary embodiment described herein, the control begins at step S900, where it proceeds to step S905. In step S905, it is determined if the battery array 30 temperature is nominal. If it is not (S905: No), the control proceeds to step S910, where it is determined if the battery array temperature above a predetermined limit. If it is determined the battery array temperature is not above a predetermined limit (S910: No), the control proceeds to step S915, where the regenerative braking command is increased. The control then proceeds to step S965, where it returns to the beginning. If the battery array temperature is above a predetermined limit (S910: Yes), the control proceeds to step S920, where the regenerative braking command is reduced. The control then proceeds to step S965, where it returns to the beginning.

[0106] If in step S905 it is determined that the battery array temperature is nominal (S905: Yes), the control proceeds to step S925 where it is determined if the cooling system temperature is nominal. If it is not (S925: No), the control proceeds to step S930, where it is determined if the cooling system temperature is above a predetermined limit. If it is determined the cooling system temperature is not above a predetermined limit (S930: No), the control proceeds to step S935, where the regenerative braking command is increased. The control then proceeds to step S965, where it returns to the beginning. If the cooling system temperature is above a predetermined limit (S930: Yes), the control proceeds to step S940, where the regenerative braking command is reduced. The control then proceeds to step S965, where it returns to the beginning.

[0107] If in step S925 it is determined that the cooling system temperature is nominal (S925: Yes), the control proceeds to step S945 where it is determined if the drive motor temperature is nominal. If it is not (S945: No), the control proceeds to step S950, where it is determined if the drive motor temperature is above a predetermined limit. If it is determined the drive motor temperature is not above a predetermined limit (S950: No), the control proceeds to step S955, where the regenerative braking command is increased. The control then proceeds to step S965, where it returns to the beginning. If the drive motor temperature is above a predetermined limit (S950: Yes), the control proceeds to step S960, where the regenerative braking command is reduced. The control then proceeds to step S965, where it returns to the beginning.

[0108] It will be appreciated by those skilled in the art that the ECU can be implemented using a single special purpose integrated circuit (e.g., ASIC) having a main or central processor section for overall, system-level control, and separate sections dedicated to performing various different specific computations, functions and other processes under control of the PLC. The ECU also can be a plurality of separate dedicated or programmable integrated or other electronic circuits or devices (e.g., hardwired electronic or logic circuits such as discrete element circuits, or programmable logic devices such as PLDs, PLAs, PALs, DSPs or the like). The ECU can be implemented using a suitably programmed general purpose computer, e.g., a microprocessor, microcontroller or other processor device (CPU or MPU), either alone or in conjunction with one or more peripheral (e.g., integrated circuit) data and signal processing devices. In general, any device or assembly of devices on which a finite state machine capable of implementing the flowcharts shown in FIGS. 8-12 and described herein can be used as the ECU. A distributed processing architecture can be used for maximum data/signal processing capability and speed.

[0109] While the invention has been described with reference to various exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed embodiments or constructions. To the contrary, the invention is intended to cover various modifications and equivalent arrangements. In addition, while the various elements of the disclosed invention are shown in various combinations and configurations, which are exemplary, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the invention.

Claims

1. A method for adaptively controlling a hybrid electric vehicle including an energy generation system, an energy storage system receiving electric current at least from the energy generation system, and at least one electric drive motor receiving current from the energy storage system, comprising: monitoring the status of various vehicle systems; monitoring user inputs for removal of acceleration command inputs and application of braking inputs; determining if the vehicle is in one of a plurality of regenerative braking modes, including determining which regenerative braking mode the vehicle is in; determining an appropriate level of regenerative braking to be applied in a braking event, given the monitored status of vehicle systems and the determination of the regenerative braking mode; generating a command signal to the electric drive motor to generate the determined level of regenerative braking; determining the effect of the regenerative braking command on the status of the vehicle systems; and adaptively generating further command signals to the electric drive motor altering the level of regenerative braking applied.

2. The method of claim 1, wherein a state of charge of the energy storage system is monitored and the step of determining an appropriate level of regenerative braking to be applied is determined based on the monitored state of charge and the determined regenerative braking mode.

3. The method of claim 1, further comprising: monitoring for the signal of one or more vehicle fault states; determining if a fault state is related to energy storage or drive motor systems; and reducing or eliminating regenerative braking commands if the fault is related to energy storage or drive motor systems.

4. The method of claim 1, further comprising: monitoring the temperature of energy storage, electric drive motor, and/or cooling systems temperatures; reducing or eliminating regenerative braking commands if one or more monitored temperatures are above a predetermined level; and increasing regenerative braking commands if one or more monitored temperatures are below a predetermined level.

5. The method of claim 1, further comprising: monitoring for a signal indicating that vehicle anti-lock braking or traction control systems are actively affecting vehicle braking or propulsion; and reducing or eliminating regenerative braking commands if one or more of the monitored systems are active.

6. The method of claim 1, further comprising: monitoring the rotational speeds or one or more driving wheels; determining if monitored wheel rotation velocity exceeds an expected velocity range relative to other monitored wheels or to a predicted velocity; generating a greater regenerative braking command to reduce wheel rotation velocity if the monitored velocity is greater than an expected upper velocity limit; and generating a reduced regenerative braking command to reduce de-acceleration of wheel rotational velocity if the monitored velocity is less than an expected lower velocity limit.

7. The method of claim 1, wherein the vehicle further includes an electrical load bank for dissipation of electrical energy to heat or mechanical work, and the method further comprises: monitoring a state of charge of the energy storage system; monitoring when regenerative braking commands are active; determining when the state of charge of the energy storage system meets or exceeds an upper limit and regenerative braking is active; generating a command to allow electrical energy created by regenerative braking to be diverted to the electrical load bank; and reducing or eliminating the command allowing electrical energy to be diverted to the electrical load bank upon reduction or elimination of the regenerative braking command.

8. The method of claim 1, further comprising: determining if the vehicle is in at least one of a first regenerative braking mode, a second regenerative braking mode and a third regenerative braking mode; decreasing regenerative braking, if the vehicle is in the first regenerative braking mode; decreasing regenerative braking if a battery state of charge is approaching an upper control limit and the vehicle is in the second regenerative braking mode; increasing regenerative braking if the battery state of charge is approaching a lower control limit and the vehicle is in the second regenerative braking mode; and increasing regenerative braking, if the vehicle is in the third regenerative braking mode.

9. A hybrid electric vehicle, comprising: an energy generation system; an energy storage system receiving electric current at least from the generation system; at least one electric motor receiving current from the energy storage system; and a vehicle controller that: monitors a status of various vehicle systems; monitors user inputs for removal of acceleration command inputs and application of braking inputs; determines if the vehicle is in one of a plurality of regenerative braking modes, including determining which regenerative braking mode the vehicle is in; determines an appropriate level of regenerative braking to be applied in a braking event, given the monitored status of vehicle systems and the determination of the regenerative braking mode; generates a command signal to the electric drive motor to generate the determined level of regenerative braking; determines an effect of the regenerative braking command on the status of the vehicle systems; and adaptively generates further command signals to the electric drive motor altering the level of regenerative braking applied.

10. The hybrid electric vehicle of claim 9, wherein the controller: monitors a state of charge of the energy storage system and determines the appropriate level of regenerative braking to be applied based on the monitored state of charge and determined regenerative braking mode.

11. The hybrid electric vehicle of claim 9, wherein the controller: monitors for the signal of one or more vehicle fault states: determines if the fault state is related to energy storage or drive motor systems; and reduces or eliminates regenerative braking commands if the fault is related to energy storage or drive motor systems.

12. The hybrid electric vehicle of claim 9, wherein the controller: monitors the temperature of energy storage, electric drive motor, and/or cooling systems temperatures; reduces or eliminates regenerative braking commands if one or more monitored temperatures are above a predetermined level; and increases regenerative braking commands if one or more monitored temperatures are below a predetermined level.

13. The hybrid electric vehicle of claim 9, wherein the controller: monitors for a signal indicating that vehicle anti-lock braking or traction control systems are actively affecting vehicle braking or propulsion; and reduces or eliminates regenerative braking commands if one or more monitored systems are active.

14. The hybrid electric vehicle of claim 9, wherein the controller: monitors rotational speeds or one or more driving wheels; determines if the monitored wheel rotation velocity exceeds an expected velocity range relative to other monitored wheels or to a predicted velocity; generates a greater regenerative braking command to reduce wheel rotation velocity if the monitored velocity is greater than an expected upper velocity limit; and generates a reduced regenerative braking command to reduce de-acceleration of wheel rotational velocity if the monitored velocity is less than an expected lower velocity limit.

15. The hybrid electric vehicle of claim 9, wherein an electrical load bank is available for dissipation of electrical energy to heat or mechanical work and wherein the controller: monitors a state of charge of the energy storage system; monitors when regenerative braking commands are active; determines when the state of charge of the energy storage system meets or exceeds an upper limit and regenerative braking is active; generates a command to allow electrical energy created by regenerative braking to be diverted to the electrical load bank; and reduces or eliminates the command allowing electrical energy to be diverted to the electrical load bank upon reduction or elimination of the regenerative braking command.

16. The hybrid electric vehicle of claim 9, wherein the controller: determines if the vehicle is in at least one of a first regenerative braking mode, a second regenerative braking mode and a third regenerative braking mode; decreases regenerative braking, if the vehicle is in the first regenerative braking mode; decreases regenerative braking if a battery state of charge is approaching an upper control limit and the vehicle is in the second regenerative braking mode; increasing regenerative braking if the battery state of charge is approaching a lower control limit and the vehicle is in the second regenerative braking mode; and increases regenerative braking, if the vehicle is in the third regenerative braking mode.

17. A method for adaptively controlling propulsion of a hybrid electric vehicle including an energy generation system, an energy storage system receiving electric current at least from the energy generation system, and at least one electric drive motor receiving current from the energy storage system, comprising: generating a first signal having a value indicative of an accelerator command to a controller; generating a second signal having a value proportional to the first signal and indicative of a demand of the at least one electric drive motor from the controller to a motor controller; determining if the value of the first signal is smaller than the value of the second signal; increasing the value of a command signal to the at least one electric motor, if the value of the first signal is not smaller than the value of the second signal; and decreasing the value of the command signal, if the value of the first signal is smaller than the value of the second signal.

18. A hybrid electric vehicle, comprising: an energy generation system; an energy storage system receiving current at least from the energy generation system; at least one electric drive motor receiving current from the energy storage system; at least one motor controller that controls the at least one electric drive motor; a sensor that generates a first signal having a value indicative of an accelerator command; and a controller that: receives the first signal from the sensor; generates a second signal having a value proportional to the first signal and indicative of a demand of the at least one electric drive motor and sends the second signal to the motor controller; determines if the value of the first signal is smaller than the value of the second signal; increases the value of a command signal to operate the at least one electric motor, if the value of the first signal is not smaller than the value of the second signal; and decreases the value of the command signal, if the value of the first signal is smaller than the value of the second signal.

19. The hybrid electric vehicle of claim 18, wherein the energy generation system includes an internal combustion engine connected to a generator.

20. The hybrid electric vehicle according to claim 19, wherein the energy storage system includes a battery array.

21. The hybrid electric vehicle according to claim 19, wherein the vehicle is a series type hybrid.