The present application finds particular application in hybrid commercial vehicle brake systems, particularly involving regenerative braking. However, it will be appreciated that the described technique may also find application in other vehicle type systems, other braking systems, or other energy conservation systems.
Conventional approaches to regenerative braking involve dissipating power in the air compressor when the vehicle is traveling downhill. The compressor is driven to a higher pressure to create an artificial loss when driven by the regenerative braking system. This additional load on the vehicle also assists in braking. In one approach, a fuel cell powers the compressor during acceleration or constant velocity. Another approach involves an air compressor that supplies air at a higher rate when the vehicle is coasting. This system involves storing the kinetic energy of the vehicle as a higher air pressure when the compressor is kept running during coasting.
Another conventional approach involves an air compressor control system that drives an air compressor when the vehicle is going downhill as long as the metal head temperature is less than a predetermined value. In this manner, the compressor is used as a torque absorber during downhill operation. Yet another classical approach relates to a power management system for a hybrid vehicle. A traction motor is used to charge the battery when the engine load is low. When the vehicle is going uphill, the additional loads, such as the compressor, are disconnected from the battery.
The present innovation provides new and improved systems and methods for controlling state of charge in a hybrid commercial vehicle high voltage battery as a function of vehicle pitch systems and methods, which overcome the above-referenced problems and others.
In accordance with one aspect, a motor controller unit (MCU) that facilitates modifying pressure thresholds for an air compressor motor in a hybrid commercial vehicle as a function of vehicle pitch comprises a memory that stores computer-executable instructions for modifying compressor cut-in and cut-out pressure thresholds as a function of vehicle pitch, and a processor configured to execute the computer-executable instructions. The instructions comprise monitoring a pitch of the vehicle, determining that the vehicle is on an uphill grade, and reducing compressor cut-in and cut-out pressure thresholds for an on-board air compressor motor to conserve state-of-charge (SOC) until the pitch of the vehicle falls below a predetermined percentage of a maximum pitch detected on the uphill grade. The instructions further comprise, once the pitch of the vehicle falls below a predetermined percentage of the maximum pitch detected on the uphill grade, increasing the compressor cut-in and cut-out pressure thresholds to increase available air pressure and brake regeneration for the vehicle.
In accordance with another aspect, a method of modifying pressure thresholds for an air compressor motor in a hybrid commercial vehicle as a function of vehicle pitch comprises monitoring a pitch of the vehicle, determining that the vehicle is on an uphill grade, and reducing compressor cut-in and cut-out pressure thresholds for an on-board air-compressor motor to conserve state-of-charge (SOC) until the pitch of the vehicle falls below a predetermined percentage of a maximum pitch detected on the uphill grade. The method further comprises, once the pitch of the vehicle falls below a predetermined percentage of the maximum pitch detected on the uphill grade, increasing the compressor cut-in and cut-out pressure thresholds to increase available air pressure and brake regeneration for the vehicle.
According to another aspect, a system that facilitates modifying pressure thresholds for an air compressor motor in a hybrid commercial vehicle as a function of vehicle pitch comprises an air compressor having a compressor motor, and a motor controller unit (MCU) having a memory that stores computer-executable instructions for modifying compressor cut-in and cut-out pressure thresholds for the compressor motor as a function of vehicle pitch. The MCU further comprises a processor configured to monitor a pitch of the vehicle, determine that the vehicle is on an uphill grade, and reduce compressor cut-in and cut-out pressure thresholds for the compressor motor to conserve state-of-charge (SOC) until the pitch of the vehicle falls below a predetermined percentage of a maximum pitch detected on the uphill grade. The processor is further configured to, once the pitch of the vehicle falls below a predetermined percentage of the maximum pitch detected on the uphill grade, increase the compressor cut-in and cut-out pressure thresholds to increase available air pressure and brake regeneration for the vehicle.
In accordance with another aspect, an apparatus for modifying pressure thresholds for an air compressor motor in a hybrid commercial vehicle as a function of vehicle pitch comprises means for monitoring a pitch of the vehicle, means for determining that the vehicle is on an uphill grade, and means for reducing compressor cut-in and cut-out pressure thresholds for an on-board air-compressor motor to conserve state-of-charge (SOC) until the pitch of the vehicle falls below a predetermined percentage of a maximum pitch detected on the uphill grade. The apparatus further comprises means for increasing the compressor cut-in and cut-out pressure thresholds to increase available air pressure and brake regeneration for the vehicle, once the pitch of the vehicle falls below a predetermined percentage of the maximum pitch detected on the uphill grade.
Still further advantages of the subject innovation will be appreciated by those of ordinary skill in the art upon reading and understanding the following detailed description.
The innovation may take form in various components and arrangements of components, and in various steps and arrangements of steps. The drawings are only for purposes of illustrating various aspects and are not to be construed as limiting the invention.
The MCU 14 communicates with other vehicle controllers (not shown). Additionally, the MCU communicates with a pitch monitoring device, such as an inclinometer 26, an anti-lock brake system 28, an engine, a transmission or some other suitable source of real-time vehicle pitch information, and acquires vehicle pitch status information over a vehicle serial bus 29 (e.g. a J1939 controller area network (CAN) bus or the like). The MCU continuously or periodically monitors vehicle pitch status in order to intelligently control the energy required to maintain vehicle air pressure, to create brake regeneration opportunities, as well as to preserve a state of charge (SOC) of a high voltage vehicle battery 30. The battery 30 may be, for example, a lithium ion battery, a nickel metal hydride battery, a lead acid battery, a variant of the foregoing battery types, or any other suitable battery. The battery 30 is coupled via power lines 31 to the MCU. Although the battery described herein is a high voltage vehicle battery (e.g., 200V, 300V, etc.), it will be appreciated that the described systems and methods may be employed with any suitable power source, as well as with any suitable air compressor or load on the power source.
The intelligent control approach regulates the vehicle's air tank pressure to be in concert with other vehicle controllers and vehicle operational status by varying the compressor motor speed and pressure thresholds. The MCU monitors the pitch of the vehicle to determine whether it is desirable to adjust the cut-in and cut-out thresholds of the air compressor motor in order to conserve SOC (i.e., by reducing the cut-in and cut-out thresholds in order to cause the compressor motor to maintain lower air tank pressures) or to store air pressure for a braking event and create a brake regeneration opportunity (i.e., by increasing the cut-in and cut-out thresholds in order to cause the compressor to store air at higher pressures, thereby consuming SOC).
The MCU comprises pitch monitoring module 32 that monitors the pitch of the vehicle (e.g., periodically or continuously) and provides vehicle pitch status information to a processor 34. In one embodiment, the pitch status information is received from one or more of the inclinometer 26 and the ABS system 28, and stored in memory 36 for evaluation by the processor 34. In another embodiment, vehicle pitch is inferred by the pitch monitoring module 32 as a function of measured engine load (e.g., an engine pulling a constant load will have to expend more energy pulling the load uphill than it will on a flat or downhill grade). In still another embodiment, vehicle pitch is determined from coordinate information and topographical or elevation information received by the processor and/or pitch monitoring module from an on-board GPS unit 52. For instance, the processor and/or pitch monitoring module can cross reference the coordinates of the vehicle to topographical map information and determine from the vehicle's direction of travel whether the vehicle is traveling uphill, downhill, or on a relatively flat road.
The memory additionally stores one or more compressor adjustment routines 38 for adjusting (e.g., increasing or decreasing) air tank pressure and/or compressor motor speed, when executed by the processor. The compressor adjustment routines 38 include a pressure threshold increase routine 40 that, when executed, increases the compressor motor cut-in (ON) pressure threshold and the compressor motor cut-out (OFF) pressure threshold, and a pressure threshold decrease routine 42 that, when executed, decreases the compressor motor cut-in (ON) pressure threshold and the compressor motor cut-out (OFF) pressure threshold. The compressor adjustment routines 38 also include a motor speed increase routine 44 that increases compressor motor speed when executed, and a motor speed decrease routine 46 that decreases compressor motor speed when executed.
If the pitch of the vehicle is above a first predetermined pitch threshold (e.g., 5° from horizontal, 10° from horizontal, or some other predetermined threshold) as determined by the pitch monitoring module 32, then the vehicle is determined to be on an uphill grade. To improve energy conservation, the processor executes the pressure threshold decrease routine 42 that lowers the compressor cut-in and cut-out pressure thresholds in order to maintain a lower level of pressurized air in the air tanks while conserving SOC to make room for energy generated from a brake regeneration event (i.e., after the vehicle reaches the crest of the uphill grade and begins to travel downhill). Additionally or alternatively, the processor can execute the motor speed reducing routine 46, which runs the compressor motor at lower RPM thereby maintaining the sufficient pressure for a braking event while conserving SOC should the vehicle need to activate an onboard traction motor to maintain speed up the incline.
As stated above, the pitch of the vehicle is continuously or periodically monitored, such that when the processor determines that the pitch of the vehicle has decreased to below a second predetermined pitch threshold (i.e., the uphill grade is leveling out or cresting), the processor initiates the threshold increase routine 40 that raises the compressor cut-in and cut-out pressure thresholds and in order to quickly store air at a higher pressure, while reducing SOC to make room for energy generated from a brake regeneration event (i.e., after the vehicle reaches the crest of the uphill grade and begins to travel downhill).
Additionally or alternatively, the processor can execute the motor speed increase routine 44, which runs the compressor motor at higher RPM thereby maintaining the higher pressure and continuing the draw on the SOC. This approach both stores energy as higher air pressure and lowers the SOC, freeing up battery storage capacity for brake regeneration on a subsequent downhill grade. The higher air pressure is then available for subsequent braking events while the reduced SOC increases capacity for brake energy regeneration opportunities.
In one embodiment, the second predetermined pitch threshold is the same as the first predetermined pitch threshold, such that when the pitch of the vehicle is greater than or equal to the predetermined pitch threshold, the vehicle is deemed to be on an incline, and when the pitch of the vehicle is below the predetermined threshold, the vehicle is deemed not to be on an incline. In another embodiment, the second predetermined pitch threshold is calculated as a function of a maximum detected pitch of the vehicle (e.g., 30% of maximum pitch, 50% of maximum pitch, or some other percentage). In this example pitch is continuously or periodically monitored, and the second predetermined pitch threshold is continuously or periodically updated. Once the vehicle pitch falls below the second predetermined pitch threshold, the processor clears the memory of the second predetermined pitch threshold. When the vehicle is again determined to be on an incline (for exceeding the first predetermined threshold), then the processor recalculates a new second pitch threshold using the same predetermined percentage or function.
According to another aspect, the vehicle may be determined to be on an uphill grade when SOC is lower than a desired level, such that there is relatively less energy available to drive the compressor. In this case, the MCU processor conserves SOC by initiating a threshold decrease routine 42 and the motor speed decrease routine 46 in order to reduce the pressure thresholds and compressor RPM. Additionally, the MCU can send an alert to the driver via a user interface 48 to initiate a generator regeneration protocol, such as by engaging a traction motor 50 and/or initiating brake energy regeneration to recharge the battery 30. The traction motor also serves as an energy regeneration device. In another embodiment, the MCU automatically sends a command directly to the traction motor 50 to recharge the battery to a nominal level (e.g., 70% of full charge or more). The MCU thus controls the compressor to more slowly build air pressure to a lower pressure threshold using less energy and conserving SOC until brake regeneration or traction motor restores the SOC. By monitoring the SOC and modifying the compressor operation, brake regeneration is facilitated. Increased brake regeneration opportunities result in improved energy recovery, less brake wear, and safer vehicle operation.
In another embodiment, the driver of the vehicle initiates one or both of the uphill pressure threshold and motor speed adjustments and the downhill pressure threshold and motor speed adjustments. For instance, when the system detects that the vehicle is on an incline, the driver is prompted via the user interface to select (via the user interface) the uphill adjustment routine(s). Similarly, when the system has determined that the vehicle has leveled off, the driver is prompted to terminate the uphill adjustment routines and/or initiate flat surface or downhill adjustment routines. In a related embodiment, the driver is prompted via the user interface to confirm the adjustment routines suggested by the MCU. In yet another embodiment, the driver determines whether the vehicle is on an incline, flat surface, or decline and initiates and terminates corresponding adjustment routines via the interface.
Additionally, if the vehicle is determined to be on a downhill grade, the MCU 14 sends a command to the vehicle air system 20 to cycle an air dryer (not shown) and/or open a vent in the air line 23 leading to the brake system 24 so as to consume and/or release air. Additionally, the cut-in and cut-out pressure thresholds are increased by executing the threshold increase routine 40 and compressor speed increases. The compressor is run continuously to maintain the air pressure between the cut-in and cut-out thresholds to reduce SOC, thereby creating storage capacity. In this manner, SOC is continually reduced so that there is consistent capacity within the high voltage batteries to store brake regeneration energy and permit brake regeneration drag to control the vehicle speed without using the foundation brakes. Brake regeneration time is increased to reduce brake wear and heat and to improve brake safety, which is useful in lengthy downhill runs where too much braking leads to severe drum brake fading and brake heating.
It will be appreciated that although the herein-described systems and methods relate to an air compressor system that is manipulated to control vehicle battery SOC, any suitable electrical system on the vehicle (e.g., a hydraulic system, etc.) may be employed in a similar fashion, and that the described systems and methods are not limited to being employed in conjunction with an air compressor. It will further be appreciated that although
The innovation has been described with reference to several embodiments. Modifications and alterations may occur to others upon reading and understanding the preceding detailed description. It is intended that the innovation be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.