Parallel control loops for hybrid electric vehicles

Description

BACKGROUND 1. Field

[0001] The present disclosure relates to control schemes for aircraft, and more particularly to control loops for hybrid electric aircraft.2. Description of Related Art

[0002] To control the power request for a hybrid electric aircraft, the control system is required to calculate the power request for both the thermal engine and the electric motor system components. In addition, e.g. for a turboprop aircraft, a propeller / engine speed is commanded for the low speed / power portion of flight.

[0003] It is required to transition into and out of the various control loops without any adverse transient or steady state effects while meeting the constraints of the electrical and thermal engine such as maximum output, response rate, protection functions, and the like.

[0004] The conventional techniques have been considered satisfactory for their intended purpose. However, there is an ever present need for improved systems and methods for control loops for hybrid electric aircraft. This disclosure provides a solution for this need.

[0005] Examples of the prior art are provided by US2018346139 A1 and US2020140106 A1.SUMMARY

[0006] A method of controlling a hybrid-electric aircraft powerplant includes, for a hybrid-electric aircraft powerplant having a thermal engine and an electric motor, running a first control loop for command of the thermal engine based on the total response commanded for the hybrid-electric powerplant and torque feedback from the thermal engine. The method includes running a second control loop in parallel with the first control loop for commanding the thermal engine based on the maximum thermal engine output and torque feedback from the thermal engine. The method includes using a low selector between the first control loop and the second control loop to command the thermal engine with the lower of responses commanded from the first and second control loops. The method includes running a third control loop in parallel with the first and second control loops for commanding engine / propeller speed, wherein the third control loop outputs a speed control enable or disable status, and using a high selector between output of the third control loop and the low selector. The method includes running a fourth control loop in parallel with the first, second, and third control loops for commanding the electric motor with non-zero demand when the second control loop is above control to add response from the electric motor to response from the thermal engine to achieve the response commanded.

[0007] The response in total response commanded and total response in the first control loop can be torque. The response in the total response commanded in the second control loop can be torque. The response in the fourth control loop can be torque.

[0008] Commanding the thermal engine can include controlling fuel flow to the thermal engine. Commanding the electric motor can include controlling electrical power supplied to the electric motor. The electric motor and thermal engine can be connected together in parallel to a combining gear box (CGB) to drive a propeller. The combining gear box can connect to the propeller through a reduction gear box (RGB). Sensory feedback from the RGB can be combined with sensory feedback from the electric motor to determine torque feedback from the thermal engine.

[0009] A system includes a hybrid-electric powerplant for an aircraft including a thermal engine and an electric motor each operatively connected to provide torque to drive an air mover for thrust. A first control loop is connected for command of the thermal engine based on the total response commanded for the hybrid-electric powerplant and torque feedback from the thermal engine. A second control loop is connected in parallel with the first control loop for commanding the thermal engine based on the maximum thermal engine output and torque feedback from the thermal engine. A low selector is connected between the first control loop and the second control loop to command the thermal engine with the lower of responses commanded from the first and second control loops. A third control loop is connected in parallel with the first and second control loops for commanding engine / propeller speed, wherein the third control loop outputs a speed control enable or disable status. A high selector is connected between output of the third control loop and the low selector. A fourth control loop is connected in parallel with the first, second, and third control loops for commanding the electric motor with non-zero demand when the second control loop is above control to add response from the electric motor to response from the thermal engine to achieve the response commanded.

[0010] The air mover can be a propeller. The electric motor and thermal engine can be connected together in parallel to a combining gear box (CGB) to drive the propeller. The combining gear box can connect to the propeller through a reduction gear box (RGB).

[0011] These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWING

[0012] So that those skilled in the art to which the subject disclosure appertains will readily understand how to make and use the devices and methods of the subject disclosure without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to: Fig. 1 is a schematic view or simulation diagram of an embodiment of a system constructed in accordance with the present disclosure, showing the four parallel control loops.DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] For purposes of explanation and illustration, and not limitation, a partial view of an embodiment of a system in accordance with the disclosure is shown in Fig. 1 and is designated generally by reference character 100. The systems and methods described herein can be used for controlling hybrid-electric powerplants such as for driving air movers for aircraft thrust.

[0014] The system 100 includes a hybrid-electric powerplant 102 for an aircraft including a thermal engine 104 and an electric motor 106 each operatively connected to provide torque to drive an air mover, e.g. propeller 108, for thrust. The air mover is a propeller 108, however those skilled in the art will readily appreciate that any other suitable type of air mover such as a fan, ducted fan, or the like can be used without departing from the scope of this disclosure. The electric motor 106 and thermal engine 104 are connected together in parallel to a combining gear box (CGB) 110. The CGB 110 connects to the propeller 108 through a reduction gear box (RGB) 112.

[0015] A first control loop 114 is connected for command of the thermal engine 104 based on error between total torque (MrqTot) commanded, e.g. commanded from a pilot or autonomous system, for the hybrid-electric powerplant 102 and MfbTM, torque feedback from the thermal engine 104. Commanding the thermal engine 104 includes controlling fuel flow to the thermal engine.

[0016] A second control loop 116 is connected in parallel with the first control loop 114 for commanding the thermal engine 104 based on error between maximum thermal engine output (MrqTMMax) and torque feedback from the thermal engine MfbTM. A low selector 118 is connected between the first control loop 114 and the second control loop 116 to command the thermal engine 104 with the lower of the responses commanded from the first and second control loops 114, 116. While torque is used herein as an example of response used for feedback control, those skilled in the art will readily appreciate that any suitable response can be used, such as speed, power, or the like, without departing from the scope of this disclosure.

[0017] A third control loop 120 is connected in parallel with the first and second control loops 114, 116 for commanding speed of the thermal engine 104 (and / or the propeller 108). The third control loop 120 outputs a speed control enable or disable status of the speed controller 122. A high selector 124 is connected between combined output of the third control loop / speed controller 120, 122 (anded by anding component 160) and the low selector 118 to output MrqTM (torque demanded from the thermal engine 104). Sensor feedback 128 from the RGB (MfbTH in Fig. 1) is combined with sensor feedback from the electric motor (MfbEM in Fig. 1) at box 130 to determine torque feedback from the thermal engine, MfbTM. The prioritization component selects the correct commanded or requested torque MrqTM from among the first, second, and third control loops 114, 116, 120. The requested or commanded torque MrqTM is summed / differenced with the torque feedback from the thermal engine MfbTM at component 134, which outputs the error between the two (MrqTM and MfbTM). This sum / difference is passed to the major control loop 136, which outputs WfRq (fuel flow required to the thermal engine 104) to the minor control loop 138, which outputs Wf (actual fuel flow going to the thermal engine 104) to the thermal engine 104.

[0018] A fourth control loop 126 is connected in parallel with the first, second, and third control loops 114, 116, 120 for commanding the electric motor 106 with non-zero demand when the second control loop 116 is above control to add response (e.g. torque) from the electric motor 106 to response (e.g. torque) from the thermal engine 104 to achieve the response commanded. Commanding the electric motor 106 includes controlling electrical power supplied to the electric motor 106. The fourth control loop 126 outputs MrqEM, requested torque for the electric motor 106. This is summed / differenced with feedback 140 from the electric motor 106 at component 142, which outputs the error between the two (MrqEM, MfbRM). This sum / difference is passed through the major loop control 144, which outputs iEMrq (current commanded by the electronic powertrain controller or EPC) to the minor loop control 146, which outputs iEM (actual current going to the EPC) to the electric motor 118.

[0019] The first control loop 114 includes a proportional-integral-derivative (PID) integrator 148 that receives as input the output of a summation / differencing component 150. The component 150 receives total torque demanded or commanded MrqTot and torque feedback of the thermal engine 104 MfbTM, and outputs the sum / difference to the integrator 148. The integrator 148 outputs to the low selector 118.

[0020] The second control loop 116 includes a PID integrator 152 that receives the output of a summation / differencing component 154. The component 154 receives maximum torque output of the thermal engine 104 (MrqTMmax) and torque feedback of the thermal engine 104 (MfbTM), and outputs the sum / difference to the integrator 152. The integrator 152 outputs to the low selector 118 for selection of the lower of the two outputs of the first and second control loops 114, 116 as described above.

[0021] The speed controller 122 of the third control loop 120 incudes a PID integrator 156 that receives the output of a summation / differencing component 158. The component 158 receives propeller speed commanded or required (Nrq) and actual propeller speed feedback (Nfb), and outputs the sum / difference to the integrator 156. The integrator 156 outputs to the anding component 160 to the integral output is anded with the beta mode input of the third control loop 120 a described above. The beta mode in this context, and the box labeled "Beta Mode" in Fig. 1, refer to speed control mode for the engine control system.

[0022] The fourth control loop 126 includes a PID integrator 162 that receives the output of a summation / differencing component 164. The component 164 receives the difference between total torque demanded or commanded and maximum torque output of the thermal engine 104 (MrqTot minus MrqTMmax) and sums / differences this with torque feedback of the electric motor 106 (MfbEM) to outputs the sum / difference to the integrator 162. The integrator 162 outputs to the 142 as described above.

[0023] The methods herein include constantly resetting a respective integrator 148, 152, 156, 162 to the value of the loop in control, defined as the loop whose torque request is selected as MrqTM based on the prioritization component 132, while the respective control loop is running in the background and is not actively commanding, thus preventing integrator windup error and assuring seamless transition between loops actively controlling the thermal engine 104. The respective integrators 148, 152, 156, 162 are reset with a respective reset command ("Loop in ctrl" in Fig. 1) once a respective control loop 114, 116, 120 begins actively commanding.

[0024] For each control loop 114, 116, 120, 126, the PID control integrator path (including the respective integrator 148, 152, 156, 162) is reset to the value of the loop in control. For example if the first control loop 114 is in control (meaning MrqTM=signal from the integrator 148 of the first control loop 114 (Loop 1 in Fig. 1), the integrators 152, 156 of the PID controllers for the second and third control loops 116, 122 (Loops 2 and 3 in Fig. 1) are reset to the value of the signal coming from the PID controller (integrator 148) of the first control loop 114 (Loop 1 in Fig. 1). This is indicated in Fig. 1 for each of the integrators 148, 152, 156 by the respective arrow designated "Loop in ctl."

[0025] Potential benefits of this disclosure include the following. It is possible to control the power demand of a hybrid-electric powerplant without any abrupt transitions between control loops. The parallel control loops can ensure continuous control of the propulsion system. This architecture can provide an opportunity to adjust the overall system power response of the hybrid-electric powerplant by adjusting the gains and constants of the individual control loops. This can also allow for switching commands from energy / torque demand to a particular engine or propeller speed command.

[0026] The methods and systems of the present disclosure, as described above and shown in the drawings, provide for controlling hybrid-electric powerplants such as for driving air movers for aircraft thrust. While the apparatus and methods of the subject disclosure have been shown and described with reference to preferred embodiments, those skilled in the art will readily appreciate that changes and / or modifications may be made thereto without departing from the scope of the claims.

Claims

1. A method of controlling a hybrid-electric aircraft powerplant (102) comprising: for a hybrid-electric aircraft powerplant (102) having a thermal engine (104) and an electric motor (106), running a first control loop (114) for command of the thermal engine (104) based on an error between a total response commanded for the hybrid-electric aircraft powerplant (MrqTot) and torque feedback from the thermal engine (MfbTM); running a second control loop (116) in parallel with the first control loop (114) for commanding the thermal engine (104) based on an error between a maximum thermal engine output (MrqTMmax) and torque feedback from the thermal engine (MfbTM); using a low selector (118) between the first control loop (114) and the second control loop (116) to command the thermal engine (104) with the lower of responses commanded from the first and second control loops (114, 116); running a third control loop (120) in parallel with the first and second control loops (114, 116) for commanding engine / propeller speed, wherein the third control loop (120) outputs a speed control enable or disable status; using a high selector (124) between output of the third control loop (120) and the low selector (118); and running a fourth control loop (126) in parallel with the first, second, and third control loops (114, 116, 120) for commanding the electric motor (106) with non-zero demand when the second control loop (116) is above control to add response from the electric motor (106) to response from the thermal engine (104) to achieve the total response commanded for the hybrid-electric aircraft powerplant (MrqTot).

2. The method as recited in claim 1, wherein the response in total response commanded for the hybrid-electric aircraft powerplant (MrqTot) in the first control loop (114) is torque.

3. The method as recited in claim 1 or 2, wherein the response in the fourth control loop (126) is torque.

4. The method as recited in any preceding claim, wherein commanding the thermal engine (104) includes controlling fuel flow to the thermal engine (104).

5. The method as recited in any preceding claim, wherein commanding the electric motor (106) includes controlling electrical power supplied to the electric motor (106).

6. The method as recited in any preceding claim, wherein the electric motor (106) and thermal engine (104) are connected together in parallel to a combining gearbox, CGB, (110) to drive a propeller (108).

7. The method as recited in claim 6, wherein the CGB (110) connects to the propeller (108) through a reduction gearbox, RGB, (112).

8. The method as recited in claim 7, wherein sensory feedback from the RGB (128, MfbTH) is combined with sensory feedback from the electric motor (MfbEM) to determine torque feedback from the thermal engine (MfbTM).

9. A system (100) comprising: a hybrid-electric powerplant (102) for an aircraft including a thermal engine (104) and an electric motor (106) each operatively connected to provide torque to drive an air mover (108) for thrust; a first control loop (114) connected for command of the thermal engine (104) based on an error between a total response commanded for the hybrid-electric powerplant (MrqTot) and torque feedback from the thermal engine (MfbTM); a second control loop (116) connected in parallel with the first control loop (114) for commanding the thermal engine (104) based on an error between a maximum thermal engine output (MrqTMmax) and torque feedback from the thermal engine (MfbTM); a low selector (118) connected between the first control loop (114) and the second control loop (116) to command the thermal engine (104) for the lower of responses commanded from the first and second control loops (114, 116); a third control loop (120) connected in parallel with the first and second control loops (114, 116) for commanding engine / propeller speed, wherein the third control loop (120) outputs a speed control enable or disable status; a high selector (124) connected between output of the third control loop (120) and the low selector (118); and a fourth control loop (126) connected in parallel with the first, second, and third control loops (114, 116, 120) for commanding the electric motor (106) with non-zero demand when the second control loop (116) is above control to add response from the electric motor (106) to response from the thermal engine (104) to achieve the total response commanded for the hybrid-electric powerplant (MrqTot).

10. The system (100) as recited in claim 9, wherein the air mover (108) is a propeller.

11. The system (100) as recited in claim 10, wherein the electric motor (106) and thermal engine (104) are connected together in parallel to a combining gearbox, CGB, (110) to drive the propeller (108).

12. The system (100) as recited in claim 11, wherein the CGB (110) connects to the propeller (108) through a reduction gearbox, RGB, (112).