Hybrid vehicle apparatuses, processes, and systems

Abstract

A vehicle system includes an engine, a transmission coupled with the engine, a set of ground contacting wheels, a hybrid axle assembly including a set of axles coupled with the set of ground contacting wheels, a differential coupled with the set of axles and the transmission, an electric machine fastened to the hybrid axle assembly, and means for mitigating losses of the electric machine, the hybrid axle assembly being configured to transmit driveline torque received from the engine and the transmission to the set of ground contacting wheels and to selectably transmit machine torque output by the electrical machine to the set of ground contacting wheels, an energy storage system (ESS) operatively coupled with the electric machine, and an electronic control system (ECS) configured to selectably operate the electric machine, the energy storage system, and the means for mitigating losses in a plurality of modes.

Description

Atorney Docket No. CMI002-00201HYBRID VEHICLE APPARATUSES, PROCESSES, AND SYSTEMSCROSS-REFERENCE

[0001] The present disclosure claims priority to and the benefit of U.S. Application No. 63 / 727,917 filed December 4, 2024 and the same is hereby incorporated by reference.TECHNICAL FIELD

[0002] The present application relates to hybrid vehicle apparatuses, processes, and systems.BACKGROUND

[0003] Present approaches to hybrid vehicle apparatuses, processes, and systems suffer from a number of drawbacks, disadvantages, and shortcomings including those respecting efficiency, efficacy, and losses, among others. There is a significant need for the unique apparatuses, processes, and systems disclose herein.Page 1 of 26195473619vlAtorney Docket No. CMI002-00201DISCLOSURE OF EXAMPLE EMBODIMENTS

[0004] For the purposes of clearly, concisely, and exactly describing example embodiments of the present disclosure, the manner, and process of making and using the same, and to enable the practice, making and use of the same, reference will now be made to certain example embodiments, including those illustrated in the figures, and specific language will be used to describe the same. It shall nevertheless be understood that no limitation of the scope of the invention is thereby created, and that the invention includes and protects such alterations, modifications, and further applications of the example embodiments as would occur to one skilled in the art.SUMMARY OF THE DISCLOSURE

[0005] Some example embodiments include unique hybrid vehicle apparatuses. Some example embodiments include unique hybrid vehicle processes. Some example embodiments include unique hybrid vehicle systems. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Fig. 1 is a schematic diagram depicting certain aspects of an example vehicle system.

[0007] Fig. 2 is a schematic diagram depicting certain aspects of an embodiment of the example vehicle system of Fig. 1.

[0008] Fig. 3 is a schematic diagram depicting certain aspects of another embodiment of the example vehicle system of Fig. 1.

[0009] Fig. 4 is a schematic diagram depicting certain aspects of an example embodiment of an energy storage system of the example vehicle system of Fig. 1.

[0010] Fig. 5 is a flow diagram depicting certain aspects of an example process.

[0011] Figs. 6A and 6B are a flow diagram depicting certain aspects of the example process of Fig. 5.Page 2 of 26195473619vlAtorney Docket No. CMI002-00201DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0012] With reference to Fig. 1, there is illustrated an example vehicle system 10. Vehicle system 10 may be configured and provided in a number of forms. In the illustrated embodiment, vehicle system 10 is configured and provide in the form of a medium duty vehicle, for example, a medium duty truck specified under the Federal Highway Administration (FHWA) gross vehicle weight rating (GVWR) system as Class 3, Class 4, Class 5, or Class 6. In other embodiment, vehicle system 10 may be configured and provided in a number of other forms as will occur to one of skill in the art with the benefit and insight of the present disclosure.

[0013] Vehicle system 10 includes a chassis 22 which is operatively coupled with and supported by a set of ground contacting wheels 9a, 9b. More particularly, the chassis 22 is coupled with a hybrid axle assembly 14 by suspension system 23 which is depicted schematically in Fig. 1. In turn, hybrid axle assembly 14 is coupled with the set of ground contacting wheels 9a, 9b. While the set of ground contacting wheels is depicted as comprising two wheels, it shall be appreciated that the set of ground contacting wheels may comprise other numbers of ground contacting wheels depending on the type and configuration of vehicle system 10.

[0014] Vehicle system 10 includes a powertrain including an engine 12 operatively coupled with a transmission 13. Engine 12 may be configured and provided in a number of forms. In some forms, engine 12 may be configured and provided as a four-stroke, compression ignition form. In other forms, engine 12 may be provided as a spark ignition and liquid-spark ignition forms. In various forms, engine 12 may be configured for combustion of a number of fuels including, for example, diesel fuel, gasoline, natural gas, other gaseous hydrocarbons, hydrogen, alcohols, or other fuels or combinations of fuels as will occur to one of skill in the art with the benefit and insight of the present disclosure. Engine 12 may include a block including a plurality of cylinders and a head coupled with the block. The head typically includes intake ports, intake valves configured to selectively open and close the intake ports, exhaust ports, exhaust valves configured to selectively open and close the exhaust ports, injector bores, fuel injectors disposed in the injector bores. A plurality of pistons may be provided in respective ones of the plurality of cylinders. A crankshaft may be coupled with the plurality of pistons and configured to translate reciprocating motion of the plurality of pistons to output engine torque, for example, to a flywheel or a flexplate operatively coupled with engine 12 and transmission 13.Page 3 of 26195473619vlAtorney Docket No. CMI002-00201

[0015] Transmission 13 may be configured and provided in a number of forms. Tn some forms, transmission 13 may be configured and provided as an automatic transmission. In other forms transmission 13 may be configured and provided as a manual transmission, an automated manual transmission, a continuously variable transmission, or another type of transmission as will occur to one of skill in the art with the benefit and insight of the present disclosure. Transmission 13 is configured to receive torque output by engine 12 and to output torque to hybrid axle assembly 14.

[0016] Referring now additionally to Fig. 2, hybrid axle assembly 14 may include a differential 50, an electric machine system 70, and a set of axles 8a, 8b. Respective ones of the set of axles 8a, 8b which are coupled with respective ones of the set of ground contacting wheels 9a, 9b. Differential 50 is coupled with the set of axles 8a, 8b and the transmission 13 and is configured to transmit torque from engine 12 and transmission 13 to drive the set of axles 8a, 8b. Electric machine 70 is fastened to differential 50 and comprises at least a portion of a means for mitigating losses of the electric machine system 70. Hybrid axle assembly 14 is configured to transmit driveline torque received from the engine 12 and the transmission 13 to the set of ground contacting wheels 9a, 9b. Hybrid axle assembly 14 is configured to selectably transmit machine torque output by the electric machine system 70 to the set of ground contacting wheels 9a, 9b.

[0017] Electric machine 70 may be fastened to and mechanically integrated with the hybrid axle assembly 14 in a number of manners. For example, as illustrated in Fig. 2, a housing 71 of electric machine system 70 may be directly coupled with and mounted to a housing 501 of differential 50 to provide an integrated differential-electrical machine unit.

[0018] An input shaft 502 of differential 50 is configured to receive driveline torque from transmission 13 to rotate a pinion gear 504. Pinion gear 504 is operatively coupled with and configured to drive ring gear 506. Ring gear 506 is operatively coupled with spider gears 510a, 510b by carriers 508a, 508b and is and configured to drive spider gears 510a, 510b. Spider gears 510a, 510b are operatively coupled with and configured to drive side gears 512a, 512b. Side gears 512a, 512b are operatively coupled with and configured to drive axles 81, 8b to drive ground contacting wheels 91, 9b, respectively.

[0019] Electric machine 70 includes a stator 705 which is operatively coupled with and configured to selectably drive a rotor 710 when electric machine 70 is operated as a motor, and to be generate electrical energy in response to rotation of rotor 710 when electric machine system 70 is operated as a generator. Rotor 710 is coupled with a motor shaft 712 which is operativelyPage 4 of 26195473619vlAtorney Docket No. CMI002-00201 coupled with motor pinion gear 514. Motor pinon gear 514 is operatively coupled with and configured to drive ring gear 506 to provide motor torque to drive to drive ground contacting wheels 91, 9b via carriers 508a, 508b, spider gears 510a, 510b, side gears 512a, 512b, and axles 8a, 8b.

[0020] In some forms, a clutch 713 may be operatively coupled with and provided intermediate rotor 710 and motor pinon gear 514 and controllable to selectably coupled and decouple rotor 710 and motor pinion gear 514 in response to control signals from ECS 30. In some such forms, clutch 713 may comprise an integral component of hybrid axle assembly 14. For example, clutch 713 and electric machine 70 may be provided within a common housing such as housing 701. In other such forms, clutch 713 and differential 50 may be provided within a common housing, it being appreciated that, for a given differential housing not otherwise containing clutch 713, a volume and / or dimensions of the given differential may be modified to accommodate inclusion and housing of clutch 713. In other such forms, clutch 713 may be provided withing a housing or housing portion that is interposed and integrally coupled with a housing containing differential 50 and a housing containing electric machine 70 to provide a multi -unit integrated housing of hybrid axle assembly 14. As indicated by the phantom dashed lines of clutch 713, in some forms, clutch 713 may be omitted and rotor 710 may be permanently coupled with motor pinon gear 514, for example, by motor shaft 712.

[0021] In the illustrated example, power electronics 750 are fastened to and mechanically integrated with hybrid axle assembly 14. More particularly, power electronics 750 are disposed in and mechanically integrated within a common housing 701 of electric machine system 70. Power electronics 750 may be configured and provided in the form of a segmented microinverter comprising a plurality of independently operable inverter switching segments integrated with electric machine 702.

[0022] Vehicle system 10 includes an electronic control system (ECS) 30 which preferably includes one or more programmable microcontrollers of a solid-state, integrated circuit type, and one or more non-transitory memory media configured to store instructions executable by the one or more microcontrollers. For purposes of the present disclosure the term microcontroller shall be understood to encompass true microcontrollers as well as microprocessors and other types of integrated circuit processors and controllers. ECS 30 is in operative communication with and may be adapted and configured to control operation of and / or receive inputs from one or more sensorsPage 5 of 26195473619vlAtorney Docket No. CMI002-00201 and one or more controllers configured and adapted to control operation of various systems and components of vehicle system 10. ECS 30 may include one or more electronic control units (ECU) which are in operative communication with one another over one or more communication links such as one or more controller-area networks (CAN) or other communication links.

[0023] ECS 30 can be implemented in any of a number of ways that combine or distribute the control function across one or more control units in various manners. The ECS 30 may execute operating logic that defines various control, management, and / or regulation functions. This operating logic may be in the form of dedicated hardware, such as a hardwired state machine, analog calculating machine, programming instructions, and / or a different form as would occur to those skilled in the art. The ECS 30 may be provided as a single component or a collection of operatively coupled components, and may comprise digital circuitry, analog circuitry, or combination of digital and analog circuitry. When of a multi-component form, the ECS 30 may have one or more components remotely located relative to the others in a distributed arrangement. The ECS 30 can include multiple processing units arranged to operate independently, in a pipeline processing arrangement, in a parallel processing arrangement, or the like. It shall be further appreciated that the ECS 30 and / or any of its constituent components may include one or more signal conditioners, modulators, demodulators, Arithmetic Logic Units (ALUs), Central Processing Units (CPUs), limiters, oscillators, control clocks, amplifiers, signal conditioners, filters, format converters, communication ports, clamps, delay devices, memory devices, Analog to Digital (A / D) converters, Digital to Analog (D / A) converters, and / or different circuitry or components as would occur to those skilled in the art to perform the desired communications.

[0024] Vehicle system 10 includes an energy storage system (ESS) 40 operatively coupled with the electric machine system 70. In some forms, ESS 40 may be provided in the form of a micro-energy storage system comprising a kilowatt hour (kWh) capacity of about IkWh or less, for example, about 0.5-1 kWh, about 0.1-0.51 kWh, or about 0.1-1 kWh. In some forms, ESS 40 may be provided in the form of an energy storage system comprising a kilowatt hour (kWh) capacity of about 0.5-5 kWh, about 1-5 kWh, about 0.5-10 kWh, or about 1-10 kWh. In some forms ESS 40 may be provided in a form comprising a kilowatt hour (kWh) capacity about 10 kWh or less or about 5 kWh or less. In other forms, ESS 40 may be provided in the form of an energy storage system comprising greater kilowatt hour (kWh) capacities. Certain further aspects of an example embodiment of ESS 40 are illustrated and described in connection with Fig. 4.Page 6 of 26195473619vlAtorney Docket No. CMI002-00201

[0025] Electric machine system 70 is configured and provided with one or more means for mitigating no-load losses. No-load losses of an electric machine refer to losses resulting from rotation of the rotor of an electrical machine while the electrical machine is unloaded meaning that it is neither operated as a motor to output positive torque, nor as a generator driven by positive torque and providing a negative torque load.

[0026] In some embodiments, electric machine 702 may be configured and provided as a permanent magnet machine. Permanent magnet machines exhibit high no-load losses, particularly at high speeds. For example, a rotating permanent magnet electrical machine, even when unloaded, generates significant stator iron losses and rotor iron losses. Such losses comprise hysteresis losses and eddy current losses. Hysteresis losses are linearly proportional to the machine speed (f(w)). Eddy current losses have a quadratic relationship with the speed (f(wA2)).

[0027] In some embodiments, the means for mitigating losses of the electric machine may comprises means for demagnetizing a rotor of the electric machine. In some form including means for demagnetizing a rotor of the electric machine, the electric machine may be provided in the form of an electric machine with a rotor comprising one or more permanent magnets. In such forms, the means for demagnetizing the rotor may comprise one or more permanent magnets configured to be demagnetized by injection of D-axis which may be performed, for example, by power electronics 750 under the control of ECS 30. In or in connection with such means for demagnetizing the rotor, ECS 40 may be configured with permanent magnet field weakening controls executed control d-axis current to selectably magnetize one or more permanent magnets of the electrical machine in a first mode, and selectably demagnetize the one or more permanent magnets of the electrical machine in a second mode. In some such forms, the permanent magnets may be configured and provided as soft ferromagnetic magnets or semi-soft ferromagnetic magnets comprising low or relatively low coercivity. Soft ferromagnetic magnets may comprise manganese-zinc ferrite or nickel-zinc ferrite. Semi-soft ferromagnetic magnets may comprise Cobalt ferrite.

[0028] In some form including means for demagnetizing a rotor of the electric machine, the electric machine may be provided in the form of an electric machine with a rotor comprising one or more electromagnets. In such forms, the means for demagnetizing the rotor may comprise one or more rotor windings that can be selectably energized to magnetize the rotor and selectably deenergized to demagnetize the rotor.Page 7 of 26195473619vlAtorney Docket No. CMI002-00201

[0029] In some embodiments, electric machine system 70 may be provided with means for mitigating no-load losses in the form a hybrid reluctance permanent magnet machine, including a combination of permanent magnets and electromagnets. The permanent magnets may be demagnetized as described herein above and / or may be reduced in magnitude of magnetic field to mitigate losses during no load operation.

[0030] In some embodiments, the means for mitigating losses of the electric machine may comprises a clutch, such as clutch 713, The clutch may be engaged in a first mode to transmit torque between an electrical machine and the set of ground contacting wheels. The clutch may be disengaged in a second mode to decouple the electrical machine and the set of ground contacting wheels such that torque is not transmitted therebetween.

[0031] ECS 30 is operatively coupled with and configured to selectably operate electric machine system 70, ESS 40, and the means for mitigating no-load losses in a plurality of modes. In a first example mode, the ESS powers electric machine system 70 to drive the set of ground contacting wheels 9a, 9b and the means for mitigating losses is inactive. The means for mitigating losses being inactive may be accomplished through active operation of ECS 30, an innate response characteristic of the means for mitigating losses to operation of electrical machine or other operating conditions of vehicle system 10, or a combination thereof.In a second example mode, electric machine 70 is driven by the set of ground contacting wheels 9a, 9b to power ESS 40 and the means for mitigating losses is inactive. The means for mitigating losses being inactive may be accomplished through active operation of ECS 30, an innate response characteristic of the means for mitigating losses to operation of electrical machine or other operating conditions of vehicle system 10, or a combination thereof. In a third example mode, electric machine 70 is under a no-load condition and the means for mitigating losses is active. The means for mitigating losses being active may be accomplished through active operation of ECS 30, an innate response characteristic of the means for mitigating losses to operation of electrical machine or other operating conditions of vehicle system 10, or a combination thereof.

[0032] With reference to Fig. 3, there is illustrated an example vehicle system 10’ which includes many of the same features as vehicle system 10 which are indicated with the same reference numerals utilized in connection therewith. Vehicle system 10’ differs from vehicle system 10 in that electric motor system 70 is configured and provided as a set of two or morePage 8 of 26195473619vlAtorney Docket No. CMI002-00201 electric machines 70a, 70b which are operatively coupled with and configured to drive respective ones of the set of ground contacting wheels 9a, 9b directly.

[0033] With reference to Fig. 4, there are illustrated certain aspects of an example, implementation of ESS 40. In the illustrated example, ESS 40 includes energy storage components comprising one or more supercapacitors 402 (illustrated as supercapacitor 402a and supercapacitor 402b in Fig. 4) and battery 404 which are coupled with positive rail 408 and negative rail 409 of power bus 410. Battery 404 may be configured and provided as a high-temperature battery system, for example, rated for operation at 100 degrees C or higher.

[0034] Positive rail 408 is conductively coupled with flexible power cabling 414 which, in turn, is conductively coupled with power electronics 750 of hybrid axle assembly 14 and negative rail 409 of power bus 410. Negative rail 409 of power bus 410 is conductively coupled with flexible power cabling 412 which, in turn, is conductively coupled with and grounded by chassis 22 of vehicle system 10. One or more switches 403 may be provided in combination with power bus 410 to selectably coupled and decouple battery 404 from one or both of positive rail 408 and negative rail 409 of power bus 410.

[0035] In the illustrated example, ESS 40 is attached to and supported by chassis 22 of vehicle system 10 and is at least partially mechanically isolated from force encountered by ground contacting wheels 9a, 9b and hybrid axle assembly 14 during operation of vehicle system 10. In other embodiments, some or all of ESS 40 may be attached to and supported by hybrid axle assembly 14, for example, by being integrated with hybrid axle assembly 14.

[0036] ESS 40 is operatively coupled with and controllable by ECS 30 to provide energy to power electronics 750 to drive electric machine 702 of hybrid axle assembly, and to receive energy from power electronics 750 from electric machine 702 when driven by the set of ground contacting wheels 9a, 9b. Such operations may be coordinated and controlled by ECS 30.

[0037] A number of additional forms of ESS are contemplated. In some forms, one or more supercapacitors provide substantially all of the energy storage of ESS 40 and battery 404 may be omitted. In some such forms, a single super capacitor provides substantially all of the energy storage of ESS 40. In some such forms, a single super capacitor stack comprising two or more supercapacitors connected in series between positive rail 408 and negative rail 409 provides substantially all of the energy storage of ESS 40. In some such forms, two or more supercapacitors connected parallel between positive rail 408 and negative rail 409 provides substantially all of thePage 9 of 26195473619vlAtorney Docket No. CMI002-00201 energy storage of ESS 40. In some such forms, two or more supercapacitors connected parallel between positive rail 408 and negative rail 409 provides substantially all of the energy storage of ESS 40.

[0038] With reference to Fig. 5 there is illustrated an example control process 300 which may be implemented in and executed in connection with one or more controllers of an electronic control system, such as one or more controllers of ECS 30 or one or more controllers of another electronic controls system according to the present disclosure. For purposes of illustration, certain aspects of process 300 are described in relation to certain components of vehicle system 10, it being appreciated that process 300 is not so limited and may be performed in connection with other components of other vehicle systems according to the present disclosure.

[0039] Process 300 begins at start operation 302 and proceeds to operation 302 which a means for mitigating no-load losses of an electric machine such as electric machine system 70, electric machine 70a, or electric machine 70b is inactive, for example, by active operation of ECS 30, an innate response characteristic of the means for mitigating losses to operation of electrical machine or other operating conditions of vehicle system 10, or a combination thereof. The means for mitigating no-load losses of an electric machine may be configured and provided in a number of forms according to the present disclosure including those described in connection with

[0040] From operation 304, process 300 proceeds to conditional 306 which evaluates whether a positive machine torque condition is true. If conditional 306 evaluates affirmative, process 300 proceeds to operation 309 which performs a positive machine torque operation. The positive machine torque operation may comprise ECS 30 operating ESS 40, power electronics 750, and electric machine 702 to output positive torque to drive motor pinion gear 514 to the set of ground contacting wheels 9a, 9b. If conditional 306 evaluates negative, process 300 proceeds to conditional 308.

[0041] Conditional 308 evaluates whether a negative machine torque condition is true. If conditional 308 evaluates affirmative, process 300 proceeds to operation 309 which performs a negative machine torque operation. The negative machine torque operation may comprise the set of ground contacting wheels 9a, 9b driving electric machine 702 to generate power and ECS 30 operating ESS 40, power electronics 750, and electric machine 702 to receive electrical power charge ESS 40. If conditional 308 evaluates negative, process 300 proceeds to conditional 310.

[0042] Conditional 310 evaluates whether a no-load machine condition is true. If conditionalPage 10 of 26195473619vlAtorney Docket No. CMI002-00201308 evaluates affirmative, process 300 proceeds conditional 312. Tf conditional 308 evaluates negative, process 300 proceeds to operation 304.

[0043] Conditional 312 evaluates whether a machine speed is treater than a speed loss threshold. If conditional 312 evaluates affirmative, process 300 proceeds to operation 313 which at which the means for mitigating no load losses is activated. If conditional 312 evaluates negative, process 300 proceeds to conditional 310.

[0044] With reference to Figs. 6A and 6B there are illustrated further details of an example process 370 which is an implementation of conditional 306 of process 300, it being appreciated that process 300 and process 370 may be implemented as separate processes or as different aspects of a common process. In the illustrated example, after process 300 proceeds to conditional 306, process 370 begins at conditional 372 which evaluates whether one or more vehicles launch boost conditions are true. The one or more vehicles launch boost conditions may comprise vehicle speed being zero or below predetermined speed threshold, and a state of charge of ESS 40 being greater than a predetermined threshold. If conditional 372 evaluates affirmative, process 370 proceeds to operation 373 which sets a positive machine torque operation to a vehicle launch boost operation which supplements driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during a vehicle launch operation. From operation 373, process 370 proceeds to operation 307 of process 300. If conditional 372 evaluates negative, process 370 proceeds to conditional 374.

[0045] Conditional 374 evaluates whether one or more transmission shift boost conditions are true. The one or more transmission shift boost conditions may comprise a clutch state indicating a shifting operation, a transmission state indicating a shifting operation, the vehicle not being on a downhill grade, and a state of charge of ESS 40 being greater than a predetermined threshold. If conditional 374 evaluates affirmative, process 370 proceeds to operation 375 which sets a positive machine torque operation to a transmission shift boost operation which replaces at least in part driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during a transmission shift operation. From operation 375, process 370 proceeds to operation 307 of process 300. If conditional 374 evaluates negative, process 370 proceeds to conditional 376.

[0046] Conditional 376 evaluates whether one or more maximum torque boost conditions are true. The one or more maximum torque boost conditions may comprise an engine operating atPage 11 of 26195473619vlAtorney Docket No. CMI002-00201 maximum rated torque, for example, due to an increased load on vehicle system 10 which may be transient (e.g., a stump pulling-type operation wherein vehicle system 10 is operated over a short duration at maximum rated torque, such as might occur when pulling a tree stump) or durable (e.g., a towing operation or receipt of a heavy payload). If conditional 376 evaluates affirmative, process 370 proceeds to operation 377 which sets a positive machine torque operation to a maximum torque boost operation which supplements driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during a maximum torque operation of engine 12. From operation 377, process 370 proceeds to operation 307 of process 300. If conditional 376 evaluates negative, process 370 proceeds to conditional 378.

[0047] Conditional 378 evaluates whether one or more coasting torque boost conditions are true. The one or more coasting torque boost conditions may comprise the vehicle system 10 being in a coasting mode or undergoing a coasting operation and a state of charge of ESS 40 being greater than a predetermined threshold. If conditional 378 evaluates affirmative, process 370 proceeds to operation 379 which sets a positive machine torque operation to a coasting torque boost operation. From operation 379, process 370 proceeds to operation 307 of process 300 which replaces at least in part driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during a vehicle coasting operation. If conditional 378 evaluates negative, process 370 proceeds to conditional 380.

[0048] Conditional 380 evaluates whether one or more cylinder deactivation torque boost operations conditions are true. The one or more cylinder deactivation torque boost operations conditions may comprise engine 12 being in a cylinder deactivation mode wherein one or more cylinders is not fueled while one or more other cylinders are fueled. If conditional 380 evaluates affirmative, process 370 proceeds to operation 381 which sets a positive machine torque operation to a cylinder deactivation torque boost operation which supplements driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during a cylinder deactivation operation of engine 12. From operation 381, process 370 proceeds to operation 307 of process 300. If conditional 380 evaluates negative, process 370 proceeds to conditional 382.

[0049] Conditional 382 evaluates whether one or more adaptive cruise control boost operations are true. The one or more one or more adaptive cruise control boost operations conditions mayPage 12 of 26195473619vlAtorney Docket No. CMI002-00201 comprise vehicle 10 being in an adaptive cruise control mode, a following distance criterion being met, and a state of charge of ESS 40 being greater than a predetermined threshold. The following distance criterion may comprise one or both of a following distance being less than a target following distance and a following distance being greater than the target following distance. If conditional 382 evaluates affirmative, process 370 proceeds to operation 383 which sets a positive machine torque operation to an adaptive cruise control boost operation which supplements driveline torque provided to the set of ground contacting wheels 9a, 9b from engine 12 and transmission 14 with machine torque from electric machine system 70 during an adaptive cruise control operation of engine 12. From operation 383, process 370 proceeds to operation 307 of process 300. If conditional 382 evaluates negative, process 370 proceeds to conditional 384.

[0050] Conditional 384 evaluates whether one or more other positive torque conditions are true. The one or more other positive torque conditions may comprise one or more other conditions under which torque driveline torque from engine 12 and transmission 14 is supplemented or replaced at least in part by machine torque from electric machine system 70. If conditional 384 evaluates affirmative, process 370 proceeds to operation 385 which sets one or more other positive machine torque operations. From operation 385, process 370 proceeds to operation 307 of process 300. If conditional 382 evaluates negative, process 370 proceeds to conditional 308 of process 300.

[0051] As illustrated by this detailed description, the present disclosure contemplates multiple embodiments including the following example embodiments.

[0052] Example embodiment 1 is a vehicle system comprising: an engine; a transmission coupled with the engine; a set of ground contacting wheels; a hybrid axle assembly including a set of axles coupled with the set of ground contacting wheels, a differential coupled with the set of axles and the transmission, an electric machine fastened to the hybrid axle assembly, and means for mitigating losses of the electric machine, the hybrid axle assembly being configured to transmit driveline torque received from the engine and the transmission to the set of ground contacting wheels and to selectably transmit machine torque output by the electrical machine to the set of ground contacting wheels; an energy storage system (ESS) operatively coupled with the electric machine; an electronic control system (ECS) configured to selectably operate the electric machine, the energy storage system, and the means for mitigating losses in a plurality of modes including: a first mode wherein the ESS powers the electrical machine to drive the set of ground contacting wheels and the means for mitigating losses is inactive, a second mode wherein the electric machinePage 13 of 26195473619vlAtorney Docket No. CMI002-00201 is driven by the set of ground contacting wheels to power the ESS and the means for mitigating losses is inactive, and a third mode wherein electric machine is under a no load condition and the means for mitigating losses is active.

[0053] Example embodiment 2 includes the features of example embodiment 1, wherein the means for mitigating losses of the electric machine comprises means for demagnetizing a rotor of the electric machine.

[0054] Example embodiment 3 includes the features of example embodiment 2, wherein the means for demagnetizing the rotor of the electric machine comprises one or more rotor windings being selectably deenergized to demagnetize the rotor.

[0055] Example embodiment 4 includes the features of example embodiment 3, wherein the ECS to is configured to control excitation current to the one or more rotor winding of the electric machine to deenergize the one or more rotor windings to demagnetize the rotor.

[0056] Example embodiment 5 includes the features of example embodiment 2, wherein the means for demagnetizing the rotor of the electric machine comprises one or more soft ferromagnetic permanent magnets being selectably deenergized by injection of D-axis current.

[0057] Example embodiment 6 includes the features of example embodiment 5, wherein the means for mitigating losses of the electric machine comprises permanent magnet field weakening controls executed by the ECS to control d-axis current to selectably magnetize one or more low coercivity magnets of the electrical machine in the first mode, and selectably de-magnetize the one or more low coercivity magnets of the electrical machine in the second mode.

[0058] Example embodiment 7 includes the features of example embodiment 1, comprising a segmented microinverter integrally packaged with the electrical machine and controllable by the electronic control system to control operation of the electrical machine.

[0059] Example embodiment 8 includes the features of example embodiment 1, wherein the means for mitigating losses of the electric machine comprises a hybrid reluctance permanent magnet machine.

[0060] Example embodiment 9 includes the features of example embodiment 1, wherein the means for mitigating losses of the electric machine comprises a clutch, the clutch being engaged in the first mode to transmit torque between the electrical machine and the set of ground contacting wheels, the clutch being disengaged in the second mode.

[0061] Example embodiment 10 includes the features of example embodiment 1, wherein thePage 14 of 26195473619vlAtorney Docket No. CMI002-00201 machine torque operation comprises a vehicle launch boost operation wherein one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop in combination with torque from the transmission, and one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop while the engine is stopped.

[0062] Example embodiment 11 includes the features of example embodiment 1, wherein the machine torque operation comprises a transmission shift boost operation wherein the wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a shift event of the transmission effective to mitigate a loss of speed of the vehicle system otherwise resulting from the shift event.

[0063] Example embodiment 12 includes the features of example embodiment 1, wherein the machine torque operation comprises a maximum torque boost operation wherein one or more supercapacitors of the ESS is discharged to supplement the driveline torque during a maximum torque output operation of the engine.

[0064] Example embodiment 13 includes the features of example embodiment 1, wherein the machine torque operation comprises a coasting boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a coasting event wherein the vehicle is in motion and the engine is one of turned off and disengaged from the differential by the transmission.

[0065] Example embodiment 14 includes the features of example embodiment 1, wherein the machine torque operation comprises a cylinder deactivation boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a cylinder deactivation transition operation wherein a first set of cylinders of the engine is active and a second set of cylinders of the engine is one of activated and deactivated to change a number of active cylinders.

[0066] Example embodiment 15 includes the features of example embodiment 1, wherein the machine torque operation comprises an adaptive cruise control boost operation wherein one or more supercapacitors of the ESS is one of discharged to drive the set of ground contacting wheels during an adaptive cruise control acceleration operation, and charged to brake the set of ground contacting wheels during an adaptive cruise control deceleration operation.

[0067] Example embodiment 16 includes the features of example embodiment 1, wherein the ESS comprises one or more supercapacitors.Page 15 of 26195473619vlAtorney Docket No. CMI002-00201

[0068] Example embodiment 17 includes the features of example embodiment 16, wherein one or more supercapacitors of the ESS provide substantially all of the energy storage of the energy storage system.

[0069] Example embodiment 18 includes the features of example embodiment 1, wherein the ESS includes a high-temperature battery system and a combination of one or more supercapacitors of the ESS and the high-temperature battery system provides substantially all of the energy storage of the energy storage system.

[0070] Example embodiment 19 is a process comprising: operating a vehicle system including an engine, a transmission coupled with the engine, a set of ground contacting wheels, a hybrid axle assembly including a set of axles coupled with the set of ground contacting wheels, a differential coupled with the set of axles and the transmission, an electric machine fastened to the hybrid axle assembly, the hybrid axle assembly being configured to transmit driveline torque received from the engine and the transmission to the set of ground contacting wheels and to selectably transmit machine torque output by the electrical machine to the set of ground contacting wheels, an energy storage system (ESS) operatively coupled with the electric machine, and an electronic control system (ECS) in operatively communication with the electric machine and the energy storage system; operating the ECS to control the electric machine and the energy storage system in a first mode wherein the ESS powers the electrical machine to drive the set of ground contacting wheels; operating the ECS to control the electric machine and the energy storage system in a second mode wherein the electric machine is driven by the set of ground contacting wheels to power the ESS; and operating the ECS to control the electric machine and the energy storage system in a third mode wherein electric machine is under a no load condition.

[0071] Example embodiment 20 includes the features of example embodiment 19, wherein: the vehicle system includes means for mitigating losses of the electric machine; the means for mitigating losses is inactive in the first mode and the second mode; and the means for mitigating losses is inactive in the first mode and the second mode and is active in the third mode.

[0072] Example embodiment 21 includes the features of example embodiment 19, wherein the means for mitigating losses of the electric machine comprises any one or more of: one or more rotor windings being selectably deenergized to demagnetize the rotor, one or more soft ferromagnetic permanent magnets being selectably deenergized by injection of D-axis current, permanent magnet field weakening controls executed by the ECS to control d-axis current toPage 16 of 26195473619vlAtorney Docket No. CMI002-00201 selectably magnetize one or more low coercivity magnets of the electrical machine in the first mode, and selectably de-magnetize the one or more low coercivity magnets of the electrical machine in the second mode, a hybrid reluctance permanent magnet machine, and a clutch, the clutch being engaged in the first mode to transmit torque between the electrical machine and the set of ground contacting wheels, the clutch being disengaged in the second mode.

[0073] Example embodiment 22 includes the features of example embodiment 19, wherein the machine torque operation comprises a vehicle launch boost operation wherein one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop in combination with torque from the transmission, and one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop while the engine is stopped.

[0074] Example embodiment 23 includes the features of example embodiment 19, wherein the machine torque operation comprises a transmission shift boost operation wherein the wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a shift event of the transmission effective to mitigate a loss of speed of the vehicle system otherwise resulting from the shift event.

[0075] Example embodiment 24 includes the features of example embodiment 19, wherein the machine torque operation comprises a maximum torque boost operation wherein one or more supercapacitors of the ESS is discharged to supplement the driveline torque during a maximum torque output operation of the engine.

[0076] Example embodiment 25 includes the features of example embodiment 19, wherein the machine torque operation comprises a coasting boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a coasting event wherein the vehicle is in motion and the engine is one of turned off and disengaged from the differential by the transmission.

[0077] Example embodiment 26 includes the features of example embodiment 19, wherein the machine torque operation comprises a cylinder deactivation boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a cylinder deactivation transition operation wherein a first set of cylinders of the engine is active and a second set of cylinders of the engine is one of activated and deactivated to change the number of active cylinders.

[0078] Example embodiment 27 includes the features of example embodiment 19, wherein thePage 17 of 26195473619vlAtorney Docket No. CMI002-00201 machine torque operation comprises an adaptive cruise control boost operation wherein one or more supercapacitors of the ESS is one of discharged to drive the set of ground contacting wheels during an adaptive cruise control acceleration operation, and charged to brake the set of ground contacting wheels during an adaptive cruise control deceleration operation.

[0079] Example embodiment 28 includes the features of example embodiment 19, wherein the ESS comprises one or more supercapacitors.

[0080] Example embodiment 29 includes the features of example embodiment 28, wherein one or more supercapacitors of the ESS provide substantially all of the energy storage of the energy storage system.

[0081] Example embodiment 30 includes the features of example embodiment 19, wherein the ESS includes a high-temperature battery system and a combination of one or more supercapacitors of the ESS and the high-temperature battery system provides substantially all of the energy storage of the energy storage system.

[0082] It shall be appreciated that terms such as “a non-transitory memory,” “a non-transitory memory medium,” and “a non-transitory memory device” refer to a number of types of devices and storage mediums which may be configured to store information, such as data or instructions, readable or executable by a processor or other components of a computer system and that such terms include and encompass a single or unitary device or medium storing such information, multiple devices or media across or among which respective portions of such information are stored, and multiple devices or media across or among which multiple copies of such information are stored.

[0083] It shall be appreciated that terms such as “determine,” “determined,” “determining” and the like when utilized in connection with a control method or process, an electronic control system or controller, electronic controls, or components or operations of the foregoing refer inclusively to a number of acts, configurations, devices, operations, and techniques including, without limitation, calculation or computation of a parameter or value, obtaining a parameter or value from a lookup table or using a lookup operation, receiving parameters or values from a datalink or network communication, receiving an electronic signal (e.g., a voltage, SENT, current, or pulse-width modulation (PWM) signal) indicative of the parameter or value, receiving output of a sensor indicative of the parameter or value, receiving other outputs or inputs indicative of the parameter or value, reading the parameter or value from a memory location on a computer-readablePage 18 of 26195473619vlAtorney Docket No. CMI002-00201 medium, receiving the parameter or value as a run-time parameter, and / or by receiving a parameter or value by which the interpreted parameter can be calculated, and / or by referencing a default value that is interpreted to be the parameter value.

[0084] While example embodiments of the disclosure have been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain example embodiments have been shown and described and that all changes and modifications that come within the spirit of the claimed inventions are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicates that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and / or “a portion” is used the item can include a portion and / or the entire item unless specifically stated to the contrary.Page 19 of 26195473619vl

Claims

Atorney Docket No. CMI002-00201CLAIMS1. A vehicle system comprising: an engine; a transmission coupled with the engine; a set of ground contacting wheels; a hybrid axle assembly including a set of axles coupled with the set of ground contacting wheels, a differential coupled with the set of axles and the transmission, an electric machine fastened to the hybrid axle assembly, and means for mitigating losses of the electric machine, the hybrid axle assembly being configured to transmit driveline torque received from the engine and the transmission to the set of ground contacting wheels and to selectably transmit machine torque output by the electrical machine to the set of ground contacting wheels; an energy storage system (ESS) operatively coupled with the electric machine; an electronic control system (ECS) configured to selectably operate the electric machine, the energy storage system, and the means for mitigating losses in a plurality of modes including: a first mode wherein the ESS powers the electrical machine to drive the set of ground contacting wheels and the means for mitigating losses is inactive, a second mode wherein the electric machine is driven by the set of ground contacting wheels to power the ESS and the means for mitigating losses is inactive, and a third mode wherein electric machine is under a no-load condition and the means for mitigating losses is active.

2. The vehicle system of claim 1, wherein the means for mitigating losses of the electric machine comprises means for demagnetizing a rotor of the electric machine.

3. The vehicle system of claim 2, wherein the means for demagnetizing the rotor of the electric machine comprises one or more rotor windings being selectably deenergized to demagnetize the rotor.Page 20 of 26195473619vlAtorney Docket No. CMI002-002014. The vehicle system of claim 3, wherein the ECS to is configured to control excitation current to the one or more rotor winding of the electric machine to deenergize the one or more rotor windings to demagnetize the rotor.

5. The vehicle system of claim 2, wherein the means for demagnetizing the rotor of the electric machine comprises one or more soft ferromagnetic permanent magnets being selectably deenergized by injection of D-axis current.

6. The vehicle system of claim 5, wherein the means for mitigating losses of the electric machine comprises permanent magnet field weakening controls executed by the ECS to control d-axis current to selectably magnetize one or more low coercivity magnets of the electrical machine in the first mode, and selectably de-magnetize the one or more low coercivity magnets of the electrical machine in the second mode.

7. The vehicle system of claim 1 comprising a segmented microinverter integrally packaged with the electrical machine and controllable by the electronic control system to control operation of the electrical machine.

8. The vehicle system of claim 1, wherein the means for mitigating losses of the electric machine comprises a hybrid reluctance permanent magnet machine.

9. The vehicle system of claim 1, wherein the means for mitigating losses of the electric machine comprises a clutch, the clutch being engaged in the first mode to transmit torque between the electrical machine and the set of ground contacting wheels, the clutch being disengaged in the second mode.

10. The vehicle system of claim 1 wherein the machine torque operation comprises a vehicle launch boost operation wherein one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop in combination with torque from the transmission, and one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop while the engine is stopped.Page 21 of 26195473619vlAtorney Docket No. CMI002-0020111. The vehicle system of claim 1 wherein the machine torque operation comprises a transmission shift boost operation wherein the wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a shift event of the transmission effective to mitigate a loss of speed of the vehicle system otherwise resulting from the shift event.

12. The vehicle system of claim 1 wherein the machine torque operation comprises a maximum torque boost operation wherein one or more supercapacitors of the ESS is discharged to supplement the driveline torque during a maximum torque output operation of the engine.

13. The vehicle system of claim 1 wherein the machine torque operation comprises a coasting boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a coasting event wherein the vehicle is in motion and the engine is one of turned off and disengaged from the differential by the transmission.

14. The vehicle system of claim 1 wherein the machine torque operation comprises a cylinder deactivation boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a cylinder deactivation transition operation wherein a first set of cylinders of the engine is active and a second set of cylinders of the engine is one of activated and deactivated to change the number of active cylinders.

15. The vehicle system of claim 1 wherein the machine torque operation comprises an adaptive cruise control boost operation wherein one or more supercapacitors of the ESS is one of discharged to drive the set of ground contacting wheels during an adaptive cruise control acceleration operation, and charged to brake the set of ground contacting wheels during an adaptive cruise control deceleration operation.

16. The vehicle system of claim 1, wherein the ESS comprises one or more supercapacitors.Page 22 of 26195473619vlAtorney Docket No. CMI002-0020117. The vehicle system of claim 16, wherein one or more supercapacitors of the ESS provide substantially all of the energy storage of the energy storage system.

18. The vehicle system of claim 1, wherein the ESS includes a high-temperature battery system and a combination of one or more supercapacitors of the ESS and the high-temperature battery system provides substantially all of the energy storage of the energy storage system.

19. A process comprising: operating a vehicle system including an engine, a transmission coupled with the engine, a set of ground contacting wheels, a hybrid axle assembly including a set of axles coupled with the set of ground contacting wheels, a differential coupled with the set of axles and the transmission, an electric machine fastened to the hybrid axle assembly, the hybrid axle assembly being configured to transmit driveline torque received from the engine and the transmission to the set of ground contacting wheels and to selectably transmit machine torque output by the electrical machine to the set of ground contacting wheels, an energy storage system (ESS) operatively coupled with the electric machine, and an electronic control system (ECS) in operatively communication with the electric machine and the energy storage system; operating the ECS to control the electric machine and the energy storage system in a first mode wherein the ESS powers the electrical machine to drive the set of ground contacting wheels; operating the ECS to control the electric machine and the energy storage system in a second mode wherein the electric machine is driven by the set of ground contacting wheels to power the ESS; and operating the ECS to control the electric machine and the energy storage system in a third mode wherein electric machine is under a no-load condition.

20. The process of claim 19, wherein: the vehicle system includes means for mitigating losses of the electric machine; the means for mitigating losses is inactive in the first mode and the second mode; and the means for mitigating losses is inactive in the first mode and the second mode and is active in the third mode.Page 23 of 26195473619vlAtorney Docket No. CMI002-0020121. The process of claim 19, wherein the means for mitigating losses of the electric machine comprises any one or more of one or more rotor windings being selectably deenergized to demagnetize the rotor, one or more soft ferromagnetic permanent magnets being selectably deenergized by injection of D-axis current, permanent magnet field weakening controls executed by the ECS to control d-axis current to selectably magnetize one or more low coercivity magnets of the electrical machine in the first mode, and selectably de-magnetize the one or more low coercivity magnets of the electrical machine in the second mode, a hybrid reluctance permanent magnet machine, and a clutch, the clutch being engaged in the first mode to transmit torque between the electrical machine and the set of ground contacting wheels, the clutch being disengaged in the second mode.

22. The process of claim 19 wherein the machine torque operation comprises a vehicle launch boost operation wherein one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop in combination with torque from the transmission, and one or more supercapacitors of the ESS is discharged to accelerate the vehicle system from a resting stop while the engine is stopped.

23. The process of claim 19 wherein the machine torque operation comprises a transmission shift boost operation wherein the wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a shift event of the transmission effective to mitigate a loss of speed of the vehicle system otherwise resulting from the shift event.

24. The process of claim 19 wherein the machine torque operation comprises a maximum torque boost operation wherein one or more supercapacitors of the ESS is discharged to supplement the driveline torque during a maximum torque output operation of the engine.Page 24 of 26195473619vlAtorney Docket No. CMI002-0020125. The process of claim 19 wherein the machine torque operation comprises a coasting boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a coasting event wherein the vehicle is in motion and the engine is one of turned off and disengaged from the differential by the transmission.

26. The process of claim 19 wherein the machine torque operation comprises a cylinder deactivation boost operation wherein one or more supercapacitors of the ESS is discharged to drive the set of ground contacting wheels during a cylinder deactivation transition operation wherein a first set of cylinders of the engine is active and a second set of cylinders of the engine is one of activated and deactivated to change the number of active cylinders.

27. The process of claim 19 wherein the machine torque operation comprises an adaptive cruise control boost operation wherein one or more supercapacitors of the ESS is one of discharged to drive the set of ground contacting wheels during an adaptive cruise control acceleration operation, and charged to brake the set of ground contacting wheels during an adaptive cruise control deceleration operation.

28. The process of claim 19, wherein the ESS comprises one or more supercapacitors.

29. The process of claim 28, wherein one or more supercapacitors of the ESS provide substantially all of the energy storage of the energy storage system.

30. The process of claim 19, wherein the ESS includes a high-temperature battery system and a combination of one or more supercapacitors of the ESS and the high-temperature battery system provides substantially all of the energy storage of the energy storage system.Page 25 of 26195473619vl

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