Hybrid Controller Segmentation for Vehicle Conversion
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Solution Overview
Problem
Converting a conventional vehicle to a hybrid vehicle is challenging due to the need for significant modifications to the chassis and control system, including the integration of an electric drive system and a controller, which is costly and difficult, especially when space constraints and proprietary knowledge are involved.
Innovation Solution
An apparatus comprising a transmission, an engine, an electromechanical device, a differential, and a controller that monitors and controls the operation based on travel range estimates and operating characteristics of the engine, transmission, and electromechanical device, allowing for efficient hybrid vehicle operation without extensive modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a conventional vehicle is converted to a hybrid vehicle by integrating an electric drive system and controller, then fuel efficiency is improved, but the complexity of the control system and chassis modifications increases significantly
Solution Approach 1:
The control system is divided into two separate components: an existing engine controller that manages the internal combustion engine, and a new hybrid controller that manages the electric motor and power flow. This segmentation allows the electric drive system to be controlled independently without modifying the proprietary engine controller, reducing overall system complexity while maintaining fuel efficiency benefits
Solution Approach 2:
The hybrid controller acts as an intermediary between the engine controller and the electric motor components. It receives vehicle operation data from the engine controller and independently controls the electric motor, power flow, and energy management, serving as a mediator that eliminates the need to modify the existing engine controller while achieving integrated hybrid vehicle control
2Adaptability or versatility
If the engine controller is modified to control both engine and motor components, then integration is achieved, but the cost and difficulty of modification increases due to proprietary microprocessor requirements
Solution Approach 1:
The hybrid controller serves as an intermediary device that bridges the gap between the existing engine controller and the electric motor system. It receives necessary vehicle operation information from the engine controller through standard interfaces and independently performs hybrid vehicle control functions, eliminating the need for costly and difficult modifications to the proprietary engine controller microprocessor
Solution Approach 2:
The hybrid controller is designed as a universal control unit that can manage multiple functions including electric motor control, power flow management, regenerative braking, and coordination with the engine controller. This multi-functional design achieves comprehensive hybrid vehicle integration without requiring modifications to vehicle-specific proprietary controllers, reducing manufacturing complexity and cost
3Volume of moving object
If space constraints are considered in the vehicle chassis, then the ability to couple an electric drive system between the engine and transmission is limited
Solution Approach 1:
The electric drive system is segmented into modular components (electric motor, power flow management, hybrid controller) that can be independently positioned and integrated into available spaces within the chassis. This modular segmentation allows flexible arrangement of components to accommodate space constraints while maintaining full hybrid vehicle functionality
Data Source
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AI summary
An apparatus includes a transmission (14), an engine (12) coupled to an input side of the transmission (14), and an electromechanical device (30) coupled to an output side of the transmission (14). The apparatus also includes a differential (16) coupled to the output side of the electromechanical device (30) and a controller (44) coupled to the electromechanical device (30). The controller (44) is programmed to receive a travel range estimate, monitor an operating characteristic of the engine (12), and monitor an operating characteristic of the transmission (14). The controller (44) is further programmed to monitor an operating characteristic of the electromechanical device (30) and control operation of the electromechanical device (30) based on the travel range estimate, the operating characteristic of the engine (12), the operating characteristic of the transmission (14), and the operating characteristic of the electromechanical device (30).