Hybrid Drive Control System Thermal Management
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Solution Overview
Problem
In hybrid vehicles, the differential gear system's lubrication issues lead to insufficient lubrication of pinion gears and pins during electric propulsion, causing friction and potential damage, especially when the carrier is halted, and existing solutions require significant modifications that enlarge the vehicle drive unit.
Innovation Solution
A drive control system that calculates the duration of the first operating mode's cessation and estimates the temperature of the power distribution device to inhibit the mode when temperatures are high, ensuring sufficient lubrication and preventing thermal damage by allowing the second operating mode to extend the duration of electric propulsion, thus improving fuel efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the carrier is halted by the braking device during electric propulsion mode, then the torque of the first motor can be multiplied through the power distribution device, but the pinion gears and pinion pins may not be lubricated sufficiently leading to thermal damage
Solution Approach 1:
The control device monitors the operating time of the first operating mode and uses this temporal parameter to estimate temperature changes in the pinion gears and pinion pins. By changing the control parameter from direct temperature measurement to time-based estimation, the system can predict thermal conditions and adjust operation accordingly, preventing thermal damage while maintaining torque multiplication capability
Solution Approach 2:
The control device implements a feedback mechanism where the operating time of the first operating mode is continuously monitored and used to estimate temperature conditions. This feedback loop allows the system to adjust the duration and frequency of the first operating mode based on accumulated thermal stress, ensuring reliable operation while maximizing torque multiplication benefits
2Duration of action of moving object
If the first operating mode is extended to improve fuel efficiency, then the duration of electric propulsion increases, but the temperature of the power distribution device rises causing thermal damage
Solution Approach 1:
The control device enables periodic operation of the first operating mode by monitoring accumulated operating time and temporarily disabling the mode when temperature thresholds are approached. This creates a periodic pattern of operation where the system alternates between high-efficiency electric propulsion and cooling periods, allowing extended overall duration of electric propulsion while preventing thermal damage through controlled interruptions
3Reliability
If additional lubricant receiver is installed to improve lubrication, then the pinion gears may be lubricated sufficiently, but the vehicle drive unit would be enlarged and modified significantly
Solution Approach 1:
The invention replaces the mechanical solution of adding a lubricant receiver with a control-based system that monitors operating time and manages thermal conditions through control logic. This substitution eliminates the need for additional mechanical components and significant drive unit modifications while achieving the same goal of preventing thermal damage through intelligent operation management
Data Source
AI summary
A drive control system for preventing damage from a power distribution device under a motor mode and for improving fuel efficiency. A time duration from termination of the first operating mode where a torque of the first motor is applied to the power distribution device while halting a carrier (at step S4), and a temperature of the power distribution device is estimated based on the calculated time duration (at step S13). The first operating mode is enabled if the estimated temperature is lower than a predetermined allowable temperature (at step S15), and inhibited if the estimated temperature is higher than the allowable temperature (at step S10).