Hybrid Drivetrain Control for Catalyst Heating Without Extra DC Hardware
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Solution Overview
Problem
Existing methods for supplying electrical power to an electrically heatable catalyst device in hybrid vehicles require high electrical currents, leading to increased installation space, weight, and cost due to the need for additional components like 12V or 24V DC systems or DC/DC converters.
Innovation Solution
A control device that utilizes a bidirectional converter and a clutch to manage electrical current flow through AC electric machine windings for starting the engine, charging the battery, and heating the catalyst, eliminating the need for additional components by leveraging existing drivetrain components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a 12V or 24V DC electrical system or DC/DC converter is used to supply electrical power to the heating resistance of the catalyst device, then the catalyst can be heated effectively, but the installation space, weight, and cost increase due to additional components and high electrical currents
Solution Approach 1:
The patent makes the AC electric machine windings serve multiple functions: they function as motor windings during engine starting and torque supply operations, and as heating elements for the catalyst device during engine warm-up. The control device switches the windings between motor operation mode and heating mode by controlling current flow direction and magnitude, eliminating the need for separate heating components.
Solution Approach 2:
The patent combines the catalyst heating function with the existing AC electric machine windings, merging two separate functions (motor operation and catalyst heating) into a single component. This integration eliminates the need for separate DC/DC converters or additional heating elements, reducing system complexity, weight, and installation space.
2Temperature
If high electrical currents are supplied to the heating resistance, then the catalyst heats up quickly, but the wiring and control means require considerable installation space and increase cost
Solution Approach 1:
The AC electric machine windings are designed to handle high currents for both motor operation and heating purposes. By utilizing the existing windings' current-carrying capacity for dual purposes, the system achieves rapid catalyst heating without requiring separate high-current wiring harnesses or additional control equipment.
Solution Approach 2:
The AC electric machine windings serve themselves by providing both motor function and heating function. The control device simply redirects current flow to utilize the windings' inherent electrical properties for catalyst heating, eliminating the need for dedicated heating infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides efficient electrical power supply to the catalyst without significantly increasing cost, weight, or installation space, using existing drivetrain components to heat the catalyst effectively.
Implementation Method 1
a heating resistance (R) of an electrically heatable catalyst device (5)
Data Source
AI summary
The teachings of the present disclosure may include operation of a drivetrain system for a vehicle with multiple operation modes. The first includes coupling the AC electric machine with the internal combustion engine for starting the internal combustion engine or for supplying an additional torque. The second includes coupling the internal combustion engine with the AC electric machine for charging the electric battery. The third includes decoupling the AC electric machine from the internal combustion engine and connecting an AC winding to a heating resistance of a catalyst device for electrically heating the catalyst device. The fourth includes coupling the internal combustion engine with the AC electric machine to the heating resistance for electrically heating the catalyst device.