Hybrid Powertrain Power Blending for Cold-Weather Thermal Loads
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Solution Overview
Problem
Hybrid electric vehicles face challenges in managing power allocation between the internal combustion engine and high-voltage battery to support external AC loads, particularly during cold conditions or low fuel situations, without a dedicated human-machine interface for power source selection.
Innovation Solution
A control system with a controller that determines available engine-based power, switches to high-voltage battery power when insufficient, and transitions back to engine power once sufficient, considering coolant temperature and load requirements, ensuring smooth power blending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the internal combustion engine is used to support thermal loads during cold conditions, then power availability for external AC loads is improved, but fuel consumption increases and emissions are generated
Solution Approach 1:
The control system dynamically adjusts engine operation based on real-time conditions including coolant temperature, battery state of charge, and power demand. The engine transitions between off, idle, and various power levels based on whether thermal loads are active and whether sufficient power is available from the battery, optimizing the balance between power availability and fuel consumption
Solution Approach 2:
The system changes operational parameters such as engine speed, battery discharge rate, and power allocation ratios based on temperature conditions. During cold conditions, the system adjusts the threshold for engine activation and modifies the blending ratio between battery and engine power to ensure adequate thermal management while minimizing fuel consumption
2Loss of energy
If the high-voltage battery is used to support thermal loads during cold conditions, then fuel consumption is reduced, but the battery temperature decreases and power capacity is limited
Solution Approach 1:
The control system continuously monitors battery temperature and state of charge, dynamically adjusting the power allocation strategy. When the battery is cold, the system limits the duration and magnitude of high-power draws, and transitions to engine-assisted power delivery once thermal conditions improve, thereby protecting battery capacity while maintaining power availability
Solution Approach 2:
The system performs preliminary assessment of battery thermal state and power capacity before committing to battery-only operation. The controller predicts whether the battery can sustain required power levels throughout the cold condition duration, and pre-adjusts the power strategy to prevent capacity depletion or excessive temperature drop
3Power
If the engine is continuously running to provide power during cold conditions, then power availability is maintained, but the time to warm up the engine and reach optimal operating temperature increases
Solution Approach 1:
The system uses periodic monitoring of engine coolant temperature and power demand to determine when to activate the engine. Rather than continuous operation, the engine is cycled on and off based on whether thermal loads are active and whether the battery can meet current power demands, reducing unnecessary warm-up time while maintaining power availability when needed
4Ease of operation
If a dedicated human-machine interface is added for power source selection, then user control over power allocation is improved, but device complexity increases
Solution Approach 1:
The control system automatically manages power source selection and allocation based on sensor inputs regarding temperature, power demand, and component state. The system makes intelligent decisions about when to use the battery, when to engage the engine, and how to blend power sources without requiring user intervention, thereby maintaining ease of operation while avoiding the complexity of additional user interfaces
Data Source
AI summary
A powertrain and control method that generates and transfers drive torque to a driveline of a hybrid electric vehicle is provided. The powertrain includes an internal combustion engine (ICE), at least one electric motor powered by a high-voltage battery, an integrated dual charge module (IDCM) and a controller. The controller is configured to: determine whether an external load is connected to the vehicle through the IDCM; determine an available engine-based power; determine whether the available engine-based power is above a threshold to support thermal loads; command power consumption from the high-voltage battery based on a determination that available engine-based power is not above the threshold; command power consumption from the ICE based on a determination that available engine-based power is above the threshold; and command a blending of power between the high-voltage battery and the ICE.