Single Dynamo Hybrid System with Torque Coupling
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Solution Overview
Problem
Current hybrid electric vehicle systems are expensive due to the requirement of two dynamos and two inverters to operate various modes, necessitating a more cost-effective configuration that maintains functionality.
Innovation Solution
A hybrid vehicle system utilizing a single dynamo and a torque coupling device with directional clutches and a planetary gear set to variably couple the engine to the dynamo, enabling multiple modes of operation without the need for two dynamos and two inverters, including propulsion, starting, regenerative braking, and charging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two dynamos and two inverters are used to operate various modes, then the system functionality is maintained, but the manufacturing cost increases
Solution Approach 1:
The patent combines the functions of two dynamos and two inverters into a single dynamo and single inverter system. The first and second dynamos are merged into one dynamo that can operate in multiple modes (motor mode for propulsion, generator mode for charging). The two inverters are consolidated into one inverter that handles both motor control and regenerative braking. This merging reduces component count and manufacturing cost while maintaining all required system functionalities through intelligent control of the single dynamo's operational modes.
Solution Approach 2:
The single dynamo is designed with multi-functionality to replace the roles of two separate dynamos. It can operate as a motor for vehicle propulsion, as a generator for regenerative braking and battery charging, and can be coupled to the engine for starting or compression braking. The single inverter serves universal purposes of controlling the dynamo in both motor and generator modes. This universality achieves cost reduction while preserving adaptability across all operating modes.
2Ease of manufacture
If a single dynamo is used instead of two dynamos, then manufacturing cost is reduced, but the device complexity increases due to the torque coupling device
Solution Approach 1:
The torque coupling device acts as an intermediary mechanism between the single dynamo and the engine, enabling multiple operational modes without requiring two separate dynamo systems. The torque coupling device with directional clutches and planetary gear set mediates the torque transmission paths, allowing the dynamo to be coupled or decoupled from the engine as needed for different modes (propulsion, starting, compression braking). This intermediary approach achieves component reduction while managing the complexity through a dedicated coupling mechanism.
3Ease of manufacture
If the engine is coupled to the dynamo for starting, then the starter motor is eliminated, but the system complexity increases
Solution Approach 1:
The single dynamo is designed with multi-functionality to serve as both the propulsion motor and the engine starter, eliminating the need for a separate starter motor. The torque coupling device enables the dynamo to be coupled to the engine crankshaft, allowing it to crank the engine during starting operations. This universal design achieves further component reduction beyond the initial two-dynamo configuration, though it requires the torque coupling mechanism to manage the additional functional requirement of engine starting.
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
The system reduces manufacturing costs by eliminating the need for two dynamos and two inverters while maintaining the functionality of existing hybrid electric vehicle systems, offering efficient propulsion, quiet starting, and robust braking capabilities.
Implementation Method 1
The single dynamo is configured to operate in a motor mode for propelling the vehicle
Implementation Method 2
The single dynamo is configured to operate in a generator mode for charging the energy storage device
Implementation Method 3
a planetary gear set interposed between the dynamo and the engine
Implementation Method 4
The torque coupling device includes a first directional clutch coupling the engine to the dynamo
Data Source
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AI summary
A system for operating a hybrid vehicle that includes a chargeable energy storage device, a single dynamo (motor / generator combination) an internal combustion engine, and a torque coupling device configured to variably couple the engine to the dynamo. The torque coupling device is such that using only a single dynamo, the system is able to operate in different modes expected of hybrid vehicles, such as: electric drive only, engine drive only, electric and engine drive combined, and charging of the chargeable energy storage device.