Method for controlling torque output of a hybrid powertrain system

A method for controlling output torque of a hybrid powertrain system includes determining a constrained output torque in response to an operator torque request, and determining maximum and minimum output torque limits. A time-rate change in the constrained output torque at each of a plurality of torque breakpoints is determined. A desired output torque is determined. A preferred output torque is determined as the desired output torque adjusted using the time-rate changes in the constrained output torque at the plurality of torque breakpoints and limited within the maximum and minimum output torque limits. Torque outputs of torque generators of the hybrid powertrain system are controlled in response to the preferred output torque.

TECHNICAL FIELD

This disclosure is related to powertrain systems including electric-powered torque machines and electric power control schemes.

BACKGROUND

Vehicle systems include powertrain systems that provide output torque for propulsion. Powertrain systems include hybrid systems, all-electric systems, and extended-range electric systems that may be configured to operate in various operating modes to generate and transfer torque to a driveline. Such powertrain systems use torque-generative devices, clutches and transmissions. Torque-generative devices may include internal combustion engines and electrically-powered motor/generators, i.e., electric machines. Known electric machines interact with energy storage devices, e.g., high-voltage batteries. Known high-voltage batteries include those fabricated from lithium-ion cells. Known energy storage device devices configured to store electric energy on-vehicle include high-voltage electrical cells and ultracapacitors, among others.

Known parameters associated with monitoring an energy storage device include a state-of-charge, current, and voltage. Available battery power describes battery power limits that include an allowable range between minimum and maximum allowable battery power levels. Allowable battery power limits are preferably established at threshold levels to prevent either overcharging or overdischarging of an energy storage device. Exceeding allowable battery power limits may result in damage that reduces service life of an energy storage device. It is known that overaggressive limitations in the allowable battery power limits may result in underutilization, with attendant reduction in output torque generated using electric power. In hybrid powertrain systems and extended-range electric systems, there may be a corresponding increase in output torque generated using an internal combustion engine and an associated increase in fuel consumption.

Known hybrid controls systems determine commanded output torque by subjecting an operator torque request to system constraints that include motor torque limits, battery power limits, and clutch torque limits. When an output torque request violates any of the limits, the output torque is modified to protect the hardware. Such operation may not be consistent with minimizing fuel consumption or achieving optimal fuel economy. Known control schemes control the output torque to optimize battery power and/or minimize fuel consumption, with a torque determination control scheme that determines an output torque that consumes optimum battery power. A battery power-based optimum output torque may differ from an operator torque request. When a battery power-based optimum output torque is used as a commanded output torque, drivability may be negatively affected.

SUMMARY

A method for controlling output torque of a hybrid powertrain system includes determining a constrained output torque in response to an operator torque request, and determining maximum and minimum output torque limits. A time-rate change in the constrained output torque at each of a plurality of torque breakpoints is determined. A desired output torque is determined. A preferred output torque is determined as the desired output torque adjusted using the time-rate changes in the constrained output torque at the plurality of torque breakpoints and limited within the maximum and minimum output torque limits. Torque outputs of torque generators of the hybrid powertrain system are controlled in response to the preferred output torque.

DETAILED DESCRIPTION

Referring now to the drawings, wherein the showings are for the purpose of illustrating certain exemplary embodiments only and not for the purpose of limiting the same,FIG. 1schematically shows vehicle5including an embodiment of a hybrid powertrain system20coupled to a driveline60and controlled by a control system10. Like numerals refer to like elements throughout the description. The hybrid powertrain system20may be configured as any one of a battery-electric system (EV), an extended-range electric system (EREV), an electric-hybrid system including one of a series-hybrid system, a parallel-hybrid system, and a compound-hybrid system, or another configuration without limitation. The embodiment of the vehicle5including the hybrid powertrain system20is illustrative.

The hybrid powertrain system20employs communications paths55, mechanical power paths57, and high-voltage electric power paths59. The mechanical power paths57mechanically couple elements that generate, use, and/or transfer torque, including such elements as an internal combustion engine40, first and second electrically-powered torque machines35and36, respectively, a transmission50, and driveline60. The high-voltage electric power paths59electrically connect elements that generate, use, and/or transfer high-voltage electric power, including such elements as an energy storage device25, an inverter module30, and the first and second electrically-powered torque machines35and36. The high-voltage electric power paths59include a high-voltage DC bus29.

The communications path55may include direct data transfer lines and high-speed data transfer lines to effect communications within the control system10and effect communications between the control system10and elements of the vehicle5. The communications path55may include one or more of a direct analog connection, a digital connection, a serial peripheral interface (SPI) bus, and a high-speed communications bus18that may include a controller area network, i.e., a CAN bus.

The engine40is preferably a multi-cylinder direct fuel injection internal combustion engine that converts fuel to mechanical power through a combustion process. The engine40is equipped with a plurality of sensing devices and actuators configured to monitor operation and deliver fuel to form a combustion charge to generate torque. In one embodiment, the engine40is configured to operate as a spark-ignition engine with timing of combustion and the associated engine torque being controlled by advancing or retarding spark ignition timing. In one embodiment the engine40is configured as a spark-ignition direct-injection (SIDI) engine that operates in either a spark-ignition (SI) combustion mode or a controlled auto-ignition (HCCI) combustion mode. Alternatively, the engine40is configured to operate as a compression-ignition engine with timing of combustion and the associated engine torque controlled by advancing or retarding timing of fuel injection events. The engine40is configured to execute autostart and autostop control schemes and fuel cutoff (FCO) control schemes during ongoing operation of the vehicle system5. By way of definition, the engine40is considered to be in an OFF state when it is not being fueled and is not spinning. The engine40is considered to be in an FCO state when it is spinning but is not being fueled.

The first and second torque machines35and36preferably include multi-phase electric motor/generators electrically connected to the inverter module30that are configured to convert stored electric energy to mechanical power and convert mechanical power to electric energy that may be stored in the energy storage device25. The first and second torque machines35and36have limitations in power outputs in the form of torque and rotational speeds.

The inverter module30includes first and second inverters32and33that electrically connect to the first and second torque machines35and36, respectively. The first and second torque machines35and36interact with the respective first and second inverters32and33to convert stored electric energy to mechanical power and convert mechanical power to electric energy that may be stored in the energy storage device25. The first and second electric power inverters32and33are operative to transform high voltage DC electric power to high-voltage AC electric power and also operative to transform high voltage AC electric power to high-voltage DC electric power. Electric power originating in the first torque machine35may be transferred electrically to the energy storage device25via the inverter module30and the high-voltage bus29and to the second torque machine36via the inverter module30. Electric power originating in the second torque machine36may be transferred electrically to the energy storage device25via the inverter module30and the high-voltage bus29and to the first torque machine35via the inverter module30and the high-voltage bus29. Monitored electric power associated with the energy storage device25, the inverter module30and the high-voltage bus29include current and voltage. Monitored outputs from the first and second torque machines35and36include torques and rotational speeds.

The transmission50preferably includes one or more differential gear sets and activatable clutch components to effect torque transfer between the engine40, the first and second torque machines35and36, and an output member62that couples to the driveline60. In one embodiment the transmission50is a two-mode transmission device configured to operate in conjunction with the first and second torque machines35and36to transfer torque in one of two or more distinct gear trains referred to as Mode1and Mode2in one embodiment. The two or more distinct gear trains referred to as Mode1and Mode2may include either or both fixed gear operation and continuously variable operation.

The driveline60may include a differential gear device65that mechanically couples to an axle64or half-shaft that mechanically couples to a wheel66in one embodiment. The differential gear device65is coupled to the output member62of the hybrid powertrain system20, and transfers output power therebetween. The driveline60transfers tractive power between the transmission50and a road surface.

Mechanical power originating in the engine40may be transferred via an input member42to the first torque machine35and to the output member62via the transmission50. Mechanical power originating in the first torque machine35may be transferred to the engine40via the transmission50and the input member42, and may be transferred to the output member62via the transmission50. Mechanical power originating in the second torque machine36may be transferred via the transmission50to the output member62. Mechanical power may be transferred between the transmission50and the driveline60via the output member62.

The energy storage device25may be any energy storage device, e.g., a high-voltage battery. One exemplary energy storage device25is a high-voltage battery fabricated from a plurality of lithium-ion cells. It is appreciated that the energy storage device25may include a plurality of electrical cells, ultracapacitors, and other electrochemical devices configured to store energy and provide electric energy on-vehicle. When the energy storage device25is a high-voltage battery, it is electrically connected via the high-voltage bus29to the inverter module30that connects to the first and second torque machines35and36to transfer electric power therebetween. In one embodiment, an external connector26electrically connects to the high-voltage battery25and is connectable to an external AC power source to provide electric power for charging the high-voltage battery25.

Parameters associated with the energy storage device25include a state-of-charge (SOC), temperature, available voltage, and available battery power, each of which is monitored by the control system10. The available battery power describes battery limits that include an allowable range between maximum and minimum allowable battery powers, described as a maximum battery power (Pbat_max) and a minimum battery power (Pbat_min), respectively. It is appreciated that the battery power is measured in terms of parameters that may be regularly monitored, including e.g., battery current and battery voltage, and may be measured in kilowatts (kW). The allowable battery power limits are preferably established at threshold levels to prevent either overcharging or overdischarging of the energy storage device25that may result in damage that reduces service life thereof.

An electric power management system may be either a charge-depleting system or a charge-sustaining system. The terms charge-depleting system and charge-sustaining system define and indicate an operating strategy for using and managing stored electric power in a vehicle, e.g., an embodiment of the vehicle5during a key-on cycle. During a key-on cycle, a charge-depleting system preferentially generates output torque exclusively using the torque machines until the SOC of the energy storage device25is less than a predetermined threshold, at which time an internal combustion engine is activated to generate torque for either or both output torque and electric power generation. During a key-on cycle, a charge-sustaining system generates output torque using both the engine and the torque machines, with the intent of maintaining the SOC of the energy storage device25within a predetermined range during the entire key-on cycle, and with the intent that the SOC at the end of the key-on cycle is substantially the same as the SOC at the beginning of the key-on cycle. Magnitudes of threshold states described herein are determined and correspond to whether the electric power management system is a charge-depleting system or a charge-sustaining system.

The control system10includes a control module12that signally connects to an operator interface14. The operator interface14is used to collectively indicate a plurality of human/machine interface devices through which the vehicle operator commands operation of the vehicle5. It is appreciated that human/machine interface devices may include, e.g., an ignition switch to enable an operator to crank and start the engine40, an accelerator pedal, a brake pedal, and a transmission range selector, i.e., PRNDL. Vehicle operator commands include an operator torque request that indicates an operator request for a magnitude of output torque delivered to the driveline60to effect vehicle acceleration. It is appreciated that vehicle acceleration includes positive and negative acceleration events.

The control module12signally connects to sensing devices of each of the energy storage device25, the inverter module30, the first and second torque machines35and36, the engine40, and the transmission50. The control module12operatively connects to actuators of the inverter module30including the first and second inverters32and33, the engine40, and the transmission50either directly or via the communications bus18to control operation thereof in accordance with executed control schemes that are stored in the form of routines and calibrations, including control scheme100.

The control module12is illustrated as a single, unitary element for ease of depiction. The control module12preferably has a distributed architecture including a plurality of control modules. The functions described as being performed by the control module12may be combined into one or more control modules. Preferably a master control module device oversees and directs operations of individual control modules of the distributed architecture that are associated with the individual control modules. The individual control modules may be assigned to and may be physically located near one of the energy storage device25, the inverter module30, the first and second torque machines35and36, the engine40, and the transmission50to monitor and control operation thereof. As such, individual control modules of the control module12may directly signally connect to individual sensing devices and directly operatively connect to individual actuators, including the energy storage device25, the inverter module30, the first and second torque machines35and36, the engine40, and the transmission50to monitor and control operation thereof.

Communications between the master control module device and individual control modules of the control module12, and between the individual control modules and individual ones of the energy storage device25, the inverter module30, the first and second torque machines35and36, the engine40, and the transmission50are accomplished using the communications paths55including the communications bus18. Communicated messages may be in the form of sensor signals and actuator commands using communications protocols associated with the specific elements of the communications path55, e.g., serial communications. The communications protocols for the high-speed communications bus18preferably includes executing communications in a structured manner by periodically sending messages, e.g., on a 12.5 ms loop cycle.

Control module, module, control, controller, control unit, processor and similar terms mean any one or various combinations of one or more of Application Specific Integrated Circuit(s) (ASIC), electronic circuit(s), central processing unit(s) (preferably microprocessor(s)) and associated memory and storage (read only, programmable read only, random access, hard drive, etc.) executing one or more software or firmware programs or routines, combinational logic circuit(s), input/output circuit(s) and devices, appropriate signal conditioning and buffer circuitry, and other components to provide the described functionality. Software, firmware, programs, instructions, routines, code, algorithms and similar terms mean any controller executable instruction sets including calibrations and look-up tables. The control module has a set of control routines executed to provide the desired functions. Routines are executed, such as by a central processing unit, and are operable to monitor inputs from sensing devices and other networked control modules, and execute control and diagnostic routines to control operation of actuators. Routines may be executed at regular intervals, for example each 3.125, 6.25, 12.5, 25 and 100 milliseconds during ongoing engine and vehicle operation. Alternatively, routines may be executed in response to occurrence of an event.

FIG. 2schematically shows details of the control scheme100in flowchart form for controlling and managing output torque of a hybrid powertrain system in response to an operator torque request. The output torque of the hybrid powertrain system is generated by an internal combustion engine in conjunction with one or a plurality of torque machine(s). The control scheme100is described with reference to the vehicle5including the hybrid powertrain system20controlled by the control system10ofFIG. 1. It is appreciated that the vehicle5and hybrid powertrain system20are illustrative of one embodiment, and the concepts described herein may be applied to other hybrid powertrain systems that employ an internal combustion engine and one or a plurality of torque machine(s) to generate output torque.

FIG. 3graphically shows relative magnitude of achievable torque (%)310in relation to elapsed time305for a plurality of torque parameters described herein with reference toFIG. 2. Table 1 is provided as a key wherein the numerically labeled blocks and the corresponding functions are set forth as follows.

TABLE 1BLOCKBLOCK CONTENTS102Monitor Treq104Determine To_const in response to Treq106Determine To_min, To_max108Divide To_const into i torque breakpointsbetween a minimum achievable output torque anda maximum achievable output torque110Calculate ΔTo/Δt at each of the i torquebreakpoints for To_const112Determine OptTo(FE)114Adjust OptTo(FE) using ΔTo/Δt calculated at thei torque breakpoints116Determine To_final using OptTo(FE) adjusted byΔTo/Δt calculated at the i torque breakpoints andlimited within To_min, To_max118Control Te, Tm in response to To_final

Execution of the control scheme100includes the following steps, preferably executed in order. An operator torque request (Treq) is ongoingly monitored (102). An exemplary operator torque request is shown inFIG. 3as line320.

A constrained output torque (To_constr) is determined by subjecting the operator torque request to system constraints (104). System constraints preferably include maximum and minimum torque limits for the torque machine(s), maximum and minimum battery power limits, maximum clutch torque limits, and others. If the operator torque request320causes the hybrid powertrain system to violate any of the aforementioned system constraints, the output torque is constrained to protect component(s) associated with the constraint that may be violated, i.e., the torque machine(s), battery, and clutches. Such constraints are known. The constrained output torque (To_constr) is determined in response to the operator torque request with response time delays introduced to accommodate engine response delays including manifold delays and output torque constraints and limitations that accommodate battery power limits and system constraints. The constrained output torque is shown inFIG. 3as Line330.

The manifold delays associated with fill times and other dynamics are considered in determining the constrained output torque. An internal combustion engine is unable to respond infinitely fast due at least in part to air transport lag. It is appreciated that as an engine throttle opens or closes, there is a time delay prior to a resulting increase or decrease in crankshaft torque. Such time delays must be accounted for. System delays are introduced by saving the last20constrained driver output torque request values. In one embodiment, the system delays are a set of simple calibrations that are associated with powertrain operating conditions. One condition includes setting the time delays to zero under conditions wherein engine torque and an operator torque request must be delivered to respond to transient events occurring in the system, such as during transmission gear shift events, engine autostarts and engine autostops. One condition includes setting the time delays to calibrated values when the torque machine(s) is providing torque assistance. One condition includes setting the time delays to calibrated values when the torque machine(s) is not providing torque assistance and the output torque is being modified in response to an optimum battery power.

Minimum and maximum output torque limits associated with the operator torque request are determined (To_min, To_max) (106). Exemplary minimum and maximum output torque limits are shown inFIG. 3as lines322and324, respectively. The minimum and maximum output torque limits are employed to limit output torque to achieve a preferred battery power usage. Initially, the minimum and maximum output torque limits are calculated by adding and subtracting torque offsets from a delayed version of the constrained operator torque request. These torque offsets are preferably a set of calibrations based on output speed and certain powertrain conditions. One condition includes setting the torque offsets to zero under conditions wherein engine torque and an operator torque request must be delivered in response to transient events occurring in the system, such as during transmission gear shift events, engine autostarts and engine autostops. One condition includes setting the torque offsets to calibrated values when the torque machine(s) is providing torque assistance. One condition includes setting the torque offsets to calibrated values when the torque machine(s) is not providing torque assistance and the output torque is being modified in response to an optimum battery power. During transitions, rate-limits are applied to the torque offsets in order to make transition less harsh from a drivability perspective.

The constrained output torque is analyzed with reference to magnitude of achievable output torque, preferably on a scale of 0% to 100% of the achievable output torque. This includes dividing the output torque into a quantity of i torque breakpoints between a minimum achievable output torque and a maximum achievable output torque (108). The minimum and maximum achievable output torques are defined with reference to the capability of the powertrain system20. The torque breakpoints are created by selecting specific torque levels between achievable output torques of 0% and 100%, with one of the i torque breakpoints selected every 10% of the achievable output torque, i.e., at 10%, 20%, 30% . . . 90%. Example torque breakpoints are shown as iso-torque lines312,314,316, and318corresponding to achievable output torque levels of 20%, 40%, 60% and 80% inFIG. 3. Other breakpoints may be selected.

The constrained output torque is analyzed, including calculating a time-rate change in the constrained output torque at each of the i torque breakpoints (110). This preferably includes determining a change in torque in relation to a change in time for each of the i breakpoints for an increasing torque request (Δinc(i)) and for a decreasing torque request (Δdec(i)). These are shown as elements332,334, and336corresponding to achievable torque levels of 40%, 60% and 80% for the increasing torque request inFIG. 3, and elements331,333, and335correspond to achievable torque levels of 80%, 60%, and 40% for the decreasing torque request inFIG. 3.

A desired output torque in response to the operator torque request (OptTo(FE)) is determined and is shown as line340inFIG. 3(112). In one embodiment, the desired output torque in response to the operator torque request is an output torque associated with an optimum fuel economy for operating the hybrid powertrain system20in response to the operator torque request. A desired output torque associated with an operating parameter other than an optimum fuel economy for operating the hybrid powertrain system20in response to the operator torque request may be used with similar effect. The output torque associated with an optimum fuel economy corresponds to an optimum battery power for operating the hybrid powertrain system20in response to the operator torque request. In one embodiment, the optimum battery power is a minimum battery power that is required to achieve the output torque, and accounts for converting between mechanical torque and electric power in terms of efficiency and power loss without considering other system constraints such as clutch limits.

The desired output torque in response to the operator torque request is adjusted at each of the i breakpoints with the corresponding change in the constrained output torque in relation to the change in time (114). The adjustments including the corresponding changes in the constrained output torque in relation to the change in time are shown as elements352,354, and356, which correspond to torque levels of 40%, 60% and 80% for the increasing torque request inFIG. 3, and shown as elements351,353, and355, which correspond to torque levels of 80%, 60%, and 40% for the decreasing torque request inFIG. 3. Thus, the constrained output torque is shaped.

A final torque command (To_final) is determined, and includes the output torque associated with optimum fuel economy for operating the hybrid powertrain system20in response to the operator torque request adjusted at each of the i breakpoints with the corresponding change in the constrained output torque in relation to the change in time, rate-limited within the minimum and maximum output torque limits (116). The final output torque command including the operator torque request that has been constrained, shaped, and rate-limited, is shown as line350inFIG. 3.

Torque commands for the engine (Te) and the electric machine(s) (Tm) are generated using torque distribution control schemes in response to the final torque command and used to control operation of the hybrid powertrain system20(118).

By way of definition, maximum levels for battery power and current are associated with electrical discharging, and minimum levels for battery power and current are associated with electrical charging.