Hybrid device with segmented waveform converter

• US 10,148,202 B2
• Filed: 10/06/2016
• Issued: 12/04/2018
• Est. Priority Date: 10/16/2015
• Status: Active Grant

• Current Assignee: Discovery Energy LLC
• Original Assignee: Kohler Company
• Inventors: Frampton, Isaac S., Larson, Adam, Rotter, Terrence, Baumann, Todd
• Primary Examiner(s): Gonzalez R., Julio C.
• Application Number:
  US15/287,485
• Publication Number:
  US 20170110991A1
• Time in Patent Office: 789 Days
• Field of Search: 322 59, 322 44, 322 28, 322 89, 322 7, 180 6526, 180 65512, 290 40 C, 290 40 R, 56 148, 56 147, 56 101
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 1/20 Energy regeneration from auxiliary equipment
• CPC Class Codes: H02M 5/271 from a three phase input voltage
• CPC Class Codes: H02P 27/08 with pulse width modulation
• CPC Class Codes: H02P 27/16 using ac to ac converters without intermediate conversion to dc H02P27/05 takes precedence
• CPC Class Codes: H02P 5/74 controlling two or more ac dynamo-electric motors H02P5/46, H02P5/60 take precedence
• CPC Class Codes: H02P 6/16 Circuit arrangements for detecting position
• CPC Class Codes: H02P 9/00 Arrangements for controlling electric generators for the purpose of obtaining a desired output
• CPC Class Codes: H02P 9/14 by variation of field H02P9/08, H02P9/10 take precedence

Abstract

An apparatus includes a controlled field alternator or utility source of electrical power, a segmented waveform converter, and a controller. The source of electrical power is configured to generate a polyphase signal. The synchronous inverter includes multiple switches connected between the polyphase signal of the source of electrical power and an output filter. The controller is configured to provide a control signal for the switches based on measured electrical quantities associated with the output filter and may provide a field control signal to the controlled field alternator. The apparatus may be applied to a vehicle, a lawnmower, a zero turn radius lawnmower, or another type of machine.

Claims

1. An apparatus comprising:

an input coupled to a controlled field alternator and configured to receive a polyphase signal from the controlled field alternator;

a segmented waveform converter including a plurality of switches connected to the polyphase signal of the controlled field alternator and generate a drive signal for at least one motor;

an output filter circuit configured to modify the drive signal based on at least one setting for the motor; and

a controller configured to generate a control signal to set states of the plurality of switches to generate the drive signal for the at least one motor, wherein the control signal is based on sensor data,

wherein the sensor data includes data generated by a position sensor for a steering device for a vehicle including the at least one motor.

2. The apparatus of claim 1, wherein when the controller is configured to identify a position of the steering device from the sensor data.

3. The apparatus of claim 2, wherein the controller identifies a turn in a direction of an inner wheel and generates a nominal adjustment for the at least one motor coupled to the inner wheel.

4. The apparatus of claim 1, wherein the sensor data includes orientation data and the control signal sets a speed for the at least one motor according to the orientation data.

5. The apparatus of claim 4, wherein when the orientation data indicates uphill travel, the speed for the at least one motor is increased and when the orientation data indicates downhill travel, the speed for the at least one motor is decreased.

6. The apparatus of claim 4, wherein the controller is configured to identify a user input for forward travel and the at least one motor includes a downhill motor and an uphill motor, the speed of the downhill motor is increased relative to the speed of the uphill motor in response to the user input for forward travel.

7. The apparatus of claim 1, wherein the at least one setting is based on physical characteristics of the motor.

8. The apparatus of claim 7, wherein the physical characteristics of the motor are associated with harmonics or resonance of the motor.

9. The apparatus of claim 1, wherein the control signal depends on a load on the at least one motor at a response time that is less than a frequency of the drive signal.

10. The apparatus of claim 1, wherein the at least one setting includes an optimal operating characteristic of the at least one motor and the control signal is based on a charging cycle for a battery and the optimal operating characteristic of the at least one motor.

11. The apparatus of claim 1, wherein the controller is configured to detect an electrical configuration of the segmented waveform converter included in the at least one setting, wherein the electrical configuration is single phase or multi-phase.

12. The apparatus of claim 11, wherein the controller is configured to adjust gains of the segmented waveform converter through the states of the plurality of switches in the control signal in response to the electrical configuration of the segmented waveform converter or a load characterization of a load of the segmented waveform converter.

13. The apparatus of claim 1, wherein the controller is configured to generate a communication signal and modulate the communication signal on the drive signal.

14. The apparatus of claim 13, further comprising:

a communication interface configured to send the drive signal including the communication signal to one or more other controllers.

15. An assembly including:

an engine;

a controlled field alternator;

at least one motor;

an input coupled to the controlled field alternator and configured to receive a polyphase signal;

a segmented waveform converter including a plurality of switches connected to the polyphase signal of the controlled field alternator and generate a drive signal for the at least one motor;

an output filter circuit configured to modify the drive signal based on at least one setting for the motor; and

a controller configured to generate a control signal to set states of the plurality of switches to generate the drive signal for the at least one motor, wherein the control signal is based on sensor data,

wherein the sensor data includes data generated by a position sensor for a steering device for a vehicle including the at least one motor.

16. The assembly of claim 15, further comprising:

a mechanical link to a user input level for receiving the at least one setting for the motor.

17. A method comprising:

receiving, at a controller, a feedback signal from a controlled field alternator;

generating, at the controller, a drive signal for at least one motor at a segmented waveform converter including a plurality of switches connected to the feedback signal of the controlled field alternator, wherein a control signal sets states of the plurality of switches to generate the drive signal for the at least one motor, wherein the control signal is based on sensor data generated by a position sensor for a steering device for a vehicle including the at least one motor; and

modifying, at an output filter circuit, the drive signal based on at least one setting for the at least one motor.

18. An apparatus comprising:

an input coupled to a controlled field alternator and configured to receive a polyphase signal from the controlled field alternator;

a segmented waveform converter including a plurality of switches connected to the polyphase signal of the controlled field alternator and generate a drive signal for at least one motor;

an output filter circuit configured to modify the drive signal based on at least one setting for the motor; and

a controller configured to generate a control signal to set states of the plurality of switches to generate the drive signal for the at least one motor, wherein the control signal is based on sensor data, wherein the sensor data includes orientation data and the control setting sets a speed for the at least one motor according to the orientation data, and wherein when the orientation data indicates travel perpendicular to an incline and the at least one motor includes a downhill motor and an uphill motor, the speed of the downhill motor is increased relative to the speed of the uphill motor.