Electric drive system having DC bus voltage control

• US 20050263329A1
• Filed: 05/25/2004
• Published: 12/01/2005
• Est. Priority Date: 05/25/2004
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Sopko, Thomas M., Kuras, Brian D.
• Granted Patent: US 7,378,808 B2
• Time in Patent Office: Days
• US Class Current: 180/65.100
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2220/18 Reluctance machines
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/26 for electrical energy, e.g. batteries or capacitors
• CPC Class Codes: B60W 20/00 Control systems specially adapted for hybrid vehicles hybrid vehicle design, B60K6/00; electric vehicles B60L
• CPC Class Codes: B60W 20/10 Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60W 2300/17 Construction vehicles, e.g. graders, excavators
• CPC Class Codes: H01M 10/482 for several batteries or cells simultaneously or sequentially
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

An electric drive system has a power source and a generator operatively connected to the power source. The generator is configured to produce a power output. The electric drive system also has at least one capacitor configured to store a supply of power. The electric drive system further has a common bus configured to direct the power output to the capacitor. The electric drive system also has at least one motor configured to receive power from the common bus. The electric drive system additionally has a controller in communication with the at least one motor and the generator. The controller is configured to receive at least one input associated with the motor, to determine a requested motor power as a function of the at least one input, and to operate the generator to produce the requested motor power.

Claims

1. An electric drive system, comprising:

a power source;

a generator operatively connected to the power source and configured to produce a power output;

at least one capacitor configured to store a supply of power;

a common bus configured to direct the power output to the capacitor;

at least one motor configured to receive power from the common bus; and

a controller in communication with the at least one motor and the generator, the controller configured to receive at least one input associated with the motor, to determine a requested motor power as a function of the at least one input, and to operate the generator to produce the requested motor power.

2. The electric drive system of claim 1, wherein the at least one input is related to at least one of a motor speed command and a motor torque command.

3. The electric drive system of claim 1, further including a speed sensor associated with the at least one motor and in communication with the controller, wherein the at least one input is a signal generated by the speed sensor indicative of motor speed.

4. The electric drive system of claim 3, wherein the controller includes a memory having stored therein motor efficiency offset values related to the speed of the at least one motor, wherein the requested motor power is further determined as a function of the motor efficiency offset values.

5. The electric drive system of claim 1, further including:

a voltage sensor associated with the at least one motor and in communication with the controller; and

a current sensor associated with the at least one motor and in communication with the controller,

wherein the at least one input is a related to signals generated by the voltage sensor and the current sensor indicative of a motor voltage level and a motor current level.

6. The electric drive system of claim 1, further including a torque sensor associated with the at least one motor and in communication with the controller, wherein the at least one input is a signal generated by the torque sensor indicative of a motor torque.

7. The electric drive system of claim 1, further including a voltage sensor configured to measure a voltage level of the common bus, wherein the at least one capacitor has a desired voltage range including an upper voltage limit and a lower voltage limit and the controller operates the generator to increase a power output rate when the voltage level drops below the lower voltage limit and to decrease a power output rate when the voltage level exceeds the upper voltage limit.

8. The electric drive system of claim 1, further including a resistive grid circuit configured to dissipate power from the common bus when a reduction in requested motor power is determined.

9. The electric drive system of claim 1, further including a resistive grid circuit configured to dissipate power from the common bus when a reduction in the requested motor power is determined and a speed of the power source exceeds the maximum speed limit.

10. A method of operating an electric drive, comprising:

operating a power source connected to a generator to produce a power output;

storing power within at least one capacitor connected to the generator via a common bus;

directing power from the common bus to at least one motor;

receiving at least one input associated with the at least one motor;

determining a requested motor power as a function of the at least one input; and

operating the generator to produce the requested motor power.

11. The method of claim 10, further including monitoring at least one of a desired motor speed command and a desired motor torque command, wherein the at least one input is related to the at least one of a desired motor speed command and a desired motor torque command.

12. The method of claim 10, further including measuring a speed associated with the at least one motor, wherein the at least one input is related to the measured speed.

13. The method of claim 12, further including comparing the measured speed with a lookup table stored on a memory associated with the electric drive to determine a motor efficiency offset value, wherein the requested motor power is further determined as a function of the motor efficiency offset value.

14. The method of claim 10, further including measuring a voltage and a current associated with the at least one motor, wherein the at least one input is determined as a function of the measured voltage and current.

15. The method of claim 10, further including measuring a torque associated with the at least one motor, wherein the at least one input is related to the measured torque.

16. The method of claim 10, further including comparing a voltage level of the common bus to a desired voltage range of the at least one capacitor;

and

operating the generator to increase a power output rate when the voltage level of the common bus drops below a lower voltage limit of the desired voltage range and to decrease a power output rate when the voltage level of the common bus exceeds an upper voltage limit of the desired voltage range.

17. The method of claim 10, further including comparing a voltage level of the common bus to a desired voltage range of the at least one capacitor;

and

dissipating power from the common bus with a resistive grid when the voltage level of the common bus exceeds an upper voltage limit of the desired voltage range.

18. The method of claim 10, wherein operating the generator includes causing the generator to motor the power source to dissipate power generated by the at least one motor.

19. The method of claim 10, further including comparing a voltage level of the common bus to a desired voltage range of the at least one capacitor;

and

dissipating power from the common bus with a resistive grid when the voltage level of the common bus exceeds an upper voltage limit of the desired voltage range and a speed of the power source exceeds a maximum speed limit.

20. A work machine, comprising:

a housing;

at least one traction device configured to support the housing;

an electric drive system, including;

a power source;

a generator operatively connected to the power source and configured to produce a power output;

at least one capacitor configured to store a supply of power;

a common bus configured to direct the power output to the capacitor;

at least one motor configured to receive power from the common bus and to drive the at least one traction device; and

a controller in communication with the at least one motor and the generator, the controller configured to receive at least one input associated with the motor, to determine a requested motor power as a function of the at least one input, and to operate the generator to produce the requested motor power.

21. The work machine of claim 20, wherein the at least one input is related to at least one of a motor speed command and a motor torque command.

22. The work machine of claim 20, further including a speed sensor associated with the at least one motor and in communication with the controller, wherein the at least one input is a signal generated by the speed sensor indicative of motor speed.

23. The work machine of claim 22, wherein the controller includes a memory having stored therein motor efficiency offset values related to the speed of the at least one motor, wherein the requested motor power is further determined as a function of the motor efficiency offset values.

24. The work machine of claim 20, further including a voltage sensor configured to measure a voltage level of the common bus, wherein the at least one capacitor has a desired voltage range including an upper voltage limit and a lower voltage limit and the controller operates the generator to increase a power output rate when the voltage level drops below the lower voltage limit and to decrease power output rate when the voltage level exceeds the upper voltage limit.

25. The work machine of claim 20, further including a resistive grid circuit configured to dissipate power from the common bus when a reduction in requested motor power is determined.