Regenerative braking methods for a hybrid locomotive

• US 20060076171A1
• Filed: 08/09/2005
• Published: 04/13/2006
• Est. Priority Date: 08/09/2004
• Status: Active Grant

• Current Assignee: Railpower, LLC
• Original Assignee: Railpower, LLC
• Inventors: Bailey, Ronald B., Donnelly, Frank Wegner, Tarnow, Andrew C., Watson, John David
• Granted Patent: US 7,940,016 B2
• Time in Patent Office: Days
• US Class Current: 180/65.225
• CPC Class Codes: B60L 15/38 with automatic control
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2220/12 Induction machines
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/18 Reluctance machines
• CPC Class Codes: B60L 2220/20 DC electrical machines
• CPC Class Codes: B60L 2260/28 Four wheel or all wheel drive
• CPC Class Codes: B60L 50/30 using propulsion power stored mechanically, e.g. in fly-wheels
• CPC Class Codes: B60L 50/40 using propulsion power supplied by capacitors
• CPC Class Codes: B60L 50/53 in combination with an external power supply, e.g. from overhead contact lines
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 53/57 Charging stations without connection to power networks
• CPC Class Codes: B60L 7/04 for vehicles propelled by dc motors
• CPC Class Codes: B60L 7/06 for vehicles propelled by ac motors
• CPC Class Codes: B60L 7/12 for vehicles propelled by dc motors
• CPC Class Codes: B60L 7/14 for vehicles propelled by ac motors
• CPC Class Codes: B60L 7/18 Controlling the braking effect B60L7/12, B60L7/14, B60L7/16 take precedence
• CPC Class Codes: B60L 9/00 Electric propulsion with power supply external to the vehicle electric propulsion for monorail vehicles, suspension vehicles or rack railways B60L13/00; in combination with batteries or fuel cells within the vehicle B60L50/53
• 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 10/92 : Energy efficient charging or discharging systems for batteries, ultracapacitors, supercapacitors or double-layer capacitors specially adapted for vehicles
• CPC Class Codes: Y02T 90/12 : Electric charging stations

Abstract

The present invention relates generally to regenerative braking methods for a hybrid vehicle such as a hybrid locomotive, which are compatible with optimum management of a large battery pack energy storage system. Four methods for recovering energy from regenerative braking and for transferring this energy to an energy storage systems are disclosed. These methods may also be used with battery operated vehicles.

Claims

1. An off road vehicle, comprising:

(a) at least one motor operable to displace the off road vehicle and generate electrical energy when the vehicle is decelerating;

(b) an energy storage system operable to store electrical energy and provide electrical energy to the at least one motor;

(c) a prime power source operable to provide electrical energy to at least one of the energy storage system and at least one motor;

(d) a direct current (DC) bus interconnecting the at least one motor, energy storage system, and prime power source; and

(e) a pulse sequencer operable to provide, to the energy storage system, pulsed electrical energy generated by a selected motor.

2. The off road vehicle of claim 1, wherein the at least one motor is configured, in a braking mode, to alternately store electrical energy in and discharge energy from a winding of the at least one motor, wherein electrical energy generated by first and second motors is pulsed to provide first and second sets of pulses, respectively, and wherein the first and second sets of pulses are temporally offset from one another.

3. The off road vehicle of claim 2, wherein the winding comprises a field coil and an armature coil, the field and armature coils being connected in series, and wherein the at least one motor comprises a switchable contact reverser operable to switch electrical energy in opposite directions of flow through the one of the armature and field coils while maintaining a same flow direction in the other of the armature and field coils.

4. The off road vehicle of claim 2, wherein the winding comprises a field coil and an armature coil and further comprising:

an auxiliary power supply providing, in the braking mode, a field current to the field coil of the at least one motor, wherein, in a motoring mode, electrical energy flows through the armature and field coils in a common direction, wherein, in the braking mode, electrical energy generated by the at least one motor flows through the armature and field coils in different directions, and wherein the field current is opposite to the direction of flow of the electrical energy generated by the at least one motor.

5. The off road vehicle of claim 3, further comprising a power control apparatus, the power control apparatus controlling electrical energy in the at least one motor, wherein, in a motoring mode, electrical energy flows in a first direction through at least one of the armature and field coils, wherein, in a braking mode, electrical energy flows in a second opposite direction through the at least one of the armature and field coils, and wherein, in a first braking mode configuration, electrical energy flows through a free wheeling path and is substantially blocked from flowing to the energy storage system and, in a second braking mode configuration, electrical energy flows is permitted to flow to the energy storage system.

6. The off road vehicle of claim 3, wherein, in the motoring mode, a voltage of the at least one motor is provided by the equation:

7. The off road vehicle of claim 6, wherein, in the braking mode, a voltage of the at least one motor is provided by the equation:

8. An off road vehicle, comprising:

(a) a plurality of motors to displace the off road vehicle and generate electrical energy when the vehicle is decelerating, each of the plurality of motors having an armature and a field coil;

(b) an energy storage system operable to store electrical energy and provide electrical energy to the at least one motor;

(c) a prime power source operable to provide electrical energy to at least one of the energy storage system and at least one motor;

(d) a direct current (DC) bus interconnecting the at least one motor, energy storage system, and prime power source; and

(e) a plurality of power control apparatuses, wherein the field coils of the motors are connected in series, wherein the armature coils are connected in parallel to the field coils, and wherein a field coil power control apparatus varies a field current passing through series-connected field coils to control an armature current passing through the armature coils during vehicular deceleration.

9. The off road vehicle of claim 8, wherein each of the armature coils are connected in series and each has a corresponding armature power control apparatus and the armature power control apparatuses are different from the field coil power control apparatus.

10. The off road vehicle of claim 8, wherein at least one of the following is true:

(I) in a motoring mode, the plurality of traction motors are connected in parallel relative to the DC bus and are at a lower voltage than the energy storage system and, in a braking mode, at least two of the traction motors are connected in series relative to the DC bus, whereby the motors have a higher voltage than a voltage of the energy storage system so that electrical energy provided by the series-connected motors is provided to the energy storage system;

(ii) in a motoring mode, the traction motors are at a lower voltage than the energy storage system, and, in a braking mode, a traction motor boost circuit steps up an output voltage of at least one of the traction motors, whereby the stepped up output voltage is higher than the voltage of the energy storage system so that electrical energy provided by the motors is provided to the energy storage system;

(iii) the energy storage system comprises a plurality of battery modules, wherein, in a motoring mode, the plurality of battery modules are connected in series and are at a higher voltage than the at least one motor, and, in a braking mode, at least two of the plurality of battery modules are connected in parallel, whereby the voltage of the parallel-connected battery modules is lower than an output voltage of the at least one motor; and

(iv) an energy storage system boost circuit, positioned between the DC bus and the energy storage system, wherein, in a braking mode, the energy storage system boost circuit steps up an input voltage to the energy storage system, whereby the stepped up input voltage is higher than the voltage of the DC bus and the voltage of the energy storage system so that electrical energy provided by the motors is provided to the energy storage system.

11. The off road vehicle of claim 10, wherein (I) is true.

12. The off road vehicle of claim 11, wherein electrical energy flows through the field coils is in the same direction in both the motoring and braking modes, wherein at least one power control apparatus is interposed between the motors and the DC bus, and wherein the interposed power control apparatus maintains a charging current flow to the 5 energy storage system below a first predetermined level, a voltage of the energy storage system below a second predetermined level, and a state of charge of the energy storage system below a third predetermined level.

13. The off road vehicle of claim 11, wherein a first pair of motors is connected in series, a second pair of motors is connected in series, and the first and second pairs of motors are connected in parallel.

14. The off road vehicle of claim 10, wherein (ii) is true.

15. The off road vehicle of claim 14, wherein the boost circuit comprises an energy storage inductor, an energy storage capacitor, a diode, and a switch, wherein the switch is connected in parallel with the energy storage inductor, and diode, and wherein the energy storage capacitor is connected in series with the energy storage inductor, diode, and switch.

16. The off road vehicle of claim 15, wherein, in a motoring mode, the switch is closed to bypass the diode and energy storage inductor and, in a braking mode, the switch is opened to direct electrical energy through the diode and energy storage inductor.

17. The off road vehicle of claim 8, wherein the field coil power control apparatus, in the braking mode, varies the flow of electrical energy through the field coils to vary a voltage associated with the motors and an amount of energy provided by the motors to the energy storage system.

18. The off road vehicle of claim 10, wherein (iii) is true.

19. The off road vehicle of claim 18, wherein, in the braking mode, a first set of battery modules are series connected and a second set of battery modules are parallel connected.

20. The off road vehicle of claim 19, wherein the first set of battery modules comprises first and second series connected battery modules and third and fourth series connected battery modules and wherein the second set of battery modules comprises the first and second series connected battery modules connected in parallel with the third and fourth series connected battery modules.

21. The off road vehicle of claim 10, wherein (iv) is true.

22. A method for operating an off road vehicle, the off road vehicle including a plurality of traction motors to displace the off road vehicle and generate electrical energy when the vehicle is decelerating, an energy storage system to store electrical energy and provide electrical energy to the motors, a prime power source to provide electrical energy to at least one of the energy storage system and at least one motor, and a direct current (DC) bus interconnecting the at least one motor, energy storage system, and prime power source, the method comprising:

(a) decelerating the vehicle; and

(b) while the vehicle is decelerating, the energy storage system receiving, in discrete time intervals, electrical energy generated by a selected motor.

23. The method of claim 22, wherein at least one motor is configured, in a braking mode, to alternately store electrical energy in and discharge energy from a winding of the at least one motor, whereby electrical energy provided by the motor is provided discontinuously to the energy storage system by the at least one motor.

24. The method of claim 23, wherein the winding comprises a field coil and an armature coil, the field and armature coils being connected in series, and wherein the at least one motor comprises a switchable contact reverser operable to switch electrical energy in opposite directions of flow through the one of the armature and field coils while maintaining a same flow direction in the other of the armature and field coils.

25. The method of claim 22, wherein electrical energy generated by first and second motors is pulsed to provide first and second sets of pulses, respectively, and wherein the first and second sets of pulses are temporally offset from one another.

26. The method of claim 22, further comprising a power control apparatus, the power control apparatus controlling electrical energy in the at least one motor, wherein, in a motoring mode, electrical energy flows in a first direction through at least one of the armature and field coils, wherein, in a braking mode, electrical energy flows in a second 5 opposite direction through the at least one of the armature and field coils, and wherein, in a first braking mode configuration, electrical energy flows through a free wheeling path and is substantially blocked from flowing to the energy storage system and, in a second braking mode configuration, electrical energy flows is permitted to flow to the energy storage system.

27. The method of claim 22, wherein, in the motoring mode, a voltage of at least one motor is provided by the equation:

28. The method of claim 27, wherein, in the braking mode, a voltage of the at least one motor is provided by the equation:

29. The method of claim 26, further comprising:

when in the first braking configuration, determining a magnitude of the electrical energy flowing through the free wheeling path;

when the determined magnitude is at least a second predetermined level but is less than a first predetermined level, switching to the second decelerating configuration;

when the determined magnitude is no more than a third predetermined level, switching to the first braking configuration, wherein the first predetermined level is more than the second predetermined level and the second predetermined level is more than the third predetermined level.

30. The method of claim 29, wherein the at least one motor comprises a plurality of traction motors and further comprising:

determining a power capacity of the energy storage system at each of a number of successive time intervals;

determining an effective pulse width to achieve a desired energy flow from each motor to control the energy flow to the energy storage system; and

sequentially pulsing power from each motor to the energy storage system for a duration necessary to achieve a selected energy flow to the energy storage system during each of the successive time intervals.

31. The method of claim 30, wherein power pulses from each motor are increased by increasing pulse width while maintaining a pulse frequency substantially constant.

32. The method of claim 30, wherein first and second motors provide energy to the energy storage system at different times by starting a first power pulse from the first motor at an offset from a second temporally adjacent power pulse from the second motor.

33. The method of claim 32, wherein the first and second power pulses are nonoverlapping, whereby the first and second power pulses are not additive when inputted into the energy storage system.

34. The method of claim 29, wherein the at least one motor comprises a plurality of traction motors and further comprising:

determining a power capacity of the power dissipating circuit at each of a number of successive time intervals;

determining an effective pulse width to achieve a desired energy flow from each motor to control the energy flow to the power dissipating circuit; and

sequentially pulsing power from each motor to the power dissipating circuit for a duration necessary to achieve a selected energy flow to the power dissipating circuit during each of the successive time intervals.

35. A method, comprising:

(a) providing an off road vehicle comprising;

(i) a plurality of motors to displace the off road vehicle and generate electrical energy when the vehicle is decelerating, each of the plurality of motors having an armature and a field coil, the field coils of at least first and second motors being connected in series;

(ii) an energy storage system operable to store electrical energy and provide electrical energy to the at least one motor;

(iii) a prime power source operable to provide electrical energy to at least one of the energy storage system and at least one motor;

(iv) a direct current (DC) bus interconnecting the at least one motor, energy storage system, and prime power source; and

(v) a plurality of power control apparatuses; and

(b) when the vehicle is decelerating, varying a field current passing through series-connected field coils to control an armature current passing through the armature coils during vehicular deceleration.

36. The method of claim 35, wherein the field coils of the motors are connected in series, wherein the armature coils are connected in parallel to one another and to the field coils, and wherein a field coil power control apparatus varies the field current.

37. The method of claim 35, wherein, in step (b), one or more the following steps is performed:

(i) switching at least two of the traction motors from parallel to series connection relative to the DC bus, whereby the series-connected motors have a higher voltage than a voltage of the energy storage system so that electrical energy provided by the series-connected motors is provided to the energy storage system;

(ii) stepping up an output voltage of at least one of the traction motors, whereby the stepped up output voltage is higher than the voltage of the energy storage system so that electrical energy provided by the series-connected motors is provided to the energy storage system;

(iii) switching at least two battery modules of the energy storage system from series to parallel connection, whereby the series connected battery modules are at a higher voltage than one or more of the motors and the parallel connected battery modules are at a lower voltage than one or more of the motors; and

(iv) stepping up an input voltage from the DC bus to the energy storage system, whereby the stepped up input voltage is higher than the voltage of the DC bus and the voltage of the energy storage system so that electrical energy provided by the motors is provided to the energy storage system.

38. The method of claim 37, wherein step (I) is performed.

39. The method of claim 38, wherein each of the motors comprises a field coil and an armature coil, wherein the field coil of the series-connected motors are connected in series and armature coils are connected in parallel to one another and the series-connected field coils.

40. The method of claim 39, wherein the series-connected motors are controlled by a common excitation chopper circuit, wherein electrical energy flow through the field coils is in the same direction when the vehicle is both accelerating and decelerating, wherein at least one power control apparatus is interposed between the 5 motors and the DC bus, and wherein the chopper circuit maintains a charging energy flow to the energy storage system below a first predetermined level, a voltage of the energy storage system below a second predetermined level, and a state of charge of the energy storage system below a third predetermined level.

41. The method of claim 38, wherein a first pair of motors is connected in series, a second pair of motors is connected in series, and the first and second pairs of motors are connected in parallel.

42. The method of claim 37, wherein step (ii) is performed.

43. The method of claim 42, wherein the output voltage is stepped up by a boost circuit, the boost circuit comprising an energy storage inductor, an energy storage capacitor, a diode, and a switch, wherein the switch is connected in parallel with the energy storage inductor and diode, and wherein the energy storage capacitor is connected in series with the energy storage inductor, diode, and switch.

44. The method of claim 43, wherein, when the vehicle is accelerating, the switch is closed to bypass the diode and energy storage inductor and, when decelerating, the switch is opened to direct electrical energy through the diode and energy storage inductor.

45. The method of claim 44, wherein each traction motor has a corresponding field coil and armature coil, wherein the field coils are connected in series with one another, wherein the series-connected field coils are connected in parallel with one another and with the armature coils, wherein the armature coils are connected in parallel with one another, and wherein the vehicle further includes a chopper circuit and further comprising when the vehicle is decelerating:

varying the flow of electrical energy through the field coils to vary a voltage associated with the motors and an amount of energy provided by the motors to the energy storage system.

46. The method of claim 37, wherein step (iii) is performed.

47. The method of claim 46, wherein, when the vehicle is decelerating, a first set of battery modules are series connected and a second set of battery modules are parallel connected.

48. The method of claim 47, wherein the first set of battery modules comprises first and second series connected battery modules and third and fourth series connected battery modules and wherein the second set of battery modules comprises the first and second series connected battery modules connected in parallel with the third and fourth series connected battery modules.

49. The method of claim 37, wherein step (iv) is performed.

50. A method, comprising:

(a) providing an off road vehicle comprising;

(i) a plurality of motors to displace the off road vehicle and generate electrical energy when the vehicle is decelerating, each of the plurality of motors having an armature coil and a field coil, the field coils of at least first and second motors being connected in series;

(ii) an energy storage system operable to store electrical energy and provide electrical energy to the at least one motor;

(iii) a prime power source operable to provide electrical energy to at least one of the energy storage system and at least one motor;

(iv) a direct current (DC) bus interconnecting the at least one motor, energy storage system, and prime power source; and

(v) a plurality of power control apparatuses; and

(b) when the vehicle is decelerating, allowing at least a portion of the electrical energy generated by the motors to flow back to an alternator of the prime power source, wherein, in response to the flow of electrical energy, the alternator turns a crank shaft of the prime power source, thereby dissipating electrical energy.

51. The method of claim 50, further comprising:

(c) when step (b) is not performed, directing the electrical energy generated by the motors to the energy storage system;

(d) when at least one of a state of charge of the energy storage system, a rate of charge of the energy storage system, and an electrical energy level flowing into the energy storage system exceeds a selected threshold, thereafter performing step (b).

52. The method of claim 50, further comprising:

(c) when step (b) is not performed, directing at least some of the electrical energy generated by the motors to a dissipating resistive grid;

(d) when the dissipating resistive grid has a temperature above a selected threshold, thereafter performing step (b).

53. A method for controlling an off road vehicle, comprising:

(a) when the vehicle is decelerating, determining a current level in each of a plurality of armature windings when each of a plurality of traction motors is in a free-wheeling mode, the current being generated by the traction motors;

(b) when each of the measured current levels does not exceed a first predetermined level and when each of the measured current levels exceeds a second predetermined level less than the first predetermined level, switching from the free-wheeling mode to a regeneration mode in which electrical energy is provided by the traction motors to an energy storage system; and

(c) when the current level is less than a third predetermined level less than the second predetermined level, switching back to the free-wheeling mode.

54. The method of claim 53, further comprising:

(d) determining a power capacity of the energy storage system at each of a number of successive time intervals;

(e) determining a necessary effective power pulse width to achieve a desired flow of electrical energy from each motor so as to apportion an energy flow between the energy storage system and a dissipating device; and

(f) sequentially pulsing power from each motor to at least one of the energy storage system and dissipating device to achieve the determined effective power pulse width over each of the successive time intervals.

55. The method of claim 54, wherein power pulses from each motor are increased by increasing pulse width while maintaining pulse frequency substantially constant.

56. The method of claim 54, wherein electrical energy provided to the energy storage system is input at different times from different motors by starting power pulses from each motor at an offset relative to temporally adjacent power pulses from other motors.

57. The method of claim 56, wherein the offsets are substantially maximized.

58. The method of claim 53, further comprising:

(d) determining a speed of the vehicle;

(e) determining a Direct Current (DC) bus voltage of a bus interconnecting the energy storage system and motors;

(f) determining a voltage of the energy storage system and a State-Of-Charge (SOC) of the energy storage system;

(g) determining whether at least one of the energy storage system voltage and SOC is below a fourth predetermined level;

(h) when the at least one of the energy storage system voltage and SOC is not below the fourth predetermined level, not performing step (b) and decreasing an excitation current to each of the traction motors; and

(i) when the at least one of the energy storage system voltage and SOC is not below the fourth predetermined level, performing step (b).