ELECTRIC DRIVE VEHICLE RETROFIT SYSTEM AND ASSOCIATED METHOD

• US 20080276825A1
• Filed: 05/07/2007
• Published: 11/13/2008
• Est. Priority Date: 05/07/2007
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Salasoo, Lembit, Kumar, Ajith Kuttannair, King, Robert Dean
• Granted Patent: US 8,001,906 B2
• Time in Patent Office: Days
• US Class Current: 105/50
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: B60K 6/32 characterised by the fuel cells
• CPC Class Codes: B60K 6/405 Housings
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2270/40 related to technical updates when adding new parts or software
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• 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 2510/083 Torque
• CPC Class Codes: H01M 10/052 : Li-accumulators
• CPC Class Codes: H01M 10/345 : Gastight metal hydride accumulators
• CPC Class Codes: H01M 10/44 : Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/615 : Heating or keeping warm
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/633 : characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• 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 10/72 : Electric energy management in electromobility

Abstract

A system is provided for retrofitting an electrically propelled vehicle. The vehicle has an engine-driven generator, and at least a first traction motor and a second traction motor coupled to the generator. The system includes an energy storage device capable of being coupled to at least the first traction motor; and a control system operable to control a distribution of propulsive power between the first traction motor and the second traction motor. An associated method and a retrofit kit are provided, also.

Claims

1. A system for retrofitting an electrically propelled vehicle having an engine-driven generator, and at least a first traction motor coupled to the generator and a second traction motor, comprising:

a control system operable to control a distribution of propulsive power between the first traction motor and the second traction motor; and

an energy storage device capable of being coupled to at least the second traction motor.

2. The system as defined in claim 1, wherein the electrically propelled vehicle is a locomotive.

3. The system as defined in claim 1, further comprising a diesel engine coupled to the generator.

4. The system as defined in claim 1, wherein the first traction motor and the second traction motor are part of a plurality of traction motors.

5. The system as defined in claim 1, wherein the energy storage device comprises a high temperature battery that operates at a temperature in a range of from about 260 degrees Celsius to about 450 degrees Celsius.

6. The system as defined in claim 1, wherein the energy storage device is a metal halide battery.

7. The system as defined in claim 1, wherein the energy storage device comprises one or more of a lithium battery, a nickel metal hydride battery, a flywheel, or an ultracapacitor.

8. The system as defined in claim 1, wherein the energy storage device is coupled to the second traction motor via at least one of a diode, a contactor, a manual disconnect switch, or a silicon controlled rectifier.

9. The system as defined in claim 1, wherein the control system is operable to control the vehicle at relatively lower speeds, at relatively higher torque, or both at relatively higher torque and lower speeds, by using the second traction motor alone or in combination with the first traction motor, and the control system is operable to control the vehicle at moderate torque or at high torque by using at least the first traction motor.

10. The system as defined in claim 1, wherein the first energy storage device has a first portion and a second portion, and the first portion and the second portion are switchable from a first operating mode in which the first portion and the second portion are electrically connected in parallel, and a second operating mode in which the first portion and the second portion are electrically connected in serial.

11. The system as defined in claim 1, further comprising a temperature control system capable of affecting a temperature in the energy storage device.

12. The system as defined in claim 11, wherein the energy storage device comprises a first portion and a second portion, both of which are disposed in a common housing, and the common housing is in operational association with the temperature control system.

13. The system as defined in claim 12, wherein the temperature control system comprises at least one temperature sensor, at least one temperature control device, and a thaw controller that communicates with the sensor and controls the thermal source to change or maintain the environment inside the common housing.

14. The system as defined in claim 11, wherein the energy storage device comprises a first portion and a second portion, and the first portion and the second portion are disposed in a respective first housing and second housing, and each of the first housing and the second housing is in operational association with the temperature control system.

15. The system as defined in claim 14, wherein the temperature control system comprises at least one temperature sensor in each of the first housing and the second housing, at least one thermal source in each of the first housing and the second housing, and a thaw controller that communicates with each sensor and controls each thermal source to change or maintain an environment inside at least a respective one of the first housing and the second housing.

16. The system as defined in claim 15, wherein the thaw controller is operable to initiate a thaw process by controlling the thermal source to increase a local environment temperature up to and within an operating temperature range based on determined heat ramp rates.

17. The system as defined in claim 15, wherein the thaw controller is operable to initiate a cooling process to control the thermal source to decrease a local environment temperature down to and within an operating temperature range.

18. A vehicle comprising the system as defined in claim 1.

19. The vehicle as defined in claim 18, wherein the control system is further operable to:

initiating a braking event calling for an amount of a required braking power for a vehicle having an electric motor that can drive a wheel, and having an energy storage device, an electric converter, and a power switch coupled to the electric motor;

determining a first available braking power based on a component limiting factor determined by at least one of;

power capacity of the electric motor,

torque capacity of the electric motor,

maximum adhesion limit of the wheel on a wheel-bearing surface,

electrical uptake capacity of the energy storage device,

electrical rating capacity of the electronic converter, or

electrical rating capacity of the power switch; and

comparing the first available braking power to the required braking power;

meeting the required braking power first with the first available braking power; and

supplementing the first available braking power with a second available braking power where the first available braking power is insufficient to meet the required braking power, and the second available braking power is based on at least a capacity of a dynamic braking grid resistor array coupled thereto.

20. The vehicle as defined in claim 18, wherein the control system is further operable to initiate the first traction motor to propel an electrically driven vehicle at a first, slower speed and high torque by supplying electricity at a first, lower voltage from the energy storage device to the first traction motor;

and to initiate the second traction motor to propel the vehicle at a second, faster speed and moderate torque by supplying electricity at a second, higher voltage from an engine-driven generator to the second traction motor.

21. The vehicle as defined in claim 18, further wherein the control system is further operable to monitor for component failure in a second traction drive system that contains the second traction motor and the energy storage device;

and the control system is further operable to respond to a component failure indication of the second traction drive system by;

routing energy to and from the second traction motor to a second energy storage device, or

routing energy to and from the energy storage device to a traction motor other than the second traction motor.

22. A method of retrofitting a vehicle having an engine driven generator, and at least two traction motors coupled to the generator, the method comprising:

uncoupling at least one of the traction motors from the generator to provide a first uncoupled traction motor; and

coupling the first uncoupled traction motor to an energy storage device.

23. The method as defined in claim 22, further comprising placing in operational contact a control system of the vehicle so that the control system communicates with at least the first uncoupled traction motor after recoupling.

24. The method as defined in claim 23, further comprising adding in and out (I/O) data channels to the control system to monitor at least one function associated with the energy storage device.

25. The method as defined in claim 24, further comprising monitoring at least one function associated with the energy storage device selected from the group consisting of temperature, voltage, and state of charge.

26. A retrofit system for a vehicle having a heat engine, a generator coupled to the heat engine, and at least two traction motors coupled to the generator, comprising:

means for uncoupling at least one of the traction motors from the generator to provide a first uncoupled traction motor; and

means for coupling the first uncoupled traction motor to an energy storage device.

27. A kit for retrofitting an engine propelled vehicle having at least one propulsive axel coupled to the engine and at least one non-propulsive axel that is not coupled to the engine, comprising:

a traction motor configured to couple to the non-propulsive axel of the vehicle;

an energy storage device capable of coupling to the traction motor to define a hybrid axel, and wherein the energy storage device is capable of supplying energy to the traction motor and is further capable of receiving energy generated by the traction motor; and

a control system that is operable to monitor a propulsion demand from an operator of the vehicle and operable to control the propulsive effort of the propulsive axel and the hybrid axel so that their combined propulsive effort substantially meets the propulsive demand.

28. The kit as defined in claim 27, wherein the control system is further operable to preferentially meet the propulsive demand using the hybrid axel propulsive effort, and to fill any deficiency in meeting the propulsive demand using the hybrid axel with additional propulsive effort using the propulsive axel.

29. The kit as defined in claim 27, further comprising a sensor array that is capable of monitoring one or more property of the energy storage device, and is capable of communicating information of that one or more property to the control system, wherein the control system is operable to control a distribution of the combined propulsive effort based on the information.

30. The kit as defined in claim 27, wherein the vehicle is a locomotive.

31. The kit as defined in claim 30, wherein the engine is coupled to a generator that can supply energy at a voltage in a range of from about 800 volts to about 1500 volts, and the kit further comprising additional electronic components rated for use at a voltage in a range of from about 800 volts to about 1500 volts.

32. The kit as defined in claim 30, wherein the engine is coupled to a generator that can supply energy at a voltage in a range of from about 1500 volts to about 3000 volts, and the kit further comprising additional electronic components rated for use at a voltage in a range of from about 1500 volts to about 3000 volts.

33. The kit as defined in claim 27, wherein the vehicle is a marine vehicle.

34. The kit as defined in claim 27, wherein the vehicle is an off-highway vehicle.

35. The kit as defined in claim 27, further comprising an electrical activity monitor coupled to the energy storage device and operable either to lock out access to electrical components having a voltage that is sufficiently high to injure a person in contact therewith, to indicate that the electrical components are electrically active to a person proximate thereto, or to perform both a lock out and an electrical activity indication.