Mobile, off-road, heavy-duty haulage vehicle

• US 4,719,361 A
• Filed: 08/18/1986
• Issued: 01/12/1988
• Est. Priority Date: 08/18/1986
• Status: Expired due to Term

• Current Assignee: Komatsu Dresser Company (Komatsu Ltd.)
• Original Assignee: Dresser Industries Incorporated (Halliburton Company)
• Inventors: Brubaker, Richard R.
• Primary Examiner(s): Shoop, Jr., William M.
• Assistant Examiner(s): Duncanson, Jr., W. E.
• Application Number:
  US06/897,598
• Time in Patent Office: 512 Days
• Field of Search: 290/14, 290/17, 290/45, 322/18, 322/19, 322/21, 322/28
• US Class Current: 290/45
• CPC Class Codes: B60L 50/12 using AC generators and DC motors
• CPC Class Codes: F02B 3/06 with compression ignition compression ignition engines using air or gas for blowing fuel into compressed air in cylinder F02B13/02
• CPC Class Codes: Y02T 10/64 Electric machine technologies in electromobility
• 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

Abstract

An off-road, heavy duty, haulage vehicle includes a diesel engine driving an alternator (generator) for producing electrical power for motorized rear wheels. An alternator field converter is electrically connected to the alternator and an armature converter and a motor field converter are electrically connected to the two motors of the motorized rear wheels. A computerized control center includes control systems including an alternator field converter control system, a motor field control system, and a vehicle operation and maintenance control system. Tertiary windings are used as a source of excitation and the phase angle controlled armature converter is used in conjunction with alternator voltage control system for holding the alternator at an increment of voltage higher than the motors but not at a constant maximum voltage level. Other operating functions are under control of an additional control system for providing warnings of impending trouble, detection of system faults and records of operating information for diagnostic purposes and maintenance and repair.

Claims

1. An off-road, heavy-duty, haulage vehicle comprising:

(a) a vehicle having an electrical motor driven wheel means including a voltage monitoring means for continuously monitoring the motor voltage; and

(b) a generator means for producing electrical power, said generator means including a power control means responsive to the motor voltage for producing a tracking voltage which tracks the motor voltage always at a higher increment up to the maximum allowable voltage output of the generator means.

2. An off-road, heavy-duty, haulage vehicle comprising:

(a) a vehicle having an electrical motor driven wheel means including a voltage monitoring means for continuously monitoring the motor voltage; and

(b) a generator means for producing electrical power, said generator means including a computerized power control means responsive to the motor voltage for producing a tracking voltage which tracks the motor voltage always at a computer determined higher increment up to the maximum allowable voltage output of the generator means.

3. An off-road, heavy-duty, haulage vehicle according to claim 2 wherein the computerized control means includes means for adding to the motor voltage a constant voltage representing a normal difference between the motor voltage and the voltage of the generator means for producing a normal voltage signal, a first comparator means for comparing the normal voltage signal of the generator means to a preselected minimum desired voltage for the generator means and selecting the higher signal as a minimum voltage for the generator means, and a second comparator means for comparing the output of the first comparator to a selected maximum allowable voltage for the generator and selecting the lower value for controlling the generator means for producing the motor tracking voltage.

4. An off-road, heavy duty, haulage vehicle comprising:

(a) a vehicle having drive wheels, and motors responsive to electric power for driving the drive wheels, the motors having armatures and motor fields; and

(b) a prime mover electric traction drive system including a combustion engine, an alternator means operatively connected to the combustion engine for producing electrical energy, a control center including an armature converter control means responsive to motor operation outputs for producing armature converter control signals, an armature converter operatively connected to the alternator means and motor armatures, said armature converter responsive to the electrical energy and control signals for producing forward motion and reversing and regulating the flow of energy from the motors for selectively producing regeneration power into the combustion engine whereby low speed retarding is provided, a motor voltage monitoring means for continuously monitoring the motor voltage, and a power control means responsive to the motor voltages for producing a tracking voltage which tracks the motor voltage as a higher increment up to a maximum allowable voltage.

5. An off-road, heavy-duty, haulage vehicle according to claim 4 further including a motor field converter operatively connected to the alternator means and motor fields, said field converter responsive to the electrical energy and control means for controlling field excitation, said motor field converter comprising positive and negative fullwave, single phase SCR bridges, positive and negative clamps operatively connected to a corresponding positive and negative bridge for interlocking the bridges and a SCR firing control means for synchronously firing the SCRs of both bridges simultaneously, whereby the positive bridge controls forward propel and reverse retarding and the negative bridge controls reverse propel and forward retarding.

6. An off-road, heavy-duty, haulage vehicle according to claim 5 further including an alternator field converter operatively connected to the alternator means, said alternator field converter responsive to the output of the alternator means for producing exciter current whereby the alternator means is self exciting.

7. An off-road, heavy-duty haulage vehicle comprising:

(a) a support frame;

(b) front wheels and motorized rear wheels operatively connected to the support frame, each motor of said motorized rear wheel having an armature and a field exciter means; and

(c) a prime mover electric traction drive system operatively connected to the support frame and motorized rear wheels, said prime mover electric traction drive system including a prime mover, an alternator having multiple windings operatively connected to the prime mover for producing a plurality of ac power sources, a control means including an alternator voltage control means operatively connected to the motor for receiving motor feedback voltages and adding a preselected voltage increment for providing an operating voltage other than a constant maximum voltage level to the alternator for controlling the operating voltages, an armature converter and a field converter responsive to the ac alternator for producing dc power, respectively, for the armature and field exciter of the motorized rear wheel motor whereby the armature and field currents closely track each other without the field always lagging armature current.

8. An off-road, heavy-duty, haulage vehicle according to claim 7 further including a cab supported by the support frame, said cab housing a steering means operatively connected to the front wheels for steering the vehicle during motion, and an accelerator pedal and a retard pedal and a forward/neutral/reverse control switching means operatively connected to the alternator voltage control means for determining the speed of the vehicle and for controlling the direction of motion.

9. An off-road, heavy-duty, haulage vehicle according to claim 7 further including a deck means for supporting the cab above the prime mover electric traction drive system in line with the rear wheel for providing a clear view of the rear wheel, a control means cabinet located adjacent to the cab for housing the control means, and means including a canopy extending above the deck for protecting the cab and control means cabinet.

10. An off-road, heavy-duty, haulage vehicle according to claim 7 wherein the field converter includes a high power semiconductor circuit having double single phase controlled rectifying means having a positive bank of SCRs for use in forward propel and reverse retarding and a negative bank of SCRs for use in reverse propel and forward retarding, the positive and negative banks of SCRs being interlocked to prevent short circuit operation should both conduct simultaneously.

11. An off-road, heavy-duty, haulage vehicle according to claim 10 wherein the alternator includes a 3 phase armature winding and the armature converter includes a phase controlled high power semiconductor circuit having an SCR bridge whereby when in the retard mode under a preselected speed value power flows from the motor armature through the armature converter to the alternator armature winding for motoring the prime mover to retard the vehicle.

12. An off-road, heavy-duty, haulage vehicle according to claim 7 further including a high power semiconductor alternator field converter responsive to an ac output of the alternator for producing dc for self excitation of the alternator.

13. An off-road, heavy-duty, haulage vehicle according to claim 7 wherein the control means includes a plurality of sensors responsive to the prime mover electric traction drive system components for producing status information signals, a decision making means responsive to the sensor status information signals for producing decision making information signals for controlling the prime mover electric traction drive system component'"'"'s actions.

14. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the decision making means is a digital computing means and further including an analog to digital isolation and scaling means operatively connected to the decision making means and responsive to the analog output of the high power semiconductor circuits for digitizing the analog output for the digital computing means.

15. An off-road, heavy-duty, haulage vehicle according to claim 14 further including a ground fault detection means responsive to the resistance between the high power circuits and the support frame for detecting a less than a minimum acceptable resistance, and a low power conditioner means operatively connected to the isolation and scaling means for conditioning the low level leakage current for the isolation and scaling means.

16. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the plurality of sensors responsive to the prime mover electric traction drive system components include analog sensors selected from the group consisting of the:

altnerator voltage, alternator dc and ac field currents, motor voltage, motor armature current, motor dc and ac motor field currents, speed limit potentiometer, preset speed limit potentiometer, retard control potentiometer, battery voltage, battery boost voltage, and motor temperature.

17. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the plurality of sensors responsive to the prime mover electric traction drive system components include magnetic pick-up devices with high level output for speed inputs including engine speed and motor speed.

18. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the plurality of sensors responsive to the prime mover electric traction drive system components include timing means for providing timing inputs for detecting zero crossings for SCR firing synchronization selected from the group consisting of armature phases A, B and C positive and negative, motor field positive and negative and alternator field positive and negative.

19. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the decision making means is a digital computer responsive to selected sensor inputs for providing digital signals selected from the group consisting of:

battery boost trigger, ground fault warning, motor over temperature warning, system fault warning, throttle solenoid and retard lamp relay drive, low idle solenoid drive, control power latch, auxilary 3 mph relay drive, motor overspeed warning, armature hardware clamp and field hardware clamp.

20. An off-road, heavy-duty, haulage vehicle according to claim 13 further including a digital to analog converter responsive to the output of the decision making means for producing analog outputs indicative of the supply voltage for retarding potentiometer and 0-1 millimeter speedometer signal.

21. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the decision making means is responsive to sensor inputs for producing pulse train signals for firing the SCRs selected from the control group consisting of armature converter SCRs 1-6, positive and negative motor field converter SCRs and alternator field SCRs.

22. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the plurality of sensors for the control means includes a temperature sensor means positioned adjacent to the motor of the motorized rear wheels for detecting the motor temperature.

23. An off-road, heavy-duty, haulage vehicle according to claim 13 wherein the decision making means is a computer means and further including a diagnostic means including a display means having warning lights responsive to the computer means for providing warning, fault, input, logic, and output functions.

24. An off-road, heavy-duty, haulage vehicle according to claim 23 wherein the decision making means further includes a test means operatively connected to the computer means for selectively exercising all inputs including switch, speed signal, analog, and combustion thereof by switch selection.

25. An off-road, heavy-duty, haulage vehicle according to claim 24 wherein the test means includes power sources including an oscillator circuit for speed signals, adjustable direct current voltage for analog signals and 24 volts for switch inputs.

26. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for recording at sample frequency for a first preselected time and every second for a second preselected time variables selected from the group consisting of:

engine speed, total motor armature voltage, motor armature current, calculated alternator input power, speed of each motor, voltage of higher voltage motor, motor field current, alternator field current, alternator voltage, volts across boost resistor, and motor temperatures.

27. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for recording at sample frequency for a preselected last time the status of selected input, logic, output and warning functions.

28. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for recording the highest value since last interrogation of analog functions selected from the group consisting of:

engine speed, total motor armature voltage, motor armature current, calculated alternator input power, speed of the motors, voltage of higher voltage motor, motor field current, alternator field current and voltage, volts across boost resistor and motor temperatures.

29. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for recording the count of digital functions since the last interrogation including warning, fault, input logic throttle solenoid and low idle solenoid functions.

30. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for stopping recording any time a fault function is detected.

31. An off-road, heavy-duty, haulage vehicle according to claim 23 further including a recorder means responsive to the computer means for recording maintenance and repair information, said recorder having a first serial link for permitting interrogation of recorded data by an off board device for analysis and permanent recording and a second serial link for permitting hand interrogation of the recorded data by an on board display.

32. An off-road, heavy-duty haulage vehicle according to claim 31, wherein the alternator means includes a three phase armature for producing three phase ac power, a first tertiary stator winding for producing power to excite the motorized wheel electric motor;

and

said converter means including an alternator converter including a single phase full rectifying bridge operatively connected to the alternator first stator winding for producing dc power, and a coil responsive to the dc output for self-exciting the the alternator armature winding;

dual single phase full rectifying bridges operatively connected to the alternator second stator winding for selectively exciting the motorized wheels electric drive motor field coils in the forward propel/reverse retard modes, and in the reverse propel/forward retard mode; and

a three-phase, full wave rectifier bridge operatively connected to the motorized wheel electric motor for receiving power from the motor acting as a generator during retard and to the alternator three-phase armature for motoring the internal combustion engine and providing a retard without contactors at low speed.

33. An off-road, heavy-duty haulage vehicle according to claim 32 wherein the full wave rectifier bridges comprise silicon controlled rectifiers.

34. An off-road, heavy-duty haulage vehicle according to claim 33 further including contact means operatively connected to gates of the silicon controlled rectifiers of the full wave rectifiers for controlling firing.

35. An off-road, heavy duty, haulage vehicle according to claim 7, wherein said alternator further includes an alternator field converter for rectifying alternating current into direct current for self-excitation of the alternator and wherein the armature and field converters are responsive to the electrical power output of the alternator for selectively driving the motorized wheels in forward propel and reverse retard operational modes and reverse propel and forward retard modes, and responsive to power generated by the electric motors when acting as generators in the retard mode for producing in the prime mover retarding forces at speeds below a preselected speed.