Method and apparatus for propelling and retarding off-road haulers

• US 5,103,923 A
• Filed: 11/30/1989
• Issued: 04/14/1992
• Est. Priority Date: 11/30/1989
• Status: Expired due to Term

• Current Assignee: LeTourneau, Inc. (Valaris Ltd.)
• Original Assignee: Marathon LeTourneau Company (Valaris Ltd.)
• Inventors: Johnston, Ronald A., Baker, Dwight, Nelson, Gary L.
• Primary Examiner(s): Kashnikow, Andres
• Assistant Examiner(s): Johnson, Brian L.
• Application Number:
  US07/443,177
• Time in Patent Office: 866 Days
• Field of Search: 180/65.2, 180/65.3, 180/65.4, 180/65.5, 180/65.8, 180/2.1, 191/4, 191/5, 290/14, 290/15, 290/17, 318/148
• US Class Current: 180/65.24
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/20 DC electrical machines
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 50/20 using propulsion power generated by humans or animals
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 7/04 for vehicles propelled by dc motors
• CPC Class Codes: B60L 7/12 for vehicles propelled by 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 10/62 Hybrid vehicles
• 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
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

An improved method and apparatus for powering and controlling the operation of large diesel-electric off-road haulers of the type in which hauler drive wheels are propelled and retarded by DC electric wheel motors powered from on-board generators, optionally supplemented by DC power, from external trolley lines. In the disclosed system, thyristor-type converters connected into the system AC power grid are used to receive supplemental external power from DC trolley lines and supply it into the AC power distribution grid in the propel mode. The use of such thyristor-type converters makes possible the use of supplement trolley line power without provision of separate switching or control gear to operate the DC wheel motors when trolley line power is received. Thyristor-type converters also may be used to supply current generated by wheel motors in the retarding mode to retarding resistors, making possible the use of the initial electrical power generated by the wheel motors to replace load requirements of the diesel engine, resulting in substantial fuel savings.

Claims

1. A system for propelling an off-road hauler, said system comprising:

an internal combustion engine;

AC generator means adapted to be driven by said engine to generate AC electric power;

AC power distribution means electrically connected to said AC generator means and comprising means for distributing AC electric power generated by said generator means;

voltage regulator means electrically connected to said AC power distribution means and comprising means for regulating the voltage of said AC electric power;

DC wheel motor means on said hauler and adapted to deliver propelling power to a drive wheel of said hauler;

armature thyristor converter means electrically connected to said AC power distribution means and said DC wheel motor means and adapted to receive AC electric power from said AC power distribution means and to deliver DC electric power to said DC wheel motor means;

field current generating means associated with said DC wheel motor means and comprising means for generating a DC current field for said DC wheel motor means;

field current thyristor converter means electrically connected to said AC power distribution means and said field current generating means and comprising means for receiving AC power from said AC power distribution means and supplying DC power to said field current generating means;

line power connection means on said hauler for selectively connecting said system to DC line power from a source external to said hauler;

line power thyristor converter means electrically connected to said line power connection means and said AC power distribution means and comprising means for receiving DC electrical power from said line power connection means and supplying AC electrical power to said AC power distribution means; and

control means electrically connected to said voltage regulator means, armature thyristor converter means, field current thyristor converter means and line power thyristor converter means and comprising means for controlling the operation of said voltage regulator means, armature thyristor converter means, field current thyristor converter means and line power thyristor converter means;

whereby said off-road hauler may be propelled by one of (1) power generated on-board by said AC generator means, (2) DC line power from said source external to said hauler and (3) by power supplied simultaneously by both said AC generator means and said DC line power from said source external to said hauler, without the necessity for electrical switching apparatus for switching between said power generated on-board and said DC line power.

2. The system according to claim 1 wherein said AC generator means is adapted, when said system is supplied with electrical power from said source external to said hauler, to act as an AC electric motor to deliver power to said engine, whereby said DC line power from said source external to said hauler may be utilized to substantially eliminate loading on said engine so as to substantially reduce fuel consumption by said engine.

3. The system according to claim 1 wherein said armature thyristor converter means comprises a single armature thyristor converter connected to said AC power distribution means and wherein said DC wheel motor means comprise a pair of DC wheel motors connected in series to the DC side of said armature thyristor converter.

4. The system according to claim 3 wherein said field current thyristor converter means comprise a pair of field current thyristors connected to said AC power distribution means and wherein said field current generating means comprise a pair of field current coils, each of said field current coils being electrically connected to one of said field current thyristors and associated with one of said pair of DC wheel motors connected in series, whereby each of said field current thyristor converters may be controlled independently by said control means to thereby control independently the field current in each of said field current coils and the amount of torque generated by each of said pair of DC wheel motors.

5. In a system for propelling an off-road hauler of the type in which an internal combustion engine drives an AC generator to produce AC current, an AC grid electrically connected to said AC generator distributes said AC current, a first thyristor-type converter electrically connected to said AC grid and a DC electrical wheel motor receives AC power from the AC power distribution grid and delivers DC power to said DC electric wheel motor which, in turn, delivers motive power to a drive wheel for said hauler, the improvement comprising:

line power connection means on said hauler for selective electric connection to DC line power from a source external to said hauler; and

a second thyristor-type converter electrically connected to said line power connection means and said AC grid, said second thyristor-type converter comprising means for receiving DC power from said line power connection means and delivering AC power to said AC grid;

whereby electrical power from said source external to said hauler may be used to replace AC power supplied by said AC generator, to thereby reduce fuel consumption by said internal combustion engine, without electrically disconnecting said AC generator from said AC grid and without using electrical switching apparatus for switching between AC power supplied by said AC generator and DC power supplied from said line power source external to said hauler.

6. The system according to claim 5 wherein said line power connection means comprise means for electrically connecting said hauler to an overhead DC trolley line.

7. A system selectively operable in propel and retarding modes for, selectively, propelling and retarding an off-road hauler, said system comprising:

an internal combustion engine;

AC generator means mechanically connected to said engine and adapted, when said system is operated in said propel mode, to be powered by said engine to generate AC electric power and adapted, when said system is operated in said retarding mode, to act as an AC electric motor and to deliver power to said engine;

AC power distribution means electrically connected to said AC generator means and adapted, when said system is operated in said propel mode, to distribute AC electric power generated by said generator means and adapted, when said system is operated in said retarding mode, to deliver AC electric power to said generator means;

voltage regulator means electrically connected to said AC power distribution means, said voltage regulator means comprising means for regulating the voltage of said AC electric power;

DC wheel motor means on said hauler and adapted, when said system is operated in said propel mode, to deliver propelling torque to a drive wheel of said hauler and adapted, when said system is operated in said retarding mode, to act as a DC generator, receiving motive power from said drive wheel of said hauler and generating DC electric power to thereby exert retarding torque on said drive wheel;

armature thyristor converter means electrically connected to said AC power distribution means and said DC wheel motor means and adapted, when said system is operated in said propel mode, to receive AC electric power from said AC power distribution means and to deliver DC electric power to said DC wheel motor means and adapted, when said system is operated in said retarding mode, to receive DC power generated by said DC wheel motor means and to deliver AC electric power to said AC power distribution means;

field current generating means associated with said DC wheel motor means, said field current generating means comprising means for generating a DC current field for said DC wheel motor means;

field current thyristor converter means electrically connected to said AC power distribution means and said field current generating means, said field current thyristor converter means comprising means for receiving AC power from said AC power distribution means and supplying DC power to said field current generating means;

means associated with said DC wheel motor means for selectively causing said DC wheel motor means to act as a motor when said system is operated in said propel mode and to act as a DC generator when said system is operated in said retarding mode;

retarding resistor means adapted, when said system is operated in said retarding mode, to consume electric power generated by said DC electric wheel motor means;

retarding resistor thyristor converter means electrically connected to said AC power distribution means and said retarding resistor means, said retarding resistor thyristor converter means comprising means for receiving AC electric power from said AC power distribution means and supplying DC electric power to said retarding resistor means; and

control means electrically connected to said voltage regulator means, armature thyristor converter means, field current thyristor converter means and retarding resistor thyristor converter means, said control means comprising means for controlling the operation of said voltage regulator means, armature thyristor converter means, field current thyristor converter means and retarding resistor thyristor converter means to thereby control the direction and amount of propelling and retarding torque exerted by said DC wheel motor means;

whereby, when said system is operated in said retarding mode, electric power generated by said DC wheel motor means may be used first to reduce the power requirements for said internal combustion engine, with excess electric power generated by said DC electric wheel motor means being supplied to said retarding resistor means.

8. The system according to claim 7 comprising additionally line power connection means for selectively connecting said system to DC line power from a source external to said hauler and for supplying said external DC line power to the DC side of said retarding resistor thyristor converter means, whereby DC line power from said external source may be converted to AC electric power by said retarding resistor thyristor converter means and supplied to said AC power distribution means to replace AC power generated by said AC generator and to reduce the power requirements for said internal combustion engine.

9. The system according to claim 8 wherein said line power connection means is connected into said system at a DC voltage opposite in polarity to that normally existing across said retarding resistor means and comprising additionally a power diode connected in said system between said line power connection means and said retarding resistor means, whereby when said external DC line power is connected to said system through said line power connection means, said opposite polarity of said DC line power will reverse bias said power diode and block said DC line power from feeding into said retarding resistor means, while permitting said DC line power to feed into said retarding resistor thyristor converter means for conversion to AC power.

10. The system according to claim 7 wherein said means for selectively causing said DC wheel motor means to act as a motor when said system is operated in said propel mode and to act as a DC generator when said system is operated in said retarding mode comprises means for selectively reversing said DC current field.

11. The system according to claim 7, 8, 9 or 10 wherein said armature thyristor converter means comprises a single armature thyristor converter connected to said AC power distribution and wherein said DC wheel motor means comprises a pair of DC wheel motors connected in series to the DC side of said armature thyristor converter.

12. The system according to claim 11 wherein said field current thyristor converter means comprises a signal field current thyristor converter and wherein said field current generating means comprise a pair of field current coils connected in series to the DC side of said field current thyristor converter and in association with said pair of DC electric wheel motors, whereby said DC electric wheel motors will opersate to deliver substantially equal amounts of propelling torque when said system is oiperated in said propel mode and will generate substantially equal amounts of retarding torque when said system is operated in said retard mode.

13. The system according to claim 11 wherein said field current thyristor converter means comprise a pair of field current thyristor converters connected to said AC power distribution means and wherein said field current generating means comprise a pair of field current coils, each of said field current coils being electrically connected to one of said field current thyristor and associated with one of said pair of DC wheel motors connected in series, whereby each of said field current thyristor converters may be controlled independently by said control means to thereby control the amount of current in each of said field current coils so as to control independently the amount of torque generated by each of said pair of DC wheel motors.

14. The system according to claim 7, 8, 9, or 10 where in said armature thyristor converter means comprise a plurality of armature thyristor converters in parallel to said AC power distribution means and wherein said DC wheel motor means comprise a plurality of DC wheel motors, each of said DC wheel motors being electrically connected to one of said armature thyristor converters.

15. The system according to claim 7 wherein said retarding resistor means comprise a plurality of staged resistors adapted to convert excess electrical power generated in said system into heat and comprising additionally means for dissipating the heat produced by said resistors.

16. A system for selectively propelling and retarding an off-road hauler, said system comprising:

an internal combustion engine;

an AC generator mechanically connected to said engine;

an AC power distribution grid electrically connected to said AC generator;

a voltage regulator electrically connected to said AC power distribution grid for regulating the voltage of AC electric power in said AC power distribution grid;

an armature converter electrically connected to said AC power distribution grid;

a DC electric wheel motor electrically connected to said armature thyristor converter;

a drive wheel for said off-road hauler mechanically connected to said DC electric wheel motor;

an electrical coil associated with said DC electric wheel motor for generating a DC current field for said DC electric wheel motor;

a field current thyristor converter electrically connected to said coil and to said AC power distribution grid;

a plurality of retarding resistors for dissipating excess electrical power generated in said system;

a retarding resistor thyristor converter electrically connected to said plurality of retarding resistors and electrically connected to said AC power distribution grid; and

a controller for controlling the operation of said voltage regulator, armature thyristor converter, field current thyristor converter and retarding resistor converters;

whereby said system may be operated in a propel mode in which said internal combustion engine drives said AC generator to produce AC power for supply to said AC power distribution grid, said armature thyristor converter converts AC power to DC power for said DC electric wheel motor, and said DC wheel motor exerts a desired propelling torque on said drive wheel; and

whereby said system also may be operated in a retarding mode in which the direction of current in one of said DC current field and said DC electric wheel motor is reversed in polarity, said drive wheel of said hauler powers said DC electric wheel motor, causing said DC electric wheel motor to generate DC electrical power which is converted by said armature thyristor converter to AC electrical power and supplied to said AC power distribution grid, said AC generator is powered by AC power from said AC power distribution grid, causing said AC generator to operate as an AC motor, driving said internal combustion engine, so as to reduce the fuel requirements for said engine and excess AC electrical power generated by said DC electric wheel motor is converted to DC electrical power by said retarding thyristor converter and is consumed by said retarding resistors and dissipated as heat.

17. The system according to claim 16 comprising additionally;

line power connection means selectively engageable with a source of DC line power external to said hauler and electrically connected to the DC side of said retarding resistor thyristor converter, whereby electrical power from said external source selectively may be supplied to said AC power distribution grid of said system without electrically disconnecting said AC generator from said AC power distribution grid and without using electrical switching apparatus for switching between AC power supplied by said AC generator and DC power supplied from said external source.

18. The apparatus according to claim 16 comprising additionally a power diode electrically connected in said system between said line power connection means and said retarding resistors and wherein said line power connection means is adapted to supply said DC line power from said external source to said system in a polarity opposite to that normally supplied to said retarding resistors, whereby said power diode automatically will prevent said DC line power from being supplied to said retarding resistors.

19. The system according to claim 16, 17 or 18 wherein two DC electrical wheel motors and two armature thyristor converters are provided, each wheel motor being connected to a drive wheel of said hauler and to an armature thyristor converter, with said armature thyristor converters being connected in parallel to said AC power distribution system, whereby each of said DC electric wheel motors may operate at a maximum voltage approximately equal to the maximum voltage supplied by said AC generator.

20. The system according to claim 16, 17 or 18 wherein a pair of DC electric wheel motors are provided, each said DC electric wheel motor being connected to a drive wheel of said hauler and wherein said pair of DC electric wheel motors are electrically connected in series to a single armature thyristor converter, whereby each of said DC electric wheel motors may operate at a maximum voltage equal to approximately one-half of the maximum voltage supplied by said AC generator.

21. The system according to claim 20 wherein said field current thyristor converter comprises a single field current thyristor converter and wherein said electrical coil comprises a pair of field current coils connected in series to the DC side of said field current thyristor converter and in association with said pair of DC electric wheel motors, whereby said DC electric wheel motors will operate to deliver substantially equal amounts of propelling torque when said system is operated in said propel mode and will generate substantially equal amounts of retarding torque when said system is operated in said retard mode.

22. The system according to claim 20 wherein said field current thyristor converter comprises a pair of field current thyristor converters connected in parallel to said AC power distribution grid and wherein said electrical coil for generating a DC current field comprises a pair of such electrical coils, each of said pair of electrical coils being electrically connected to one of said field current thyristor converters and associated with one said pair of DC wheel motors connected in series, whereby each of said field current thyristor converters may be controlled independently by said contol means to thereby control the amount of current in each of said electrical coils to control independently the amount of torque generated by each of said pair of DC wheel motors.

23. An electrical propulsion and distribution system for a vehicle, comprising:

an AC grid;

an AC generator coupled to said AC grid, and adapted to be coupled to an internal combustion engine;

a trolley converer, having DC terminals, having a control input, and having AC terminals coupled to said AC grid, for inverting DC power applied to said DC terminals and applying the inverted DC power to said AC grid responsive to control signals received at the control input of said trolley converter;

a DC motor, having a field coil and an armature;

a field converter for applying power from said AC grid to the field coil of a DC motor responsive to signals received at a control input;

an armature converter for applying power from said AC grid to the armature of a DC motor responsive to signals received at a control input; and

a controller, having outputs coupled to the control input of said trolley converter, to the control input of said field converter, and to the control input of said armature converter, said controller also having an input for sensing DC power applied to said DC terminals of said trolley converter, said controller for controlling said field converter and said armature converter to apply power from said AC grid to said field coil and armature, respectively, and for gating said trolley converter in such a manner to apply the inverted DC power to said AC grid simultaneously with said AC generator applying AC power to said AC grid.

24. The system of claim 23, wherein said controller has inputs for receiving speed command, armature power, and field coil power parameters, so that said controller is also for controlling said trolley converter in such a manner that, responsive to said field coil and armature converters applying sufficient power from said AC grid, said AC grid powers said AC generator as a synchronous motor.

25. The system of claim 23, wherein said trolley converter comprises a three-phase full-wave controlled thyristor rectifier.

26. An electrical propulsion and distribution system for a vehicle, comprising:

an AC grid;

an AC generator coupled to said AC grid, and adapted to be coupled to an internal combustion engine;

a trolley converter, having DC terminals, having a control input, and having AC terminals coupled to said AC grid, for inverting DC power applied to said DC terminals and applying the inverted DC power to said AC grid responsive to control signals received at the control input of said trolley converter;

a DC motor, having a field coil and an armature;

a field converter for applying power from said AC grid to the field coil of a DC motor responsive to signals received at a control input;

an armature converter for applying power from said AC grid to the armature of a DC motor responsive to signals received at a control input;

a retard load connected across said DC terminals; and

a controller, having output coupled to the control input of said trolley converter, to the control input of said field converter, and to the control input of said armature converter, said controller also having an input for sensing DC power applied to said DC terminals of said trolley converter, said controller for controlling said field converter and said armature converter to apply power from said AC grid to said field coil and armature, respectively, and for gating said trolley converter in such a manner to apply the inverted DC power to said AC grid;

wherein said controller, in a retard mode, is also for controlling said field coil converter to apply reversed current to the field coil so that said armature converter applies power to said AC grid in such a manner that said AC grid powers said AC generator as a synchronous motor, and for controlling said trolley converter in such a manner that said retard load receives power from said AC grid.

27. The system of claim 26, wherein said retard load comprises a resistor and a diode connected in series between said DC terminals in such a manner that said diode is reverse biased when DC power is applied to said DC terminals.

28. An electrical propulsion and distribution system for a vehicle, comprising:

an AC grid;

an AC generator coupled to said AC grid, and adapted to be coupled to an internal combustion engine;

a trolley converter, having DC terminals, having a control input, and having AC terminals coupled to said AC grid, for inverting DC power applied to said DC terminals and applying the inverted DC power to said AC grid responsive to control signals received at the control input of said trolley converter;

a DC motor, having a field coil and an armature;

a field converter for applying power from said AC grid to the field coil of a DC motor responsive to signals received at a control input;

an armature converter for applying power from said AC grid to the armature of a DC motor responsive to signals received at a control input;

a retard load connected across said DC terminals; and

a controller, having outputs coupled to the control input of said trolley converter, to the control input of said field converter, and to the control input of said armature converter, said controller also having an input for sensing DC power applied to said DC terminals of said trolley converter, said controller for controlling said field converter and said armature converter to apply power from said AC grid to said field coil and armature, respectively, and for gating said trolley converter in such a manner to apply the inverted DC power to said AC grid;

wherein said controller, in a retard mode, is also for controlling said armature converter to apply reversed current to the armature and to apply power to said AC grid in such a manner that said AC grid powers said AC generator as a synchronous motor, and for controlling said trolley converter in such a manner that said retard load receives power from said AC grid.

29. The system of claim 28, wherein said retard load comprises a resistor and a diode connected in series between said DC terminals in such a manner that said diode is reverse biased when DC power is applied to said DC terminals.