Electric golf car with low-speed regenerative braking

• US 6,462,506 B2
• Filed: 12/14/2000
• Issued: 10/08/2002
• Est. Priority Date: 12/30/1999
• Status: Expired due to Term

• Current Assignee: Textron IPMP L.P
• Original Assignee: Textron Inc
• Inventors: Hearn, Carlton W., Cochoy, John
• Primary Examiner(s): Hsieh, Shih-Yung
• Assistant Examiner(s): SMITH, TYRONE W
• Application Number:
  US09/736,657
• Publication Number:
  US 20010043049A1
• Time in Patent Office: 663 Days
• Field of Search: 318/254, 318/139, 318/800, 318/801, 318/812, 318/813, 318/287, 318/493, 180/65, 388/801
• US Class Current: 318/801
• CPC Class Codes: B60L 2200/22 Microcars, e.g. golf cars
• CPC Class Codes: B60L 50/52 characterised by DC-motors
• CPC Class Codes: B60L 7/003 Dynamic electric braking by short circuiting the motor
• CPC Class Codes: B60L 7/12 for vehicles propelled by dc motors
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

A control system for an electric vehicle, such as a golf car, that includes a plurality of power MOSFETs. The vehicle includes a shunt wound motor including an armature coil and a field coil. One of the MOSFETs is connected in parallel across the armature coil and another MOSFET is connected in series with the armature coil. The MOSFET across the armature coil includes a freewheel diode. When the motor is operating below its base speed, i.e., when the back EMF is below the power supply voltage, a current flow can be induced by momentarily turning on the series MOSFET, shorting the armature coil. Because of the residual inductance in the motor, a current flow in the counter clockwise direction is initiated at which point the series MOSFET is turned off. Consequently, a large voltage spike across the motor occurs which results in current flow back into the battery pack. By quickly turning the series MOSFET on and off the current flow can be maintained, and the regenerative braking can occur even at slow speeds. The control system also allows the vehicle to be operated at speeds below its base speed, and provide field current control by measuring the armature current in the negative quadrant of the field map.

Claims

1. A control system for controlling the current and voltage of an electric shunt wound motor associated with an electric vehicle, said motor including an armature coil and a field coil, said system comprising:

a plurality of switching devices electrically coupled in an H-bridge circuit and electrically coupled to the field coil;

a plurality of switching devices electrically coupled in a half H-bridge circuit, wherein a first switching device Is electrically coupled in parallel with the armature coil and a second switching device is electrically coupled in series with the armature coil; and

a freewheel diode electrically coupled in parallel with the armature coil; and

means for measuring armature current in a negative quadrant of a field coil map, said system selecting a field coil current for controlling the field coil based on the measured armature current.

2. The system according to claim 1 wherein the freewheel diode is formed as part of a MOSFET device, said MOSFET device being the first switching device.

3. The system according to claim 1 wherein the plurality of switching devices in the H-bridge circuit and the half H-bridge circuit are MOSFET devices.

4. The system according to claim 1 further comprising means for switching the first switching device on and off so as to control the armature current traveling through the armature coil to provide regenerative braking of the speed of the electrical vehicle from a base speed to zero.

5. The system according to claim 4 wherein the means for switching includes means for controlling an armature pulse width modulation (PWM) signal so as to control the speed of the electric vehicle below its base speed.

6. The system according to claim 5 wherein the means for controlling includes a pedal position device for determining an accelerator pedal position, a speed sensing device for determining the speed of the vehicle and an armature PWM control circuit for generating the armature PWM signal, said pedal position device generating a speed reference signal and said speed sensing device generating a speed sensor signal, said speed sensor signal and said speed reference signal being applied to a summing junction, said summing junction generating a speed signal that is applied to the armature control circuit.

7. The system according to claim 5 wherein the PWM signal is applied to the second switching device.

8. The system according to claim 1 further comprising means for controlling motor armature current between a minimum value and a maximum value as a function of speed.

9. The system according to claim 8 wherein the means for controlling includes a speed sensor circuit having a summing junction responsive to a speed sensor signal and responsive to a current sensor signal from a current sensing circuit, said summing junction generating a controlled speed sensor signal for controlling the speed of the vehicle.

10. The system according to claim 1 further comprising means for generating a field current, said means for generating a field current including a summing junction responsive to and summing the field current and a field current reference signal, and including a field pulse width modulation (PWM) circuit generating a PWM signal from the summed signal.

11. The system according to claim 1 wherein the electric vehicle is an electric golf car.

12. An electric golf car including a braking system, a battery system and a shunt wound motor, said motor having an armature coil and a field coil, said golf car comprising:

a plurality of MOSFET devices electrically coupled in a H-bridge circuit and electrically coupled to the field coil;

a plurality of MOSFET devices electrically coupled in a half H-bridge circuit, wherein a first MOSFET device is electrically coupled in parallel with the armature coil and a second MOSFET device is electrically coupled in series with the armature coil;

a freewheel diode electrically coupled in parallel with the armature coil;

a current sensor for measuring armature current through the armature coil;

a speed pedal position switch for determining the position of an accelerator pedal of the golf car, said pedal position switch generating a speed reference signal; and

a control system, said control system switching the first MOSFET device on and off so as to control the armature current traveling through the armature coil to provide regenerative braking of the speed of the golf oar from a base speed to zero, wherein the control system includes means for measuring armature current in a negative quadrant of a field coil map, said control system selecting a field coil current for controlling the field coil based on the measured armature current.

13. The golf car according to claim 12 further comprising a speed sensor circuit for determining the speed of the vehicle and an armature PWM control circuit for generating an armature pulse width modulation (PWM) signal, said pedal position switch determining the speed of the vehicle and said speed sensor circuit generating a speed sensor signal, said speed sensor signal and said speed reference signal being applied to a summing junction, said summing junction generating a speed signal that is applied to the armature control circuit.

14. The golf car according to claim 13 wherein the PWM signal is applied to the second MOSFET device.

15. The golf car according to claim 12 wherein the control system includes means for controlling motor armature current between a minimum value and a maximum value as a function of speed.

16. The golf car according to claim 12 wherein the control system includes means for generating a field current, said means for generating a field current including a summing junction responsive to and summing the field current and a field current reference signal, and including a field pulse width modulation (PWM) circuit generating a PWM signal from the summed signal.

17. A method of controlling the speed of an electric vehicle, said electric vehicle including a shunt wound motor having an armature coil and a field coil, said method comprising the steps of:

electrically coupling a first switching device in parallel across the armature coil of the motor;

providing a current path in parallel to the first switching device to dissipate a residual current through the armature;

turning the switching device on and off to control the armature current through the armature coil so as to provide regenerative braking below a base speed of the motor; and

measuring armature current in a negative quadrant of a field map coil, and controlling the field coil current based on the measured armature current.

18. The method according to claim 17 wherein the step of electrically coupling a first switching device includes electrically coupling a MOSFET device in parallel with the armature coil.

19. The method according to claim 17 further comprising the step of electrically coupling a second switching device in series with the armature coil.

20. The method according to claim 17 further comprising the step of controlling the vehicle speed between zero and the base speed of the motor.

21. The method according to claim 20 wherein the step of controlling the vehicle speed below the base speed includes controlling a pulse width modulation signal applied to the armature coil and sensing accelerator pedal position and vehicle speed.

22. The method according to claim 20 wherein the step of controlling the vehicle speed includes applying the PWM signal to a switching device in electrical series with the armature coil.

23. The method according to claim 17 further comprising the step of controlling motor armature current between a minimum value and a maximum value as a function of speed.

24. The method according to claim 23 wherein the step of controlling armature current includes determining armature current, determining vehicle speed, and combining the vehicle speed and the armature current to control the speed of the vehicle.