Generator voltage stabilization system and method

• US 7,825,530 B2
• Filed: 06/29/2007
• Issued: 11/02/2010
• Est. Priority Date: 06/29/2007
• Status: Expired due to Fees

• Current Assignee: Sheppard, Mullin, Richter & Hampton LLP
• Original Assignee: ISE Incorporated (ISE Group of Companies)
• Inventors: Schulte, Juergen J., Mazaika, David M.
• Primary Examiner(s): GONZALEZ, JULIO CESAR
• Application Number:
  US11/770,951
• Publication Number:
  US 20090001732A1
• Time in Patent Office: 1,222 Days
• Field of Search: 290/40.B, 290/40.C, 290/1.R, 180/65.24, 180/65.26, 180/65.28, 180/65.285, 180/65.31, 180/65.51, 180/65.8, 180/65.21
• US Class Current: 290/40.00B
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2240/427 Voltage
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 58/21 having the same nominal voltage
• 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 2050/001 Proportional integral [PI] controller
• CPC Class Codes: B60W 2710/08 Electric propulsion units
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• 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

A generator voltage stabilization system of a heavy-duty vehicle hybrid-electric drive system, which has an engine and a generator coupled with the engine for generating power that varies with rotational speed of the engine, includes one or more circuits having at least one of a DC/DC converter and an DC/AC converter configured to be coupled to the generator, and receive varying power input from the generator and provide stabilized voltage output power; and a control computer coupled to the one or more circuits to control the one or more circuits to provide stabilized voltage output power with varying power input from the generator.

Claims

1. A system for operating a heavy-duty vehicle hybrid-electric drive system of a heavy-duty vehicle over 10,000 pounds GVWR, the heavy-duty vehicle hybrid-electric drive system including an engine configured to provide a rotating output, the system comprising:

a generator mechanically coupled to the engine, the generator configured to generate an AC power having a variable AC voltage that varies with rotational speed of the engine rotating output;

a rectifier electrically coupled to the generator, the rectifier configured to rectify the generated AC power, and further configured to output a first DC power having a variable DC voltage that varies with rotational speed of the engine rotating output;

a DC/DC converter electrically coupled to the rectifier, the DC/DC converter configured to receive the first DC power, and further configured to output a second DC power;

a controller configured to control the DC/DC converter such that the second DC power outputted from the DC/DC converter is outputted having a stabilized DC voltage that does not vary with rotational speed of the engine;

a DC/AC inverter electrically coupled to the DC/DC converter, the DC/AC inverter configured to invert the second DC power and output an AC power having a stabilized AC voltage that does not vary with rotational speed of the engine; and

,

an electric motor electrically coupled to the DC/AC inverter and mechanically coupled to at least one drive wheel of the heavy-duty vehicle, the electric motor configured to be driven using the AC power having the stabilized AC voltage,

wherein the generator is further configured to generate three-phase AC power;

wherein the rectifier is further configured to rectify the generated three-phase AC power;

wherein the DC/AC inverter comprises three phases of a four-phase IGBT inverter;

wherein the electric motor comprises a three-phase electric motor and is electrically coupled to the three phases of the four-phase IGBT inverter;

wherein the DC/DC converter comprises a reactive inductor and an IGBT solid state high power switching circuit in a choppered configuration, and,

wherein the IGBT solid state high power switching circuit comprises a fourth phase of the four-phase IGBT inverter.

2. The system of claim 1, wherein the engine is further configured to provide a variable rotating output in response to load power demands, and to operate at an optimum efficiency.

3. The system of claim 1, wherein the rectifier comprises one or more multiple-diode rectifiers.

4. The system of claim 1, wherein the controller is configured to provide an output power having a stabilized voltage, that does not vary with rotational speed of the engine, to drive at least one of the following vehicle accessories:

an air conditioner, a hydraulic pump, an air compressor, one or more fans, one or more blowers, a water pump, an oil pump, a fuel pump, a vacuum pump, and an electric hydraulic actuator.

5. The system of claim 1, wherein the controller is configured to provide an output power having a stabilized voltage, that does not vary with rotational speed of the engine, to charge an energy storage device.

6. The system of claim 1, wherein the generator is further configured to generate multiple-phase AC power;

and,

wherein the rectifier is further configured to rectify the generated multiple-phase AC power.

7. The system of claim 1, wherein the generator is further configured to generate three-phase AC power;

and,

wherein the rectifier is further configured to rectify the generated three-phase AC power.

8. A method for operating a heavy-duty vehicle hybrid-electric drive system of a heavy-duty vehicle over 10,000 pounds GVWR, the heavy-duty vehicle hybrid-electric drive system including an engine configured to provide a rotating output and a generator mechanically coupled to the engine, the method comprising:

generating an AC power via the generator, the AC power having a variable AC voltage that varies with rotational speed of the engine rotating output;

rectifying the generated AC power via a rectifier;

outputting a first DC power from the rectifier, the first DC power having a variable DC voltage that varies with rotational speed of the engine rotating output;

receiving the first DC power into a DC/DC converter electrically coupled to the rectifier;

outputting a second DC power from the DC/DC converter;

controlling the DC/DC converter via a controller, such that the second DC power is outputted having a stabilized DC voltage that does not vary with rotational speed of the engine;

inverting the second DC power through a DC/AC inverter electrically coupled to the DC/DC converter;

outputting an AC power having a stabilized AC voltage, that does not vary with rotational speed of the engine, from the DC/AC inverter; and

,

driving an electric motor electrically coupled to the DC/AC inverter and mechanically coupled to at least one drive wheel of the heavy-duty vehicle using the stabilized AC voltage;

wherein the generator is further configured to generate three-phase AC power;

wherein the rectifier is further configured to rectify the generated three-phase AC power;

wherein the DC/AC inverter comprises three phases of a four-phase IGBT inverter;

wherein the electric motor comprises a three-phase electric motor and is electrically coupled to the three phases of the four-phase IGBT inverter;

wherein the DC/DC converter comprises a reactive inductor and an IGBT solid state high power switching circuit in a choppered configuration, and,

wherein the IGBT solid state high power switching circuit comprises a fourth phase of the four-phase IGBT inverter.

9. The method of claim 8, wherein the engine is further configured to provide a variable rotating output in response to load power demands, and to operate at an optimum efficiency.

10. The method of claim 8, wherein the rectifier comprises one or more multiple-diode rectifiers.

11. The method of claim 8, wherein the controller is configured to provide an output power having a stabilized voltage, that does not vary with rotational speed of the engine, to drive at least one of the following vehicle accessories:

an air conditioner, a hydraulic pump, an air compressor, one or more fans, one or more blowers, a water pump, an oil pump, a fuel pump, a vacuum pump, and an electric hydraulic actuator.

12. The method of claim 8, wherein the controller is configured to provide an output power having a stabilized voltage, that does not vary with rotational speed of the engine, to charge an energy storage device.

13. The method of claim 8, wherein the generator is further configured to generate multiple-phase AC power;

and,

wherein the rectifier is further configured to rectify the generated multiple-phase AC power.

14. The method of claim 8, wherein the generator is further configured to generate three-phase AC power;

and,

wherein the rectifier is further configured to rectify the generated three-phase AC power.