Cooling system for an electric drive machine and method

• US 7,918,296 B2
• Filed: 09/15/2008
• Issued: 04/05/2011
• Est. Priority Date: 09/15/2008
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Reddy, Suresh B.
• Primary Examiner(s): PHAN, HAU VAN
• Application Number:
  US12/210,874
• Publication Number:
  US 20100065355A1
• Time in Patent Office: 932 Days
• Field of Search: 180/68.1, 180/68.2, 180/68.3, 180/68.5, 180/339, 123/559.1, 123/564
• US Class Current: 180/68.3
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 11/06 with air cooling
• CPC Class Codes: B60K 11/08 Air inlets for cooling; Shutters or blinds therefor radiator or grille guards B60R19/52
• CPC Class Codes: B60K 2001/003 with means for cooling the electrical propulsion units
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60K 7/0007 the motor being electric
• CPC Class Codes: B60K 7/0015 the motor being hydraulic
• CPC Class Codes: B60K 7/0023 the motor being pneumatic
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 2240/441 Speed
• CPC Class Codes: B60L 2240/445 Temperature
• CPC Class Codes: B60W 10/30 including control of auxiliary equipment, e.g. air-conditioning compressors or oil pumps
• 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 2510/0638 Engine speed
• CPC Class Codes: B60W 2510/0676 Engine temperature
• CPC Class Codes: B60W 2510/081 Speed
• CPC Class Codes: B60W 2510/083 Torque
• CPC Class Codes: B60Y 2200/14 Trucks; Load vehicles, Busses
• CPC Class Codes: B60Y 2200/142 Heavy duty trucks
• CPC Class Codes: B60Y 2200/412 : Excavators
• CPC Class Codes: Y02T 10/62 : Hybrid vehicles
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility

Abstract

A cooling system (500) for an electric drive system includes a cooling duct (502) extending between a first component and a second component. A motor (336) driven fan (510) creates an airflow within the duct. A first temperature sensor measures a first temperature of the first component and a second temperature sensor measures a second temperature of the second component. An electronic controller (540) receives the first temperature and calculates a first temperature difference between the first temperature and the first temperature limit (802) to generate a first command (836) for the motor (336). A second temperature difference between the second temperature and the second temperature limit (802) generates a second command (836) for the motor (336). The controller (540) then selects the greater of the first command (836) and the second command (836) to yield the maximum command (836), and controls the motor (336) based on the maximum command (836).

Claims

1. A cooling system for cooling one or more components of an electric drive system in a machine, comprising:

a cooling duct extending between a first component and a second component of the machine;

a fan disposed to create an airflow within the cooling duct when the fan is operating;

a motor disposed to rotate the fan;

a first temperature sensor disposed to measure a first temperature of the first component, the first temperature being associated with a first temperature limit;

a second temperature sensor disposed to measure a second temperature of the second component, the second temperature being associated with a second temperature limit;

an electronic controller disposed to control operation of the motor, receive the first temperature, and receive the second temperature, and in response, to calculate a first temperature difference between the first temperature and the first temperature limit and generate a first command for the motor based on the first temperature difference, to calculate a second temperature difference between the second temperature and one of the first temperature limit and the second temperature limit to generate a second command for the motor based on the second temperature difference, to select the greater of the first command and the second command to yield the maximum command, and to control the motor based on the maximum command.

2. The cooling system of claim 1, wherein the first component and the second component are at least two of a chopper circuit, an inverter circuit, a generator bearing, a generator winding, a motor bearing, and a motor winding, that are operably associated with a machine.

3. The cooling system of claim 1, further including at least one of an ambient temperature sensor disposed to measure an air temperature of air entering the cooling duct, an engine speed sensor disposed to measure a speed of an engine associated with the machine, and a barometric pressure sensor disposed to measure a barometric pressure, wherein the electronic controller is disposed to limit each of the first airflow command and the second airflow command based on one of the air temperature, engine speed, and barometric pressure.

4. The cooling system of claim 1, further including a speed sensor disposed to measure a rotational speed of the motor and communicate a fan speed to the electronic controller, wherein the electronic controller is disposed to use the fan speed in a closed loop control system that controls the operation of the motor.

5. The cooling system of claim 1, further including:

a pump operating to circulate a flow of fluid through conduits that are connected to the motor; and

a proportional valve disposed to selectively modulate a flow rate of the flow of fluid in the conduits;

wherein fan motor is a hydrostatic motor whose rotational speed depends on a setting of the proportional valve, and

wherein the electronic controller is disposed to adjust the setting of the proportional valve.

6. The cooling system of claim 1, wherein the machine further includes a hollow drive axle forming a cavity, wherein the first component is an electric drive motor disposed at least partially within the cavity, and wherein the cavity is in fluid communication with the cooling duct and disposed to receive a portion of airflow.

7. A machine having an electric drive system, the electric drive system including an engine that is connected to a generator, the generator having an electrical output connected to a rectifier, the rectifier connected to an inverter, the inverter connected to an electric drive motor, the machine further comprising:

a cooling duct in fluid communication with a first component and a second component;

a fan motor operating a blower disposed within the cooling duct;

a first temperature sensor disposed to measure a first component temperature and to provide a first component temperature sensing signal;

a second temperature sensor disposed to measure a second component temperature and to provide a second component temperature sensing signal; and

an electronic controller disposed to receive the first component temperature sensing signal and the second component temperature sensing signal, to calculate a first difference between the first component temperature and a first component temperature limit and generate a first airflow command based on the first difference, to calculate a second difference between the second component temperature and a second component temperature limit and generate a second airflow command based on the second difference, to compare the first airflow command with the second airflow command to yield a maximum desired airflow, and to command the fan motor to operate such that the maximum desired airflow is generated within the cooling duct.

8. The machine of claim 7, wherein the first component and the second component are, at least two of a chopper circuit, an inverter circuit, a generator bearing, a generator winding, a motor bearing, and a motor winding.

9. The machine of claim 7, further including at least one of an ambient temperature sensor disposed to measure an air temperature of air entering the cooling duct, an engine speed sensor disposed to measure a speed of an engine associated with the machine, and a barometric pressure sensor disposed to measure a barometric pressure, wherein the electronic controller is disposed to limit each of the first airflow command and the second airflow command based on one of the air temperature, engine speed, and barometric pressure.

10. The machine of claim 7, further including a speed sensor disposed to measure a rotational speed of the fan motor and communicate a fan speed to the electronic controller, wherein the electronic controller is disposed to use the fan speed in a closed loop control system that commands the fan motor to operate.

11. The machine of claim 7, further including:

a pump operating to circulate a flow of fluid through conduits that are connected to the fan motor; and

a proportional valve disposed to selectively modulate a flow rate of the flow of fluid in the conduits;

wherein the fan motor is a hydrostatic motor whose rotational speed depends on a setting of the proportional valve, and

wherein the electronic controller is disposed to adjust the setting of the proportional valve.

12. The machine of claim 7, wherein the machine further includes a hollow drive axle forming a cavity, wherein the first component is an electric drive motor disposed at least partially within the cavity, and wherein the cavity is in fluid communication with the cooling duct and disposed to receive a portion of an airflow therefrom.

13. A method of operating a blower disposed in a convective cooling system associated with a first component and a second component of a machine, the cooling system including a cooling duct that directs a cooling flow of air toward the first component and the second component, and a blower operating under the control of a controller to direct a cooling flow of air through the cooling duct, the method comprising:

sensing a first temperature of the first component and providing a first temperature signal indicative of the first temperature;

sensing a second temperature of the second component and providing a second temperature signal indicative of the second temperature;

comparing the first temperature signal to a first temperature limit to yield a first temperature difference;

comparing the second temperature signal to a second temperature limit to yield a second temperature difference;

calculating a first desired airflow based on the first temperature difference;

calculating a second desired airflow based on the second temperature difference;

selecting the greater of the first desired airflow and the second desired airflow to yield a maximum desired airflow; and

operating the blower to generate a flow of air in the cooling duct that is at least equal to the maximum desired airflow.

14. The method of claim 13, wherein calculating the first desired airflow includes:

calculating a proportional term by multiplying the first temperature difference by a proportional gain to yield a proportional term, wherein the proportional gain is at least one of a constant value and a variable value that is based on the first temperature;

calculating an integral term by integrating a difference between the first difference and the first desired airflow;

calculating a feed forward term based on at least one drive parameter that is selected from the group consisting of a torque of a drive motor, a speed of the drive motor, a voltage of the drive motor, a current passing through the drive motor, a voltage between the rectifier and the inverter, a current between the rectifier and the inverter, an engine speed, and a generator excitation voltage; and

summing the proportional term, the integral term, and the feed forward term to yield the first airflow.

15. The method of claim 13, further including sensing an ambient air temperature, a barometric pressure, and an engine speed, wherein calculating the first desired airflow is based on at least one of the ambient air temperature, the barometric pressure, and the engine speed.

16. The method of claim 13, further including measuring a rotational speed of the blower, wherein operating the blower is based on a feedback signal to the electronic controller that is indicative of the rotational speed.

17. The method of claim 13, wherein the first component includes two sub-components, each sub-component having a respective one of two sub-component temperatures, and wherein the first temperature is selected to be a higher of the two sub-component temperatures within the electronic controller.

18. The method of claim 13, further including conductively cooling the first component and the second component with the airflow.

19. The method of claim 13, further including:

impelling a flow of hydraulic fluid through the motor with a pump;

metering the flow of hydraulic fluid with a proportional valve; and

adjusting a command signal that controls the proportional valve;

wherein operating the blower to generate a flow of air in the cooling duct that is at least equal to the maximum desired airflow is accomplished by adjusting the command signal.

20. The method of claim 13, wherein calculating the first desired airflow is accomplished by use of a first proportional/integral control algorithm, calculating the second desired airflow is accomplished by use of a second proportional/integral control algorithm, and operating the blower involves use of a third proportional/integral control algorithm.