Electric drive vehicle control system

• US 8,234,026 B2
• Filed: 09/11/2008
• Issued: 07/31/2012
• Est. Priority Date: 09/11/2007
• Status: Active Grant

• Current Assignee: Hydro-Gear Limited Partnership
• Original Assignee: Hydro-Gear Limited Partnership
• Inventors: Wyatt, Christopher K., Fox, Ivan E.
• Primary Examiner(s): To, Tuan C.
• Application Number:
  US12/209,074
• Publication Number:
  US 20090069964A1
• Time in Patent Office: 1,419 Days
• Field of Search: 702/22, 180/65.8
• US Class Current: 701/22
• CPC Class Codes: A01D 34/78 electric
• CPC Class Codes: B60K 7/0007 the motor being electric
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 3/00 Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00
• CPC Class Codes: B60L 3/0092 with use of redundant elements for safety purposes
• CPC Class Codes: B60L 50/51 characterised by AC-motors
• CPC Class Codes: B60L 58/24 for controlling the temperature of batteries
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• CPC Class Codes: B60W 10/184 with wheel brakes
• CPC Class Codes: B60W 10/30 including control of auxiliary equipment, e.g. air-conditioning compressors or oil pumps
• CPC Class Codes: B60W 30/18127 Regenerative braking
• CPC Class Codes: B60W 30/1886 Controlling power supply to auxiliary devices
• CPC Class Codes: B60W 30/1888 Control of power take off [PTO]
• CPC Class Codes: H04L 12/403 with centralised control, e.g. polling
• 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 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles
• CPC Class Codes: Y10S 903/902 Prime movers comprising electrical and internal combustion motors

Abstract

Electronic control systems and related control methods for controlling electric drive motors for propelling a vehicle and electric auxiliary motors for performing work. The apparatus is shown in use with a vehicle that includes a mowing deck. Features of the control systems allow for safe and efficient use of the vehicle. These features include a power take-off timeout, automatic fail-safe brake (parking), and customized drive characteristics.

Claims

1. A control system for an electric drive system of a vehicle having at least one electric drive motor in communication with a driven wheel of the vehicle, the control system comprising:

an accelerator of the vehicle capable of causing generation of an accelerator input signal;

a plurality of sensors mounted within the vehicle and each providing a sensor input signal;

a drive controller in communication with the at least one electric drive motor to facilitate adjustment thereto based on the accelerator input signal and at least one of the sensor input signals; and

an auxiliary controller in communication with at least one electric auxiliary motor and the drive controller to facilitate adjustment of the at least one electric auxiliary motor.

2. The control system of claim 1, wherein the auxiliary controller controls the at least one electric auxiliary motor based on at least one operational state of the vehicle.

3. The control system of claim 1, further comprising a capacitor in communication with the auxiliary controller to back-drive the at least one electric auxiliary motor to stop it within a predetermined interval when a vehicle on-off key switch is moved to an off position while the at least one electric auxiliary motor is running.

4. The control system of claim 1, wherein the drive controller includes computer-executable instructions stored therein for performing energy management steps when a power supply minimum voltage threshold is reached, the steps comprising:

removing power from the at least one electric auxiliary motor; and

reducing allowed vehicle travel speed to a first specified percentage of a programmed maximum vehicle travel speed.

5. The control system of claim 4, further comprising the step of:

further reducing the allowed vehicle travel speed to a second specified percentage of the programmed maximum vehicle travel speed if the power supply minimum voltage threshold is reached after a first reduction of speed.

6. The control system of claim 5, further comprising the step of:

disabling the drive controller if the power supply minimum voltage threshold is reached after a second reduction of speed.

7. The control system of claim 5, further comprising the step of:

entering the vehicle into a hibernation state if the power supply minimum voltage threshold is reached after a second reduction of speed.

8. The control system of claim 1, wherein the at least one electric auxiliary motor drives at least one cutting blade for mowing.

9. The control system of claim 8, wherein the drive controller includes computer-executable instructions and programmable settings stored therein for manufacturer selection of mowing options of a reverse operating system.

10. The control system of claim 9, wherein one of the programmable settings allows mowing at a programmed reduced speed while traveling in reverse.

11. The control system of claim 9, wherein one of the programmable settings allows mowing at a programmed reduced speed while traveling in reverse only when a reverse operating system mode is selected by a vehicle operator.

12. The control system of claim 9, wherein one of the programmable settings prohibits mowing while traveling in reverse.

13. A control system for an electric drive system of a vehicle having at least one electric drive motor in communication with a driven wheel of the vehicle and at least one electric auxiliary motor in communication with an implement of the vehicle, the control system comprising:

an accelerator of the vehicle capable of causing generation of an accelerator input signal;

a vehicle direction switch capable of causing generation of a direction input signal,

a plurality of sensors mounted within the vehicle and each providing a sensor input signal;

a drive controller in communication with the at least one electric drive motor to facilitate adjustment thereto based on the accelerator input signal, the direction input signal, and at least one of the sensor input signals; and

an auxiliary controller in communication with the at least one electric auxiliary motor and the drive controller to facilitate adjustment of the at least one electric auxiliary motor based on one or more operational states of the vehicle.

14. The control system of claim 13, wherein the drive controller is in communication with the auxiliary controller via a CAN bus.

15. The control system of claim 13, wherein the auxiliary controller is programmed to stop the at least one electric auxiliary motor if the vehicle is not moving for a predetermined period of time.

16. The control system of claim 13, wherein the auxiliary controller is programmed to regulate a PWM frequency used in driving the electric auxiliary motor in response to sensed changes in the one or more operational states of the vehicle.

17. The control system of claim 13, wherein the auxiliary controller communicates with the drive controller to initiate a vehicle speed reduction when the at least one electric auxiliary motor is under a predetermined load increase.

18. The control system of claim 13, wherein the drive controller is programmed to engage a brake of the vehicle if the vehicle is in an emergency state.

19. The control system of claim 13, wherein the drive controller is programmed to operate the at least one electric drive motor within a reduced speed range when the at least one electric auxiliary motor is in operation.

20. The control system of claim 13, further comprising:

a manual release mechanism in communication with a brake of the vehicle; and

a switch integrated with the manual release mechanism and in communication with the drive controller, the switch cooperating with the drive controller to disable the at least one electric drive motor when actuated.

21. The control system of claim 13, wherein the drive controller is programmed to control the at least one electric drive motor based on one or more acceleration and deceleration curves.

22. The control system of claim 21, wherein an operator of the vehicle can select the one or more acceleration and deceleration curves.