Braking regeneration energy shunt system

• US 8,630,781 B2
• Filed: 08/24/2012
• Issued: 01/14/2014
• Est. Priority Date: 01/28/2008
• Status: Active Grant

• Current Assignee: Textron Innovations Incorporated (Textron Inc)
• Original Assignee: Textron Inc
• Inventors: O'Connor, Sean C., Wilson, Kenneth R., Millard, Jeffrey A.
• Primary Examiner(s): Trammell, James
• Assistant Examiner(s): Do, Truc M
• Application Number:
  US13/593,573
• Publication Number:
  US 20120316721A1
• Time in Patent Office: 508 Days
• Field of Search: 701/71, 701/22, 701/64, 701/90, 320/116, 324/427, 318/139
• US Class Current: 701/71
• CPC Class Codes: A01D 34/78 electric
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2220/20 DC electrical machines
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2250/10 by alarm
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 50/16 with provision for separate direct mechanical propulsion
• CPC Class Codes: B60L 50/64 Constructional details of batteries specially adapted for electric vehicles
• CPC Class Codes: B60L 58/15 Preventing overcharging
• 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: B60L 7/22 Dynamic electric resistor braking, combined with dynamic electric regenerative braking
• 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

Abstract

A regeneration energy shunt system utilizes a module to monitor the power bus voltage and can divert excess regeneration energy to a resistor array to dissipate the excess regeneration energy. The module can monitor the state of charge of an energy storage device to ascertain when excess regeneration energy condition exists. The resistor array can include a plurality of resistors. The module can ascertain the number of resistors needed dissipate the excess regeneration energy and selectively direct the excess regeneration energy to the required number of resistors. The module can dynamically switch which resistors are used to dissipate the excess regeneration energy and can thereby even out the loading across the resistors. The module can ascertain a state of health of the individual resistors and remove unhealthy resistors from service, report the state of health of the resistors, and initiate changes in operation based thereon.

Claims

1. A braking regeneration energy shunt system for a turf maintenance vehicle comprising:

a power bus;

a traction motor coupled to the power bus, the traction motor developing a back electromotive force that can be directed into the power bus as regeneration energy;

an energy storage device coupled to the power bus, the energy storage device selectively providing electric current to the power bus and selectively receiving electric current from the power bus;

a resistor array having a plurality of resistors, the resistor array selectively dissipating regeneration energy into heat;

a control module monitoring at least one of a voltage of the power bus and a state of charge of the energy storage device, the control module selectively directing regeneration energy created by the traction motor into the resistor array for dissipation as heat based on at least one of the voltage of the power bus and the state of charge of the energy storage device;

wherein the control module ascertains the number of resistors needed to dissipate the regeneration energy directed to the resistor array and directs the regeneration energy simultaneously to the ascertained number of resistors.

2. The system of claim 1, wherein the control module monitors both the voltage of the power bus and the state of charge of the energy storage device and selectively directs the regeneration energy into the resistor array based on both the voltage of the power bus and the state of charge of the energy storage device.

3. The system of claim 1, wherein the control module ascertains a state of health of the resistors and selectively directs the regeneration energy only to one or more of the resistors that are ascertained as healthy.

4. The system of claim 3, wherein the control module determines an impedance of each of the resistors and ascertains the state of health of each of the resistors based on the impedance.

5. The system of claim 3, wherein the control module signals when the state of health of a resistor is below a predetermined value.

6. The system of claim 1, wherein the resistor array includes a temperature sensor sending a signal to the control module indicative of a temperature of the resistor array and the control module monitors the temperature of the resistor array and prevents the regeneration energy from being directed to the resistor array when the temperature exceeds a threshold value.

7. The system of claim 1, wherein the control modules ascertains the number or resistors needed based on the voltage of the power bus.

8. The system of claim 7, wherein the control module increases the number of resistors simultaneously being directed the regeneration energy as the voltage of the power bus increases.

9. The system of claim 1, wherein the control module compares the voltage of the power bus to a plurality of predetermined values and changes the number of resistors simultaneously being directed the regeneration energy based on the comparison.

10. The system of claim 1, wherein when the ascertained number of resistors is less than a total number of resistors, the control module distributes loading of the regeneration energy over all of the resistors by actively switching which resistors are directed the regeneration energy as the regeneration energy is being dissipated.

11. The system of claim 1, wherein when the energy storage device is fully charged, the control module directs the regeneration energy to the resistor array.

12. A turf maintenance vehicle comprising:

an energy storage device;

a power bus coupled to the energy storage device and receiving electrical energy therefrom;

at least one driven wheel;

at least one electric motor coupled to the power bus and operable to drive the at least one driven wheel, the at least one electric motor creating regeneration energy during deceleration, the regeneration energy operable to provide energy to the energy storage device;

a resistor array having a plurality of resistors, the resistor array selectively dissipating regeneration energy directed thereto into heat; and

a control module monitoring at least one of a voltage of the power bus and a state of charge of the energy storage device, the control module selectively directing the regeneration energy created by the at least one motor into the resistor array for dissipation as heat based on at least one of the voltage of the power bus and the state of charge of the energy storage device;

wherein the control module ascertains the number of resistors needed to dissipate the regeneration energy directed to the resistor array and directs the regeneration energy simultaneously to the ascertained number of resistors.

13. The turf maintenance vehicle of claim 12, wherein the control module ascertains a state of health of the resistors and selectively directs the regeneration energy only to one or more of the resistors that are ascertained as healthy.

14. The turf maintenance vehicle of claim 13, wherein the control module determines an impedance of each of the resistors and ascertains the state of health of each of the resistors based on the impedance.

15. The turf maintenance vehicle of claim 13, wherein the control module signals when the state of health of a resistor is below a predetermined value.

16. The turf maintenance vehicle of claim 12, wherein the resistor array includes a temperature sensor sending a signal to the control module indicative of a temperature of the resistor array and the control modules monitors the temperature of the resistor array and prevents the regeneration energy from being directed to the resistor array when the temperature exceeds a threshold value.

17. The turf maintenance vehicle of claim 12, wherein the control modules ascertains the number or resistors needed based on the voltage of the power bus.

18. The turf maintenance vehicle of claim 17, wherein the control module increases the number of resistors simultaneously being directed the regeneration energy as the voltage of the power bus increases.

19. The turf maintenance vehicle of claim 12, wherein the control module compares the voltage of the power bus to a plurality of predetermined values and changes the number of resistors simultaneously being directed the regeneration energy based on the comparison.

20. The turf maintenance vehicle of claim 12, wherein when the ascertained number of resistors is less than a total number of resistors, the control module distributes loading of the regeneration energy over all of the resistors by actively switching which resistors are directed the regeneration energy as the regeneration energy is being dissipated.

21. The turf maintenance vehicle of claim 12, wherein when the state of charge of the energy storage device exceeds a predetermined threshold, the control module directs the regeneration energy to the resistor array.

22. The turf maintenance vehicle of claim 12, further comprising an engine and a generator operable to supply electrical power to the power bus, the engine and generator being a primary source of electrical power supplied to the power bus and wherein the energy storage device selectively supplements the primary source of electrical power during high load conditions.

23. The turf maintenance vehicle of claim 12, wherein the control module monitors both the voltage of the power bus and the state of charge of the energy storage device and selectively directs the regeneration energy into the resistor array based on both the voltage of the power bus and the state of charge of the energy storage device.

24. A method of dissipating regeneration energy created in a turf maintenance vehicle having a power bus, an energy storage device, and a resistor array having a plurality of resistors, the method comprising:

monitoring a voltage of the power bus;

monitoring a state of charge of the energy storage device;

creating regeneration energy during deceleration of the turf maintenance vehicle;

selectively routing the regeneration energy to the energy storage device when the state of charge is less than a predetermined value;

selectively routing the regeneration energy to the resistor array when the state of charge is greater than the predetermined value;

dissipating the regeneration energy with at least two of the resistors in the resistor array when the regeneration energy is routed to the resistor array;

determining the number of resistors needed to dissipate the regeneration energy directed to the resistor array; and

directing the regeneration energy simultaneously to the ascertained number of resistors.

25. The method of claim 24, further comprising ascertaining a state of health of the resistors in the resistor array and wherein dissipating the regeneration energy includes dissipating the regeneration energy with only resistors ascertained as being healthy.

26. The method of claim 25, further comprising monitoring an impedance of each of the resistors and wherein ascertaining the state of health includes comparing the impedance of each of the resistors to a predetermined standard.

27. The method of claim 25, further comprising signaling when the state of health of a resistor is below a predetermined value.

28. The method of claim 25, wherein selectively routing the regeneration energy to the resistor array includes routing the regeneration energy to the resistor array when the rechargeable power source is fully charged.