Resistor grid assembly

• US 8,692,647 B2
• Filed: 12/15/2011
• Issued: 04/08/2014
• Est. Priority Date: 12/15/2011
• Status: Active Grant

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Bailey, Bradley S., Brown, Gerald M.
• Primary Examiner(s): LEE, KYUNG S
• Application Number:
  US13/326,875
• Publication Number:
  US 20130154523A1
• Time in Patent Office: 845 Days
• Field of Search: 338/279, 338/280, 338/281, 338/283, 338/284, 338/287, 338/288, 338/291
• US Class Current: 338/279
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2210/30 AC to DC converters
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 2220/14 Synchronous machines
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 50/61 by batteries charged by engine-driven generators, e.g. series hybrid electric vehicles
• CPC Class Codes: B60L 7/22 Dynamic electric resistor braking, combined with dynamic electric regenerative braking
• CPC Class Codes: H01C 1/08 Cooling, heating or ventilating arrangements
• CPC Class Codes: H01C 3/00 Non-adjustable metal resistors made of wire or ribbon, e.g. coiled, woven or formed as grids
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• 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 resistor unit adapted to be used in a resistor grid assembly. The resistor unit includes a supporting element and a resistor element. The supporting element has an aperture formed therein. The resistor element has a body portion and a tip portion at an end, which is adapted to be received in the aperture to mount the resistor element to the supporting element. Further, a tab extends from the end of the resistor element forming a part of the resistor element. The tab is configured to provide a heat shield between the supporting element and the resistor element.

Claims

1. A resistor unit adapted to be used in a resistor grid assembly, the resistor unit comprising:

a supporting element having an aperture formed therein;

a resistor element having a body portion extending along a longitudinal direction and a tip portion disposed at an end of the body portion, the tip portion of the resistor element adapted to be received in the aperture to mount the resistor element on the supporting element; and

a tab extending from the end of the body portion in a substantially transverse direction, the tab is configured to provide a heat shield between the supporting element and the resistor element.

2. The resistor unit of claim 1, wherein the supporting element is in the shape of a block made of insulating material.

3. The resistor unit of claim 1, wherein the resistor element is formed from a continuous strip made of resistive material.

4. The resistor unit of claim 1, wherein the resistor element includes a series of reflexed portions formed at opposite longitudinal sides.

5. The resistor unit of claim 1, wherein the resistor element further includes a slot adjacent to the end of the body portion.

6. The resistor unit of claim 5, wherein the slot extends along the longitudinal direction.

7. The resistor unit of claim 1, wherein the tab forms a part of the resistor element.

8. The resistor unit of claim 6, wherein the tab is formed by bending a portion of the resistor element.

9. The resistor unit of claim 1, wherein the tab is fastened to the body portion at the end.

10. A resistor grid assembly comprising:

a housing;

two or more resistor units disposed in the housing, the resistor unit including;

a plurality of supporting elements affixed to the housing, the supporting elements have multiple apertures formed therein;

one or more resistor elements having a body portion extending along a longitudinal direction and a tip portion disposed at an end of the body portion, the tip portion adapted to be received in the multiple apertures to mount the one or more resistor elements to the plurality of supporting elements, and

a tab extending from the end in a transverse direction, the tab is configured to provide a heat shield between the supporting element and the resistor element; and

a conducting member configured to electrically connect the two or more resistor units in the housing.

11. The resistor grid assembly of claim 10, wherein the housing is cylindrical in shape.

12. The resistor grid assembly of claim 10, wherein the supporting element is in the shape of a block made of insulating material.

13. The resistor grid assembly of claim 10, wherein the one or more resistor elements are disposed substantially parallel to each other in the housing.

14. The resistor grid assembly of claim 10, wherein the resistor element is formed from a continuous strip made of resistive material.

15. The resistor grid assembly of claim 10, wherein the resistor element includes a slot adjacent to the end of the body portion and extending along the longitudinal direction.

16. The resistor grid assembly of claim 10, wherein the tab forms a part of the resistor element.

17. The resistor grid assembly of claim 16, wherein the tab is formed by bending a portion of the resistor element.

18. The resistor grid assembly of claim 10, wherein the tab is fastened to the body portion at the end.

19. A dynamic braking system for a machine including a power source operatively associated with a plurality of drive motors to drive a set of drive wheels, the dynamic braking system comprising:

a control unit configured to generate a braking signal based at least in part on an operator command, the braking signal reverses a torque polarity of the plurality of drive motors to generate electric power from the set of drive wheels; and

a resistor grid assembly as set forth in claim 10.

20. The dynamic braking system of claim 19 further including an energy storage unit to store the electric power for use in the machine.