Systems and methods for cooling a controller assembly

• US 9,756,788 B1
• Filed: 02/13/2015
• Issued: 09/12/2017
• Est. Priority Date: 06/26/2009
• Status: Active Grant

• Current Assignee: Hydro-Gear Limited Partnership
• Original Assignee: Hydro-Gear Limited Partnership
• Inventors: Hauser, Raymond, Reid, Bruce E., Rousser, Donald, Keller, Scott W.
• Primary Examiner(s): Will, Thomas B
• Assistant Examiner(s): Misa, Joan D
• Application Number:
  US14/622,340
• Time in Patent Office: 942 Days
• Field of Search: 180 681, 180 686, 2961801, 2961805, 296 91, 56 1, 56 119, 56 128, 56 168, 56 175, 563201
• CPC Class Codes: A01D 34/64 mounted on a vehicle, e.g. a tractor, or drawn by an animal or a vehicle A01D34/695 takes precedence
• CPC Class Codes: A01D 34/78 electric
• CPC Class Codes: A01D 34/81 Casings; Housings A01D34/71 takes precedence
• CPC Class Codes: A01D 42/00 Mowers convertible to apparatus for purposes other than mowing; Mowers capable of performing operations other than mowing mowers combined with apparatus performing additional operations while mowing A01D43/00
• CPC Class Codes: A01D 69/02 electric
• CPC Class Codes: B60L 1/003 to auxiliary motors, e.g. for pumps, compressors
• CPC Class Codes: B60L 2200/40 Working vehicles
• CPC Class Codes: B60L 2220/44 Wheel Hub motors, i.e. integrated in the wheel hub
• CPC Class Codes: B60L 2240/36 Temperature of vehicle components or parts
• CPC Class Codes: B60L 2270/145 Structure borne vibrations
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/66 Arrangements of batteries
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries

Abstract

Apparatus and methods for cooling controller assemblies for electric utility vehicles are disclosed. Auxiliary implements powered by electric motors onboard a utility vehicle create airflow that is captured and directed to provide increased ambient airflow across heat sinks used to dissipate heat from heat generating components. Airflow across heated surfaces is further created by vehicle movement and vacuum pressure. Fins and other heat dissipating architecture are employed. Features of the cooling systems enable increased controller assembly functionality and/or decreased controller assembly package size.

Claims

1. A drive system for a utility vehicle including a pair of driven wheels, a pair of non-driven wheels, and a mowing deck disposed on a vehicle frame and having at least one cutting blade for cutting vegetation, the drive system comprising:

a pair of electric drive motors disposed on the vehicle frame, each of the pair of electric drive motors engaged to and driving one of the pair of driven wheels;

an electric auxiliary motor disposed on the mowing deck and driving an output shaft extending through the mowing deck for driving the at least one cutting blade; and

a controller for managing the pair of electric drive motors, the controller comprising a controller housing mounted on a first side of the mowing deck, and a thermal conducting base plate connected to the controller housing and extending through the mowing deck to a second side of the mowing deck,

wherein the at least one cutting blade is located on the second side of the mowing deck and the at least one cutting blade generates an airflow that comes into contact with the thermal conducting base plate.

2. The drive system of claim 1, wherein the controller is located at a position on the mowing deck where the at least one cutting blade does not pass directly beneath the controller.

3. The drive system of claim 1, wherein the at least one cutting blade comprises three cutting blades and the controller is located at a position on the mowing deck where none of the three cutting blades pass directly beneath the controller.

4. The drive system of claim 1, wherein the controller is disposed at a first height with respect to the at least one cutting blade and the electric auxiliary motor is disposed at a second height, different from the first height, with respect to the at least one cutting blade.

5. The drive system of claim 4, wherein the second height is greater than the first height.

6. The drive system of claim 1, wherein the controller comprises a gasket disposed between the controller housing and the base plate to form a seal there between, and wherein the base plate comprises a member forming a heat sink and extending downwardly from a generally planar surface on the base plate.

7. A utility vehicle comprising:

a frame;

a pair of driven wheels disposed on the frame;

a mowing deck disposed on the frame and having a top surface and a bottom surface;

an electric auxiliary motor disposed adjacent to the top surface of the mowing deck and having an output shaft extending through to the bottom surface of the mowing deck;

at least one cutting blade engaged to and driven by the output shaft, wherein the at least one cutting blade is disposed below the bottom surface of the mowing deck;

a pair of electric drive motors disposed on the frame, each electric drive motor being engaged to and driving one of the pair of driven wheels, and each of the pair of electric drive motors being engaged to and electrically controlled by a controller disposed on the mowing deck, wherein the controller comprises a controller housing disposed above the top surface of the mowing deck, and a heat sink connected to the controller housing, wherein the heat sink extends through a cutaway in the mowing deck to the bottom surface so as to come into contact with an airflow generated by the at least one cutting blade.

8. The utility vehicle of claim 7, wherein the at least one cutting blade comprises a plurality of cutting blades connected to the output shaft by a belt and pulley system.

9. The utility vehicle of claim 7, wherein the controller comprises a gasket disposed between the controller housing and a base plate to form a seal there between, and wherein the heat sink comprises a member extending downwardly from the base plate.

10. The utility vehicle of claim 7, wherein the controller is disposed at a first height with respect to the at least one cutting blade and the electric auxiliary motor is disposed at a second height, different from the first height, with respect to the at least one cutting blade.

11. The utility vehicle of claim 10, wherein the second height is greater than the first height.

12. The utility vehicle of claim 11, wherein the controller is located at a position on the mowing deck where the at least one cutting blade does not pass directly beneath the controller.

13. The utility vehicle of claim 12, wherein the at least one cutting blade comprises three cutting blades and the controller is located at a position on the mowing deck where none of the three cutting blades pass directly beneath the controller.

14. A utility vehicle comprising:

a mowing deck disposed on a vehicle frame, the mowing deck having a first side and a second side, opposite to the first side, and at least one cutting blade disposed below the second side;

a pair of electric drive motors disposed on the vehicle frame, each drive motor being engaged to and driving one of a pair of driven wheels; and

an electric auxiliary motor disposed adjacent to the first side of the mowing deck and having an output shaft extending through to the second side of the mowing deck and driving the at least one cutting blade, wherein the electric auxiliary motor is engaged to and electrically controlled by a controller disposed on the first side of the mowing deck, and wherein the controller comprises a heat sink that extends through a cutaway in the mowing deck to the second side so as to come into contact with an airflow generated on the second side by the at least one cutting blade.

15. The utility vehicle of claim 14, wherein the at least one cutting blade comprises a plurality of cutting blades connected to the output shaft by a belt and pulley system.

16. The utility vehicle of claim 15, wherein the controller comprises a gasket disposed between a controller housing and a base plate to form a seal there between, and wherein the heat sink comprises a member extending downwardly from the base plate.

17. The utility vehicle of claim 15, wherein the controller is disposed at a first height with respect to the at least one cutting blade and the electric auxiliary motor is disposed at a second height, greater than the first height, with respect to the plurality of cutting blades.

18. The utility vehicle of claim 14, wherein the at least one cutting blade comprises three cutting blades and the controller is located at a position on the mowing deck where none of the three cutting blades pass directly beneath the controller.

19. The utility vehicle of claim 14, wherein the controller is located at a position on the mowing deck where the at least one cutting blade does not pass directly beneath the controller.