Electric drive vehicle retrofit system and associated method

• US 8,001,906 B2
• Filed: 05/07/2007
• Issued: 08/23/2011
• Est. Priority Date: 05/07/2007
• Status: Active Grant

• Current Assignee: General Electric Company
• Original Assignee: General Electric Company
• Inventors: Salasoo, Lembit, Kumar, Ajith Kuttannair, King, Robert Dean
• Primary Examiner(s): Le; Mark T
• Application Number:
  US11/745,180
• Publication Number:
  US 20080276825A1
• Time in Patent Office: 1,569 Days
• Field of Search: 104/289, 104/288, 104/287, 105/35, 105/26.05, 105/49, 105/50, 105/61, 320/101, 320/125, 320/126, 320/137, 320/140, 320/166, 320/167, 320/150, 180/65.3, 180/65.4, 290/14, 290/17, 290/25, 290/40.R, 290/50, 290/51, 290/9, 318/139, 318/376, 318/432
• US Class Current: 105/61
• CPC Class Codes: B60K 1/02 comprising more than one electric motor
• CPC Class Codes: B60K 6/26 characterised by the motors or the generators
• CPC Class Codes: B60K 6/28 characterised by the electric energy storing means, e.g. batteries or capacitors
• CPC Class Codes: B60K 6/30 characterised by chargeable mechanical accumulators, e.g. flywheels
• CPC Class Codes: B60K 6/32 characterised by the fuel cells
• CPC Class Codes: B60K 6/405 Housings
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2270/40 related to technical updates when adding new parts or software
• 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 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 50/62 charged by low-power generators primarily intended to support the batteries, e.g. range extenders
• CPC Class Codes: B60L 58/26 by cooling
• CPC Class Codes: B60L 58/27 by heating
• CPC Class Codes: B60W 10/06 including control of combustion engines
• CPC Class Codes: B60W 10/08 including control of electric propulsion units, e.g. motors or generators
• 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 20/10 Controlling the power contribution of each of the prime movers to meet required power demand
• CPC Class Codes: B60W 2510/083 Torque
• CPC Class Codes: H01M 10/052 : Li-accumulators
• CPC Class Codes: H01M 10/345 : Gastight metal hydride accumulators
• CPC Class Codes: H01M 10/44 : Methods for charging or discharging circuits for charging H02J7/00
• CPC Class Codes: H01M 10/48 : Accumulators combined with arrangements for measuring, testing or indicating the condition of cells, e.g. the level or density of the electrolyte constructional details of current conducting connections for detecting conditions inside cells or batteries, e.g. details of voltage sensing terminals, H01M50/569
• CPC Class Codes: H01M 10/613 : Cooling or keeping cold
• CPC Class Codes: H01M 10/615 : Heating or keeping warm
• CPC Class Codes: H01M 10/625 : Vehicles
• CPC Class Codes: H01M 10/633 : characterised by algorithms, flow charts, software details or the like
• CPC Class Codes: H01M 10/637 : characterised by the use of reversible temperature-sensitive devices, e.g. NTC, PTC or bimetal devices; characterised by control of the internal current flowing through the cells, e.g. by switching means for preventing undesired use or discharge H01M50/572
• CPC Class Codes: Y02E 60/10 : Energy storage using batteries
• 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 system is provided for retrofitting an electrically propelled vehicle. The vehicle has an engine-driven generator, and at least a first traction motor and a second traction motor coupled to the generator. The system includes an energy storage device capable of being coupled to at least the first traction motor; and a control system operable to control a distribution of propulsive power between the first traction motor and the second traction motor. An associated method and a retrofit kit are provided, also.

Claims

1. A system for retrofitting an electrically propelled vehicle having an engine-driven generator, and at least a first traction motor coupled to the generator and a second traction motor, comprising:

a control system for controlling a distribution of propulsive power between the first traction motor and the second traction motor, wherein;

the control system controls the vehicle at a first speed, at a first torque, and both at the first speed and the first torque, by using the second traction motor alone in one mode of operation, and by using the second traction motor in combination with the first traction motor in another mode of operation;

the control system controls the vehicle at a second torque and a second speed by using the first traction motor, wherein the second speed is higher than the first speed and the second torque is lower than the first torque; and

an energy storage device coupled to at least the second traction motor;

the control system initiates a braking event calling for an amount of a required braking power for a vehicle having an electric motor that can drive a wheel, and having an energy storage device, an electric converter, and a power switch coupled to the electric motor;

the control system determines a first available braking power based on a component limiting factor determined by at least one of;

power capacity of the electric motor, torque capacity of the electric motor, maximum adhesion limit of the wheel on a wheel-bearing surface, electrical uptake capacity of the energy storage device, electrical rating capacity of the electronic converter, or electrical rating capacity of the power switch;

the control system compares the first available braking power to the required braking power;

the control system meets the required braking power first with the first available braking power; and

the control system supplements the first available braking power with a second available braking power where the first available braking power is insufficient to meet the required braking power, and the second available braking power is based on at least a capacity of a dynamic braking grid resistor array coupled thereto.

2. The system as defined in claim 1, wherein the electrically propelled vehicle is a locomotive.

3. The system as defined in claim 1, further comprising a diesel engine coupled to the generator.

4. The system as defined in claim 1, wherein the first traction motor and the second traction motor are part of a plurality of traction motors.

5. The system as defined in claim 1, wherein the energy storage device comprises a high temperature battery that operates at a temperature in a range of from about 260 degrees Celsius to about 450 degrees Celsius.

6. The system as defined in claim 1, wherein the energy storage device is a metal halide battery.

7. The system as defined in claim 1, wherein the energy storage device comprises one or more of a lithium battery, a nickel metal hydride battery, a flywheel, or an ultracapacitor.

8. The system as defined in claim 1, wherein the energy storage device is coupled to the second traction motor via at least one of a diode, a contactor, a manual disconnect switch, or a silicon controlled rectifier.

9. The system as defined in claim 1, wherein the first energy storage device has a first portion and a second portion, and the first portion and the second portion are switchable from a first operating mode in which the first portion and the second portion are electrically connected in parallel, and a second operating mode in which the first portion and the second portion are electrically connected in serial.

10. The system as defined in claim 1, further comprising a temperature control system capable of affecting a temperature in the energy storage device.

11. The system as defined in claim 10, wherein the energy storage device comprises a first portion and a second portion, both of which are disposed in a common housing, and the common housing is in operational association with the temperature control system.

12. The system as defined in claim 11, wherein the temperature control system comprises at least one temperature sensor, at least one temperature control device, and a thaw controller that communicates with the sensor and controls the thermal source to change or maintain the environment inside the common housing.

13. The system as defined in claim 10, wherein the energy storage device comprises a first portion and a second portion, and the first portion and the second portion are disposed in a respective first housing and second housing, and each of the first housing and the second housing is in operational association with the temperature control system.

14. The system as defined in claim 13, wherein the temperature control system comprises at least one temperature sensor in each of the first housing and the second housing, at least one thermal source in each of the first housing and the second housing, and a thaw controller that communicates with each sensor and controls each thermal source to change or maintain an environment inside at least a respective one of the first housing and the second housing.

15. The system as defined in claim 14, wherein the thaw controller is operable to initiate a thaw process by controlling the thermal source to increase a local environment temperature up to and within an operating temperature range based on determined heat ramp rates.

16. The system as defined in claim 14, wherein the thaw controller is operable to initiate a cooling process to control the thermal source to decrease a local environment temperature down to and within an operating temperature range.

17. A vehicle comprising the system as defined in claim 1.

18. The vehicle as defined in claim 17, wherein the control system initiates the second traction motor to propel the vehicle at the first speed and the first torque by supplying electricity at a first voltage from the energy storage device to the second traction motor;

and initiates the first traction motor to propel the vehicle at the second speed and the second torque by supplying electricity at a second voltage from an engine-driven generator to the first traction motor, wherein the second speed is higher than the first speed, the second torque is lower than the first torque, and the second voltage is higher than the first voltage.

19. The vehicle as defined in claim 17, further wherein the control system monitors for component failure in a second traction drive system that contains the second traction motor and the energy storage device;

and the control system is further operable to respond to a component failure indication of the second traction drive system by;

routing energy to and from the second traction motor to a second energy storage device, or routing energy to and from the energy storage device to a traction motor other than the second traction motor.