Electric powertrain system having bidirectional DC generator

• US 8,310,180 B2
• Filed: 09/20/2010
• Issued: 11/13/2012
• Est. Priority Date: 04/30/2007
• Status: Expired due to Fees

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Adra, Rodwan Tarek
• Primary Examiner(s): Ro, Bentsu
• Assistant Examiner(s): Paul, Antony M
• Application Number:
  US12/885,981
• Publication Number:
  US 20110024212A1
• Time in Patent Office: 785 Days
• Field of Search: 318/375, 318/376, 318/400.01, 318/722, 318/757, 318/799, 318/800, 318/801, 180/65.21, 180/165
• US Class Current: 318/375
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 2220/18 Reluctance machines
• CPC Class Codes: B60L 50/11 using DC generators and DC motors
• 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

An electric powertrain for use with an engine and a traction device is disclosed. The electric powertrain has a DC motor/generator operable to receive at least a portion of a first mechanical output from the engine and produce a DC power output. The DC motor/generator is also operable to receive DC power and produce a second mechanical output. The electric powertrain further has a drivetrain operable to receive the DC power output and use the DC power output to drive the traction device. The drivetrain is also operable to generate DC power when the traction device is operated in a dynamic braking mode.

Claims

1. An electrical powertrain for use with an engine and a traction device, comprising;

a DC motor/generator operable to;

receive a first portion of a first mechanical output from the engine and produce a first DC power output for the traction device; and

receive DC power from the traction device and produce a second mechanical output to drive the engine;

an AC alternator operable to;

receive a second portion of the first mechanical output from the engine and produce an AC power output;

a rectifier coupled with the AC alternator, the rectifier operable to;

convert the AC power output to a second DC power output combinable with the first DC power output of the DC motor/generator; and

a drivetrain operable to;

receive and use the first and second DC power output to drive the traction device in a forward mode; and

generate DC power using a bidirectional power converter directed to the DC motor/generator to drive the engine when the traction device is operated in a dynamic braking mode.

2. The electric powertrain of claim 1, further including a braking grid operable to dissipate as heat a portion of the DC power generated by the drivetrain.

3. The electric powertrain of claim 2, further including a chopper operable to control an amount of DC power dissipated by the braking grid.

4. The electric powertrain of claim 1, wherein the drivetrain includes at least one DC traction motor operable to act as a DC motor and a DC generator.

5. The electric powertrain of claim 1, wherein the drivetrain includes at least one AC traction motor operable to act as an AC motor and an AC generator.

6. The electric powertrain of claim 1, further including a controller operable to:

set the DC motor/generator to act as a DC motor;

set the DC motor/generator to act as a DC generator; and

block a current from flowing from the rectifier to the AC alternator.

7. The electric powertrain of claim 1, wherein the engine is rated to produce a first amount of mechanical power and to receive a second amount of mechanical power, the second amount of mechanical power being less than the first amount of mechanical power;

the DC motor/generator is sized based on the second amount of mechanical power; and

the AC alternator is sized based on a difference between the first and second amounts of mechanical power.

8. The electric powertrain of claim 7, wherein the AC alternator is further sized based on a frequency of the first portion of the first mechanical output delivered to the AC alternator.

9. The electric powertrain of claim 1, wherein:

the engine is rated to produce a maximum amount of mechanical power; and

the DC motor/generator is sized based on the maximum amount of mechanical power.

10. The electric powertrain of claim 1, wherein the drivetrain includes:

at least one AC traction motor operable to act as an AC motor and an AC generator; and

a bidirectional power converter coupled between the DC motor/generator and the at least one AC traction motor, the bidirectional power converter being operable to act as an inverter to receive the first and second DC power output from the DC motor/generator and the rectifier connecting the AC alternator, respectively, to drive the at least one AC traction motor in the forward mode, and operable as a rectifier to generate the DC power directed to the DC motor/generator to drive the engine when the at least one AC traction motor is operated in the dynamic braking mode.

11. The electric powertrain of claim 1, further including a connection to an off-board DC power source, the connection operable to receive DC power from the off-board DC power source to supplement the generated DC power.

12. The electric powertrain of claim 11, wherein the DC motor/generator is further operable to convert at least a portion of the DC power received from the off-board DC power source to at least a portion of the second mechanical output.

13. An electric powertrain for use with an engine and a traction device, comprising:

a differential configured to receive a first mechanical output from the engine and split the mechanical output into a first portion and a second portion;

a DC motor/generator configured to receive the first portion of the first mechanical output and produce a first DC power output for the traction device, and to receive DC power from the traction device and produce a second mechanical output to drive the engine via the differential;

an AC alternator operable to receive the second portion of the first mechanical output and produce an AC power output;

a rectifier coupled with the AC alternator, the rectifier operable to convert the AC power output to a second DC power output combinable with the first DC power output of the DC motor/generator;

at least one AC traction motor operable to act as an AC motor and an AC generator;

and a bidirectional power converter coupled between the DC motor/generator and the at least one AC traction motor, the bidirectional power converter being operable to act as an inverter to receive the first and second DC power output from the DC motor/generator and the rectifier connecting the AC alternator, respectively, to drive the at least one AC traction motor in the forward mode, and operable as a rectifier to generate the DC power directed to the DC motor/generator to drive the engine when the at least one AC traction motor is operated in the dynamic braking mode.

14. The electric powertrain of claim 13, further including a braking grid operable to dissipate as heat a portion of the DC power generated by the bidirectional power converter.

15. The electric powertrain of claim 14, further including a chopper operable to control an amount of DC power dissipated by the braking grid.

16. The electric powertrain of claim 13, further including a connection to an off-board DC power source, the connection operable to receive DC power from the off-board DC power source to supplement the generated DC power.

17. An electric powertrain for use with an engine and a traction device, comprising:

a differential having a first rotatable shaft and a second rotatable shaft configured to produce first and second portions of a first mechanical output received from the engine, the first rotatable shaft rotating at a faster rate than the second rotatable shaft;

a motor/generator configured to;

receive the first portion of a the first mechanical output from the engine and produce a first power output for the traction device; and

receive power from the traction device and produce a second mechanical output to drive the engine;

an AC alternator operable to receive the second portion of the first mechanical output and produce an AC power output at a frequency related to the rotational rate of the first rotational shaft of the differential;

a rectifier coupled with the AC alternator, the rectifier operable to convert the AC power output to a second DC power output combinable with the first DC power output of the DC motor/generator;

a drivetrain configured to;

receive and use the first and second power output to drive the traction device in a forward mode; and

generate power directed to the motor/generator to drive the engine when the traction device is operated in a dynamic braking mode.

18. The electric powertrain of claim 17, wherein the engine is rated to produce a first amount of mechanical power and to receive a second amount of mechanical power, the second amount of mechanical power being less than the first amount of mechanical power;

the motor/generator has a capacity corresponding to the second amount of mechanical power; and

the alternator has a capacity corresponding to a difference between the first and second amount of mechanical power.