POWER SUPPLY SYSTEM FOR A VEHICLE RETARDER, AUTONOMOUS RETARDER AND METHOD FOR MAKING A RETARDER AUTONOMOUS.

Abstract

Power supply system for a vehicle retarder, self-contained retarder, and method for making a retarder self-contained. The power supply system (1) is for a retarder (10) comprising two rotors (11) fixed to a rotating shaft (32) and a stator (12) located between the rotors (11), supported on bearings (33) coupled to the shaft (32). The retarder (10) is fitted with a newly designed modified flange (15). The power supply system (1) comprises a generator (20), with a rotor assembly (21) and a stator (22) for supplying electrical power to the retarder. The modified flange (15) is mounted on the retarder (10), to which the rotor assembly (21) of the generator (20) is attached, thereby unifying the kinematic chain of the generator with that of the retarder.

Description

[0001] POWER SUPPLY SYSTEM FOR A VEHICLE RETARDER, AUTONOMOUS RETARDER AND METHOD FOR MAKING A RETARDER AUTONOMOUS

[0002] RETARDER

[0003] DESCRIPTION

[0004] Technical field of the invention

[0005] The invention belongs to the field of automotive braking systems, more specifically, it relates to electromagnetic braking systems that use eddy currents as the principle. These braking systems require an electrical supply and operate without wear or friction.

[0006] State of the Art

[0007] Electromagnetic retarders generally consist of a central stator and two end rotors, one on each side of the stator. Their operation is based on the variation in the mechanical resistance offered by the rotors as they rotate in a magnetic field. The magnetic field is created by a specific number of electromagnets fixed in a housing and distributed evenly. These retarders require an electrical power supply to supply current to the coils formed by the electromagnets fixed to the stator. The power supply is usually provided by batteries incorporated in the vehicles in which these retarders are installed. The requirements for these batteries are demanding, since the amount of current required is high, to the point where prolonged use of the retarder causes a drop in battery voltage. This drop in voltage requires reducing the retarder's power and even disabling it.

[0008] Brief description of the invention

[0009] The invention relates to a power supply system for a vehicle retarder that resolves or at least mitigates the problems and limitations observed in the prior art, according to the first independent claim. The invention also relates to a set of steps, according to the independent method claim, that make a retarder autonomous by installing at least one generator.

[0010] The power supply system is coupled to a retarder that includes a central stator and two side rotors. Each side rotor is located externally on a different side of the stator. The power supply system includes at least one generator that is coupled to the retarder through coupling means. The generator comprises a rotor assembly and a stator. The coupling of one or more generators to the retarder results in a compact assembly. Thanks to the generator, the retarder is autonomous, providing itself with the electrical energy it requires for operation.

[0011] It's also possible to configure the generator so that, in addition to supplying power to the retarder, it can also supply power to batteries. These batteries store reserve energy and improve energy efficiency.

[0012] Preferably, the generator stator includes a series of coils, and the generator rotor assembly includes a series of permanent magnets arranged in alternating polarity. In operation, the rotor assembly, acting as an inductor, generates a magnetic flux so that the stator, acting as an armature, transforms the magnetic flux into electricity in this configuration.

[0013] Coupling involves assembling non-moving parts. The generator stator is attached to the retarder stator via arms that form a rigid connection between the two.

[0014] The coupling also includes assembling moving parts. For the moving parts, a newly designed flange is provided, located at the end of the retarder. This flange not only secures the vehicle's cardan shaft, but also forms the generator's powertrain. With this configuration, both the retarder rotors and the generator rotor rotate simultaneously on a single axis. The generator rotor is a robust and dynamically balanced component, preferably made of cast aluminum or non-magnetic stainless steel. The permanent magnets that form the pole masses are assembled on its surface, positioned equidistantly and with alternating magnetic poles.To integrate the generator rotor into the rotating part of the retarder, the generator rotor is preferably mounted to a rotor-holder bushing using cotter pins and Seeger washers, thus forming the generator rotor assembly, which is secured to the output flange mounted on the retarder by means of bolts. The generator stator preferably consists of an armature formed by a set of magnetic steel sheets in the shape of a circular crown, assembled and electrically insulated from each other. Slots are provided around its inner perimeter to house the induced coils. Other slots are provided externally for coupling and assembly in an aluminum housing that, with its external cover, closes the assembly.

[0015] The components that allow the generator to be mounted to the retarder, as well as the generator itself, are preferably newly designed, with the unique feature of not having bearings, as they share the retarder's own. It should be noted that, advantageously, the operation of the entire assembly does not alter the functional or cooling characteristics of the retarder or the generator.

[0016] Optionally, the power supply system includes a control module for controlling the generator excitation current according to a control signal. Optionally, the control module includes a rectifier and a voltage stabilizer.

[0017] Thanks to its assembly and configuration, the power system is compact. It is also more versatile, as it can be sized for one or more generators and can be configured to supply the necessary power to the retarder and / or additional elements that require it. For example, the power system can store energy in batteries for use by various vehicle components.

[0018] It is also another object of the invention a self-contained retarder that includes a retarder with the power system, as well as a method for converting a non-self-contained retarder into a self-contained retarder for a vehicle.

[0019] Brief description of the figures

[0020] FIG. 1: Exploded view of an embodiment of the power supply system with a generator. FIG. 2: Sectional representation of FIG. 1.

[0021] FIG. 3: Detailed sectional representation of an assembly sequence from the generator to the retarder drivetrain.

[0022] FIG. 4: Sectional representation of the generator rotor attached to the rotor housing and the new retarder output flange. FIG. 5: Sectional representation AA of several rotating elements of the dual-generator system.

[0023] FIG. 6: Sectional representation AA of several static elements of the dual-generator system. FIG. 7: Sectional representation AA of the complete system with built-in dual generator and vehicle cardan drives.

[0024] FIGS. 8A-8G: Sequence of steps for transforming a vehicle-mounted retarder into a self-contained retarder with two generators.

[0025] FIGS. 9A-9C: Three-dimensional representation of an embodiment of a retarder with the integrated power supply system for installation on a vehicle chassis.

[0026] NUMERICAL REFERENCES

[0027] I Power system.

[0028] 10 Retarder.

[0029] II Retarder rotors. 12 Retarder stator.

[0030] 13 Fixing arm (from the generator stator to the retarder stator).

[0031] 15 Modified flange (new design).

[0032] 20 Generator.

[0033] 21 Rotor assembly (rotor housing with generator rotor). 22 Generator stator.

[0034] 23 Generator rotor.

[0035] 24 Induction coils (from the generator).

[0036] 25 Rotor-holder bushing (for securing the generator rotor, forming the generator rotor assembly). 26 Permanent magnets.

[0037] 27, 27a, 27b Through holes.

[0038] 28 Closing cover (of the generator stator housing).

[0039] 29 Keyways.

[0040] 31 Cardan transmission of the vehicle 32 Axis of rotation.

[0041] 33 Bearings.

[0042] 35 Conventional flange (mounted on a retarder without generator).

[0043] 39 Screw.

[0044] 40 Support.

[0045] 41 Silentblock.

[0046] Detailed description of the invention

[0047] With reference to the figures, several non-limiting embodiments are described, where various advantages and characteristics of the present invention can be appreciated.

[0048] It is interesting for industrial vehicles such as trucks, buses, heavy vans, etc.

[0049] This is achieved by incorporating one or more generators, providing electrical power to the retarder, allowing it to operate autonomously. Generally, not all of the electrical energy generated is used by the retarder. Surplus electrical energy can be stored in batteries or used by other vehicle devices that require it, keeping in mind that it may need to be adapted to the specifications of each device.

[0050] FIG. 1 illustrates a three-dimensional exploded view of one embodiment of the system 1 for installation in a vehicle. The power system 1 includes a single permanent magnet generator 20 that is coupled to a retarder 10.

[0051] FIG. 2 illustrates a section of the embodiment of FIG. 1 assembled on a cardan transmission 31. Both figures are explained below.

[0052] The retarder 10 incorporates two rotors 11, each rotor 11 is placed on a different side of the stator 12. Both rotors 11 rotate around the same rotation axis 32 which generally coincides with the cardan transmission 31 of the vehicle.

[0053] Generator coupling:

[0054] The retarder 10 must have the newly designed modified flange 15 mounted. The stator 22 of the generator 20 must be fixed to the stator 12 of the retarder 10 through the fixing arms 13. Next, the rotor assembly 21 of the generator 20 is mounted to the modified flange 15 with the retarder 10. Subsequently, the closing cover is mounted; both the stator housing and the closing cover 28 have openings for ventilation.

[0055] The rotor assembly 21 is formed externally by a rotor 23, which is an annular piece in which permanent magnets 26 are mounted, and internally by a bushing 25. The permanent magnets 26 are distributed circumferentially around the rotor 23 and are assembled with the alternating magnetic poles NSN. The bushing 25 has holes 27 and Seeger rings. The holes 27 are preferably through holes for axial connection to the flange 15, for example, with screws 39. The bushing 25 acts as a carrier for the rotor 23 and also has machined keyways 29. A keyway is understood to mean a groove for receiving a key and thereby preventing relative movement of the two parts. The keyways 29, together with the key, secure the bushing 25 and the rotor 23.To improve the insulation of the stator 22 of the generator 20 from the outside environment, a closing cover 28 is provided with slots made in its surface for cooling, the slots can be radially distributed.

[0056] The generator 20 has a stator 22 where the induction coils 24 are arranged. The stator 22 has a housing, preferably made of cast aluminum, where the other end of the fixing arm 13 is attached.

[0057] The assembly of the generator 20 with the retarder 10 is carried out by first fixing the stator 22 of the generator 20, without the closing cover 28, to the stator 12 of the retarder 10, through the fixing arms 13. The length of the fixing arm 13 is calculated to establish an adequate separation between the generator 20 and retarder 10 that ensures cooling. The fixing arms 13 support the weight of the stator 22 of the generator 20, so that it does not require its own bearings.

[0058] On the other hand, the rotor 23 is fixed to the bushing 25, forming the rotor assembly 21 of the generator 20. The rotor assembly 21 is joined to the new modified flange 15 of the retarder 10. Thus, the rotor assembly 21 of the generator 20 is integrated with the rotation axis 32 of the retarder 10.

[0059] It should be mentioned that the mass of the rotor 21 of the generator 20 is much smaller than that of the rotor 11 of the retarder 10. For this purpose, the modified flange 15 of the retarder 10 is provided, which allows the rotor assembly 21 to be joined to the rotation axis 32 of the retarder 10. Likewise, the flange 15 also joins the rotor 11 of the retarder 10 to the rotation axis 32 through screws for holes 27b as is usually the case.

[0060] FIG. 3 further illustrates the assembly of different parts of a generator 20 with the modified flange 15 and with the end of the vehicle's powertrain where the cardan transmission 31 is located on the right.

[0061] A rotor assembly 21 of the generator coupled to the modified flange 15 is illustrated in FIG. 4. This figure and the previous one are explained together.

[0062] The conventional flange 35 is shown next to the modified flange 15 for a better appreciation of the new design made in FIG. 3. The modified flange 15 has through holes 27a and 27b to join the cardan transmission 31 to it and also to fix the rotor assembly 21 of the generator 20 to said flange.

[0063] In FIG. 4, the poles of permanent magnets 26 can be seen assembled in the rotor 23, which is coupled with the bushing 25 by means of keys, thus forming the rotor assembly 21 of the generator 20 (which fit into the keyways 29). Induction coils 24 are mounted on the stator 22 of the generator 20. By means of the fixing arms 13, the stator 22 is fastened to the stator 12 of the retarder 10 (not shown), which would be on the left.

[0064] The rotating elements with a section AA of the system 1 are illustrated in FIG. 5, rotating in unison around a retarder rotation axis 32. The rotor assembly 21 of the generator is mounted on the modified flange 15 incorporated in the retarder.

[0065] FIG. 6 shows the static elements with a section AA of the system 1, in which the fixing of the stators 22 of the generator 20 to the stator 12 of the retarder 10 can be seen, through four fixing arms 13 made of rigid material and located in equidistant positions. The fixing arms 13 define a separation between the generator 20 and the retarder 10.

[0066] In FIG. 7, the rotating and static elements are illustrated together with an AA section of system 1. The arrangement of the rotors 11, 21 fixed to each other by the modified flange 15 can be seen so that they rotate around the axis 32, establishing a kinematic chain for the rotor 21 of the generator 20, which rotates in solidarity with the cardan transmission 31.

[0067] Independently, the stators 12, 22 are observed fixed to each other by the fixing arms 13, allowing a certain axial clearance for adequate ventilation. FIG. 8A to FIG. 8G illustrate a schematic assembly sequence for a method for making a vehicle retarder autonomous, starting from a conventional retarder to which two generators are incorporated, one generator on one side and another on the opposite side. However, it could be a single generator.

[0068] FIG. 8A shows the initial state with a retarder 10 without generators coupled to the vehicle's powertrain via cardan transmission 31.

[0069] FIG. 8B shows the disassembly step of the cardan transmission 31 to release the retarder 10.

[0070] The disassembly step of the original flanges 35 of the retarder 10 is shown in FIG. 8C.

[0071] FIG. 8D shows the step of replacing the original flanges 35 with modified flanges 15.

[0072] In FIG. 8E the mounting step of a stator 22 of a generator 20 to the stator 12 of the retarder 10 with the fixing arms 13 is shown. This is done on both sides of the retarder 10 in this embodiment.

[0073] FIG. 8F shows the assembly step of a rotor 23 of a generator 20 to the rotor-holder bushing 25 forming the rotor assembly 21.

[0074] FIG. 8G shows the assembly step of the vehicle's cardan transmission 31 to the retarder flange 15.

[0075] The assembly step of the rotor assembly 21 of the generator 20 to the retarder flange 15 is shown in FIG. 8H.

[0076] As can be seen in the previous sequence of figures, the cardan transmission 31 does not need to be replaced or modified.

[0077] The described power supply system may include electronic circuits for regulating and monitoring its operation. For example, it may incorporate a control module that receives a brake-related control signal from the vehicle's main processor as input. This control signal may be manual or automatic.

[0078] The control module may be connected to a control bus for information transmission. For example, this may be a CAN (Controller Area Network) bus. Furthermore, the control module may be integrated with other active safety systems in the vehicle. For example, the use of the retarder 10 in combination with the vehicle's brake pedal may be enabled. A separate control may also be incorporated to manually activate the retarder. In both cases, the braking torque may be regulated from zero to 100 percent of the power available at the retarder 10.

[0079] The control module can manage voltage regulation. For example, through an electronic circuit composed of active and passive components such as thyristors, transistors, diodes, capacitors, resistors, etc. Electrical and electronic components are responsible for sequentially activating or deactivating the retarder or battery power supply.

[0080] Both the retarder's operation and battery charging require direct current. To achieve this, the power supply system may include a rectifier and a regulator. For example, the three-phase alternating current generated in the generator's stator passes to a rectifier diode plate, where the current is rectified and becomes direct current. To take advantage of both the positive and negative half-waves of each phase—that is, double or full-wave rectification—two diodes are placed per phase, one on the positive side and one on the negative side. Therefore, six power diodes are required. The rectified output current does not correspond to an ideal direct current, as it is pulsed.The ripple of the pulsed three-phase current is further reduced by incorporating a regulator that includes a ripple filter circuit, in order to reduce the amplitude variations of the current and ensure that it is as continuous as possible in the load to be supplied.

[0081] In FIGS. 9A to 9C, different views can be seen of how the retarder 10, which incorporates the power supply system 1 with the generator 20 and the fixing arms 13, would be arranged externally for mounting on a vehicle. It can also be seen how it would be fixed to the vehicle frame (not shown), where there are supports 40 with silent blocks 41.

[0082] The embodiments described herein provide multiple advantages and benefits. One is compatibility, since the operation of the system does not alter the functional or cooling characteristics of the retarder or the generator. For example, they maintain adequate separation for cooling air to circulate through each device. For example, the tolerance of the retarder parts is not exceeded by including a generator, since the increase in mass is not appreciable. The generator does not have its own bearings and instead uses the retarder's bearings. Advantageously, the generator is free of a commutator and brushes. Additionally, several specific features are mentioned for one embodiment of the present system. The generator stator may consist of an armature preferably formed by a set of magnetic steel sheets, in the shape of a circular crown, assembled and electrically insulated from each other.On its inner perimeter, there are slots to accommodate the induced coils. Other slots are provided on the outside for coupling and assembly into the housing, which is sealed by an external cover. Preferably, three coils are included, connected to each other and electrically insulated from the housing. These coils are evenly distributed around the entire perimeter. The housing and the outer cover of the stator are preferably made of cast aluminum, with openings and fins to facilitate cooling. The generator rotor is preferably made of cast aluminum or non-magnetic stainless steel.

Claims

CLAIMS 1. Power supply system (1) for a vehicle retarder (10), wherein the retarder (10) comprises two rotors (11) fixed to a rotating shaft (32) and a stator (12) situated between the rotors (11), wherein the stator (12) is supported on bearings (33) coupled to the rotating shaft (32), wherein the power supply system (1) comprises: at least one generator (20) configured to supply electrical power to the retarder (10), wherein the generator (20) comprises a rotor assembly (21); and a stator (22) comprising a plurality of induction coils (24); characterized in that the feeding system (1) comprises: a modified flange (15) that joins a first rotor (11) of the retarder (10) with the rotation shaft (32) and with the rotor assembly (21) of the generator (20) to simultaneously rotate the rotor assembly (21) of the generator (20), the rotation shaft (32) and the first rotor (11) of the retarder (10);a plurality of fixing arms (13) that join and support the stator (22) of the generator (20) to the stator (12) of the retarder (10) maintaining a separation distance.; 2. Power supply system (1) according to claim 1 comprising a second generator (20) configured to supply electrical power to the retarder (10), a second modified flange (15), and a plurality of second fixing arms (13); wherein the second generator (20) comprises a rotor assembly (21) and a stator (22); wherein a second modified flange (15) connects the second rotor (11) of the retarder (10) to the rotation shaft (32) and to the rotor assembly (21) of the second generator (20) to simultaneously rotate the rotor assembly (21) of the generator (20), the rotation shaft (32), and the second rotor (11) of the retarder (10); wherein a plurality of second fixing arms (13) connect and support the stator (22) of the second generator (20) to the stator (12) of the retarder (10) while maintaining a separation distance.

3. Feeding system (1) according to claim 1 or 2, wherein the rotor assembly (21) of the generator (20) comprises a rotor (23) and a bushing (25), wherein the rotor (23) mounts a plurality of circumferentially distributed permanent magnets (26) with magnetically alternating poles, and wherein the rotor assembly (21) is fixed to the modified flange (15) such that the plurality of permanent magnets (26) cooperate with the plurality of induction coils (24) of the stator (22) of the generator (20).

4. Power supply system (1) according to any one of claims 1 to 3, comprising a battery for storing electrical energy generated by the generator (20).

5. Power supply system (1) according to any one of claims 1 to 4, wherein the stator housing (22) of the generator (20) comprises a closing cover (28) with radial slots for air cooling.

6. Feeding system (1) according to any one of claims 1 to 5, wherein the bearings (33) extend along the axis (32) of rotation limited on each side by a rotor (11) of the retarder (10).

7. Feeding system (1) according to any one of claims 1 to 6, wherein the rotor material (23) of the generator (20) comprises non-magnetic aluminum or stainless steel.

8. Feeding system (1) according to any one of claims 1 to 7, comprising a control module configured to act on the retarder (10).

9. Self-contained retarder comprising: a retarder (10) comprising: a first rotor (11) fixed to a first side of a rotating shaft (32); a second rotor (11) fixed to a second side of the rotating shaft (32), the second side being opposite the first side; a stator (12) situated between the first side and the second side, wherein the stator (12) is supported on bearings (33) coupled to the rotating shaft (32); a power supply system (1) according to any one of claims 1 to 8, configured to supply electrical power to at least the retarder (10).

10. Method for making a retarder (10) of a vehicle autonomous, comprising the following steps: - mounting a generator (20) between the retarder (10) and the cardan shaft (31), wherein the generator (20) is configured to supply electrical power and comprises a stator (22) and a rotor assembly (21), wherein the retarder (10) comprises two rotors (11) fixed to a rotating shaft (32) and a stator (12) located between the rotors (11), wherein the stator (12) is supported on bearings (33) coupled to the rotating shaft (32); characterized in that mounting the generator (20) comprises the steps of: - remove an original flange (35) that secures the cardan shaft (31) of the vehicle to one side of the retarder (10); - mount a modified flange (15) that secures the cardan shaft (31) of the vehicle to one side of the retarder (10); - assembling the stator (10) of the generator (20) to the stator (12) of the retarder (10) by means of a plurality of fixing arms (13) that join and support the stator (22) of the generator (20) to the stator (12) of the retarder (10); - joining the rotor assembly (21) of the generator (20) to the modified flange (15) mounted on the retarder (10); - mount a closing cover (28) to the stator (22) of the generator (20); - mount the vehicle's cardan transmission (31).

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