AC generator-charged transport refrigeration unit with prime mover energy storage

Abstract

A transport refrigeration unit (TRU) and power system. The TRU (26) and power system include a compressor (58) configured to compress refrigerant, an evaporator heat exchanger (76) operably coupled to the compressor (58), and an evaporator fan (98) configured to provide a return air flow (134) and cause the return air flow (134) to flow through the evaporator heat exchanger (76). The system also includes a return air temperature (RAT) sensor (142) disposed in the return air flow (134) and configured to measure the temperature of the return air flow (134); a TRU controller (82) operably coupled to the RAT sensor (142) and configured to perform a process for determining an AC power demand for the TRU (26) based at least on the RAT (142); a generator power converter (164a) configured to receive a generator three-phase AC power and provide DC power (165b) to an energy storage system; and a power management system (124) configured to direct power to the TRU (26) based on the AC power demand.

Description

Technical Field

[0001] The subject matter disclosed herein relates generally to transport refrigeration units, and more particularly to an apparatus and method for powering a transport refrigeration unit utilizing a generator and an energy storage device. Background Art

[0002] Conventional refrigerated cargo trucks or refrigerated tractor trailers, such as those utilized for transporting cargo by sea, rail or road, are trucks, trailers or cargo compartments (or containers, i.e., containers), typically defining a cargo compartment, and modified to include a refrigeration system located at one end of the truck, trailer or cargo compartment. The refrigeration system typically includes a compressor, a condenser, an expansion valve, and an evaporator, which are connected in series by refrigerant lines in a closed refrigerant circuit according to a known refrigerant vapor compression cycle. A power unit such as an internal combustion engine drives the compressor of the refrigeration unit, and may be a diesel-powered, natural gas-powered, or other type of engine. In many tractor trailer transport refrigeration systems, the compressor is driven by an engine shaft or by a belt drive or by a mechanical shaft-to-shaft connection. In other systems, the engine of the refrigeration unit drives a generator, which generates electrical power, which in turn drives the compressor.

[0003] With current environmental trends, improvements in transport refrigeration units are desirable, particularly with respect to efficiency, sound, and environmental impact. With environmentally friendly refrigeration units, improvements in reliability, cost, and weight reduction are also desirable. Summary of the invention

[0004] According to one embodiment, a transport refrigeration unit (TRU) and power system are described herein. The TRU and power system include: a compressor configured to compress a refrigerant, the compressor having a compressor motor configured to drive the compressor; an evaporator heat exchanger operably coupled to the compressor; an evaporator fan configured to provide a return air flow from a return air inlet and cause the return air flow to flow through the evaporator heat exchanger; and a return air temperature (RAT) sensor disposed in the return air flow and configured to measure the temperature of the return air flow. The TRU and power system also include a TRU controller operably connected to the RAT sensor and configured to perform a process for determining an AC power demand for the TRU based on at least the RAT. The TRU and power system also include a generator power converter configured to receive a generator three-phase AC power provided by an AC generator and transmit a second DC power; an energy storage system configured to receive the second DC power and provide / receive three-phase AC power; and a power management system configured to receive the three-phase AC power based on the AC power demand and direct at least a portion of the three-phase AC power to the TRU.

[0005] Additionally or alternatively to one or more of the above features, further embodiments may include a grid power source configured to provide grid three-phase AC power to the power management system.

[0006] In addition to one or more of the above features, or as an alternative, further embodiments may include: the generator power converter includes an AC / DC converter, and the generator three-phase AC power exhibits a first AC voltage and a first AC current at a first frequency, and the second DC power exhibits a second DC voltage and a second DC current.

[0007] In addition to one or more of the above features, or as an alternative, further embodiments may include: a generator power converter operably connected to the TRU controller, the generator power converter including a voltage control function, a current control function, wherein at least the voltage control function is responsive to AC power demand.

[0008] In addition to one or more of the above features, or as an alternative, further embodiments may include: the energy storage system includes an energy storage device; a switching device; and at least one of a DC / AC converter and an AC / DC converter, the DC / AC converter being configured to provide another three-phase AC power to the power management system based on AC power demand, and the AC / DC converter being configured to convert at least a portion of the three-phase AC power to supply the energy storage device.

[0009] In addition to one or more of the above features, or as an alternative, further embodiments may include: the switching device is configured to guide the DC power flow in the energy storage system based on the AC power demand. The guidance includes: guiding the second DC voltage to at least one of the DC / AC converter and the DC / AC converter and the energy storage device; guiding the DC power from the energy storage device to the DC / AC converter; and receiving the DC power from the AC / DC converter and providing it to the energy storage device.

[0010] In addition to or as an alternative to one or more of the above features, further embodiments may include that the energy storage device includes at least one of a battery, a fuel cell, and a flow battery.

[0011] Additionally or alternatively to one or more of the above features, further embodiments may include a battery management system operably connected to the TRU controller and configured to monitor at least a state of charge of the energy storage device.

[0012] In addition to one or more of the above features, or as an alternative, further embodiments may include: the DC / AC converter and the AC / DC converter are integrated, and wherein the DC / AC converter or the AC / DC converter is operably connected to the TRU controller and configured to direct power flow to and from the power management system based on at least one of the AC power demand and the charge state of the energy storage device.

[0013] Additionally or alternatively to one or more of the above features, further embodiments may include synchronizing the other three-phase AC power to match the grid three-phase AC power.

[0014] In addition to one or more of the above features, or as an alternative, further embodiments may include: the power management system is configured to receive three-phase AC power from an energy storage system and a grid power connection, the energy storage system is configured to provide three-phase AC power, and the grid power connection is configured to provide three-phase grid power to the power management system, and wherein the power management system is configured to provide selected three-phase AC power to at least one of the TRU and the energy storage system.

[0015] In addition to one or more of the above features, or as an alternative, further embodiments may include: the power management system includes a power control switching device, which is responsive to the TRU controller and is configured to direct multiple power flows in the TRU and the power system, the multiple power flows are based on at least AC power demand and a charge state of an energy storage device of the energy storage system.

[0016] In addition to one or more of the above features, or as an alternative, further embodiments may include: a first portion of the power flows in the multiple power flows includes: if the grid power source is inoperable, receiving grid three-phase AC power from the grid; and if the TRU is operational and the energy storage device of the energy storage system exhibits a charge state less than a selected threshold, directing at least a portion of the grid three-phase AC power to the TRU and the energy storage system; or if the TRU is operational and the energy storage device of the energy storage system exhibits a charge state greater than or equal to approximately the selected threshold, directing at least a portion of the grid three-phase AC power to the TRU; or if the TRU is inoperable and the energy storage device of the energy storage system exhibits a charge state less than a second selected threshold, directing at least a portion of the grid three-phase AC power to the energy storage system.

[0017] In addition to one or more of the above features, or as an alternative, further embodiments may include: a second portion of the power flow of the multiple power flows includes: receiving three-phase AC power from the energy storage system; if the grid AC power source is operational, receiving grid three-phase AC power from the grid power source; synchronizing and combining the three-phase AC power from the energy storage system with the grid three-phase AC power; and if the TRU is operational and the energy storage device of the energy storage system exhibits a charge state greater than or equal to approximately another selected threshold, directing the combined three-phase AC power to the TRU.

[0018] In another embodiment, a method of generating and directing power to a transport refrigeration unit (TRU) system is also described herein, the system having: a compressor configured to compress a refrigerant; an evaporator heat exchanger operably connected to the compressor; an evaporator fan configured to provide a return air flow from a return air inlet and flow the return air flow through the evaporator heat exchanger; a return air temperature (RAT) sensor disposed in the return air flow and configured to measure the temperature of the return air flow; and a TRU controller. The method includes operably connecting the RAT sensor to the TRU controller; determining an AC power demand for the TRU based at least on the RAT; and operably connecting a generator power converter to the AC generator, the generator power converter configured to receive a generator three-phase AC power provided by the AC generator and transmit a second DC power. The method also includes operably connecting an energy storage system, the energy storage system operable to receive the second DC power and provide / receive three-phase AC power; and operably connecting a power management system to the generator power converter and the TRU, the power management system configured to receive the second three-phase AC power based on the AC power demand to direct power to the TRU.

[0019] Additionally or alternatively to one or more of the above features, further embodiments may include connecting a grid power source to provide grid three-phase AC power to the power management system.

[0020] In addition to one or more of the above features, or as an alternative, further embodiments may include: the generator power converter includes an AC / DC converter, and the generator three-phase AC power exhibits a first AC voltage and a first AC current at a first frequency, and the second DC power exhibits a second DC voltage and a second DC current.

[0021] In addition to one or more of the above features, or as an alternative, further embodiments may include: the energy storage system includes an energy storage device, a switching device, and at least one of a DC / AC converter and an AC / DC converter, the DC / AC converter being configured to provide another three-phase AC power to the power management system based on AC power demand, and the AC / DC converter being configured to convert at least a portion of the three-phase AC power to supply the energy storage device.

[0022] In addition to one or more of the above features, or as an alternative, further embodiments may include configuring the switching device to direct the DC power flow in the energy storage system based on the AC power demand. The directing includes applying a second DC voltage to a DC / AC converter and at least one of the DC / AC converter and the energy storage device; applying DC power from the energy storage device to the DC / AC converter; and receiving DC power from the AC / DC converter and providing it to the energy storage device.

[0023] In addition to one or more of the above features, or as an alternative, further embodiments may include: configuring the power management system with a power control switching device, which is responsive to the TRU controller and configured to direct multiple power flows in the TRU and the power system, wherein the multiple power flows are based on at least AC power demand and a charge state of an energy storage device of the energy storage system.

[0024] Technical effects of embodiments of the present disclosure include a transport refrigeration unit coupled to and powered by an external generator system via a generator power converter, wherein power generated by the generator and converted by the generator power converter is based on AC power requirements of the transport refrigeration unit.

[0025] Unless otherwise expressly indicated, the aforementioned features and elements may be combined in various combinations without exclusivity. These features and elements and their operation will become more apparent from the following description and accompanying drawings. However, it should be understood that the following description and accompanying drawings are intended to be illustrative and explanatory in nature and are non-restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The subject matter regarded as the present disclosure is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the present disclosure will become apparent from the following detailed description taken in conjunction with the accompanying drawings, in which:

[0027] The following description should not be considered limiting in any way. Referring to the drawings, similar elements are numbered similarly:

[0028] Figure 1is a perspective view of a transport refrigeration system having a transport refrigeration unit as a non-limiting transport refrigeration system according to an embodiment of the present disclosure;

[0029] Figure 2 is a schematic diagram of a transport refrigeration unit according to an embodiment of the present disclosure;

[0030] Figure 3 is a block diagram of a transport refrigeration unit and power system according to an embodiment of the present disclosure;

[0031] Figure 4A depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0032] Figure 4B depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0033] Figure 4C depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0034] Figure 4D depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0035] Figure 4E depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0036] Figure 4F depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0037] Figure 4G depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0038] Figure 4H depicts the power flow of a power management system according to an embodiment of the present disclosure;

[0039] Figure 5 is a block diagram of a transport refrigeration unit and power system according to an embodiment of the present disclosure; and

[0040] Figure 6 is a block diagram of a transport refrigeration unit and power system according to an embodiment of the present disclosure. DETAILED DESCRIPTION

[0041] A detailed description of one or more embodiments of the disclosed apparatus and methods is given herein by way of illustration and not limitation with reference to the accompanying drawings.

[0042] Reference Figure 1, a transport refrigeration system 20 of the present disclosure is shown. In the illustrated embodiment, the transport refrigeration system 20 may include a tractor or vehicle 22, a cargo box 24, and a transport refrigeration unit (TRU) 26. The cargo box 24 may be pulled by the vehicle 22. It should be understood that the embodiments described herein may be applied to transport boxes transported by rail, sea, air, or any other suitable cargo box, and thus the vehicle may be a truck, train, ship, airplane, helicopter, etc.

[0043] The vehicle 22 may include an operator's cabin or cab 28 and an internal combustion engine 42, which is part of the powertrain or drive system of the vehicle 22. In some cases, the vehicle 22 may be a hybrid or all-electric configuration with an electric motor for providing propulsion for the vehicle. In some configurations, the TRU system 26 may be engineless. In some embodiments, a small engine or the engine of the vehicle 22 may be used to provide power (or electricity, i.e., power) or partially power the TRU 26. The cargo compartment 24 may be coupled to the vehicle 22 and thus pulled or propelled to a desired destination. The trailer may include a top wall 30, a bottom wall 32 that is opposite to and spaced from the top wall 30, two side walls 34 that are spaced and opposite to each other, and opposite front and rear walls 36, 38, wherein the front wall 36 is closest to the vehicle 22. The cargo compartment 24 may further include a door (not shown) at the rear wall 38 or any other wall. Walls 30, 32, 34, 36, 38 together define the boundaries of cargo compartment 40. Typically, transport refrigeration system 20 is used to transport and distribute cargo, such as perishables and environmentally sensitive items (referred to herein as perishables). Perishables may include, but are not limited to, fruits, vegetables, grains, beans, nuts, eggs, dairy products, seeds, flowers, meat, poultry, fish, ice, blood, medicines, or any other suitable cargo that requires cold chain transportation. In the illustrated embodiment, TRU 26 is associated with cargo compartment 24 to provide desired environmental parameters, such as, for example, temperature, pressure, humidity, carbon dioxide, ethylene, ozone, light exposure, vibration exposure, and other conditions to cargo compartment 40. In a further embodiment, TRU 26 is a refrigeration system capable of providing a desired temperature and humidity range.

[0044] Reference Figure 1 and Figure 2, the cargo box 24 is generally configured to store cargo (not shown) in a compartment 40. The TRU 26 is generally integrated into the cargo box 24 and can be mounted to the front wall 36. The cargo is maintained at a desired temperature by cooling the compartment 40 via the TRU 26 that circulates a refrigerated air flow into and through the cargo compartment 40 of the cargo box 24. It is further contemplated and understood that the TRU 26 may be applied to any transport compartment (e.g., a shipping or transport box), not necessarily those used in tractor-trailer systems. In addition, the transport box 24 can be part of the vehicle 22, or be configured to be removed from the frame and wheels (not shown) of the cargo box 24 for alternative modes of transportation (e.g., sea, rail, flight, and others).

[0045] The components of the TRU 26 may include a compressor 58, an electric compressor motor 60, a condenser 64, which may be air cooled, a condenser fan assembly 66, a receiver 68, a filter dryer 70, a heat exchanger 72, an expansion valve 74, an evaporator 76, an evaporator fan assembly 78, a suction regulating valve 80, and a controller 82, which may include a computer-based processor (e.g., a microprocessor), etc., as will be further described herein. The operation of the TRU 26 can be best understood by starting at the compressor 58, where a suction gas (e.g., natural refrigerant, hydrofluorocarbon (HFC) R-404a, HFC R-134a, etc.) enters the compressor 58 at a suction port 84 and is compressed to a higher temperature and pressure. The refrigerant gas is discharged from the compressor 58 at an outlet port 85 and may then flow into the tube(s) 86 of the condenser 64.

[0046] The air flowing through a plurality of condenser coil fins (not shown) and tubes 86 cools the gas to its saturation temperature. The air flow through the condenser 64 can be promoted by one or more fans 88 of the condenser fan assembly 66. The condenser fan 88 can be driven by a corresponding condenser fan motor 90 of the fan assembly 66, which can be electric. By removing latent heat, the refrigerant gas in the tube 86 is condensed into a high-pressure and high-temperature liquid and flows to the receiver 68, which provides storage for excess liquid refrigerant during low-temperature operation. The liquid refrigerant can pass from the receiver 68 through the subcooler heat exchanger 92 of the condenser 64, through the filter-dryer 70 that keeps the refrigerant clean and dry, and then to the heat exchanger 72 that increases the subcooling of the refrigerant, and finally to the expansion valve 74.

[0047] As the liquid refrigerant passes through the orifice of the expansion valve 74, some of the liquid vaporizes into a gas (i.e., flash gas). Return air from the refrigerated space (i.e., the cargo compartment 40) flows over the heat transfer surface of the evaporator 76. As the refrigerant flows through the plurality of tubes 94 of the evaporator 76, the remaining liquid refrigerant absorbs heat from the return air and is thereby evaporated, thereby cooling the return air.

[0048] The evaporator fan assembly 78 includes one or more evaporator fans 96, which can be driven by corresponding fan motors 98 that can be electric. The air flow through the evaporator 76 is promoted by the evaporator fan 96. Then, the refrigerant can flow from the evaporator 76 through the suction regulating valve 80 in the form of vapor and return to the compressor 58. The expansion valve 74 can be thermostatic or electrically adjustable. In one embodiment, as depicted, the expansion valve 74 is thermostatic. A thermostatic expansion valve bulb sensor 100 can be located near the outlet of the evaporator tube 94. The bulb sensor 100 is intended to control the thermostatic expansion valve 74, thereby controlling the refrigerant superheat at the outlet of the evaporator tube 94. It is further considered and understood that the above generally describes a single-stage vapor compression system that can be used for HFCs such as R-404a and R-134a and natural refrigerants such as propane and ammonia. Other refrigerant systems using carbon dioxide (CO2) refrigerants can also be applied, and they can be two-stage vapor compression systems. In another embodiment, the expansion valve 74 may be an electronic expansion valve. In this case, the expansion valve is commanded to a selected position by the controller 82 based on the operating conditions of the vapor compression cycle and the needs of the system.

[0049] A bypass valve (not shown) can facilitate flash gas of the refrigerant to bypass the evaporator 76. This will allow the evaporator coils to be filled with liquid and fully "wetted" to improve heat transfer efficiency. With CO2 refrigerant, this bypass flash gas can be reintroduced into the middle stage of the two-stage compressor 58.

[0050] The compressor 58 and the compressor motor 60 may be coupled via an interconnected drive shaft 102. The compressor 58, the compressor motor 60, and the drive shaft 102 may all be sealed within a common housing 104. The compressor 58 may be a single compressor. The single compressor may be a two-stage compressor, a scroll compressor, or other compressor suitable for compressing HFCs or natural refrigerants. The natural refrigerant may be CO2, propane, ammonia, or any other natural refrigerant that may include a global warming potential (GWP) of approximately one (1).

[0051] Continue with Figure 2 , which continues to refer to Figure 1 . Figure 2Also shown is the air flow through the TRU 26 and the cargo compartment 40. With the aid of the TRU 26, the air flow is circulated into, through, and out of the cargo compartment 40 of the cargo compartment 24. The return air flow 134 flows from the cargo compartment 40 through the return air inlet 136 and through the evaporator 76 via the fan 96 to the TRU 26, thereby adjusting the return air flow 134 to a selected or predetermined temperature. The conditioned return air flow 134, now referred to as the supply air flow 138, is supplied to the cargo compartment 40 of the cargo compartment 24 through the refrigeration unit outlet 140, which is located near the top wall 30 of the cargo compartment 24 in some embodiments. The supply air flow 138 cools the perishable items in the cargo compartment 40 of the cargo compartment 24. It will be appreciated that the TRU 26 can be further reversed to heat the cargo compartment 24 when, for example, the outside temperature is very low.

[0052] A temperature sensor 142 (i.e., a thermistor, thermocouple, RTD, etc.) is placed in the air stream, on the evaporator 76, at the return air inlet 136, etc., to monitor the temperature of the return air stream 134 from the cargo compartment 40. A sensor signal, designated RAT, indicative of the temperature of the return air stream is operably connected to the TRU controller 82 via line 144 to facilitate control and operation of the TRU 26. Similarly, a temperature sensor 146 is placed in the supply air stream 138, on the evaporator 76, at the refrigeration unit outlet 140, to monitor the temperature of the supply air stream 138 directed into the cargo compartment 40. Similarly, a sensor signal, designated SAT 14, indicative of the temperature of the supply air stream is operably connected to the TRU controller 82 via line 148 to facilitate control and operation of the TRU 26.

[0053] system

[0054] Reference at this time Figure 3 , which also continues to refer to Figure 1 and Figure 2, the TRU 26 may include or operably interact with a power supply interface, generally shown as 120. The power supply interface 120 may include interfaces to various power sources, generally indicated as 122, and more specifically as follows herein for the TRU 26 and its components. In one embodiment, the power sources 122 may include, but are not limited to, an energy storage device 152, a generator 162, and grid power 182. Each of the power sources 122 may be configured to selectively power the TRU 26 including the compressor motor 60, the condenser fan motor 90, the evaporator fan motor 98, the controller 82, and other components 99 of the TRU 26 (which may include various solenoids and / or sensors). The controller 82, through a series of data and command signals on various paths 108, may control the application of power to the electric motors 60, 90, 98, for example, as dictated by the cooling needs of the TRU 26.

[0055] The TRU 26 may include an AC or DC architecture, wherein selected components utilize alternating current (AC) and others utilize direct current (DC). For example, in one embodiment, the motors 60, 90, 98 may be configured as AC motors, while in other embodiments, the motors 60, 90, 98 may be configured as DC motors. When the power source 122 supplies power to the TRU 26, the operation of the power source 122 may be managed and monitored by the power management system 124. The power management system 124 is configured to determine the status of the various power sources 122 based on the various needs of the TRU 26, control their operation, and direct power to and from the various power sources 122, etc. In one embodiment, the TRU controller 82 receives various signals indicating the operating status of the TRU 26 and determines the power demand for the TRU system 26 accordingly, and directs the power supply interface 120 and particularly the power management system 124 to direct power accordingly to address the needs of the TRU 26. In one embodiment, the TRU system 26 is controlled to a temperature set point value selected by a user. The TRU controller 82 monitors the RAT and optional SAT measured by the temperature sensors 142 and 146, respectively. The TRU controller 82 estimates the power demand for the TRU 26 based on the RAT (among others), and accordingly provides commands to the various components of the power supply interface 120, and in particular the power management system 124, the energy storage system 150, and the generator power converter 164, to manage the generation, conversion, and routing (or guidance, i.e., routing) of power in the power supply interface 120 and the TRU system 26. By using the measured RAT and the set point value, an estimate of the power demand is made. More specifically, in one embodiment, if (the RAT set point value) is above a first threshold (e.g., > 10 degrees Fahrenheit), full power is required by the TRU system 26 (e.g., at a known voltage supply, the current demand is known). If (the RAT set point value) is between the first threshold and the second threshold, the current demand is limited (at a known voltage) to achieve a mid-range power (e.g., ~50% power or something less than 100% power). If (RAT set point value) is below a second threshold, then current is limited (at voltage) to obtain minimum power (e.g., ~20% power).

[0056] The TRU controller 82 is configured to control components in the TRU 26 and components of the power supply interface 120 according to the operational needs of the transport refrigeration system 20. The TRU controller 82 is communicatively coupled to the power management system 124, the DC / AC converter 156, the battery management system 154, and the generator power converter 164 components, namely, the voltage regulator 166, the current control circuit 167, the frequency converter 168, and the generator 162. For the TRU power demand, the TRU controller 82, using additional information from the BMS 154 and the generator 162, provides instructions to affect the generator output to the form of power required by the TRU 26. Additionally, the TRU controller 82 provides instructions to manage power flow via the power management system 124 according to the operating status of the various power sources (i.e., the grid power 182, the energy storage device 152, and the generator 162) coupled to the TRU 26 power demand.

[0057] As further described herein, there are three sources of power 122 - grid power 182, generator 162 / generator power converter 164, and energy storage device 152. If the TRU 26 is "on" and operating, the TRU controller 82 knows the power demand for the TRU system, and thus, what power is needed. The TRU controller 82 is also programmed to determine whether grid power (e.g., 182) is available. If grid power is available and the TRU is on and the energy storage device 152 (e.g., battery) SOC indicates a full charge, the grid power will meet the TRU system 26 power demand. Conversely, if grid power 182 is available and the TRU is on and the energy storage device is not fully charged, meeting the TRU power demand is the first priority, and then the DC / AC inverter 156 is activated to provide the necessary charge to the energy storage device 152 as the second priority. In addition, if grid power 182 is available and the TRU is "off" and the energy storage device 152 is not fully charged, the DC / AC inverter 156 will be activated to provide the necessary charging current. If grid power 182 is unavailable and generator / generator power converter 162 / 164 is not operational, all TRU power demands are met by energy storage system 150 via energy storage devices. Finally, if grid power 182 is unavailable and generator / generator power converter 162 / 164 is operational, TRU power demands are met by both generator 162 and energy storage system 150.

[0058] The power management system 124 receives power from the generator 162 directly and / or via a generator power converter 164. In one embodiment, the power management system 124 can be a stand-alone unit, integrated with the generator power converter 164, and / or integrated with the TRU 26. The generator 162 can be mounted on an axle or hub and configured to recover rotational energy and convert the rotational energy into electrical energy when the transport refrigeration system 20 is in motion, such as, for example, when the axle of the vehicle 22 is rotating due to acceleration, cruising, or braking. In one embodiment, the generator 162 is configured to provide a first three-phase AC power 163, which includes a voltage V1, an AC current I1 at a given frequency f1, represented by reference numeral 163. The generator 162 can be asynchronous or synchronous. In another embodiment, the generator 162 can be DC, providing a first DC power 163a, which includes a DC voltage and a DC current, represented as V 1a , and DC current I 1a In one or more embodiments, generator power converter 164 produces second three-phase AC power 165 including AC voltage V2 at selected frequency f2, second AC current I2, and is transmitted from generator power converter 164 to power management system 124 or otherwise as described herein.

[0059] As described herein, in operation, the TRU controller 82 identifies a power demand for the TRU 26 based at least in part on the RAT. The TRU controller 82, as necessary to meet the demand of the TRU 26, communicates the power demand to the power management system 124 and / or the generator power converter 164 to convert the first three-phase AC power 163 or the first DC power 163a to the second three-phase AC power 165.

[0060] AC generator / AC converter

[0061] In one embodiment, the generator power converter 164 is an AC / AC converter and is configured to receive three-phase AC power 163 (e.g., at an AC voltage V1, an AC current I1, a frequency f1) from the generator 162 and convert it into a second three-phase AC power, represented as 165, which includes a second three-phase AC voltage V2, a second AC current I2 at a selected frequency f2. The second three-phase AC power 165 is transmitted from the generator power converter 164 to the power management system 124. The generator power converter 164 is configured to provide the second three-phase AC power 165 based on the operating requirements of the TRU 26. In one embodiment, the generator power converter 164 includes a voltage control function 166, a current control function 167, and a frequency converter function 168, each of which is configured to facilitate conversion. In one or more embodiments, the TRU controller 82 provides command signals represented as 169, 170, and 171 to the voltage control function 166, the current control function 167, and the frequency converter function 168, respectively. As discussed further herein, command signals 169, 170, and 171 are generated by the TRU controller 82 based on the power consumption requirements of the TRU 26. Additionally, the TRU controller 82 may receive status information depicted by 172 regarding the generator 162, the generator power converter 164, or the power management system 124 for mode selection and diagnostic purposes. The generator power converter 164 may be a separate unit configured proximate to the generator 162 or even integral with the generator 162. In another embodiment, the generator power converter 164 may be integral with the power management system 124 and / or the TRU 26.

[0062] Continue with Figure 3 and generator power converter 164, in one embodiment, voltage control function 166 includes voltage regulation function and is configured to monitor the output voltage from generator 162 and maintain a constant voltage from voltage control function 166. Voltage control function 166 communicates the status to TRU controller 82. Current control function 167 monitors the status of the current drawn from generator 162 and communicates it to TRU 26. In one embodiment, the current can be limited according to the power demand of TRU 26. Finally, frequency converter function 168 monitors the frequency of three-phase power 163 generated by generator 162 and converts three-phase power 163 into three-phase power 165 exhibiting the desired frequency determined by voltage control function 166 and TRU controller 82 for supply to power management system 124 and ultimately to TRU 26. In one embodiment, communication can be through a standard communication interface such as CAN, RS-485, etc. In addition, as further discussed herein, communication can be wired or wireless.

[0063] DC generator / AC converter

[0064] In another embodiment, for example, when the generator 162 is a DC generator, the generator power converter 164 is a DC / AC converter and is configured to receive the DC power 163a (eg, at a DC voltage V 1a , DC current I 1a ) and converts it into a second three-phase AC power 165, which includes a second three-phase AC voltage V2, a second AC current I2 at a selected frequency f2. As described herein, the second three-phase AC power 165 is transmitted from the generator power converter 164 to the power management system 124. Again, as described above, the generator power converter 164 is configured to provide the second three-phase AC power 165 based on the needs of the TRU 26 as described above. In this embodiment, the generator power converter 164, including the voltage control function 166, the current control function 167, and the frequency converter function 168, is configured to facilitate DC / AC conversion. In this embodiment, again the TRU controller 82 provides command signals represented as 169, 170, and 171 to the voltage control function 166, the current control function 167, and the frequency converter function 168, respectively, based on the power consumption needs of the TRU 26, as further discussed herein. In this embodiment, the voltage control function 166 includes a voltage regulation function and is configured to monitor the output DC voltage from the generator 162 and maintain a constant AC voltage from the voltage control function 166. The current control function 167 monitors the state of the current drawn from the generator 162 and communicates it to the TRU 26. Finally, the frequency converter function 168 monitors the frequency of the three-phase power 165 generated by the generator converter 164 to ensure that it exhibits the desired frequency determined by the voltage control function 166 and the TRU controller 82 for supply to the power management system 124 and ultimately to the TRU 26.

[0065] Energy storage systems

[0066] Continue with Figure 3and the architecture of various power sources 122 and power supply interfaces 120 employed to power the TRU 26 and its components. In one embodiment, one of the power sources 122 may include, but is not limited to, an energy storage system 150 operably coupled to the power management system 124. As described herein, another power source 122 (from which the power management system 124 receives power) is a generator 162, whether directly and / or via a generator power converter 164. In addition, a grid power source 182 provides three-phase AC power to the power management system 124 under selected conditions. The energy storage system 150 transmits three-phase power 157 to the power management system 124 and receives power from the power management system 124. The energy storage system 150 may include, but is not limited to, an energy storage device 152, and an AC / DC converter 156 and a battery management system 154. In one embodiment, the power management system 124 provides three-phase AC power 157 to the AC / DC converter 156 to formulate a DC voltage and current for charging and storing energy on the energy storage device 152. In contrast, in other embodiments, the energy storage device 152 supplies DC voltage and current to the AC / DC converter 156 , which operates as a DC / AC converter, to supply three-phase AC power 157 for powering the TRU 26 .

[0067] The battery management system 154 monitors the performance of the energy storage device 152. For example, the state of charge of the energy storage device 152, the health state of the energy storage device 152, and the temperature of the energy storage device 152 are monitored. Examples of the energy storage device 152 may include a battery system (e.g., a battery or battery pack), a fuel cell, a flow battery, and other devices capable of storing and outputting electrical energy that may be direct current (DC). The energy storage device 152 may include a battery system that may employ a plurality of batteries organized into a battery pack through which cooling air may flow for battery temperature control, as described in U.S. Patent Application Serial No. 62 / 616,077 filed on January 11, 2018, the contents of which are incorporated herein in their entirety.

[0068] If the energy storage system 150 includes a battery system for the energy storage device 152, the battery system may have a voltage potential in the range of about two hundred volts (200V) to about six hundred volts (600V). Generally, the higher the voltage, the greater the electrical power sustainability, which is preferred. However, the higher the voltage, the larger the size and weight of the battery in the energy storage device 152, for example, which is not preferred when transporting goods. Additionally, if the energy storage device 152 is a battery, in order to increase the voltage and / or current, the battery needs to be connected in series or in parallel according to electrical requirements. A higher voltage in the battery energy storage device 152 will require more batteries in series than a lower voltage, which in turn leads to a larger and heavier battery energy storage device 152. A lower voltage and higher current system can be used, however such a system may require larger cabling or bus bars. In one embodiment, the energy storage device 152 can be contained within the structure 27 of the TRU 26. In one embodiment, the energy storage device 152 is positioned with the TRU 26, but other configurations are also feasible. In another embodiment, the energy storage device 152 can be positioned with the cargo box 24, such as, for example, below the cargo compartment 40. Similarly, the AC / DC converter 156 can be positioned with the cargo box 24, such as, for example, below the cargo compartment 40, however, in some embodiments, it may be desirable to have the AC / DC converter 156 in close proximity to the power management system 124 and / or the TRU 26 and the TRU controller 82. It will be appreciated that in one or more embodiments, although specific positioning is described with respect to the connection and placement of selected components including the energy storage device 152 and / or the AC / DC converter 156, such description is illustrative only and is not intended to be limiting. Various positioning, arrangements, and configurations of the components are possible and within the scope of the present disclosure.

[0069] The battery management system 154 and the AC / DC converter 156 are operably connected to and interact with the TRU controller 82. The TRU controller 82 receives information about the status of the energy storage system 150, including the energy storage device 152, to provide control inputs to the AC / DC converter 156 to monitor the energy storage device 152, control the charging and discharging rates of the energy storage device 152, etc.

[0070] Continue with Figure 3As described earlier, the power supply interface 120 may include interfaces to various power sources 122 that are managed and monitored by the power management system 124. The power management system 124 manages and determines the flow of electrical power in the power supply interface 120 based on the operational needs of the TRU 26 and the capabilities of the components in the power supply interface 120 (e.g., the generator 162, the converter 164, the energy storage device 152, etc.). The power management system 124 is configured to determine the status of the various power sources 122, control their operation, and direct power to and from the various power sources 122, etc., based on the various needs of the TRU 26.

[0071] In one embodiment, there are five main power flows managed by the power management system 124. First, power to the power management system 124 is supplied via the generator 162 or the generator power converter 164, e.g., the second three-phase AC power 165). Second, power is provided to the power management system 124 when the TRU system 26 is operably connected to the grid power source 182. Third, power is supplied to the power management system 124 from the energy storage device 152. Fourth, power is directed from the power management system 124 to the energy storage device 152. Finally, power is directed from the power management system 124 to the TRU 26 for providing power to operate the TRU 26.

[0072] The power flows will be transmitted through different paths based on the needs of the power management system 124 and the specific configuration of the power supply interface 120. The power management system 124 operates as a central power bus to connect the various power sources 122 together to supply the power needs of the TRU 26. The power management system 124 controls switching, directing or redirecting power to / from the five power flows as needed to meet the power needs of the TRU 26. The switching, directing and redirecting can be easily achieved by using the bus-controlled switching devices 126 of the power management system 124. The bus-controlled switching devices 126 can include, but are not limited to, electromechanical and solid-state semiconductor switching devices, including relays, contactors, solid-state contactors, and semiconductor switching devices such as transistors, FETs, MOSFETs, IGBT's, thyristors, SCR's, etc. Additionally, to facilitate and enable the functionality of the power management system 124, the voltage and frequency of the power supplied by the AC / DC converter 156, the generator converter 164, the generator 162, or the grid power supply 182 of the energy storage system 150 needs to be synchronized to provide a common source of power to be supplied to the TRU 26 and / or to charge the energy storage device 152. The current draw will be determined by the TRU 26 and the need to charge the energy storage device 152.

[0073] The generator power converter 164 output (second three-phase AC power 165) and / or grid power from the grid power source 182 and / or power directed to / from the energy storage system 150 is supplied to the bus-controlled switching device 126 in an overlapping or break-before-make condition as determined by the bus-controlled switching device 126 of the power management system. The AC / DC converter 156, when operating as a DC to AC converter, synchronizes the voltage and frequency of the three-phase power (e.g., 157) generated by the energy storage system 150 with the power connected to the bus-controlled switching device 126 to facilitate the transmission of power from the energy storage device 152 to the power management system 124 (and thus the TRU 26) as needed. Similarly, once connected, the grid power provided to the power management system 124 from the grid power source 182 is directed by the bus-controlled switching device 126, and the AC / DC converter 156 monitors the bus voltage and frequency to determine whether the above parameters are equal before allowing connectivity. This will allow for minimal interruption of the power bus system. In other words, at any time there are two or more power sources available, the bus control switching device and AC / DC converter 156 ensure that the power is matched and synchronized to achieve connectivity. The power bus control device 126 communicates to the TRU controller 82 to determine the status of the connected flow. In one embodiment, the power management system 124 and or the TRU controller 82 provide a visual indication of which source (e.g., grid power source 182, generator 162, or energy storage system 150) is selected and operating on the bus control switching device 126.

[0074] Now go to Figures 4A-4H , each figure provides a simplified diagram depicting each of the eight identified power flow combinations. Figures 4A-4C The power flow for the power (eg, second three-phase AC power) supplied from the generator 162 and / or the generator power converter 164 is depicted. Figure 4A , in one embodiment, the logic employed by the TRU controller 82 to direct power in the power management system 124 determines whether the TRU 26 is operating. If so, and the energy storage system 150 indicates that the energy storage device 120 is exhibiting a state of charge less than a selected threshold, the power management system 124 directs power to the TRU 26 and the energy storage system 150 for recharging the energy storage device 152. In one embodiment, priority is given to satisfying the power needs of the TRU 26. Any remaining power may be directed to a recharging application for the energy storage system 150. It should be appreciated that although a specific threshold of 80% is disclosed and employed for the described embodiments, these values ​​and descriptions are merely illustrative. Other values ​​and applications for the threshold are possible.

[0075] Also refer to Figure 4B, which depicts a second case of power flow for power supplied from generator 162 and / or generator power converter 164. In this embodiment, if TRU 26 is operating and energy storage system 150 indicates that energy storage device 152 is exhibiting a state of charge that exceeds a selected threshold, power management system 124 directs power to only TRU 26 (because and energy storage system 150 have not yet required recharging). Similarly, in yet another embodiment, if Figure 4C 16 and 17. As depicted, a third power flow governed by the power management system 124 for power supplied from the generator 162 and / or the generator power converter 164. In this embodiment, the logic employed by the TRU controller 82 for directing power in the power management system 124 addresses the situation when the TRU 26 is not operating, and the energy storage system 150 indicates that the energy storage device 152 is exhibiting a state of charge less than a selected threshold (100% in this case, but other thresholds are possible). In this embodiment, the power management system 124 directs power only to the energy storage system 150 to recharge the energy storage device 152. In one embodiment, priority is given to satisfying the power needs of the energy storage system 150, and secondarily to providing power to the TRU 26.

[0076] Now go to Figures 4D-4F , which depicts the power flow for power supplied from grid power source 182. Figure 4D In the embodiment depicted in FIG. 1 , the logic employed by the TRU controller 82 for directing power from the grid power source 182 in the power management system 124 determines whether the TRU 26 is operating and whether the generator 162 (or the generator power converter 164) is not operating. If so, and the energy storage system 150 indicates that the energy storage device 152 is exhibiting a state of charge less than a selected threshold, the power management system 124 directs power to both the TRU 26 and the energy storage system 150 for recharging the energy storage device 152. In one embodiment, again, priority is given to satisfying the power demand of the TRU 26. Any remaining power can be directed to a recharging application for the energy storage system 150. It should be appreciated that a specific threshold value of 80% is disclosed and employed for the described embodiments, and that these values ​​and descriptions are merely illustrative. Other values ​​and applications for the threshold value are possible.

[0077] Also refer to Figure 4E, which depicts a second case of power flow for power supplied from grid power source 182 when generator 162 is not operating. In this embodiment, if TRU 26 is operating and energy storage system 150 indicates that energy storage device 152 is exhibiting a state of charge exceeding a selected threshold, the power management system directs power only to TRU 26, (because energy storage system 150 has not yet required recharging). Similarly, in yet another embodiment, as indicated by Figure 4F 1, a third power flow governed by the power management system 124 regarding power supplied from the grid power source 182 when the generator 162 is not operating is depicted. In this embodiment, the logic employed by the TRU controller 82 for directing power in the power management system 124 accounts for the situation when the TRU 26 is also not operating and the energy storage system 150 indicates that the energy storage device 152 is exhibiting a state of charge less than a selected threshold (in this case 100%, although other thresholds are also possible). In this embodiment, the power management system 124 directs power only to the energy storage system 150 to recharge the energy storage device 152. In one embodiment, priority is given to satisfying the power demand of the energy storage system 150.

[0078] Turn to Figure 4G and 4H , which depicts power flow with respect to power supplied to the TRU 26 under selected conditions also for operation from the energy storage system 150. Figure 4GIn the embodiment, the power flow to the TRU 26 is provided from the generator 162 and / or the generator power converter 164 (e.g., the second three-phase AC power 165) and from the energy storage system 150. In one embodiment, the logic used by the TRU controller 82 to direct power in the power management system 124 determines whether the TRU 26 is operating. If so, and the energy storage system 150 indicates that the energy storage device 152 is exhibiting a state of charge greater than a selected threshold, the power management system 124 directs power from both the generator 162 (or the generator power converter 164) and the energy storage system 150 to the TRU 26. In one embodiment, a threshold of 10% is employed for the state of charge of the energy storage device 152. In this embodiment, power is provided by the energy storage system 150 and the energy storage device 152 is thereby discharged. In one embodiment, priority is given to meeting the power demand of the TRU 26. This embodiment can be employed under the condition that the output power of the generator 162 and / or the generator power converter 164 is less than the power required to operate the TRU 26. It should be appreciated that although a specific threshold value of 10% is disclosed and employed for the described embodiments, such a value and description is merely illustrative. Other values ​​and applications for the threshold value are also possible. For example, in some cases, it may be desirable to prioritize the operation of the TRU 26 so that it is acceptable to completely deplete the energy storage device 152. Similarly, in other embodiments, it may be desirable to modify the functionality of the TRU 26 or reduce the operation of the TRU 26 to avoid excessively discharging the energy storage device 152.

[0079] Also refer to Figure 4H, which depicts a second case for power flow from the energy storage system 150 only. In this embodiment, if the TRU 26 is operating, but the generator 162 and / or the generator power converter 164 are not operating, the power management system 124 directs power to the TRU 26 if the energy storage system 150 indicates that the energy storage device 152 is exhibiting a state of charge that exceeds a selected threshold. In one embodiment, a threshold of 10% is employed for the state of charge of the energy storage device 152. In this embodiment, power is provided by the energy storage system 150 and the energy storage device 152 is therefore discharged. In one embodiment, priority is given to meeting the power demand of the TRU 26. Again, this embodiment can be employed under conditions where the output power of the generator 162 and / or the generator power converter 164 is less than the power required to operate the TRU 26. It should be appreciated that although a specific threshold of 10% is disclosed and employed for the described embodiments, such a value and description is merely illustrative. Other values ​​and applications for the threshold are also possible. For example, in some cases, it may be desirable to prioritize operation of TRU 26 so that it is acceptable to fully deplete energy storage device 152. Similarly, in other embodiments, it may be desirable to modify the functionality of the TRU or scale back the operation of the TRU to avoid excessively discharging energy storage device 152.

[0080] In another embodiment and dedicated operating mode and power flow for the TRU system 26 and power supply interface 120. In this embodiment, referred to as a fail-operation or "limp home" mode, the power supply interface 120 is configured such that, in a selected operating mode, power is directed from the tractor or vehicle 22 to the TRU 26. In one embodiment, if the energy storage device 152 exhibits an SOC below a selected threshold (e.g., <10%), and the generator 162 / generator power converter 164 is not operable, but the TRU system 26 is operable and requires power, the TRU power may be drawn from the tractor or truck's power system (i.e., the energy storage device or generator embedded in the tractor / truck). In addition, it should be appreciated that the described embodiments, while generally directed to the generator 162 being mounted on the trailer portion of the vehicle 22, such description is merely illustrative. In another embodiment, the generator 162 or another generator may be mounted on the hub or axle of the tractor portion of the vehicle 22 without loss of generality and still fully applicable to the described embodiments. In one embodiment, tractor / truck power may be routed to the power management system via a grid plug 185. An alternative connection may be made between the grid power source 182 and the vehicle power. For example, in operation, when the vehicle 22 trailer is in operation (e.g., at the time of delivery), the grid plug 185 would be plugged into the electric PTO of the tractor / trailer and used as a mobile grid source. The TRU controller 82 would be programmed to determine if the grid plug is active, and if so, to pull power (or supplement generator power) only when the energy storage device SOC is below a threshold as an alternative to modifying the functionality of the TRU system 26 or curtailing the operation of the TRU system 26.

[0081] AC / DC generator charging energy storage device

[0082] Now go to Figure 5, which depicts two additional embodiments of the architecture of various power sources 122 and power supply interfaces (in these cases represented as 220) employed to power the TRU 26. In one embodiment, the power source 122 may include, but is not limited to, an energy storage system 150 operably coupled to the power management system 124 and the grid power source 182. In addition, as described above, the generator 162, whether directly and / or via the generator power converter 164, is operably connected to the energy storage system 150, and more specifically to the energy storage device 152. In one embodiment, for example, when the generator 162 is an AC generator 162, the generator power converter 164 is an AC / DC converter and is configured to receive three-phase AC power 163 (e.g., at an AC voltage V1, an AC current I1, and a frequency f1) from the generator 162 and convert it to a third DC power represented as 165b, which includes a DC voltage V3, a third DC current I3. Alternatively, in another embodiment, when the generator 162 is a DC generator (indicated as 162a in the figure), the generator power converter indicated as 164a is a DC / DC converter and is configured to receive DC power indicated as 163a from the generator 162a (e.g., at a DC voltage V 1a 、DC current I 1a ) and converts it into a third DC power represented as 165b, which includes a DC voltage V3 and a third DC current I3.

[0083] In each embodiment, the third DC power 165b is transmitted directly from the generator power converter 164 (or 164a) to the energy storage system 150. Again, as described herein, the generator power converter 164, 164a is configured to provide the third DC power 165b based on the demand of the TRU 26, as described above. In this embodiment, the voltage control function 166 (e.g., see Figure 3 )、Current control function 167( Figure 3) are configured to facilitate AC / DC conversion for the generator power converter 164, and similarly DC / DC conversion for the generator power converter 164a of the alternative embodiment. In these embodiments, as further discussed herein, the TRU controller 82 again provides command signals represented as 169, 169a to the voltage control function 166, and / or the current control function 167 based on the power consumption requirements of the TRU 26, respectively. As previously described, the voltage control function 166 includes a voltage regulation function and is configured to monitor the output AC or DC voltage from the generator 162, and maintain a constant DC voltage from the voltage control function 166 for supply to the energy storage system 220 and the energy storage device 152. The current control function 167 monitors the state of the current drawn from the generator 162, 162a and communicates it to the TRU 26. Again, the state of the generator 162, 162a is monitored by the TRU controller 82 via lines 172, 172a.

[0084] Continue with Figure 5 and an embodiment of an architecture 110 of various power sources 122 and power supply interfaces 220 employed to power a TRU 26 and its components. As described above, the generator 162, 162a is operably connected to the energy storage system 150, either directly and / or via a generator power converter 164. In one embodiment, the energy storage device 152 includes an electrical switching device 158 that can be controlled by a TRU controller and / or a BMS 154 employed as a DC power manager. The electrical switching device 158 is configured to connect the power flow of the generator 162 / generator power converter 164, 164a and the battery of the energy storage device 152 to feed the DC power 155 to the DC / AC converter 156 and to the power management system 124 as needed to meet the TRU demand. Through this circuitry, the TRU demand will be met by either all power from the generator 162 / generator converter 164, 164a, all power from the battery, or some combination of power from the generator 262 / generator converter 164, 164a and the battery. For example, in one embodiment, if the TRU power demand is less than the available generator power, the TRU power demand is met with power from the generator 162 / generator converter 164, 164a, and any remaining generator power is directed to charge the batteries of the energy storage device. Control of the electrical circuit device (via the BMS 154) will manage the flow into and out of the batteries and meet the TRU demand as needed.

[0085] Continuing with the energy storage system, and more specifically to the energy storage device 152, the energy storage system 150 transmits power to and receives power from the power management system 124 via an AC / DC converter 156 operating as a DC / AC converter. Again, the energy storage system 150 includes, but is not limited to, the energy storage device 152, and the AC / DC converter 156 and the battery management system 154. In one embodiment, when operating from the grid power source 182, the power management system 124 provides three-phase AC power to the TRU 26, as described above with respect to power flow. Additionally, as needed, in order to maintain sufficient charge on the energy storage device 152, the power management system 124 may also direct the three-phase AC power to the AC / DC converter 156 to formulate a DC voltage and current to charge the energy storage device 152 and store energy on the energy storage device 152. Conversely, in another embodiment, when the grid power source 182 is unavailable, the energy storage device 152 supplies a DC voltage and current to an AC / DC converter 156 operating as a DC / AC converter to supply a three-phase AC voltage and current to the power management system 124 for powering the TRU 26. Again, provided that the state of charge of the energy storage device 152 exceeds a selected threshold, the TRU 26 can be operated from the energy storage system 150. In one embodiment, the selected threshold can be a 10% state of charge. Again, as described herein, the battery management system 154 monitors the performance of the energy storage device 152. For example, the state of charge of the energy storage device 152, the health of the energy storage device 152, and the temperature of the energy storage device 152 are monitored. The battery management system 154 and the AC / DC converter 156 are operably connected to and interact with the TRU controller 82. The TRU controller 82 receives information regarding the status of the energy storage system 150 , including the energy storage device 152 , to provide control inputs to the AC / DC converter 156 for monitoring the energy storage device 152 , controlling charging and discharging rates of the energy storage device 152 , and the like.

[0086] As described with respect to various embodiments herein, examples of energy storage devices 152 may include battery systems (e.g., batteries or battery packs), fuel cells, and other devices capable of storing and outputting electrical energy, which may be direct current (DC). In one embodiment, if the energy storage system 150 includes a battery system for the energy storage device 152, the battery system may have a voltage potential in the range of about two hundred volts (200V) to about six hundred volts (600V). In one embodiment, the energy storage device 152 may be contained within the structure 27 of the TRU 26. In one embodiment, the energy storage device 152 is positioned with the TRU 26, however other configurations are feasible. In another embodiment, the energy storage device 152 may be positioned with the cargo compartment 24, such as, for example, below the cargo compartment 40. Similarly, the AC / DC converter 156 may be positioned with the cargo compartment 24, such as, for example, below the cargo compartment 40, however, in some embodiments, it may be desirable to have the AC / DC converter 156 in close proximity to the power management system 124 and / or the TRU 26 and the TRU controller 82. It will be appreciated that, in one or more embodiments, although a particular positioning is described with respect to the connection and placement of selected components including energy storage device 152 and / or AC / DC converter 156, such description is merely illustrative and is not intended to be limiting. Various positioning, arrangements, and configurations of components are possible and within the scope of the present disclosure.

[0087] Continue with Figure 5As described earlier, the power supply interface 220 may include interfaces to various power sources 122 that are managed and monitored by the power management system 124. The power management system 124 manages and determines the flow of electrical power in the power supply interface 220 based on the operational needs of the TRU 26 and the capabilities of the components in the power supply interface 220 (e.g., the generators 162, 162a, the generator power converters 164, 164a, the energy storage device 152, the grid power source 182, etc.). The power management system 124 is configured to determine the status of the various power sources 122, control their operation, and direct power to and / or from the various power sources 122, etc. based on the various operational needs of the TRU 26. In one embodiment, the TRU controller 82 receives various signals indicating the operational status of the TRU 26 and determines the power demand for the TRU system 26 accordingly, and directs the power supply interface 220 and particularly the power management system 124 to direct power accordingly to address the needs of the TRU 26. In one embodiment, the TRU controller 82 monitors the RAT and optionally the SAT measured by the temperature sensors 142 and 146, respectively. The TRU controller 82 estimates the power requirements of the TRU 26 based on the RAT (among others) and accordingly provides commands to the various components of the power supply interface 220, particularly the power management system 124, the energy storage system 150, and the generator power converter 164, to manage the generation, conversion, and routing of power in the power supply interface 220 and the TRU system 26.

[0088] Power management system with AC / DC converter

[0089] Now go to Figure 6, which depicts two additional embodiments of the architecture of various power sources 122 employed to power the TRU 26 and power supply interfaces, represented in these cases as 320. In one embodiment, the power sources 122 may include, but are not limited to, an energy storage system 150 operably coupled to a power management system 124a, which is similar to the power management system 124 of the previous embodiment, but includes additional functionality and features, and a grid power source 182. Additionally, as described above, the generator 162 is operably coupled to the energy storage system 150, and more specifically, to the energy storage device 152, whether directly and / or via a generator power converter 164. In one embodiment, for example, when the generator 162 is an AC generator 162, the generator power converter 164 is an AC / DC converter and is configured to receive three-phase AC power 163 (e.g., at an AC voltage V1, an AC current I1, and a frequency f1) from the generator 162 and convert it to a third DC power including a DC voltage V3, a third DC current I3, represented as 165b. Alternatively, in another embodiment, when the generator 162 is a DC generator (indicated as 162a in the figure), the generator power converter indicated as 164a is a DC / DC converter and is configured to receive DC power indicated as 163a from the generator 162a (e.g., at a DC voltage V 1a 、DC current I 1a ) and converts it into a third DC power represented as 165b including a DC voltage V3 and a third DC current I3.

[0090] In each embodiment, the third DC power 165b is transmitted directly from the generator power converter 164 (or 164a) to the energy storage system 150. Again, as described herein, the generator power converter 164, 164a is configured to provide the third DC power 165b based on the demand of the TRU 26 as described above. In this embodiment, a voltage control function 166 (see, e.g., Figure 3 )、Current control function 167( Figure 3) are configured to facilitate AC / DC conversion with respect to the generator power converter 164, and similarly, DC / DC conversion with respect to the generator power converter 164a of the alternative embodiment. In these embodiments, as further discussed herein, the TRU controller 82 again provides command signals, represented as 169, 169a, to the voltage control function 166 and / or the current control function 167, respectively, based on the power consumption requirements of the TRU 26. As previously described, the voltage control function 166 includes a voltage regulation function and is configured to monitor the output AC or DC voltage from the generator 162 and maintain a constant DC voltage out of the voltage control function 166 to supply the energy storage system 320 and the energy storage device 152. The current control function 167 monitors the state of the current drawn from the generator 162, 162a and communicates it to the TRU 26. Again, the state of the generator 162, 162a is monitored by the TRU controller 82 via lines 172, 172a.

[0091] Continue with Figure 6 and an embodiment of an architecture 110 of various power sources 122 and power supply interfaces 320 employed to power a TRU 26 and its components. As described above, the generators 162, 162a, whether directly and / or via the generator power converter 164, are operably connected to the energy storage system 150. In one embodiment, the energy storage device 152 includes an electrical switching device 158 that can be controlled by a TRU controller and / or a BMS 154 employed as a DC power manager. The electrical switching device 158 is configured to connect the power flow of the generator 162 / generator power converter 164, 164a and the battery of the energy storage device 152 to feed the DC power 155 to the DC / AC converter 156 and to the power management system 124 as needed to meet the TRU demand. Through this circuit arrangement, the TRU demand will be met by all power from the generator 162 / generator converter 164, 164a, all power from the battery, or some combination of power from the generator 262 / generator converter 164, 164a and the battery. For example, in one embodiment, if the TRU power demand is less than the available generator power, the TRU power demand is met with power from the generator 162 / generator converter 164, 164a, and any remaining generator power is directed to charge the batteries of the energy storage device. Control of the electrical circuit device (via the BMS 154) will manage the flow into and out of the batteries and meet the TRU demand as needed.

[0092] Continue with Figure 6As well as embodiments of the architecture of various power sources 122 and power supply interfaces 320 employed to power the TRU 26 and its components. As described above, the generators 162, 162a, whether directly and / or via the generator power converter 164, are operably connected to the energy storage system 150, and more specifically, to the energy storage device 152. The energy storage system 150 transmits power to the power management system 124a and receives power from the power management system 124a. Again, the energy storage system 150 includes, but is not limited to, the energy storage device 152, and the AC / DC converter 156 and the battery management system 154. In one embodiment, when operating from the grid power source 182, the power management system 124a provides three-phase AC power to the TRU 26, as described above with respect to power flow. As needed, in addition to maintaining sufficient charge on the energy storage device 152, the power management system 124a can also direct the three-phase AC power to the AC / DC converter 156 to formulate a DC voltage and current to charge the energy storage device 152 and store energy on the energy storage device 152. Conversely, in another embodiment, when the grid power source 182 is unavailable, the energy storage device 152 supplies a DC voltage and current to an AC / DC converter 156 operating as a DC / AC converter to supply a three-phase AC voltage and current to the power management system 124 for powering the TRU 26. Again, provided that the state of charge of the energy storage device 152 exceeds a selected threshold, the TRU 26 can be operated from the energy storage system 150. In one embodiment, the selected threshold may be a 10% state of charge. Again, as described herein, the battery management system 154 monitors the performance of the energy storage device 152. For example, the state of charge of the energy storage device 152, the state of health of the energy storage device 152, and the temperature of the energy storage device 152 are monitored. The battery management system 154 and the AC / DC converter 156 are operably connected to and interact with the TRU controller 82. TRU controller 82 receives information regarding the status of energy storage system 150 , including energy storage device 152 , to provide control inputs to AC / DC converter 156 for monitoring energy storage device 152 , controlling charging and discharging rates for energy storage device 152 , and the like.

[0093] As previously described with respect to various embodiments herein, examples of energy storage devices 152 may include battery systems (e.g., batteries or battery packs), fuel cells, and other devices capable of storing and outputting electrical energy, which may be direct current (DC) as discussed herein.

[0094] Continue with Figure 6As described earlier, the power supply interface 320 may include interfaces to various power sources 122 that are managed and monitored by the power management system 124a. The power management system 124 manages and determines the flow of electrical power in the power supply interface 320 based on the operational needs of the TRU 26 and the capabilities of the components in the power supply interface 320 (e.g., the generators 162, 162a, the generator power converters 164, 164a, the energy storage device 152, the grid power source 182, etc.). The power management system 124a is configured to determine the status of the various power sources 122, control their operation, and direct power to and / or from the various power sources 122, etc. based on the various operational requirements of the TRU 26. In addition, in yet another embodiment, the power management system 124a may also include an AC / DC converter 128 that is configured to receive the incoming three-phase AC voltage 157 and convert a portion thereof to a DC voltage 129 to facilitate maintenance, configuration, and operation of the TRU 26. In this embodiment, the addition of the AC / DC converter 128 eliminates the need for a separate TRU battery to maintain operation of the TRU controller 82. In addition, in one embodiment, the DC voltage generated by the AC / DC converter 129 is also employed to power selected sensors and components of the TRU system 26. Advantageously, generating the required low voltage DC power in the power management system simplifies the wiring and routing of the TRU system 26 and the power supply interface 320 by eliminating an additional set of DC wiring on top of the wiring going from the energy storage device 152 to the AC / DC converter 156. Otherwise, the power management system 124a would require two sets of DC wiring coming out of the energy storage device (a high voltage set leading to the AC / DC converter 156, and an optional low voltage set leading directly to the TRU), rather than a single DC wiring in the described embodiment.

[0095] In one embodiment, the TRU controller 82 receives various signals indicative of the operating state of the TRU 26 and determines the power demand for the TRU system 26 accordingly, and directs the power supply interface 320 and, in particular, the power management system 124a to direct power accordingly to address the demand of the TRU 26. In one embodiment, the TRU controller 82 monitors the RAT and, optionally, the SAT measured by the temperature sensors 142 and 146, respectively. The TRU controller 82 estimates the power demand for the TRU 26 based on the RAT (among others), and provides commands accordingly to various components of the power supply interface 320, and in particular the power management system 124, the energy storage system 150, and the generator power converter 164, to manage the generation, conversion, and routing of power in the power supply interface 320 and the TRU system 26.

[0096] The TRU 26 may further include a renewable electricity source 110 ( Figure 1 One embodiment of the renewable electricity source 110 may be, for example, a solar panel mounted to the outside of the top wall 30 of the cargo box 24 (see also Figure 1 ). For example, the renewable power source 110 can generate all or part of the required low voltage DC power for the TRU controller 82. Again, this configuration simplifies the wiring and routing of the system design by eliminating an additional set of DC wiring in addition to the HV wiring from the energy storage device 152 to the AC / DC converter 156.

[0097] When compared to more traditional systems, the benefits of the present disclosure include no fuel carriage, fuel system and fuel consumption, and a refrigeration unit that emits less noise and has no combustion byproducts. Still further, the present disclosure includes an energy storage device that is conveniently and efficiently recharged to meet the power needs of the refrigeration unit.

[0098] As described above, embodiments may be in the form of processor-implemented processes and devices (such as processors) for practicing those processes. Embodiments may also be in the form of computer program code of instructions implemented in tangible media, such as network cloud storage, SD card, flash drive, floppy disk, CD ROM, hard drive, or any other computer-readable storage medium, wherein when the computer program code is loaded into a computer and executed by the computer, the computer becomes a device for implementing the embodiments. Embodiments may also be in the form of computer program code, for example, whether stored in a storage medium, loaded into a computer and / or executed by a computer, or transmitted on a certain transmission medium, loaded into a computer and / or executed by a computer, or transmitted on a certain transmission medium, such as on electrical wiring or wiring, through optical fiber, or via electromagnetic radiation, wherein when the computer program code is loaded into and executed by a computer, the computer becomes a device for practicing the embodiments. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create a specific logic circuit.

[0099] The term "about" is intended to include the degree of error associated with measurement of a particular quantity based on the equipment available at the time the application was filed. For example, "about" may include a range of ±8% or 5% or 2% of a given value.

[0100] The terms used herein are only for the purpose of describing specific embodiments and are not intended to limit the present disclosure. As used herein, the singular forms "a", "an" and "the" are also intended to include the plural forms, unless the context clearly indicates otherwise. It will be further understood that when used in this specification, the terms "include" and / or "comprising" specify the presence of the features, integers, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, integers, steps, operations, element parts and / or combinations thereof.

[0101] Although the present disclosure has been described with reference to one or more exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and elements thereof may be substituted with equivalents without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the present disclosure without departing from the substantive scope of the present disclosure. Therefore, it is intended that the present disclosure is not limited to the specific embodiments disclosed as the best mode intended for implementing the present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.

Claims

1. A transport refrigeration unit and power system comprising: a compressor configured to compress a refrigerant, the compressor having a compressor motor configured to drive the compressor; an evaporator heat exchanger operably coupled to the compressor; an evaporator fan configured to provide a return air flow from a return air inlet and flow the return air flow through the evaporator heat exchanger; a return air temperature sensor disposed in the return air flow and configured to measure a temperature of the return air flow; a transport refrigeration unit controller operably connected to the return air temperature sensor and configured to execute a process for determining an AC power demand for the transport refrigeration unit based on at least the return air temperature; a generator power converter configured to receive a generator three-phase AC power provided by the AC generator and to transmit a second DC power; an energy storage system configured to receive the second DC power and provide a first three-phase AC power and receive a second three-phase AC power; and A power management system is configured to receive the three-phase AC power and direct at least a portion of the first three-phase AC power to the transport refrigeration unit based at least in part on the AC power demand.

2. The transport refrigeration unit and power system of claim 1, wherein: Also included is a grid power source configured to provide grid three-phase AC power to the power management system.

3. The transport refrigeration unit and power system of claim 1, wherein: The generator power converter includes an AC / DC converter, and the generator three-phase AC power exhibits a first AC voltage and a first AC current at a first frequency, and the second DC power exhibits a second DC voltage and a second DC current.

4. The transport refrigeration unit and power system of claim 1, wherein: The generator power converter is operably connected to the transport refrigeration unit controller, the generator power converter including a voltage control function, a current control function, wherein at least the voltage control function is at least partially responsive to the AC power demand.

5. The transport refrigeration unit and power system of claim 1, wherein: The energy storage system comprises: Energy storage devices; Switching device; and and at least one of a DC / AC converter and an AC / DC converter, wherein the DC / AC converter is configured to provide the first three-phase AC power to the power management system based at least in part on the AC power demand, and the AC / DC converter is configured to receive the second three-phase AC power to supply the energy storage device.

6. The transport refrigeration unit and power system of claim 5, wherein: The switching device is configured to direct a DC power flow in the energy storage system based at least in part on the AC power demand, the directing comprising: directing a second DC voltage of the second DC power to the energy storage device and at least one of a DC / AC converter and a DC / AC converter; directing DC power from the energy storage device to the DC / AC converter; and DC power is received from the AC / DC converter and provided to the energy storage device.

7. The transport refrigeration unit and power system of claim 5, wherein: The energy storage device includes at least one of a battery, a fuel cell, and a flow battery.

8. The transport refrigeration unit and power system of claim 5, wherein: Also included is a battery management system operably connected to the transport refrigeration unit controller and configured to monitor a state of charge of at least the energy storage device.

9. The transport refrigeration unit and power system of claim 8, wherein: The DC / AC converter and AC / DC converter are integrated, and wherein the DC / AC converter or AC / DC converter is operably connected to the transport refrigeration unit controller and configured to direct power flow to and from the power management system based at least in part on at least one of the AC power demand and the state of charge of the energy storage device.

10. The transport refrigeration unit and power system of claim 9, wherein: The power management system is configured to: receive first three-phase AC power from the energy storage system and grid three-phase AC power from a grid power connection; and provide at least one of the selected three-phase AC power to the transport refrigeration unit and the second three-phase AC power to the energy storage system.

11. The transport refrigeration unit and power system of claim 9, wherein: Also includes: The power management system includes a power control switching device, which is responsive to the transport refrigeration unit controller and is configured to direct multiple power flows in the transport refrigeration unit and the power system, the multiple power flows are based at least in part on at least one of the AC power demand and the charge state of the energy storage device of the energy storage system.

12. The transport refrigeration unit and power system of claim 11, wherein: A first portion of the power flows in the plurality of power flows comprises: receiving grid three-phase AC power from the grid if the grid power source is operable; and directing at least a portion of the grid three-phase AC power to the transport refrigeration unit and the energy storage system if the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge less than a selected threshold; or directing at least a portion of the grid three-phase AC power to the transport refrigeration unit if the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge greater than or equal to the selected threshold; or If the transport refrigeration unit is inoperable and an energy storage device of the energy storage system exhibits a state of charge less than a second selected threshold, at least a portion of the grid three-phase AC power is directed to the energy storage system.

13. The transport refrigeration unit and power system of claim 11, wherein: A second portion of the power flows of the plurality of power flows comprises: receiving three-phase AC power from the energy storage system; receiving grid three-phase AC power from the grid power source if the grid power source is operable; synchronizing and combining three-phase AC power from the energy storage system with the grid three-phase AC power; and If the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge greater than or equal to another selected threshold, the combined three-phase AC power is directed to the transport refrigeration unit.

14. A method of generating electricity and directing the electricity to a transport refrigeration unit system, the system having a compressor configured to compress a refrigerant; an evaporator heat exchanger operably coupled to the compressor; an evaporator fan configured to provide a return air flow from a return air inlet and to flow the return air flow through the evaporator heat exchanger; a return air temperature sensor disposed in the return air flow and configured to measure a temperature of the return air flow; and a transport refrigeration unit controller, the method comprising: operably connecting the return air temperature sensor to the transport refrigeration unit controller; determining an AC power demand for the transport refrigeration unit based on at least the return air temperature; operatively connecting a generator power converter to the AC generator, the generator power converter configured to receive generator three-phase AC power provided by the AC generator and to transmit a second DC power; operably connected to an energy storage system operable to receive the second DC power and the three-phase AC power, provide a first three-phase AC power, and receive a second three-phase AC power; and A power management system is operably connected to the generator power converter and the transport refrigeration unit, the power management system configured to receive the second three-phase AC power to direct power to the transport refrigeration unit based at least in part on the AC power demand.

15. The method according to claim 14, characterized in that Also included is a grid power source operably connected to provide grid three-phase AC power to the power management system.

16. The method according to claim 14, characterized in that It further includes converting, by the generator power converter, the generator three-phase AC power with a first AC voltage and a first AC current at a first frequency into the second DC power with a second DC voltage and a second DC current.

17. The method according to claim 14, characterized in that Also includes at least one of the following: providing first three-phase AC power to the power management system based at least in part on the AC power demand by a DC / AC converter configured to convert first DC power to the first three-phase AC power; and receiving the second three-phase AC power from the power management system and converting the second three-phase AC power into DC power for charging the energy storage system; The energy storage system includes an energy storage device, a switching device, and at least one of an AC / DC converter and a DC / AC converter.

18. The method according to claim 17, characterized in that Also includes: configuring the switching device to direct a DC power flow in the energy storage system based on the AC power demand, the directing comprising: applying a second DC voltage of the second DC power to the DC / AC converter and at least one of the DC / AC converter and the energy storage device; applying DC power from the energy storage device to the DC / AC converter; and DC power is received from the AC / DC converter and provided to the energy storage device.

19. The method according to claim 17, characterized in that Also includes: A plurality of power flows are directed to the transport refrigeration unit system by a power control switching device of the power management system, the power control switching device being responsive to the transport refrigeration unit controller, the plurality of power flows being based at least in part on at least the AC power demand, a state of charge of an energy storage device of the energy storage system.

20. The method according to claim 19, characterized in that A first portion of the power flows in the plurality of power flows comprises: receiving grid three-phase AC power from the grid if the grid power source is operable; and directing at least a portion of the grid three-phase AC power to the transport refrigeration unit and the energy storage system if the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge less than a selected threshold; or directing at least a portion of the grid three-phase AC power to the transport refrigeration unit if the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge greater than or equal to the selected threshold; or If the transport refrigeration unit is inoperable and an energy storage device of the energy storage system exhibits a state of charge less than a second selected threshold, at least a portion of the grid three-phase AC power is directed to the energy storage system.

21. The method according to claim 19, characterized in that A second portion of the power flows of the plurality of power flows comprises: receiving the first three-phase AC power from the energy storage system; receiving grid three-phase AC power from the grid power source if the grid power source is operable; and synchronizing and combining first three-phase AC power from the energy storage system with the grid three-phase AC power, and The combined three-phase AC power is directed to the transport refrigeration unit if the transport refrigeration unit is operational and an energy storage device of the energy storage system exhibits a state of charge greater than or equal to another selected threshold.

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