Systems and methods for balancing energy loads in work vehicles

Abstract

A system for balancing energy within an energy generation and distribution system of a work vehicle. The system may generate rotational motion with a diesel engine. The rotational motion of the diesel engine may power one or more generators. The one or more generators may provide electrical energy to one or more electric motors. The one or more electric motors may provide rotational motion to one or more wheel and tire assemblies. When the work vehicle is coasting and / or braking, the one or more electric motors may be used to regenerate electrical energy. The regenerated electrical energy may reduce the load on the diesel engine. To maintain the diesel engine within a preferred operating window, an exhaust brake system may be activated when the regenerated electrical energy is above a predetermined threshold and / or when the load on the diesel engine is below a predetermined threshold.

Description

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to balancing energy loads for work vehicles, and, more specifically, to use an exhaust brake system to balance loads on a diesel engine.BACKGROUND

[0002] Work vehicles can be used to perform different work and industrial tasks. For example, one or more work vehicles can be utilized to collect or move materials around a worksite, among other suitable tasks. Work vehicles may use diesel-powered generators to power electric motors to drive the work vehicle. During deceleration, the electric motors may regenerate electricity. During periods of heavier deceleration, the electric motos may regenerate more electricity than is needed, requiring an additional load such as brake resistors to balance the energy loads within the full system. Brake resistors may be expensive and require additional systems such as cooling systems, which may add unnecessary weight, complexity, and cost to the work vehicle.SUMMARY

[0003] The present disclosure may comprise one or more of the following features and combinations thereof.

[0004] In one implementation of the present disclosure, a work vehicle is provided with a diesel engine having an exhaust brake system. The work vehicle can include one or more electric generators, each of the one or more electric generators operatively coupled to the diesel engine. The work vehicle can include one or more electric motors, each of the one or more electric motors operatively coupled to at least one of the one or more electric generators, wherein each of the one or more electric motors is configured to provide torque in a first direction to provide rotational energy to one or more external devices and provide torque in a second direction to regenerate electrical energy to the one or more generators. the exhaust brake system is configured to be activated when at least one of the one or more electric motors provides torque in the second direction.

[0005] In another implementation of the present disclosure, a system is provided with an energy generation device having an exhaust brake system. The system can include an electric generator operatively coupled to the diesel engine. The system can include an electric motor operatively coupled to the electric generator and configured to provide torque in a first direction to generate rotational motion, and provide torque in a second direction opposite the first direction to generate electrical energy. The system can include a controller communicatively coupled to the exhaust brake system and the electric motor. The controller may be configured to activate the exhaust brake system.

[0006] In a further implementation, a method is provided for balancing energy in an work vehicle. The method can include producing rotational energy with a diesel engine. The method can further include generating electrical energy by a generator with the rotational energy, wherein the generator is operatively coupled to the diesel engine. The method can further include transferring the electrical energy from the generator to an electric motor operatively coupled to the generator. The method can further include producing torque by the electric motor in a first direction or a second direction opposite the first direction. When torque is produced in the first direction the electric motor generates rotation motion, and when torque is produced in the second direction the electric motor generates electrical energy. The method can further include activating an exhaust brake system operatively coupled to the diesel engine when the electric motor produces torque in the second direction.

[0007] These and other features of the present disclosure will become more apparent from the following description of the illustrative implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure contained herein is illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.

[0009] FIG. 1 illustrates a representative work vehicle.

[0010] FIG. 2 illustrates a simplified block diagram of the components of an energy generation and transfer system of the work vehicle.

[0011] FIG. 3 illustrates a simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0012] FIG. 4 illustrates another simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0013] FIG. 5 illustrates another simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0014] FIG. 6 illustrates a simplified block diagram of the components of another energy generation and transfer system of the work vehicle.

[0015] Corresponding reference numerals are used to indicate corresponding parts throughout the several views.DETAILED DESCRIPTION

[0016] While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific implementations thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

[0017] References in the specification to“one implementation,”“an implementation,”“an illustrative implementation,” etc., indicate that the implementation described may include a particular feature, structure, or characteristic, but every implementation may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same implementation. Further, when a particular feature, structure, or characteristic is described in connection with an implementation, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other implementations whether or not explicitly described. Additionally, it should be appreciated that items included in a list in the form of “at least one A, B, and C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).

[0018] In the drawings, some structural or method features may be shown in specific arrangements and / or orderings. However, it should be appreciated that such specific arrangements and / or orderings may not be required. Rather, in some implementations, such features may be arranged in a different manner and / or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all implementations and, in some implementations, may not be included or may be combined with other features.

[0019] Implementations of the present disclosure generally relate to balancing the energy flow within a work vehicle. Additionally, implementations of the present disclosure relate to providing loads to manage the engine speed and output of a diesel engine used to power an electric generator configured on a work vehicle.

[0020] In at least certain situations, work vehicles may use diesel engines to provide energy to generators, which in turn provide electrical energy to one or more electric motors which may be used to propel the work vehicle forward. Supplemental systems such as hydraulic systems or auxiliary electrical systems may further be electrically coupled to the generator.

[0021] When the work vehicle is coasting and / or decelerating, the one or more electric motors may be used to regenerate electrical energy. This regenerated electrical energy may supplement the energy provided by the diesel engine. To balance the energy generated throughout the entire system, an additional load may be placed on the diesel engine when the energy demands on the diesel engine are reduced because of the regenerated energy.

[0022] In some implementations, an exhaust braking system may be used to place an outside load on the diesel engine when the load from the generator is reduced. The exhaust braking system may be activated when the level of energy regenerated exceeds a predetermined threshold. In some implementations, the exhaust braking system may be proportionally activated based on how far above the regenerated energy is relative to the predetermined threshold.

[0023] FIG. 1 illustrates a representative work vehicle 100. While the work vehicle 100 is illustrated as a wheel loader, it should be understood that, in implementations, the work vehicle 100 may be any suitable type of work vehicle, including but not limited to four-wheel drive loaders, tractors, front end loaders, scraper systems, cutters and shredders, hay and forage equipment, planting equipment, seeding equipment, sprayers and applicators, utility vehicles, mowers, dump trucks, backhoes, track loaders, crawler loaders, dozers, excavators, motor graders, skid steers, tractor loaders, wheel loaders, rakes, aerators, skidders, bunchers, forwarders, harvesters, swing machines, knuckleboom loaders, diesel engines, axles, planetary gear drives, pump drives, transmissions, generators, or marine engines, among other suitable equipment.

[0024] The work vehicle 100 may, or may not, be an autonomous or semi-autonomous vehicle. According to the illustrated implementation, the work vehicle 100 can include an operator cab 102 at which an operator can be positioned within the work vehicle 102 in connection with the operator operating, including, for example, controlling the movement, direction of travel, and / or speed of travel, of the work vehicle 100.

[0025] The work vehicle 100 may include one or more wheel and tire assemblies 104 that can engage the adjacent ground surface and be utilized in the propulsion and / or steering of the work vehicle 100. As illustrated, the work vehicle 100 includes four wheel and tire assemblies 104a, 104b, 104c, 104d (hidden from view). However, it should be understood that, in implementations, any suitable wheel and tire assemblies 104 may be included. In further implementations, other external devices may be included, such as tracks, output shafts, or any other suitable external devices.

[0026] The work vehicle 100 includes an energy generation and transfer system 110, which may be used to generate and transfer energy needed to propel the work vehicle and perform additional functions, as will be shown and described in more detail herein.

[0027] FIG. 2 illustrates a simplified block diagram of the components of an energy generation and transfer system 110 of the work vehicle 100. As illustrated, the energy generation and transfer system 110 includes a diesel engine 112. The diesel engine 112 may operate within a preferred operating window. The preferred operating window of the diesel engine 112 may be a preferred range of engine speeds and / or loads which maintain the operation of the diesel engine 112 in an efficient and reliable manner. The preferred operating window may be predetermined, or may be defined by the operator such as based on the use of the work vehicle 100, the conditions in which the work vehicle 100 is used, or other suitable factors. In further implementations, the diesel engine 112 may be substituted with other suitable energy generation devices, including but not limited to a gasoline engine, a hydrogen combustion engine, a biofuel combustion engine, or any other suitable known or as yet-unknown energy generation device.

[0028] The diesel engine 112 includes an exhaust system 114 including an exhaust brake system 116. The exhaust brake system 116 may be any suitable type of exhaust brake system well known or not yet known in the art, including but not limited to a closeable valve within the exhaust system, a compression brake (also known as a “Jake brake”), or any other suitable type of exhaust brake system. In some implementations, the exhaust brake system 116 may be variably controlled, such that the power of the exhaust brake system 116 and therefore associated braking effect on the diesel engine 112 may be increased or decreased incrementally. In further implementations, the exhaust brake system 116 may be electronically actuatable.

[0029] The diesel engine 112 may have a load sensor 117. The load sensor 117 may measure the load on the diesel engine 112. The load sensor 117 may be any suitable sensor for measuring the load on the diesel engine 112, including but not limited to a manifold pressure sensor, a mass airflow sensor, an intake air temperate sensor, or any other suitable sensor and / or combination of sensors.

[0030] The diesel engine 112 may have an output device 118. The output device 118 may be a crankshaft, flywheel, gear, or any other suitable output device which allows for mechanical linkage to the energy output of the diesel engine 112.

[0031] The energy generation and transfer system 110 includes a generator 120. The generator 120 may include an input device 122. The input device 122 may be a gear, a shaft, a splined coupling, or any other suitable input device. The input device 122 is operatively coupled to the output device 118 of the diesel engine 110. The generator 120 outputs electrical energy by transforming the output of the diesel engine 112. The generator 120 includes one or more electrical outputs 124. The electrical outputs 124 may be outlets, terminals, plugs, sockets, or any other suitable type of electrical outputs 124.

[0032] The energy generation and transfer system 110 includes an electric motor 130. The electric motor 130 may be any suitable type of motor, including but not limited to permanent magnet motors, brushless motors, or any other suitable type of motors. The electric motor 130 includes an electrical input 132. The electrical input 132 may be inlets, terminals, or any other suitable type of electrical inputs 132. The electric motor 130 includes a motor output device 134. The motor output device 134 may a shaft or other suitable motor output device 134.

[0033] The electrical input 132 is electrically coupled to the electrical output 124 of the generator 120, such that the electrical energy 124 is transferred to the electric motor 130 to rotate the motor output device 134. The motor output device134 may be operatively coupled to a drivetrain 106 of the work vehicle 100. The drivetrain 106 may be a driveshaft, transmission, differential, or any other suitable device for transferring the torque of the electric motor 130 to one or more wheel and tire assemblies 104. In some implementations, the motor output device 134 may be directly coupled to one or more wheel and tire assemblies 104.

[0034] One or more supplemental systems 136 may be electrically coupled to the generator 120. The one or more supplemental systems 136 may be, as a non-limiting example, hydraulic systems, external electric systems, and / or other suitable supplemental systems 136 which are commonly used with the work vehicle 102.

[0035] An energy sensor 146 may be coupled to energy generation and transfer system 110 to measure the electrical flow within the energy generation and transfer system 110.

[0036] A controller 140 is communicatively coupled to the generator 120, the exhaust brake system 116, the load sensor 117, and the energy sensor 146. The controller 140 can have a processor 142 and a memory device 144. The processor 142 can be configured to follow instructions, including control instructions contained within, or that are part of, the memory device 144, including, for example, a non-transitory machine-readable medium.

[0037] The processor 142 can be embodied as any type of processor or other compute circuit capable of performing various tasks. In some implementations, the processor 142 can be embodied as a single or multi-core processor, a microcontroller, or other processing or controlling circuit. Additionally, in some implementations, the processor 142 can be embodied as, include, or be coupled to an FPGA, an application specific integrated circuit (ASIC), reconfigurable hardware or hardware circuitry, or other specialized hardware to facilitate performance of the functions described herein. In some implementations still, the processor 142 can be embodied as a high-power processor, an accelerator co-processor, an FPGA, or a storage controller.

[0038] The memory device 144 can be of one or more types of non-transitory computer-readable media, such as a solid-state memory, electromagnetic memory, optical memory, or a combination thereof. Further, the memory device 144 can be volatile and / or nonvolatile. It should be appreciated that the memory device 144 can store information that is manipulated by the operating logic of processor 142, such as, for example, information representative of inputted signals in addition to or in lieu of storing programming instructions defining operating logic. The memory device 144 can store various software and information used during operation of the energy generation and distribution system 110, such as applications, programs, libraries, and drivers. Thus, the memory device 144 can include information, including algorithms and look-up tables, among other information, that can be used by the processor 142.

[0039] While one implementation of the energy generation and transfer system 110 is shown, it should be understood that, in implementations, the components may be arranged and / or connected in any other suitable manner as known by a person of skill in the art.

[0040] The energy generation and transfer system 110 may be arranged within the work vehicle 100 by any suitable means, including but not limited to fasteners, brackets, or any other suitable means.

[0041] FIG. 3 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 110. In the situation illustrated in FIG. 3, the work vehicle may be accelerating in a first direction.

[0042] The diesel engine 112 provides rotational energy to the generator 120 as indicated by arrow A. The rotational energy may be generated by the diesel engine 112 through combustion of diesel fuel. The diesel engine 112 and the generator 120 may be operatively coupled through any suitable means, including but not limited to the output device 118 and the input device 122 described above.

[0043] The generator 120 provides electrical energy to the electric motor 130 as indicated by arrow B. The electric motor 130 may be electrically coupled to the generator 120 through any suitable means, including but not limited to the electrical output 124 and the electrical input 132 described above.

[0044] The electrical energy allows the motor output device 134 to rotate in a first direction as indicated by arrow C. In one implementation, the motor output device 134 rotates one or more of the wheel and tire assemblies 104 by applying torque to the drivetrain 106 such that the work vehicle 100 is accelerated forward. In further implementations, the motor output device 134 is coupled to various other external devices such as tracks, output shafts, or any other suitable external devices.

[0045] The generator 120 may provide electrical energy to one or more supplemental systems 136 as indicated by arrow B, such as auxiliary electrical system and hydraulic systems configured on the work vehicle 100.

[0046] FIG. 4 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 110. In the situation illustrated in FIG. 4, the work vehicle 100 is decelerating at a first deceleration rate, such that the wheels 104 do not require torque from the electric motor 130 to continue moving forward and return energy to the electric motor 130 as indicated by arrow D. The electric motor 130 is used to regenerate electrical energy back to the generator 120 as indicated by arrow E by providing torque in a second direction, wherein the second direction is opposite from the first direction.

[0047] The electric motor 130 may generate a first level of regenerated electrical energy while the work vehicle is decelerating at the first deceleration rate. The regenerated electrical energy is transferred to the generator 120. The first level of regenerated electrical energy may be low enough such that diesel engine 110 is still needed to supply energy to the supplemental systems 136 electrically coupled to the generator 120 as indicated by arrow B while maintaining the diesel engine 112 within a preferred operating window.

[0048] The first level of regenerated electrical energy may further reduce the load on the diesel engine 112 by reducing the electrical load demands on the generator 120, which in turn reduces the load demands on the diesel engine 112. However, the reduced load on the diesel engine 112 may still maintain the diesel engine 112 within the preferred operating window.

[0049] FIG. 5 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 112. In the situation illustrated in FIG. 5, the work vehicle 100 is decelerating at a second deceleration rate, where the second deceleration rate is greater than the first deceleration rate, such that the wheels 104 do not require torque from the electric motor 130 and return energy to the electric motor 130 as indicated by arrow D. The electric motor 130 is used to regenerate electrical energy back to the generator 120 as indicated by arrow E by providing torque in a second direction, wherein the second direction is opposite from the first direction.

[0050] The electric motor 130 may generate a second level of regenerated electrical energy while the work vehicle 100 is decelerating at the second deceleration rate, where the second level of regenerated electrical energy is greater than the first level of regenerated electrical energy. The second level of regenerated electrical energy may return energy to the diesel engine from the generator 120 as indicated by arrow F. The second level of regenerated electrical energy may reduce the demands on the diesel engine 110 such that the diesel engine is operating outside of the preferred operating window.

[0051] In order to maintain the diesel engine 110 within the preferred operating window, the exhaust brake system 116 may be activated. By activating the exhaust brake system 116, the engine speed of the diesel engine 112, and therefore the associated energy produced by the diesel engine 112, may be reduced by the exhaust brake system 116 placing a load on the diesel engine 112, as indicated by arrow G. This may balance the energy generated by the energy generation and transfer system 110 with the energy required by the various components of the energy generation and transfer system 110.

[0052] In some implementations, the exhaust brake system 116 may be incrementally applied proportionally to the level of regenerated electrical energy. That is, the exhaust brake system 116 may be applied at a higher intensity so as to achieve an increased braking performance on the diesel engine 112 when the level of regenerated electrical energy is higher and / or the load on the diesel engine 112 is lower.

[0053] In some implementations, the energy sensor 146 monitors a detected level of regenerated electrical energy and communicates a signal corresponding to the detected level of regenerated electrical energy to the controller 140. If the detected level of regenerated energy is above a predetermined threshold level of regenerated electrical energy, the controller 140 may automatically activate the exhaust brake system 116.

[0054] In further implementations where the exhaust brake system 116 may be incrementally applied, the controller 140 may automatically adjust the application of the exhaust brake system 116 proportionally to the detected level of regenerated energy, such that higher levels of detected regenerated energy may result in a greater application of the exhaust brake system 116.

[0055] In yet further implementations, the load sensor 117 monitors the load on the diesel engine 112 and communicates a signal corresponding to the detected load on the diesel engine 112 to the controller 140. If the load on the diesel engine 112 falls below a threshold load, such as from the regenerated electrical energy reducing the load demands on the generator 120 which in turn reduces the load demands on the diesel engine 112, the controller 140 may automatically activate the exhaust brake system 116.

[0056] In further implementations where the exhaust brake system 116 may be incrementally applied, the controller 140 may automatically adjust the application of the exhaust brake system 116 proportionally to the detected load on the diesel engine 112, such that lower loads levels detected on the diesel engine 112 may result in a greater application of the exhaust brake system 116.

[0057] In further implementations, there may be separate controllers for the exhaust brake system 116 and the generator 120.

[0058] In some implementations, the exhaust brake system 116 may be manually activated by an operator, such as by an activation device being configured within the operator cab 102. The exhaust brake system 116 may be activated via a user input device such as a button or switch, or may be incrementally implemented such as by a slider.

[0059] FIG. 6 illustrates an energy generation and transfer system 210. The energy generation and transfer system 210 includes two generators 220. The two generators 220 may be configured in a similar manner to that described above in relation to the generator 120.

[0060] The energy generation and transfer system 210 includes four electric motors 230a, 230b, 230c, 230d. The four electric motors 230a, 230b, 230c, 230d may be configured in a similar manner to that described above in relation to the electric motor 130.

[0061] The energy generation and transfer system 210 includes a diesel engine 212. The diesel engine 212 may be configured in a similar manner to that described above in relation to the diesel engine 112, such as including an exhaust system 214 and an exhaust braking system 216.

[0062] The diesel engine 212 may be rotatably coupled to the two generators 220a,220b, such that rotational energy generated by the diesel engine 212 is output as electrical energy by the two generators 220a, 220b by transforming the output of the diesel engine 212.

[0063] The electrical energy generated by the two generators 220a, 220b is transferred to the four electric motors 230a, 230b, 230c, 230d to rotate the four motor output devices 234a, 234b, 234c, 234d. The four motor output devices 234a, 234b, 234c, 234d may be operatively coupled to the four wheel and tire assemblies 204a, 204b, 204c, 204d, such that each wheel and tire assembly 204 has an individual electric motor 230 coupled thereto.

[0064] In implementations, it should be understood that the energy generation and transfer system 210 may include any suitable number of components of the system, including but not limited to the diesel engine 212, the generators 220, the electric motors 230, the motor output devices 234, and / or the wheel and tire assemblies 204. In further implementations, it should be understood that the energy generation and transfer system 210 may be arranged on a work vehicle, including but not limited to the work vehicle 100 shown and described above.

[0065] While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative implementations thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.

Examples

Embodiment Construction

[0016]While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific implementations thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

[0017]References in the specification to“one implementation,”“an implementation,”“an illustrative implementation,” etc., indicate that the implementation described may include a particular feature, structure, or characteristic, but every implementation may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same implementation. Further, when a particular feature,...

FIELD OF THE DISCLOSURE

[0001] The present disclosure generally relates to balancing energy loads for work vehicles, and, more specifically, to use an exhaust brake system to balance loads on a diesel engine.BACKGROUND

[0002] Work vehicles can be used to perform different work and industrial tasks. For example, one or more work vehicles can be utilized to collect or move materials around a worksite, among other suitable tasks. Work vehicles may use diesel-powered generators to power electric motors to drive the work vehicle. During deceleration, the electric motors may regenerate electricity. During periods of heavier deceleration, the electric motos may regenerate more electricity than is needed, requiring an additional load such as brake resistors to balance the energy loads within the full system. Brake resistors may be expensive and require additional systems such as cooling systems, which may add unnecessary weight, complexity, and cost to the work vehicle.SUMMARY

[0003] The present disclosure may comprise one or more of the following features and combinations thereof.

[0004] In one implementation of the present disclosure, a work vehicle is provided with a diesel engine having an exhaust brake system. The work vehicle can include one or more electric generators, each of the one or more electric generators operatively coupled to the diesel engine. The work vehicle can include one or more electric motors, each of the one or more electric motors operatively coupled to at least one of the one or more electric generators, wherein each of the one or more electric motors is configured to provide torque in a first direction to provide rotational energy to one or more external devices and provide torque in a second direction to regenerate electrical energy to the one or more generators. the exhaust brake system is configured to be activated when at least one of the one or more electric motors provides torque in the second direction.

[0005] In another implementation of the present disclosure, a system is provided with an energy generation device having an exhaust brake system. The system can include an electric generator operatively coupled to the diesel engine. The system can include an electric motor operatively coupled to the electric generator and configured to provide torque in a first direction to generate rotational motion, and provide torque in a second direction opposite the first direction to generate electrical energy. The system can include a controller communicatively coupled to the exhaust brake system and the electric motor. The controller may be configured to activate the exhaust brake system.

[0006] In a further implementation, a method is provided for balancing energy in an work vehicle. The method can include producing rotational energy with a diesel engine. The method can further include generating electrical energy by a generator with the rotational energy, wherein the generator is operatively coupled to the diesel engine. The method can further include transferring the electrical energy from the generator to an electric motor operatively coupled to the generator. The method can further include producing torque by the electric motor in a first direction or a second direction opposite the first direction. When torque is produced in the first direction the electric motor generates rotation motion, and when torque is produced in the second direction the electric motor generates electrical energy. The method can further include activating an exhaust brake system operatively coupled to the diesel engine when the electric motor produces torque in the second direction.

[0007] These and other features of the present disclosure will become more apparent from the following description of the illustrative implementations.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The disclosure contained herein is illustrated by way of example and not by way of limitation in the accompanying figures. For simplicity and clarity of illustration, elements illustrated in the figures are not necessarily drawn to scale. For example, the dimensions of some elements may be exaggerated relative to other elements for clarity. Further, where considered appropriate, reference labels have been repeated among the figures to indicate corresponding or analogous elements.

[0009] FIG. 1 illustrates a representative work vehicle.

[0010] FIG. 2 illustrates a simplified block diagram of the components of an energy generation and transfer system of the work vehicle.

[0011] FIG. 3 illustrates a simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0012] FIG. 4 illustrates another simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0013] FIG. 5 illustrates another simplified flow diagram of the energy within the energy generation and transfer system of the work vehicle.

[0014] FIG. 6 illustrates a simplified block diagram of the components of another energy generation and transfer system of the work vehicle.

[0015] Corresponding reference numerals are used to indicate corresponding parts throughout the several views.DETAILED DESCRIPTION

[0016] While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific implementations thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

[0017] References in the specification to“one implementation,”“an implementation,”“an illustrative implementation,” etc., indicate that the implementation described may include a particular feature, structure, or characteristic, but every implementation may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same implementation. Further, when a particular feature, structure, or characteristic is described in connection with an implementation, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other implementations whether or not explicitly described. Additionally, it should be appreciated that items included in a list in the form of “at least one A, B, and C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C). Similarly, items listed in the form of “at least one of A, B, or C” can mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).

[0018] In the drawings, some structural or method features may be shown in specific arrangements and / or orderings. However, it should be appreciated that such specific arrangements and / or orderings may not be required. Rather, in some implementations, such features may be arranged in a different manner and / or order than shown in the illustrative figures. Additionally, the inclusion of a structural or method feature in a particular figure is not meant to imply that such feature is required in all implementations and, in some implementations, may not be included or may be combined with other features.

[0019] Implementations of the present disclosure generally relate to balancing the energy flow within a work vehicle. Additionally, implementations of the present disclosure relate to providing loads to manage the engine speed and output of a diesel engine used to power an electric generator configured on a work vehicle.

[0020] In at least certain situations, work vehicles may use diesel engines to provide energy to generators, which in turn provide electrical energy to one or more electric motors which may be used to propel the work vehicle forward. Supplemental systems such as hydraulic systems or auxiliary electrical systems may further be electrically coupled to the generator.

[0021] When the work vehicle is coasting and / or decelerating, the one or more electric motors may be used to regenerate electrical energy. This regenerated electrical energy may supplement the energy provided by the diesel engine. To balance the energy generated throughout the entire system, an additional load may be placed on the diesel engine when the energy demands on the diesel engine are reduced because of the regenerated energy.

[0022] In some implementations, an exhaust braking system may be used to place an outside load on the diesel engine when the load from the generator is reduced. The exhaust braking system may be activated when the level of energy regenerated exceeds a predetermined threshold. In some implementations, the exhaust braking system may be proportionally activated based on how far above the regenerated energy is relative to the predetermined threshold.

[0023] FIG. 1 illustrates a representative work vehicle 100. While the work vehicle 100 is illustrated as a wheel loader, it should be understood that, in implementations, the work vehicle 100 may be any suitable type of work vehicle, including but not limited to four-wheel drive loaders, tractors, front end loaders, scraper systems, cutters and shredders, hay and forage equipment, planting equipment, seeding equipment, sprayers and applicators, utility vehicles, mowers, dump trucks, backhoes, track loaders, crawler loaders, dozers, excavators, motor graders, skid steers, tractor loaders, wheel loaders, rakes, aerators, skidders, bunchers, forwarders, harvesters, swing machines, knuckleboom loaders, diesel engines, axles, planetary gear drives, pump drives, transmissions, generators, or marine engines, among other suitable equipment.

[0024] The work vehicle 100 may, or may not, be an autonomous or semi-autonomous vehicle. According to the illustrated implementation, the work vehicle 100 can include an operator cab 102 at which an operator can be positioned within the work vehicle 102 in connection with the operator operating, including, for example, controlling the movement, direction of travel, and / or speed of travel, of the work vehicle 100.

[0025] The work vehicle 100 may include one or more wheel and tire assemblies 104 that can engage the adjacent ground surface and be utilized in the propulsion and / or steering of the work vehicle 100. As illustrated, the work vehicle 100 includes four wheel and tire assemblies 104a, 104b, 104c, 104d (hidden from view). However, it should be understood that, in implementations, any suitable wheel and tire assemblies 104 may be included. In further implementations, other external devices may be included, such as tracks, output shafts, or any other suitable external devices.

[0026] The work vehicle 100 includes an energy generation and transfer system 110, which may be used to generate and transfer energy needed to propel the work vehicle and perform additional functions, as will be shown and described in more detail herein.

[0027] FIG. 2 illustrates a simplified block diagram of the components of an energy generation and transfer system 110 of the work vehicle 100. As illustrated, the energy generation and transfer system 110 includes a diesel engine 112. The diesel engine 112 may operate within a preferred operating window. The preferred operating window of the diesel engine 112 may be a preferred range of engine speeds and / or loads which maintain the operation of the diesel engine 112 in an efficient and reliable manner. The preferred operating window may be predetermined, or may be defined by the operator such as based on the use of the work vehicle 100, the conditions in which the work vehicle 100 is used, or other suitable factors. In further implementations, the diesel engine 112 may be substituted with other suitable energy generation devices, including but not limited to a gasoline engine, a hydrogen combustion engine, a biofuel combustion engine, or any other suitable known or as yet-unknown energy generation device.

[0028] The diesel engine 112 includes an exhaust system 114 including an exhaust brake system 116. The exhaust brake system 116 may be any suitable type of exhaust brake system well known or not yet known in the art, including but not limited to a closeable valve within the exhaust system, a compression brake (also known as a “Jake brake”), or any other suitable type of exhaust brake system. In some implementations, the exhaust brake system 116 may be variably controlled, such that the power of the exhaust brake system 116 and therefore associated braking effect on the diesel engine 112 may be increased or decreased incrementally. In further implementations, the exhaust brake system 116 may be electronically actuatable.

[0029] The diesel engine 112 may have a load sensor 117. The load sensor 117 may measure the load on the diesel engine 112. The load sensor 117 may be any suitable sensor for measuring the load on the diesel engine 112, including but not limited to a manifold pressure sensor, a mass airflow sensor, an intake air temperate sensor, or any other suitable sensor and / or combination of sensors.

[0030] The diesel engine 112 may have an output device 118. The output device 118 may be a crankshaft, flywheel, gear, or any other suitable output device which allows for mechanical linkage to the energy output of the diesel engine 112.

[0031] The energy generation and transfer system 110 includes a generator 120. The generator 120 may include an input device 122. The input device 122 may be a gear, a shaft, a splined coupling, or any other suitable input device. The input device 122 is operatively coupled to the output device 118 of the diesel engine 110. The generator 120 outputs electrical energy by transforming the output of the diesel engine 112. The generator 120 includes one or more electrical outputs 124. The electrical outputs 124 may be outlets, terminals, plugs, sockets, or any other suitable type of electrical outputs 124.

[0032] The energy generation and transfer system 110 includes an electric motor 130. The electric motor 130 may be any suitable type of motor, including but not limited to permanent magnet motors, brushless motors, or any other suitable type of motors. The electric motor 130 includes an electrical input 132. The electrical input 132 may be inlets, terminals, or any other suitable type of electrical inputs 132. The electric motor 130 includes a motor output device 134. The motor output device 134 may a shaft or other suitable motor output device 134.

[0033] The electrical input 132 is electrically coupled to the electrical output 124 of the generator 120, such that the electrical energy 124 is transferred to the electric motor 130 to rotate the motor output device 134. The motor output device134 may be operatively coupled to a drivetrain 106 of the work vehicle 100. The drivetrain 106 may be a driveshaft, transmission, differential, or any other suitable device for transferring the torque of the electric motor 130 to one or more wheel and tire assemblies 104. In some implementations, the motor output device 134 may be directly coupled to one or more wheel and tire assemblies 104.

[0034] One or more supplemental systems 136 may be electrically coupled to the generator 120. The one or more supplemental systems 136 may be, as a non-limiting example, hydraulic systems, external electric systems, and / or other suitable supplemental systems 136 which are commonly used with the work vehicle 102.

[0035] An energy sensor 146 may be coupled to energy generation and transfer system 110 to measure the electrical flow within the energy generation and transfer system 110.

[0036] A controller 140 is communicatively coupled to the generator 120, the exhaust brake system 116, the load sensor 117, and the energy sensor 146. The controller 140 can have a processor 142 and a memory device 144. The processor 142 can be configured to follow instructions, including control instructions contained within, or that are part of, the memory device 144, including, for example, a non-transitory machine-readable medium.

[0037] The processor 142 can be embodied as any type of processor or other compute circuit capable of performing various tasks. In some implementations, the processor 142 can be embodied as a single or multi-core processor, a microcontroller, or other processing or controlling circuit. Additionally, in some implementations, the processor 142 can be embodied as, include, or be coupled to an FPGA, an application specific integrated circuit (ASIC), reconfigurable hardware or hardware circuitry, or other specialized hardware to facilitate performance of the functions described herein. In some implementations still, the processor 142 can be embodied as a high-power processor, an accelerator co-processor, an FPGA, or a storage controller.

[0038] The memory device 144 can be of one or more types of non-transitory computer-readable media, such as a solid-state memory, electromagnetic memory, optical memory, or a combination thereof. Further, the memory device 144 can be volatile and / or nonvolatile. It should be appreciated that the memory device 144 can store information that is manipulated by the operating logic of processor 142, such as, for example, information representative of inputted signals in addition to or in lieu of storing programming instructions defining operating logic. The memory device 144 can store various software and information used during operation of the energy generation and distribution system 110, such as applications, programs, libraries, and drivers. Thus, the memory device 144 can include information, including algorithms and look-up tables, among other information, that can be used by the processor 142.

[0039] While one implementation of the energy generation and transfer system 110 is shown, it should be understood that, in implementations, the components may be arranged and / or connected in any other suitable manner as known by a person of skill in the art.

[0040] The energy generation and transfer system 110 may be arranged within the work vehicle 100 by any suitable means, including but not limited to fasteners, brackets, or any other suitable means.

[0041] FIG. 3 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 110. In the situation illustrated in FIG. 3, the work vehicle may be accelerating in a first direction.

[0042] The diesel engine 112 provides rotational energy to the generator 120 as indicated by arrow A. The rotational energy may be generated by the diesel engine 112 through combustion of diesel fuel. The diesel engine 112 and the generator 120 may be operatively coupled through any suitable means, including but not limited to the output device 118 and the input device 122 described above.

[0043] The generator 120 provides electrical energy to the electric motor 130 as indicated by arrow B. The electric motor 130 may be electrically coupled to the generator 120 through any suitable means, including but not limited to the electrical output 124 and the electrical input 132 described above.

[0044] The electrical energy allows the motor output device 134 to rotate in a first direction as indicated by arrow C. In one implementation, the motor output device 134 rotates one or more of the wheel and tire assemblies 104 by applying torque to the drivetrain 106 such that the work vehicle 100 is accelerated forward. In further implementations, the motor output device 134 is coupled to various other external devices such as tracks, output shafts, or any other suitable external devices.

[0045] The generator 120 may provide electrical energy to one or more supplemental systems 136 as indicated by arrow B, such as auxiliary electrical system and hydraulic systems configured on the work vehicle 100.

[0046] FIG. 4 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 110. In the situation illustrated in FIG. 4, the work vehicle 100 is decelerating at a first deceleration rate, such that the wheels 104 do not require torque from the electric motor 130 to continue moving forward and return energy to the electric motor 130 as indicated by arrow D. The electric motor 130 is used to regenerate electrical energy back to the generator 120 as indicated by arrow E by providing torque in a second direction, wherein the second direction is opposite from the first direction.

[0047] The electric motor 130 may generate a first level of regenerated electrical energy while the work vehicle is decelerating at the first deceleration rate. The regenerated electrical energy is transferred to the generator 120. The first level of regenerated electrical energy may be low enough such that diesel engine 110 is still needed to supply energy to the supplemental systems 136 electrically coupled to the generator 120 as indicated by arrow B while maintaining the diesel engine 112 within a preferred operating window.

[0048] The first level of regenerated electrical energy may further reduce the load on the diesel engine 112 by reducing the electrical load demands on the generator 120, which in turn reduces the load demands on the diesel engine 112. However, the reduced load on the diesel engine 112 may still maintain the diesel engine 112 within the preferred operating window.

[0049] FIG. 5 illustrates a simplified flow diagram of the energy within the energy generation and transfer system 112. In the situation illustrated in FIG. 5, the work vehicle 100 is decelerating at a second deceleration rate, where the second deceleration rate is greater than the first deceleration rate, such that the wheels 104 do not require torque from the electric motor 130 and return energy to the electric motor 130 as indicated by arrow D. The electric motor 130 is used to regenerate electrical energy back to the generator 120 as indicated by arrow E by providing torque in a second direction, wherein the second direction is opposite from the first direction.

[0050] The electric motor 130 may generate a second level of regenerated electrical energy while the work vehicle 100 is decelerating at the second deceleration rate, where the second level of regenerated electrical energy is greater than the first level of regenerated electrical energy. The second level of regenerated electrical energy may return energy to the diesel engine from the generator 120 as indicated by arrow F. The second level of regenerated electrical energy may reduce the demands on the diesel engine 110 such that the diesel engine is operating outside of the preferred operating window.

[0051] In order to maintain the diesel engine 110 within the preferred operating window, the exhaust brake system 116 may be activated. By activating the exhaust brake system 116, the engine speed of the diesel engine 112, and therefore the associated energy produced by the diesel engine 112, may be reduced by the exhaust brake system 116 placing a load on the diesel engine 112, as indicated by arrow G. This may balance the energy generated by the energy generation and transfer system 110 with the energy required by the various components of the energy generation and transfer system 110.

[0052] In some implementations, the exhaust brake system 116 may be incrementally applied proportionally to the level of regenerated electrical energy. That is, the exhaust brake system 116 may be applied at a higher intensity so as to achieve an increased braking performance on the diesel engine 112 when the level of regenerated electrical energy is higher and / or the load on the diesel engine 112 is lower.

[0053] In some implementations, the energy sensor 146 monitors a detected level of regenerated electrical energy and communicates a signal corresponding to the detected level of regenerated electrical energy to the controller 140. If the detected level of regenerated energy is above a predetermined threshold level of regenerated electrical energy, the controller 140 may automatically activate the exhaust brake system 116.

[0054] In further implementations where the exhaust brake system 116 may be incrementally applied, the controller 140 may automatically adjust the application of the exhaust brake system 116 proportionally to the detected level of regenerated energy, such that higher levels of detected regenerated energy may result in a greater application of the exhaust brake system 116.

[0055] In yet further implementations, the load sensor 117 monitors the load on the diesel engine 112 and communicates a signal corresponding to the detected load on the diesel engine 112 to the controller 140. If the load on the diesel engine 112 falls below a threshold load, such as from the regenerated electrical energy reducing the load demands on the generator 120 which in turn reduces the load demands on the diesel engine 112, the controller 140 may automatically activate the exhaust brake system 116.

[0056] In further implementations where the exhaust brake system 116 may be incrementally applied, the controller 140 may automatically adjust the application of the exhaust brake system 116 proportionally to the detected load on the diesel engine 112, such that lower loads levels detected on the diesel engine 112 may result in a greater application of the exhaust brake system 116.

[0057] In further implementations, there may be separate controllers for the exhaust brake system 116 and the generator 120.

[0058] In some implementations, the exhaust brake system 116 may be manually activated by an operator, such as by an activation device being configured within the operator cab 102. The exhaust brake system 116 may be activated via a user input device such as a button or switch, or may be incrementally implemented such as by a slider.

[0059] FIG. 6 illustrates an energy generation and transfer system 210. The energy generation and transfer system 210 includes two generators 220. The two generators 220 may be configured in a similar manner to that described above in relation to the generator 120.

[0060] The energy generation and transfer system 210 includes four electric motors 230a, 230b, 230c, 230d. The four electric motors 230a, 230b, 230c, 230d may be configured in a similar manner to that described above in relation to the electric motor 130.

[0061] The energy generation and transfer system 210 includes a diesel engine 212. The diesel engine 212 may be configured in a similar manner to that described above in relation to the diesel engine 112, such as including an exhaust system 214 and an exhaust braking system 216.

[0062] The diesel engine 212 may be rotatably coupled to the two generators 220a,220b, such that rotational energy generated by the diesel engine 212 is output as electrical energy by the two generators 220a, 220b by transforming the output of the diesel engine 212.

[0063] The electrical energy generated by the two generators 220a, 220b is transferred to the four electric motors 230a, 230b, 230c, 230d to rotate the four motor output devices 234a, 234b, 234c, 234d. The four motor output devices 234a, 234b, 234c, 234d may be operatively coupled to the four wheel and tire assemblies 204a, 204b, 204c, 204d, such that each wheel and tire assembly 204 has an individual electric motor 230 coupled thereto.

[0064] In implementations, it should be understood that the energy generation and transfer system 210 may include any suitable number of components of the system, including but not limited to the diesel engine 212, the generators 220, the electric motors 230, the motor output devices 234, and / or the wheel and tire assemblies 204. In further implementations, it should be understood that the energy generation and transfer system 210 may be arranged on a work vehicle, including but not limited to the work vehicle 100 shown and described above.

[0065] While the disclosure has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as exemplary and not restrictive in character, it being understood that only illustrative implementations thereof have been shown and described and that all changes and modifications that come within the spirit of the disclosure are desired to be protected.

Examples

Embodiment Construction

[0016]While the concepts of the present disclosure are susceptible to various modifications and alternative forms, specific implementations thereof have been shown by way of example in the drawings and will be described herein in detail. It should be understood, however, that there is no intent to limit the concepts of the present disclosure to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives consistent with the present disclosure and the appended claims.

[0017]References in the specification to“one implementation,”“an implementation,”“an illustrative implementation,” etc., indicate that the implementation described may include a particular feature, structure, or characteristic, but every implementation may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same implementation. Further, when a particular feature,...

Claims

1. A work vehicle comprising:a diesel engine having an exhaust brake system;one or more electric generators, each of the one or more electric generators operatively coupled to the diesel engine; andone or more electric motors, each of the one or more electric motors operatively coupled to at least one of the one or more electric generators, wherein each of the one or more electric motors is configured to provide torque in a first direction to provide rotational energy to one or more external devices and provide torque in a second direction to regenerate electrical energy to the one or more generators,wherein the exhaust brake system is configured to be activated when at least one of the one or more electric motors provides torque in the second direction.

2. The work vehicle of claim 1, wherein the work vehicle comprises a wheel loader.

3. The work vehicle of claim 1, wherein the exhaust brake system is configured to be activated only when an amount of electrical energy generated by the one or more electric motors is above a predetermined threshold.

4. The work vehicle of claim 3, wherein the exhaust brake system is configured to be activated proportionally based on the amount of electrical energy regenerated by the one or more electric motors.

5. The work vehicle of claim 1, wherein the one or more electric motors is configured to regenerate electrical energy while the work vehicle is decelerating.

6. The work vehicle of claim 1, wherein activating the exhaust brake system only occurs when a load on the diesel engine is below a predetermined threshold.

7. The work vehicle of claim 6, wherein the exhaust brake system is activated proportionally based on the load on the diesel engine.

8. The work vehicle of claim 1, wherein the exhaust brake system comprises one of:(a) a compression brake; or(b) a closeable valve within an exhaust system coupled to the diesel engine.

9. The work vehicle of claim 1, further comprising:one or more supplemental systems, wherein each of the one or more supplemental systems is electrically coupled to the one or more electric generators.

10. A system comprising:an energy generation device having an exhaust brake system;an electric generator operatively coupled to the energy generation device;an electric motor operatively coupled to the electric generator and configured to provide torque in a first direction to generate rotational motion, and provide torque in a second direction opposite the first direction to generate electrical energy;a controller communicatively coupled to the exhaust brake system and the electric motor, wherein the controller is configured to activate the exhaust brake system.

11. The system of claim 10, wherein the controller determines the amount of electrical energy generated by the electric motor and is configured to activate the exhaust brake system only if the amount of electrical energy generated by the electric motor is above a predetermined threshold.

12. The system of claim 11, wherein the exhaust brake system is activated proportionally based on the amount of electrical energy regenerated by the electric motor.

13. The system of claim 10, further comprising an energy sensor communicatively coupled to the system and configured to measure the electrical energy.

14. The system of claim 10, wherein the controller determines an amount of load on the energy generation device and is configured to activate the exhaust brake system only if the load is below a predetermined threshold.

15. The system of claim 14, wherein the exhaust brake system is configured to be activated proportionally based on the load on the energy generation device.

16. The system of claim 14, further comprising a load sensor coupled to the energy generation and configured to determine the load on energy generation device.

17. The system of claim 10, further comprising:one or more additional electric generators; andone or more additional electric motors.

18. A method for balancing energy in a work vehicle, the method comprising:producing rotational energy with a diesel engine;generating electrical energy by a generator from the rotational energy produced by the diesel engine, wherein the generator is operatively coupled to the diesel engine;transferring the electrical energy from the generator to an electric motor, the electric motor operatively coupled to the generator;producing torque by the electric motor in a first direction or a second direction opposite the first direction, wherein when torque is produced in the first direction the electric motor generates rotational motion, and when torque is produced in the second direction the electric motor generates electrical energy; andactivating an exhaust brake system operatively coupled to the diesel engine when the electric motor produces torque in the second direction.

19. The method of claim 18, further comprising activating the exhaust brake system only when the electric energy generated by the electric motor is above a predetermined threshold.

20. The method of claim 18, further comprising activating the exhaust brake system only when a load on the diesel engine is below a predetermined threshold.

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