Brake Chopper Resistor Cooling Control for Downhill Overheat Prevention

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Solution Overview

Problem

Existing brake choppers in electrical braking systems for vehicles, particularly those exceeding seven tons in mass, face challenges in managing overheating and mechanical wear during long downhill braking, necessitating improvements for enhanced braking performance and reduced mechanical wear.

Innovation Solution

An integrated brake chopper resistor system that combines power electronics, control systems, and a resistor within a single unit, featuring a resistor portion and control portion enclosed in a common housing, with cooling systems to dissipate electrical energy as thermal energy, reducing mechanical wear and providing heat for vehicle systems.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical braking systems are used for long downhill braking, then braking function is provided, but mechanical wear increases and brakes overheat

Engineering Contradiction:

Improvebraking performanceVSAvoidmechanical wear and overheating

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical braking with an electrical braking system that uses a motor generator to convert kinetic energy into electrical energy, which is then dissipated through a resistor. This substitution eliminates mechanical wear and overheating associated with traditional friction-based braking systems while maintaining effective braking function.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent converts the harmful kinetic energy that needs to be dissipated during braking into useful electrical energy through a motor generator. This electrical energy can then be utilized by vehicle systems such as heating, thereby transforming the waste energy from braking into a beneficial resource.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Reliability

If separate components are used for resistor, power electronics, and control systems, then each component can be optimized independently, but system complexity and weight increase

Engineering Contradiction:

Improvecomponent optimizationVSAvoidsystem structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the resistor, power electronics, and control systems into a single integrated brake chopper unit. This merging reduces system complexity, minimizes the number of connections and mounting requirements, and simplifies installation while maintaining the ability to optimize each subsystem's performance.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If electrical energy is dissipated without recovery, then braking function is achieved, but energy is wasted

Engineering Contradiction:

Improvebraking functionVSAvoidelectrical energy

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent converts the energy that would otherwise be wasted during braking into useful electrical energy through a motor generator. This recovered electrical energy can then be utilized by vehicle systems such as heating, thereby transforming the waste energy from braking into a beneficial resource and reducing overall energy consumption.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The integrated system improves braking performance by reducing mechanical wear, extends battery life, and enhances vehicle comfort by generating heat without using battery power, while simplifying energy management and reducing system weight.

Implementation Method 1

In the resistor the electrical energy may be dissipated as thermal energy

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

providing cooling to the control electronics and/or the power electronics and/or the electrical resistor... The cooling may be provided via fluid pathways arranged to guide cooling fluids or liquids through, around or adjacent to electrical components

Methodology Applied

Scientific EffectConvection cooling: Convection

Data Source

PatentUS20260077655A1Brake Chopper Resistor System and Control

Publication Date: 2026.03.19 TRACTION HOLDCO LLC

AI summary

The present disclosure relates to systems, methods, controllers and computer program products for thermal management of a brake chopper resistor. The system comprises a resistor housing portion configured to receive a cooling fluid in a cooling fluid flow path; a brake chopper resistor in the resistor housing portion; a plurality of temperature sensors in thermal communication with different respective parts of the resistor cooling flow path through the resistor housing portion and configured to measure a first temperature at a first location in the cooling fluid flow path of the brake chopper resistor and to measure a second temperature at a second location in the cooling fluid flow path of the brake chopper resistor; and control logic, configured to compare the first temperature and/or the second temperature to a threshold value or to compare the first temperature with the second temperature, and to make a determination of whether to allow activation of the brake chopper resistor in response to the comparison with the threshold value.