Retarding Torque Control via Grid Power Measurement
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Solution Overview
Problem
Existing electric drive systems face overheating issues due to significant thermal energy dissipation in retarding grids, leading to potential grid failures and reduced machine performance, especially during high-altitude braking where maximum braking capacity is required.
Innovation Solution
A system and method for controlling retarding torque in electric drive machines by measuring power in the retarding grid and adjusting torque based on these measurements, incorporating temperature control to manage heat dissipation and prevent overheating, thereby improving torque accuracy and reducing the risk of grid failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If retarding torque is increased to improve braking capacity, then braking performance is improved, but thermal energy dissipation increases causing overheating of resistors and insulators
Solution Approach 1:
The controller continuously monitors temperature measurements from sensors positioned near the resistors and insulators in the retarding grid. Based on these temperature readings, the controller dynamically adjusts the retarding torque applied to the wheel, reducing torque when temperatures approach critical thresholds and allowing maximum torque when temperatures are safe. This closed-loop feedback system enables the system to maintain optimal braking performance while preventing overheating damage.
2Temperature
If retarding torque is reduced to prevent overheating, then temperature control is improved, but braking capacity is reduced
Solution Approach 1:
The retarding torque is made dynamic rather than static. The controller continuously adjusts the torque level based on real-time temperature measurements, allowing the system to operate at maximum braking capacity when temperatures are safe and automatically reduce torque only when necessary to prevent overheating. This dynamic adjustment ensures optimal performance under varying thermal conditions.
3Force
If maximum braking capacity is used in high-altitude conditions, then braking performance is improved, but risk of grid failures increases due to overheating
Solution Approach 1:
Temperature sensors are positioned to detect heat buildup in the retarding grid before it reaches dangerous levels. The controller uses these early temperature warnings to proactively reduce retarding torque before overheating causes grid failures. This preliminary detection and action prevents catastrophic failures while maintaining braking performance within safe thermal limits.
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 solution effectively regulates retarding torque and temperature, enhancing machine performance by reducing overheating and grid failures, and ensuring accurate torque control, especially in high-altitude conditions where maximum braking is necessary.
Implementation Method 1
an electric motor associated with at least one wheel and adapted to provide retarding torque to the wheel
Implementation Method 2
a retarding grid, which includes a series of resistors and insulators, through which thermal energy is dissipated when electrical current passes through the resistors
Data Source
AI summary
The disclosure describes, in one aspect, a system for a machine having an electric drive configuration. The system includes an electric motor associated with at least one wheel and adapted to provide retarding torque to the wheel, and a controller configured to determine a power measurement of a retarding grid and control the retarding torque to the at least one wheel during retarding as a function of the power measurement.