Caterpillar Inc.

Dustin Craig Selvey

Jonathan Matthew Baumann

Alexander Cameron Crosman, Iii

Jason Lee Miller

Robert Wayne Lindsey

Robert Roy Sychra

Justin Dale Middleton

Arthur Wild

Igor Strashny

Christian D Ritchie

William James Tate

Bradley Bailey

Eric M Andris

Matthew L Hendrickson

Thomas Michael Sopko, Jr

Baojun Si

David Marchand

Adam R Rosenberger

Evan B Stumpges

Mary Jill Trumper

Andrew B Robinson

An electrical architecture that allows power to be transferred to a battery powered machine while the machine is moving and that allows the machine to be charged while stationary.

Electrical architecture for battery powered machine

A system for charging a battery unit to power a work machine. The system includes a charger to charge the battery unit, charging receptacles, power supply connectors, and a charging controller. The power supply connectors are configured to be received into the charging receptacles to attain connections between the charger and the battery unit. The charging controller is communicably coupled to the charger and is configured to receive an input corresponding to a net charge capacity of the battery unit; determine a power to be supplied to the battery unit by the charger to charge the battery unit in response to the input; and supply the power to the battery unit from the charger through the connections. The power to be supplied to the battery unit corresponds to a maximum possible power that meets the net charge capacity of the battery unit in the shortest possible time.

System and method for charging battery units of work machines

A machine may a first high voltage interlocking loop (HVIL) system to provide power to one or more components of the machine, the first HVIL system comprising: a plurality of groups of batteries; a plurality of disconnect components connected to the plurality of groups of batteries; a plurality of sets of contactors, a set of contactors, of the plurality of sets of contactors, being connected to a group of batteries of the plurality of groups of batteries. The machine may a second HVIL system to receive power from a power source, the second HVIL system comprising: a port configured to receive a connector of the power source and receive power, from the power source via the connector, to charge the plurality of groups of batteries, wherein the second HVIL system is independent with respect to the first HVIL system.

Independent high voltage interlocking loop systems

A portable charger assembly operable to charge a battery system includes a housing defining a hollow space. The portable charger assembly also includes a charging module disposed within the hollow space of the housing. The charging module is adapted to provide power supply to the battery system. The portable charger assembly further includes a base adapted to be coupled with the housing. The base includes a base member including a first portion, a second portion, and a third portion. Each of the second and third portions is inclined relative to the first portion. The base also includes a first base plate fixedly coupled to the second portion of the base member. The base further includes a second base plate fixedly coupled to the third portion of the base member.

Portable charger assembly operable to charge battery system

A charging system for a battery-operated machine is disclosed. The charging system includes a charging receptacle having a power connection and a signal connection, with the charging receptacle configured to receive electrical current via the power connection from a power supply plug. The charging system further includes a heat rejection element thermally coupled to the charging receptacle, a temperature sensor, and a charging controller operatively coupled to the temperature sensor and the charging receptacle. The charging controller is configured to receive a temperature signal from the temperature sensor, the temperature signal being indicative of a charging-receptacle temperature. The charging controller is further configured to transmit, via the signal connection to the connected plug, a control signal to adjust (e.g., raise or lower) the electrical current supplied to the power connection.

Charging system for a battery operated machine

In some aspects, a method of monitoring a battery system of an industrial vehicle is disclosed. The battery system may include a first string of battery modules including at least two battery modules connected in series; a first contactor connected to a positive end of the first string of battery modules, a second contactor connector to a negative end of the first string of battery modules; a third contactor connected to the first contactor; a fourth contactor connected to the second contactor; and one or more controllers configured to monitor the first contactor and the second contactor. The method may include receiving, at the one or more controllers, an indication of a failure of one of the first contactor and the second contactor; and opening, via the one or more controllers, at least one of the third contactor or the fourth contactor.

Battery system

The disclosure describes technology that includes a charge-port capture detection mechanism, which has a mounting base and a capture gate. The mounting is connectable to a battery electric vehicle (BEV) at a location adjacent to a high-voltage, direct current (HVDC) charge-port. The capture gate is movably attached to the mounting base, the capture gate being moveable, relative to the mounting base, between a closed position in which the capture gate captures a charge connector of a charging cable engaged in the HVDC charge-port and an open position.

Charge-port capture detection mechanism for battery electric vehicle

Systems and methods are disclosed for reducing engine fuel consumption during regenerative braking. According to certain embodiments, the regenerative braking system has an engine, a generator, a rectifier, a first inverter, a traction motor, and a reverse recovery unit. The generator is configured to be driven by the engine to produce AC electrical power. The rectifier is configured to receive AC electrical power from the generator and convert the AC power to DC power. The first inverter is configured to receive the DC power and convert the DC power to AC power. The traction motor is configured to be driven by the AC power in a traction mode, and to produce regenerated power when rotated in reverse in a regenerative braking mode. The reverse recovery unit has a second inverter and a filter. The second inverter is electrically connected in parallel with the rectifier and configured to communicate at least part of the regenerated power from the traction motor to the generator during the regenerative braking mode. The filter is electrically connected downstream of the second inverter and in parallel with the rectifier. The filter is configured to filter transient voltage generated by the second inverter during the regenerative braking mode.

Regenerative braking system for reducing fuel consumption

A drive system for an electric drive machine having an engine, a generator, a motor, final drive wheels and auxiliary devices is provided. The drive system may include an inverter circuit and an auxiliary driver. The inverter circuit may be coupled to each of the generator and the motor. The auxiliary driver may be coupled to each of the generator and the auxiliary devices. The inverter circuit and the auxiliary driver may be configured to automatically communicate power from the engine and any power from the auxiliary devices to the motor in a propel mode, and automatically communicate power from the motor to the engine, and optionally to a hybrid system if applicable, in a dynamic braking mode so as to minimize fuel consumption during the dynamic braking mode.

Method and system for eliminating fuel consumption during dynamic braking of electric drive machines

Systems and methods are disclosed for detecting a faulty ground strap connection for a machine hosting a high voltage system. In one embodiment, a fault detection and compensation system includes a ground strap, a DC power supply electrically referenced to a machine frame, a leakage detection switch connected to the machine frame, a current source controlled by the leakage detection switch, and a voltage measuring device that measures an offset voltage. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage detection switch and the current source, and determines whether the ground strap is properly connected to the machine frame.

Systems and methods for detecting a faulty ground strap connection

Systems and methods are disclosed for compensating electrical leakage and detecting balanced electrical leakage for a machine hosting an HV system. In one embodiment, a fault detection and compensation system includes a DC power supply electrically referenced to a machine frame, a leakage correction switch connected to the machine frame, a current source controlled by the leakage correction switch, and a voltage measuring device that measures an offset voltage reflecting whether the HV system is in an unbalanced fault condition. The fault detection and compensation system further includes a leakage detection and compensation controller that compensates for the unbalanced fault condition by controlling the leakage correction switch and the current source.

Growing community of inventors

Peoria, IL, United States of America

Dustin Craig Selvey