VEHICLE AND VEHICLE MANAGEMENT SYSTEM WITH A PREDICTIVE POWER SYSTEM

A vehicle comprises a power system, including an electrical energy storage system, an electrical generator electrically connected to the electrical energy storage system, an electrically powered actuator configured to receive energy from the power system; a memory configured to store a profile, and a controller configured to change an operation of the electrical generator before a change in demand from the power system based on the profile and a state of the electrical energy storage system. The vehicle management system may also comprise a communication interface, a memory configured to store data related to predicted changes in demand from a power system of a vehicle including an electrical generator and an electrical energy storage system, and a processor configured to generate a profile for control of electrical energy management of the power system of the vehicle based on the data and to transmit the profile to the vehicle through the communication interface.

TECHNICAL FIELD

This disclosure relates generally to vehicles and vehicle management systems with a predictive power system. This disclosure relates more specifically to materials-handling vehicles and materials-handling vehicle management systems with a predictive power system.

BACKGROUND

Vehicles may have multiple power sources. For example, a vehicle may include an internal combustion engine, a generator, and a battery. Energy to move the vehicle or use other systems of the vehicle may be provided from the battery and/or the generator driven by the internal combustion engine. However, this technique of generating electrical power is reactive. An operator provides an input through controls and the system generates power in response to that input.

SUMMARY OF DISCLOSURE

Some embodiments include a vehicle, comprising: a power system, including: an electrical energy storage system; and an electrical generator electrically connected to the electrical energy storage system; an electrically powered actuator configured to receive energy from the power system; a memory configured to store a profile; and a controller configured to change an operation of the electrical generator before a change in demand from the power system based on the profile and a state of charge of the electrical energy storage system.

In some embodiments, the vehicle further comprises a positioning system configured to determine a position of the vehicle; wherein the controller is further configured to change the operation of the electrical generator before the change in demand from the power system based on the position.

In some embodiments, the controller is further configured to: determine a future power demand from the power system based on the profile; and modify a present power output of the electrical generator based on the future power demand.

In some embodiments, the controller is further configured to: modify the present power output of the electrical generator such that a magnitude of a rate of change of the present power output is less than a threshold that is less than a maximum rate of change of the present power output.

In some embodiments, the controller is further configured to: modify the present power output of the electrical generator based on the future power demand and the state of charge of the electrical energy storage system.

In some embodiments, the controller is further configured to: modify the present power output of the electrical generator such that the electrical generator is operating in a maximum efficiency mode when the change in demand from the power system occurs.

In some embodiments, the electrical generator includes a fuel cell; and the electrical energy storage system includes a battery.

In some embodiments, the change in demand from the power system comprises a change in at least one of: supplying energy to the electrically powered actuator; receiving energy from the electrically powered actuator; supplying energy to a drive system of the vehicle; and receiving energy from the drive system of the vehicle.

In some embodiments, the controller is further configured to: change the operation of the electrical generator before the change in demand from the power system based on the profile to limit an input to the electrical energy storage system and/or output power from the electrical energy storage system to be less than a threshold.

In some embodiments, the controller is further configured to: limit a variation in the change the operation of the electrical generator before the change in demand from the power system based on the profile.

Some embodiments include a vehicle management system comprising: a communication interface; a memory configured to store data related to predicted changes in demand from a power system of a vehicle including an electrical generator and an electrical energy storage system; and a processor configured to: generate a profile for control of electrical energy management of the power system of the vehicle based on the data; and transmit the profile to the vehicle through the communication interface.

In some embodiments, the processor is further configured to: receive historical data from the vehicle; and generate the profile for control of the electrical energy management of the power system of the vehicle based on the historical data.

In some embodiments, the processor is further configured to: generate the profile for control of the electrical energy management of the power system of the vehicle based on the data including state of charge data for the electrical energy storage system of the power system of the vehicle.

In some embodiments, the processor is further configured to: receive environmental data associated with an operating environment of the vehicle; and generate the profile for control of the electrical energy management of the power system of the vehicle based on the environmental data.

In some embodiments, the processor is further configured to: receive scheduling data associated with an operating environment of the vehicle; and generate the profile for control of the electrical energy management of the power system of the vehicle based on the scheduling data.

Some embodiments include a method comprising: receiving data associated with future operations of a vehicle; generating a profile for controlling electrical energy management of a power system of the vehicle including an electrical generator and an electrical energy storage system based on the data associated with the future operations of the vehicle; and controlling the electrical energy management of the power system of the vehicle based on the profile.

In some embodiments, the method further comprises receiving historical data from the vehicle; and generating the profile for controlling the electrical energy management of the power system of the vehicle based on the historical data.

In some embodiments, the method further comprises generating the profile for controlling the electrical energy management of the power system of the vehicle based on the data including state of charge data for an electrical energy storage system of the power system of the vehicle.

In some embodiments, the method further comprises receiving environmental data associated with an operating environment of the vehicle; and generating the profile for controlling the electrical energy management of the power system of the vehicle based on the environmental data.

In some embodiments, the method further comprises receiving scheduling data associated with an operating environment of the vehicle; and generating the profile for controlling the electrical energy management of the power system of the vehicle based on the scheduling data.

DETAILED DESCRIPTION OF EMBODIMENTS

Example embodiments are described below with reference to the accompanying drawings. Unless otherwise expressly stated in the drawings, the sizes, positions, etc., of components, features, elements, etc., as well as any distances therebetween, are not necessarily to scale, and may be disproportionate and/or exaggerated for clarity.

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should be recognized that the terms “comprise,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless otherwise specified, a range of values, when recited, includes both the upper and lower limits of the range, as well as any sub-ranges therebetween. Unless indicated otherwise, terms such as “first,” “second,” etc., are only used to distinguish one element from another. For example, one element could be termed a “first element” and similarly, another element could be termed a “second element,” or vice versa. The section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Unless indicated otherwise, the terms “about,” “thereabout,” “substantially,” etc. mean that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art.

Unless clearly indicated otherwise, all connections and all operative connections may be direct or indirect. Similarly, unless clearly indicated otherwise, all connections and all operative connections may be rigid or non-rigid.

Like numbers refer to like elements throughout. Thus, the same or similar numbers may be described with reference to other drawings even if they are neither mentioned nor described in the corresponding drawing. Also, even elements that are not denoted by reference numbers may be described with reference to other drawings.

Many different forms and embodiments are possible without deviating from the spirit and teachings of this disclosure and so this disclosure should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete and will convey the scope of the disclosure to those skilled in the art.

Embodiments relate to vehicles and vehicle management system with a predictive power system. Reactive operation of an power system of a vehicle may operate components of the power system in a non-optimal manner and/or a manner that may decrease a lifetime of the power system. As will be described in further detail below, a vehicle may operate based on a profile such that the power system is operated in a predictive manner. As a result, the operation may be optimized, the lifetime of the power system may be increased, and/or the total cost of ownership may be reduced.

Embodiments described below may operate to maintain suitable operation for both an electrical energy generation system, for example, a fuel cell, and an electrical energy storage system, for example, a battery or battery bank. Both electrical energy generation systems and electrical energy storage systems have operational parameters that may extend the useful life of such systems. For example, fuel cells may have a longer useful life if they are operated at relatively constant electrical energy output ranges, are transitioned from one electrical energy output level to another electrical energy output level at a relatively gentle ramp rate, are provided a warm-up period and then not shut down, or are shut down relatively infrequently, during operation, are operated within select temperature ranges, and etc. Batteries may have a longer useful life if they are not overcharged, are not discharged below select levels, are operated within select temperature ranges, and are charged and discharged at select rates. Although particular operating parameters and techniques of operating electrical energy generation systems and/or electrical energy storage systems have been used as examples, other types of electrical energy generation systems and/or electrical energy storage systems may have different operating parameters and techniques of operating that may provide benefits such as those listed below. Embodiments described below, and other embodiments, balance operation of an electrical energy generation system and an electrical energy storage system to provide favorable operational parameters for both systems to enhance one or more of (1) useful life for one or both systems, (2) fuel efficiency, (3) cost effectiveness for operating one or both systems, and (4) efficient use of energy generated by recovery systems, singularly, or in any combination. Embodiments described below, and other embodiments, may balance operation of an electrical energy generation system and an electrical energy storage system to achieve other suitable objectives.

FIG.1is a block diagram of a vehicle100with a predictive power system102according to some embodiments. The vehicle100includes a power system102, a controller108, a memory110, one or more electrically powered actuators114, and a drive system116. Examples of the vehicle100include trucks, container handlers, reach stackers, top loaders, or the like.

The power system102includes an electrical energy storage system104and an electrical generator106. The electrical generator106is electrically connected to the electrical energy storage system104. Examples of the electrical energy storage system104includes a battery, a supercapacitor, flywheel system, or the like or a combination of such systems. Examples of the electrical generator106include a fuel cell system such as a hydrogen fuel cell system, a methanol fuel cell, or the like. Other examples of the electrical generator include an internal combustion engine coupled to an electrical generator, or the like. The electrical generator106may include fuel storage systems associated with the type of electrical generator106.

The electrically powered actuator114is configured to receive energy from the power system102. Examples of the electrically powered actuator114include a lifting mechanism, telescoping mechanism, hoist, crane, pulley, winch, motor, pump, or the like. The actuator114may be attached to a mechanical structure such as an arm, boom, shovel, bucket, forks, or the like. The actuator114may be configured to regenerate energy and return at least some energy to the power system102.

The drive system116includes a system configured to move the vehicle100. The drive system116may include wheels, tracks, transmissions, electric motors, or the like. The drive system116may be configured to receive power from the power system102. The drive system116may be configured to regenerate energy and return at least some energy to the power system102.

The memory110may include any storage medium. For example, the memory may include a dynamic random access memory (DRAM), according to various standards such as DDR-DDR5 or the like, static random access memory (SRAM), non-volatile memory such as Flash, spin-transfer torque magentoresistive random access memory (STT-MRAM), or Phase-Change RAM, magnetic or optical media, or the like. The memory110may include combinations of such memories.

The memory110is configured to store a profile112. The profile112includes information related to changes in the operation of the electrical generator106, information related to predicted changes in demand, or the like. The profile112may include a variety of different types of information as will be described in further detail below.

The controller108may include a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit, a microcontroller, a programmable logic device, discrete circuits, a combination of such devices, or the like. Although only one controller108is illustrated, multiple controller108may be present. The controller108or parts thereof may have a single processing core or multiple processing cores. The controllers108may be distributed across the vehicle100, such as being part of the power system102, part of the actuator114, part of the drive system116, or the like. The controllers108may be communicatively coupled together by a network such as a controller area network.

The controller108may be configured to change an operation of the electrical generator106, for example, before a change in demand from the power system102occurs where the change of operation of the electrical generator106is based on the profile112. Examples of a change in demand from the power system102include changes in energy supplied to the actuator114, changes in energy regenerated from the actuator114, changes in energy supplied to the drive system116, changes in energy regenerated from the drive system116, or other suitable changes. Using the profile112, the controller108may predict an upcoming operation for the vehicle100. Before the predicted operation occurs, the controller108may be configured to use to profile112to operate the electrical generator106, charge or discharge the electrical energy storage system104, or the like as will be described in further detail below.

In some embodiments, the controller108may be configured to change the operation of the electrical generator106based on a state of the electrical energy storage system104. A state of the electrical energy storage system104may include a state of charge (SOC) of the electrical energy storage system104, a state of health (SOH) of the electrical energy storage system104, an operating temperature of the electrical energy storage system104, similar states of any components of the electrical energy storage system104, an ambient temperature around the electrical energy storage system104, or similar states.

In some embodiments, the controller108may be configured to change the operation of the electrical generator106based on a state of other systems of the vehicle100. For example, the controller108may be configured to change the operation of the electrical generator106based on an amount of fuel remaining for the electrical generator106. In a particular example, the controller108may be configured to change the operation of the electrical generator106to operate in a higher efficiency mode based on a fuel level. The particular fuel level may be based on expected operations, limits of the electrical energy storage system104, present SOC of the electrical energy storage system104, time remaining in a work period, or the like.

In another example, the controller108may be configured to change the operation of the electrical generator106based on a state of a thermal management system of the vehicle100. In a particular example, the controller108may be configured to change the operation of the electrical generator106if a radiator of the vehicle100is clogged or damaged, the thermal management system has a low heat rejection as the ambient temperature is relatively high, the thermal management system has a high heat rejection or the vehicle100is passively cooled as the ambient temperature is relatively low or the environment is relatively windy or experiencing high wind gusts, or the like. In another example, the controller108may be configured to change the operation of the electrical generator106based on an ambient temperature around the vehicle100or particular components of the vehicle100. For example, an ambient temperature may range from about −20 degrees Celsius (C) to about 45° C.

FIG.2is a block diagram of a vehicle100awith a predictive power system102aincluding a fuel cell106aand a battery104aaccording to some embodiments. The vehicle100amay be similar to the vehicle100described above including similar components. In some embodiments, the vehicle100aincludes a power system102asimilar to the power system102. The power system102aincludes a battery104aas part of the electrical energy storage system104or operating as the electrical energy storage system104. Examples of the battery104ainclude lithium ion batteries, nickel metal hydride batteries, lead acid batteries, a combination of such batteries, banks of such batteries, or the like. Examples of the fuel cell106ainclude a hydrogen fuel cell, a methane fuel cell, a combination of such fuel cells, banks of such fuel cells, or the like.

FIG.3is a block diagram of a vehicle100bwith a predictive power system102including a positioning system according118to some embodiments. The vehicle100bmay be similar to the vehicles100and100adescribed above. However, the vehicle100bincludes a positioning system118. A positioning system118may include an external or network-based positioning system, such a wireless network positioning system (e.g., a Wi-Fi positioning system), a global navigation satellite system (GNSS), a Global Positioning System (GPS), or the like. The positioning system118may be configured to use a technique or algorithm that utilizes or takes into account the following, including, but not limited to: signal triangulation, signal trilateration, signal to noise ratio (SNR), characteristics of signals detected and/or received by the positioning system118, signal strength, signal attenuation, signal timing, signal propagation time, phase shift, and/or the like to determine a position of the vehicle100b.

The controller108may be coupled to the positioning system118. The controller108may be configured to receive position data from the positioning system118. As will be described in further detail below, the controller108may be configured to use the position data with the profile112to determine when to change the operation of the power system102before a change in power demand of the vehicle100b.

FIG.4is a block diagram of a vehicle100cwith a predictive power system102including a power dissipation system120according to some embodiments. The vehicle100cmay be similar to the vehicles100,100a, and/or100b. In some embodiments, the vehicle100cincludes a power dissipation system120. The power dissipation system120may include a circuit configured to transform electrical energy into another form of energy that may be dissipated. For example, the power dissipation system120may transform electrical energy into heat which may be dissipated into the environment. A specific example of a power dissipation system120includes a lossy electrical circuit such as a high voltage direct current (DC) to DC converter circuit such as a chopper circuit.

The controller108may be coupled to the power dissipation system120. The controller108may be configured to direct excess electrical energy from the power system102, the actuator114, the drive system116, or the like of the vehicle100cto the power dissipation system120. As will be described in further detail below, although the operation of the electrical generator106may be changed due to a predicted change in power demand to accommodate an increase in received power, the speed at which the operation of the electrical generator106may be changed, the present state of charge (SOC) of the electrical energy storage system104may be too high to store the expected regenerated power from the actuator114or drive system116, or the like such that the operation of the electrical energy storage system104may exceed a threshold without dissipating the expected power. Accordingly, the controller108may direct excess power to the power dissipation system120so that the electrical energy storage system104may remain within a desired range, the operation of the electrical generator106may remain within a desired range, or the like.

A variety of operations of system of a vehicle and interactions of the vehicle with a vehicle management system or the like will be described below. While a particular one of the vehicles100,100a,100b, and100cofFIGS.1-4may be used as an example, in other embodiments, the operations or interactions may be performed with similar vehicles. In other embodiments, a vehicle may include one, several, or all of the different components of vehicles100,100a,100b, and100cand perform associated operations of such systems as described below.

FIG.5is a chart of power demand over time of a vehicle according to some embodiments. A vehicle100may be involved in a variety of operations over time. The power demand500maybe representative of operations or events502over time. The power demand500may be positive when power is supplied by the power system102and negative when power is received by power system102as distinguished by the dashed line. Although positive is used to describe the supply of power and negative is used to describe receiving power, the polarity may be opposite depending on the particular context.

Operations502-1,502-2, and502-3represent an acceleration of the vehicle100, the vehicle100travelling at a constant speed, and the vehicle100decelerating at a destination, respectively. An initial increase in power in operation502-1may be provided by the power system102to the drive system116to accelerate the vehicle100. That power may be reduced while the vehicle100travels. Energy may be regenerated by the drive system116and returned to the power system102while decelerating.

Operations502-4represents maneuvering at the destination including raising of an actuator114. Operation502-5represents lifting a load from a stack at the destination and maneuvering to clear the load from a stack. Operation502-6represents energy being regenerated by the actuator114as the load is lowered.

Operations502-7,502-8, and502-9represent acceleration, travelling at a constant speed, and decelerating at a second destination, respectively. Operation502-10represents maneuvering at the second destination. Operation502-11represents lifting and placing the load. Operation502-12represents regeneration of energy while lowering the actuator114. Operations502-13and502-14represent acceleration and travelling to another destination, respectively.

Over these various operations, power demanded from the power system102may vary, remain relatively constant over a period, have different peaks and valleys of supply and regeneration of power or the like. While a constant power demand has been used as an example of the vehicle100maneuvering, the power demand may be different based on the environment of the vehicle100. For example, the vehicle100may be travelling uphill or downhill. The power demand may vary accordingly. Using the profile, the controller108may be configured to determine a future power demand from the power system102based on the profile112. As will be described in further detail below, the controller108may be configured to modify a present power output of the electrical generator106based on the future power demand.

FIG.6A-6Fare charts of stored energy, power supplied, and power demand in a vehicle during control of electrical energy management of a power system according to some embodiments. Referring toFIGS.3,5, and6A, the vehicle100bwill be used as an example. In some embodiments, the electrical generator106is generating a generator output606. The electrical energy storage system104has a state of charge (SOC)604. Various systems of the vehicle100bmay be demanding power demand602. The supply of power from the electrical generator106may initially match the power demand602. As a result, the SOC604may remain substantially constant.

At time608-2, the power demand602increases. For example, the vehicle100bmay use an actuator114such as a lifting mechanism to lift a load or raise the lifting mechanism to prepare to lift the load, the vehicle100bmay increase power to a drive system116to accelerate, or the like. As a result, the power demand602of the vehicle100bincreases. Any of the events ofFIG.5where the power demand500increases may correspond to the increase in power demand602at time608-2.

The increase in the power demand602may be an increase from any initial power demand602. For example, the initial power demand602may be positive or negative. The power demand602may increase at time608-2to a greater amount, whether that amount after time608-2is positive or negative.

The profile112may include information that may be used to predict the increase in power demand602at608-1and take an action before that event occurs. For example, the profile112may indicate that a load may be lifted at a particular location. The positioning system118may provide position information for the vehicle100. By comparing the position of the vehicle100b, the location of the load, a velocity of the vehicle100b, a path from the vehicle100bto the load, attributes of the electrical generator106, or the like, the controller108may determine a time608-1at which the generator output606of the electrical generator106is controlled to begin to increase, before the actual increase in demand occurs at time608-2. Although various operations where the operation of the electrical generator106may be changed prospectively based on a location of the vehicle100b, in other embodiments, the change may be based on different or additional parameters. For example, the time608-1may be predetermined time at which the generator output606of the electrical generator106of vehicle100ofFIG.1is changed.

In some embodiments, changing the generator output606of the electrical generator106prospectively may result in benefits for the vehicle100b. For example, a fuel cell106a(FIG.2) as the electrical generator106may be adversely affected by a rapid increase in supplied power. If the generator output606increases at a rate similar to the increase in the power demand602at608-2, the lifetime, reliability, or the like of the fuel cell106amay be reduced, increasing the cost of operation. By limiting the rate of change of the generator output606by increasing supplied power before vehicle100brequires an increase in supplied power and thus increasing the amount of time over which the power increase is spread, the detrimental effect on the fuel cell106amay be reduced or eliminated.

As the power demand602has not changed at time608-1, the increase in the generator output606supplied by the electrical generator106may be stored in the electrical energy storage system104. The SOC604may increase until the power demand602increases at608-2. Once the power demand increases at time608-1, the SOC604may stabilize.

Referring toFIGS.4and6B, in some embodiments, the operation of the vehicle100cmay be similar to that described with respect toFIG.6A. Optionally, a vehicle may include both a positioning system118and a power dissipation system120. However, the additional power from the electrical generator106may be dissipated rather than stored in the electrical energy storage system104. For example, the SOC604may be at or near a limit. In another example, the SOC604may not be at a limit, but an amount of energy expected to be regenerated energy from an actuator114for the drive system116may cause the SOC604to exceed the limit. The excess power may be directed towards a power dissipation system120.

Referring toFIGS.1and6C, in some embodiments, the increase in the generator output606supplied by the electrical generator106may be greater than the increase in power demand602. As a result, the SOC604may increase to a particular SOC604that may be desired at a later time. For example, the cost of fuel for the electrical generator106may be lower at a future time. The present fuel for the electrical generator106may be used to increase the SOC604with the expectation that the fuel is replenished when the cost of fuel is lower in the future. In another example, a power demand602in the future may be predicted to exceed the maximum output of the electrical generator106. The SOC604may be increased to accommodate the excess above the maximum output. Although the cost of fuel has been used as an example of a parameters used to determine a target SOC604, in other embodiments, other parameters may be used. For example, the cost of electricity may change over time, such as changing based on a load on the electrical grid. The target SOC604may be decreased so that the electrical energy storage system104may be recharged from an external source when a predicted cost of electricity is lower. In a particular example, the cost of electricity may be lower at night. Nearing the end of the session at the end of a day, the SOC604may be reduced to be otherwise lower at the end of the session and replenished at night. In another example, the vehicle100may be approaching an uphill portion of a route. The SOC604may be increased in preparation for that uphill portion such that a decrease in the SOC604during the uphill portion does not cause the SOC604to decrease below a lower limit.

Referring toFIGS.1and6D, in some embodiments, similar to increase of the SOC604inFIG.6C, the generator output606of the electrical generator106may be controlled such that the SOC604decreases even after the increase in the power demand602. For example, a predicted power demand602may be negative at a time after time608-2. For example, the electrical energy storage system104may receive power from regeneration while lowering a particularly heavy load, the vehicle100may be travelling on a route that includes a downhill portion where energy may be regenerated from braking, or the like. The increase in energy that would be stored from the regeneration at that future time may exceed the maximum capacity of the electrical energy storage system104or a threshold capacity above which the electrical energy storage system104may be damaged or the lifetime may be reduced if the SOC604was not reduced. Accordingly, the SOC604may be reduced before the event occurs such that the SOC604does not exceed the maximum or the threshold.

Although various reasons to increase or decrease the SOC604have been used as examples, in other embodiments, the SOC604may be increased or decreased for other purposes. In addition, although the SOC604has been illustrated as continuing to increase or decrease, in some embodiments, a generator output606of the electrical generator106may be changed at a time after time608-2once a desired SOC604is obtained.

In some embodiments, the generator output606levels may be adjusted such that a power supplied by the electrical energy storage system104is less than a maximum limit, a threshold limit for given operating conditions, or other suitable limit. In addition to, or alternative to, adjusting the SOC604, the generator output606of the electrical generator106may be adjusted such that the output power from the electrical energy storage system104does not exceed such a limit.

Referring toFIGS.1and6E, in some embodiments, a change in the operation of the electrical generator106may occur after a change in the power demand602. For example, at time608-1the generator output606may begin to increase before the power demand602increases at time608-2. However, the generator output606may continue to increase until time608-3after the power demand602increased. In some embodiments, the SOC604may be lower than desired if the electrical generator106generator output606stopped increasing at time608-2. Accordingly, the ramp of the generator output606may continue until the SOC604reaches the desired level. For example, a desired SOC604may be between about 20% to about 80% of a maximum SOC604. In some embodiments, a desired SOC604may be higher than 20%, such as 30%, 40%, or more. In some embodiments, a desired SOC604may be within a narrower range such as from about 40% to about 70%. A narrower range may allow for capacity to accommodate opportunity charging, recovery of the vehicle100in case of a failure, or the like. In some embodiments, a desired SOC604may be a particular value, such as about 50%, about 60%, or the like rather than a particular range. In some embodiments, a depth of discharge (DOD) of the electrical energy storage system104may be limited by operation of the electrical generator106. If the electrical energy storage system104is discharging similar to the discharging inFIG.6D, the electrical generator106generator output606may continue to increase to limit the DOD.

In another example, the electrical generator106may have a maximum power ramp rate to avoid damage or maintain lifetime of the electrical generator106. The time608-1may be too close to the time608-2when the power demand602increases. To avoid exceeding the maximum ramp rate, the ramp rate may be limited and the ramp may continue until time608-3to achieve a desired output power to meet the power demand602and to achieve a desired SOC604. For example, the controller108may make a determination that the generator output606should increase too close to the time608-2based on newly received information. In another example, a previous operation may have prevented the electrical generator106from changing operation. Regardless, the electrical generator106may not begin to increase the generator output606until time608-1. To reach the desired SOC604by time608-2, the ramp rate of the electrical generator106generator output606that would reach the desired SOC604may exceed the maximum ramp rate. Accordingly, the ramp may continue until time608-3. An example of a maximum ramp rate of a fuel cell may include about 0.5 to 1.5 kilowatts per second (kW/s). An increase in the power demand602may be about 10 to about 150 kW. Another example of a maximum ramp rate of a fuel cell may include about 1 amp per second (A/s). A fuel cell may have specified maximum ramp rates with higher magnitudes such as an increase of about 4 A/s or a decrease of about 10 A/s. A greater ramp rate may decrease a lifetime of the fuel cell. The ramp rate may be operated at a higher level during an emergency, but the ramp rate may be limited during normal operations to maintain or increase the lifetime of the fuel cell.

In some embodiments, the ramp rate of the fuel cell may be limited by filtering, hysteresis, or the like to reduce or eliminate constant fluctuations, abrupt changes, or the like. The timing of the start of a change of the operation of the electrical generator106may be adjusted to accommodate the effects of such limiting.

Referring toFIGS.1and6F, in some embodiments, a change in the operation of the electrical generator106may end before a change in the power demand602occurs. For example, at time608-1, the generator output606may begin to increase. However, at time608-4before time608-2when the power demand602increases, the change in the generator output606may end. For example, the increase in power demand602may have been expected at time608-4but did not occur until time608-2. The generator output606may be changed to limit a change in the SOC604.

In some embodiments, the various controls of the electrical generator106may be implemented at times such that the operation of the electrical generator106is within an optimum or maximum efficiency region. For example, for a given future value of an SOC of the electrical energy storage system104, the electrical generator106may be operated at an optimum efficiency mode for a longer time if the output power606is less when operating at the optimum efficiency mode.

FIGS.6A-6Fillustrate a variety of operations where the power demand602increases. In other embodiments, the power demand602may decrease. The operation of the electrical generator106may also decrease accordingly. For example, the generator output606may begin to decrease before the power demand602decreases. The timing, rate, length of change, or the like of the change in the generator output606may be similarly modified to achieve the various outcomes described above, such as a particular SOC604at a later time.

Referring toFIGS.5and6A-6F, the operations described above may be performed whenever the power demand500increases or decreases. The operations may take into account the magnitude of future operations. In addition, not all expected operations may result in a predictive change of the generator output606. For example, while the generator output606may be decreased due to an expected deceleration at502-3, the generator output606may increase or remain the same as a later lifting operation at502-5may require energy. However, the generator output606may still be decreased due to the expected regenerated energy from lowering the load at502-6. The expected changes in power demand602may be combined to determine how to operate the electrical generator106.

In some embodiments, the various operations described above may be used to optimize the operation of the electrical generator106, the electrical energy storage system104, or the like. The ramp rate of a fuel cell may be limited. The SOC604of the electrical energy storage system104may be predictively adjusted so that a future operation may be performed without charging or discharging the electrical energy storage system104beyond limits to improve a lifetime, capacity, reliability, or the like of the electrical energy storage system104. The various predicted power demand events502may be combined to optimize the operation of the electrical generator106, the electrical energy storage system104, or the like.

FIG.7is a block diagram of a vehicle management system according to some embodiments. Some embodiments include a vehicle management system700. The vehicle management system700includes a processor708, a memory710, and a communication interface720.

The processor708may include a general purpose processor, a digital signal processor (DSP), an application specific integrated circuit, a microcontroller, a programmable logic device, discrete circuits, a combination of such devices, or the like. Although only one processor708is illustrated, multiple processors708may be present, the operations may be distributed across multiple systems, servers, computers, or the like. The processor708or parts thereof may have a single processing core or multiple processing cores. The processor or processors708may be distributed across multiple systems. The processors708may be communicatively coupled together by a network such as a local area network, wide area network, the Internet, or the like.

The memory710may include any storage medium. For example, the memory may include a dynamic random access memory (DRAM), according to various standards such as DDR-DDR5 or the like, static random access memory (SRAM), non-volatile memory such as Flash, spin-transfer torque magentoresistive random access memory (STT-MRAM), or Phase-Change RAM, magnetic or optical media, or the like. The memory710may include combinations of such memories. The memory710may be physically distributed, such as a cloud storage system.

The communication interface720may include circuitry that enables the vehicle management system700and the vehicles701to communicate. The communication interface720may allow the vehicle management system700to communicate with one or more vehicles701, represented by vehicles701-1to701-n. In some embodiments, the communication interface720may include Ethernet, Bluetooth, WiFi, universal serial bus (USB), External SATA (eSATA), Firewire, a memory card slot, proprietary interfaces, or the like. With such communication interfaces720, the vehicle management system700may be configured to communicate with the vehicles701through the associated medium.

The memory710is configured to store data712related to predicted changes in demand from a power system102of a vehicle701. Examples of the data related to predicted changes in demand include data related to the vehicle701, site data, scheduling data, environmental data, or the like. Data related to the vehicle701may include energy regenerated from lowering a load, energy regenerated from braking, a maximum speed, a maximum braking speed, acceleration/deceleration data, instantaneous speed versus time, average speed, actuator lifting speed, actuator lowering speed, actual load weights, stacking height, or the like. Site data may include data about a worksite of the vehicle701. Examples of site data include locations of loads, weights of loads, heights of loads, routes to and from loads, elevation changes along the routes, condition of the routes, material of the routes, distances between loads, traffic control systems, traffic control system timing, or the like. Scheduling data may include information related to the operation of the worksite. Examples of scheduling data include sequences of particular loads, destinations of particular loads, scheduled arrival of loads, scheduled departures of loads, operator schedules, operator identities, individual operator histories, session schedules, maintenance schedules, refueling schedules, battery charging schedules, holiday schedules, or the like. Examples of environmental data include a cost of energy, power grid loading, a weather forecast, or the like.

Based on this data712, the processor708is configured to generate a profile112for operation of the power system102of a vehicle701based on the data712. The processor is configured to transmit the profile112to the vehicle701through the communication interface720. As a result, the vehicle701may operate using the profile112as described above. Each of the types of data712described above may be used to determine parameters for operation of the power system102such as an SOC of the electrical energy storage system104, an output power of the electrical generator106, a rate of change of the output power of the electrical generator106, or the like.

FIG.8is a flowchart of an operation of a vehicle management system with control of electrical energy management of a power system of a vehicle according to some embodiments. Referring toFIGS.1and7, in some embodiments, a vehicle100will be used as an example of a vehicle701. In step800, data712associated with future operations of a vehicle701is received. As described above, the data712may include a variety of different types of data. Receiving the data in step800may include receiving vehicle data from one or more vehicles701, receiving other data from external data sources722such as a site map, a database of scheduling data, a weather service, or the like. The data712may be received through the communication interface720.

In step802, a profile112for controlling electrical energy management of a power system of a power system102of the vehicle701is generated based on the data712associated with the future operations of the vehicle701. In some embodiments, the data may be used to determine conditions, states, locations at a worksite, SOC ranges, SOC schedules, refueling schedules, electrical generator106ramp rates, electrical generator106state changes, or the like. For example, the processor708may be configured to generate a distance from a load to be raised at which the electrical generator106may begin increasing the output power. The processor708may be configured to generate an estimated time of raising a load and an amount of time before that estimated time to begin increasing the output power. The processor708may be configured to indicate a change to the output of the electrical generator106or indicate a target SOC such that the SOC of the electrical energy storage system104is at a level such that capturing energy from lowering a particularly heavy load does not increase the SOC beyond a limit.

In step804, the profile112is transmitted to the vehicle701. For example, the profile112may be transmitted to the vehicle701through the communication interface720. The vehicle701may be located at a charging and/or refueling station with a corresponding communication interface. Alternatively, the processor708may be configured to transmit the profile112to the vehicle701when the vehicle701is operating in a worksite through a wireless communication interface. Alternatively, the profile112may be loaded on a removable storage device such as a USB drive, a mobile device such as a tablet computer, laptop, handheld device, or the like. The device may be connected to the vehicle701and the profile112may be transferred to the memory110of the vehicle701. Once the profile112is received, in step806, electrical energy management of the power system of the vehicle may be controlled in806based on the profile112as described above.

In some embodiments, in step800, the data712received may include historical data from the vehicle701. For example, the processor708may receive data from a vehicle701such as energy, speed, acceleration, braking, or the like as described above. In step802, the profile112for controlling electrical energy management of the power system102of the vehicle701may be generated based on the historical data. For example, the processor708may receive data indicating that the actuator114is using more energy when lifting and/or regenerating less energy when lowering. The processor708may generate the profile112for operation of the power system102of the vehicle701based on that deviation.

In some embodiments, in step800, SOC data for an electrical energy storage system104of the power system102of the vehicle701may be received. For example, the state of charge data may include data on the present SOC data of the vehicle701, maximum and/or minimum SOC data for the electrical energy storage system104, or the like. The processor708may be configured to receive SOC data from the vehicle701and/or from an external data source722, or the like. In802, the profile112for controlling electrical energy management of the power system102of the vehicle701may be generated based on the data including SOC data for the electrical energy storage system104of the power system102of the vehicle701. For example, the profile112may be generated such that when used by the vehicle701, a time at which the electrical generator106power begins to ramp up or down, the rate of change of the electrical generator106output power, or the like may be changed based on the state of charge data to achieve a desired SOC for the electrical energy storage system104, maintain the SOC within a range during future operations.

In some embodiments, in step800, environmental data associated with an operating environment of the vehicle701may be received. For example, the processor708may receive environmental data such as a cost of energy, power grid loading, a weather forecast, or the like from the external data sources722. In step802, the profile112for controlling electrical energy management of the power system102of the vehicle701may be generated based on the environmental data. For example, the cost of energy may vary over the course of a day. Parameters for the energy usage of the electrical generator106may be set in the profile112to lower the cost of refueling. In another example, the weather forecast may indicate that an upcoming day will be relatively hot. The SOC of the electrical energy storage system104may be set in the profile112to be a particular SOC, within a particular range, or the like that is higher than relatively cooler days. The additional stored energy may be used for additional cooling of the vehicle701. In another example, the electrical energy storage system104may operate better at a different SOC for a higher ambient temperature. The different SOC may be set in the profile112.

In some embodiments, in step800, scheduling data associated with an operating environment of the vehicle701may be received. In step802, the profile112for controlling electrical energy management of the power system102of the vehicle701may be generated based on the scheduling data. For example, the scheduling data may include data related to upcoming holidays. The SOC for the electrical energy storage system104may be set in the profile112such that at the end of the session before the holiday, the SOC ends at a desired SOC for storage or lack of use over the holiday. Similarly, the scheduling data may include data on transportation of the vehicle701. The profile112may indicate the SOC of the electrical energy storage system104when operations of the vehicle701end before the vehicle701is transported.

Other scheduling data may be used to adjust the profile112. For example, a number of ships, train cars, or trucks, etc. arriving with containers may be scheduled for arrival. A particular session may be relatively light or heavy based on the expected containers. The scheduling data may include schedules of operators such as how many operators are available. If fewer operators are available, the profile112may be set to achieve a higher performance from the vehicle to allow for the fewer operators to accomplish the scheduled tasks.

In a particular example, the power to raise the load may be K watts (W). A maximum ramp rate of the electrical generator106may be R watts per second (W/s). The vehicle100may have an average unloaded speed of S meters per second (m/s). The load may be located at a location L. These parameters may be included as part of the profile112. In operation, the vehicle100may determine a distance based on the present output of the electrical generator106. The electrical generator may be outputting P watts (W). The increase in power for the electrical generator106may be K−P. The time to ramp up to that power may be (K−P)/R. The distance from the load at which the power is controlled to increase may be S*(K−P)/R. The vehicle100may be configured to determine that distance and, using the location L and the present location of the vehicle100, begin the power ramp when the vehicle100is within that distance from the load. Although determining a distance from the load has been used as an example, in other embodiments, similar parameters and operations may be used to determine a time at which to begin the power ramp.

Although the use of discrete equations may be used to determine particular operations, setpoints, times, power levels, or the like, in other embodiments, a control system, a neural network, artificial intelligence, or other similar systems may be configured to receive the various inputs described above and then determine operations, setpoints, times, power levels, or other suitable controls for the power system. For example, the outputs may include the present electrical generator106output, the desired SOC of the electrical energy storage system104, or the like.

In some embodiments, the use of the profile112and a vehicle100as described above may allow for the design of the vehicle100to have a reduced cost. For example, by managing the SOC of the electrical energy storage system104in a predictive manner as described herein, a sufficient capacity of the electrical energy storage system104may be available for storage of regenerated energy for expected operations. As a result, power dissipation systems such as the power dissipation system120described above may be omitted, reducing the cost of the vehicle. Similarly, reverse or back current protection devices, hydraulic bypass valves, or the like may be omitted.

In some embodiments, the operations of steps800and802may be performed by the controller108of the vehicle100. Accordingly, the profile112may be present on the vehicle100already and would not need to be transmitted to the vehicle in804.

In some embodiments, the reception of data in800may include data returned from the vehicle100due to the control of the electrical energy management of the power system102of the vehicle100in806based on the profile. For example, during the operation of the vehicle100based on the profile in806, an amount of energy regenerated from lowering a load, an amount of energy used to lift a load, SOC604, or the like may be measured on the vehicle100. The measurement may be performed by sensors in the vehicle100, measuring the SOC604, measuring a remaining fuel for the electrical generator106, or the like. This data may be transmitted to the memory710, transmitted to the external data sources722, or the like. Eventually, the processor708may be configured to use the updated data to generate the profile in802as described above and the process may continue.

Some embodiments include a computer readable medium storing instructions that, when executed by a computer, cause the computer to perform the various operations described above. For example, a computer readable medium may store instructions for the controller108of a vehicle, instructions for the processor708, or the like that enable those systems to perform the operations described above.

Although the structures, devices, methods, and systems have been described in accordance with particular embodiments, one of ordinary skill in the art will readily recognize that many variations to the particular embodiments are possible, and any variations should therefore be considered to be within the spirit and scope disclosed herein. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims.

The claims following this written disclosure are hereby expressly incorporated into the present written disclosure, with each claim standing on its own as a separate embodiment. This disclosure includes all permutations of the independent claims with their dependent claims. Moreover, additional embodiments capable of derivation from the independent and dependent claims that follow are also expressly incorporated into the present written description. These additional embodiments are determined by replacing the dependency of a given dependent claim with the phrase “any of the claims beginning with claim [x] and ending with the claim that immediately precedes this one,” where the bracketed term “[x]” is replaced with the number of the most recently recited independent claim. For example, for the first claim set that begins with independent claim1, claim4can depend from either of claims1and3, with these separate dependencies yielding two distinct embodiments; claim5can depend from any one of claim1,3, or4, with these separate dependencies yielding three distinct embodiments; claim6can depend from any one of claim1,3,4, or5, with these separate dependencies yielding four distinct embodiments; and so on.

Elements specifically recited in means-plus-function format, if any, are intended to be construed to cover the corresponding structure, material, or acts described herein and equivalents thereof in accordance with 35 U.S.C. § 112(f). Embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows.