Abstract:
A system and method for providing additional speed retardation capacity is disclosed that utilizes parasitic loads of the vehicle. A vehicle is disclosed that includes a vehicle control system for sensing overspeed conditions, a powertrain, and a parasitic load. When an overspeed condition is detected, the parasitic load that is normally deactivated to improve efficiency is activated to remove power from the powertrain. Temperature sensors can monitor a load temperature and the parasitic loads can be controlled based on the temperature readings. A method is disclosed that includes detecting overspeed conditions, activating parasitic loads to absorb power when an overspeed condition is detected, and deactivating the loads when the overspeed condition ceases. The parasitic loads can be controlled separately or together. The method can include cumulative actions based on greater overspeed conditions.

Description:
FIELD OF THE INVENTION 
       [0001]    The present invention generally relates to the field of vehicle speed retardation and more specifically to vehicle speed retardation using parasitic loads. 
       BACKGROUND OF THE INVENTION 
       [0002]    When a vehicle, for example a dump truck, operates on a site with long, high speed downhills, it can get into situations where the vehicle powertrain enters an overspeed condition. An overspeed condition can also occur on a very steep downhill, where the operator does not have full control over the vehicle speed. The manufacturers of these vehicles apply various methods to try and avoid these overspeed conditions from occurring. The powertrain usually refers to the engine and transmission. The drivetrain usually refers to the group of components other than the powertrain that deliver engine power to the road surface, which can include for example the driveshafts, differentials, final drive and wheels. In this disclosure, powertrain will be used to refer to both the vehicle powertrain and the vehicle drivetrain. 
         [0003]    The methods that are most commonly utilized to avoid these overspeed conditions are to remove throttle control from the operator, and apply an engine brake (engine valve brake, exhaust brake or both) or a transmission retarder in an effort to slow the vehicle down. In vehicles that do not have transmission retarders, the manufacturer might utilize the vehicle&#39;s service brakes in an attempt to slow the vehicle down. 
         [0004]    These techniques may be successful in many cases, but in instances where there are extended high speed downhill operations, these measures may not be sufficient to cope with the high energy demands that are required for the continued retardation of the vehicle. It would be desirable to have additional retardation capacity available for use in cases where this capacity is beneficial or necessary to avoid or regain control from an overspeed condition. 
       SUMMARY 
       [0005]    A system and method for providing additional retardation capacity is disclosed that utilizes parasitic losses of the vehicle to add additional retardation capacity. The system and method disclosed can also be applied in instances where a vehicle rapidly increases speed on a steep downhill. A parasitic load is any undesirable energy loss in the powertrain. These losses usually rob the vehicle of energy that would normally be used to propel the vehicle forwards or backwards. This energy is usually lost in the form of heat or noise. Examples of such parasitic losses can include (but are not limited to); gear meshing losses, gear losses because of the gears turning through oil, fan losses, friction losses in bearings, hydraulic system inefficiencies, tire rolling resistance, etc. 
         [0006]    A vehicle is disclosed that includes a vehicle control unit for sensing an overspeed condition; a powertrain; and a parasitic load coupled to the vehicle control unit that draws power from the powertrain. When the vehicle control unit senses an overspeed condition, the vehicle control unit activates the parasitic load to remove power from the powertrain. The parasitic load can be a cooling system, a power loss associated with a hydraulic system, a drive axle, or other load that removes power from the powertrain. The cooling system can include a fan motor powered by the powertrain and a fan powered by the fan motor. The cooling system can be an engine cooling system, or a secondary cooling system. The cooling system can also be a hydraulic cooler or an axle cooler. 
         [0007]    The vehicle can also include a temperature sensor coupled to the vehicle control unit that monitors a load temperature associated with the parasitic load. When the vehicle control unit activates the parasitic load due to an overspeed condition, the vehicle control unit monitors the load temperature using the temperature sensor and deactivates the parasitic load when the monitored load temperature exceeds an overheat threshold. The vehicle control unit can also deactivate the parasitic load during the overspeed condition when the monitored load temperature exceeds an overheat threshold. The vehicle control unit can also reactivate the parasitic load when the monitored load temperature drops below a load activation temperature threshold. 
         [0008]    A method is disclosed for using vehicle parasitic loads to aid with speed retardation of a vehicle. The method includes monitoring a vehicle to detect overspeed conditions; activating a parasitic load to absorb power from the powertrain when an overspeed condition is detected; and deactivating the parasitic load when the overspeed condition is no longer detected. The method can also include monitoring a load temperature associated with the parasitic load and deactivating or reactivating the parasitic load based on the load temperature. The parasitic load can be deactivated when the load temperatures exceeds an overheat temperature threshold during the overspeed condition, and then reactivated when the load temperatures drops below a load activation temperature threshold during the overspeed condition. 
         [0009]    A plurality of parasitic loads can be activated when an overspeed condition is detected, and the plurality of parasitic loads can be deactivated when the overspeed condition is no longer detected. A load temperature can be associated with each separate load of the plurality of parasitic loads. Each load can be activated and deactivated based on its associated load temperature. Each load can be deactivated when its associated load temperature exceeds an overheat temperature threshold during the overspeed condition, and then reactivated when its associated load temperature drops below a load activation temperature threshold during the overspeed condition. 
         [0010]    A method is disclosed for using vehicle parasitic loads to aid with speed retardation of a vehicle, where the method includes monitoring a vehicle to detect overspeed conditions, and taking additional actions as the overspeed condition progresses. The method includes taking over of throttle control from a vehicle operator by a vehicle control unit when the vehicle speed exceeds a first overspeed threshold, and restoring throttle control to the vehicle operator by the vehicle control unit when the vehicle speed drops below the first overspeed threshold. The method includes activating at least one of transmission retardation, engine brake and service brakes by the vehicle control unit when the vehicle speed exceeds a second overspeed threshold, and deactivating any activated ones of the transmission retardation, engine brake and service brakes by the vehicle control unit when the vehicle speed drops below the second overspeed threshold. The method also includes activating a parasitic load by the vehicle control unit to absorb power from the powertrain when the vehicle speed exceeds a third overspeed threshold; and deactivating the parasitic load when the vehicle speed drops below the third overspeed threshold. The second overspeed threshold is greater than the first overspeed threshold; and the third overspeed threshold is greater than the second overspeed threshold. A plurality of parasitic loads can be activated when the vehicle speed exceeds the third overspeed threshold, and the plurality of parasitic loads are deactivated when the vehicle speed no longer exceeds the third overspeed threshold: This method can also include monitoring a load temperature associated with the parasitic load and activating or deactivating the parasitic load based on the load temperatures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]      FIG. 1  shows a portion of an exemplary vehicle layout including a vehicle control unit (VCU), a powertrain, an engine cooling system and a secondary cooling system; 
           [0012]      FIG. 2  shows an exemplary embodiment of a vehicle powertrain and drivetrain; 
           [0013]      FIG. 3  shows a simplified representation of a vehicle control unit (VCU) coupled to a hydraulic circuit positioned to reduce flow and pressure, thereby minimizing the parasitic losses; 
           [0014]      FIG. 4  shows the VCU and hydraulic circuit of  FIG. 3  with the hydraulic circuit positioned to increase flow and pressure, thereby increasing the parasitic losses; 
           [0015]      FIG. 5  illustrates an exemplary embodiment of a control method for a vehicle control system that includes controlling parasitic loads to avoid or regain control from an overspeed condition; and 
           [0016]      FIG. 6  illustrates an exemplary embodiment of a variation of the control system shown in  FIG. 5  that also activates and deactivates parasitic loads based on overheating conditions. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    For the purposes of promoting an understanding of the principles of the novel invention, reference will now be made to the embodiments described herein and illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the novel invention is thereby intended, such alterations and further modifications in the illustrated devices and methods, and such further applications of the principles of the novel invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the novel invention relates. 
         [0018]    Vehicle manufacturers and component developers have spent a considerable amount of time and money to develop components that help reduce the parasitic draws on a vehicle&#39;s powertrain. All of the power that a vehicle&#39;s non-powertrain systems absorb from the powertrain is power that the powertrain is not able to utilize for vehicle motion. Examples of systems that have been developed to reduce parasitic loads include, but are not limited to: load sensing hydraulic systems that only produce flow and pressure when it is needed, proportional fan drive systems that only turn the fan when there is a cooling requirement, disconnecting some drive axles when they are not needed, reducing the oil level in axles and gearboxes to reduce the losses generated by gears turning in oil, and numerous others. 
         [0019]    For example, a vehicle&#39;s fan drive systems can act as a parasitic load. When operating under load, the vehicle&#39;s various fan drives have the capacity to rob the vehicle of a substantial amount of power that can be used to propel the vehicle. The reverse is also true. If a fan drive is activated when the vehicle&#39;s mass is propelling it down an incline, energy from the vehicle&#39;s powertrain is transferred to the vehicle&#39;s fan drive which acts as a retarding force on the vehicle&#39;s motion. 
         [0020]    A vehicle&#39;s cooling loads can be another example of parasitic loads that could be activated to draw power from the vehicle&#39;s powertrain. Since the cooling loads may not be operational (or fully operational) when the vehicle is in motion, the cooling capacity that can be provided by the cooling loads is wasted. In an overspeed condition, one or more cooling loads could be activated to draw energy from the powertrain and to retard the speed of the vehicle. In addition, the cooling capacity provided by the cooling loads can be used to alleviate overheating of other vehicle components. Examples of these types of cooling loads can include hydraulic coolers or axle coolers. 
         [0021]      FIG. 1  shows a portion of an exemplary vehicle layout including a vehicle control unit (VCU)  100 , an engine  102 , a transmission  104 , an engine cooling system  106 , a secondary cooling system  108 , a hydraulic manifold  110 , and a pressure and flow compensated pump  112 . The engine  102  and the transmission  104  are part of the vehicle powertrain. The engine cooling system  106  includes an engine fan motor  120  and a radiator fan  122  that blows cooling air across a charge air cooler  124  and a radiator  126 . The secondary cooling system  108  includes a secondary fan motor  140  and a secondary fan  142  that blows cooling air across brakes  144 , brake hydraulics  146  and/or a transmission cooler  148 . 
         [0022]    In this embodiment, the VCU  100  is electrically coupled to the hydraulic manifold  110  which is hydraulically coupled to the pump  112 , the engine fan motor  120  and the secondary fan motor  140 . The VCU  100  is also coupled to a manifold temperature sensor  114 , an engine fan temperature sensor  130  and a secondary fan temperature sensor  150 . The manifold temperature sensor  114  monitors the temperature of the hydraulic fluid at the hydraulic manifold  110 , the engine fan temperature sensor  130  monitors the temperature of the engine cooling system  106 , and the secondary fan temperature sensor  150  monitors the temperature of the secondary cooling system  108 . A separate connection is shown between the manifold temperature sensor  114  and the VCU  100 . For clarity, a separate connection is not shown between the engine fan temperature sensor  130  or the secondary fan temperature sensor  150  and the VCU  100 . There can be more or less temperature sensors used in the system as desired. The temperature sensors can be placed on alternative or additional components to determine when to activate and deactivate the engine cooling system  106  and the secondary cooling system  108 . The temperature sensors can be directly connected to the VCU  100  or another controller, for example a transmission control unit or engine control unit. The temperature sensors can also be indirectly coupled to a control unit, for example through the hydraulic manifold  110 . 
         [0023]    In a downhill braking situation, the secondary cooling system  108  is likely to be running to cool the transmission and/or brakes but, since the engine is not under load and therefore not generating much heat when travelling down a hill, the engine cooling system  106  may not be operating, or may be operating in a low power mode. If the VCU  100  activates the engine fan motor  120  and powers the engine fan  122  to turn at its maximum speed before a vehicle overspeed condition is achieved, the additional power used to turn the engine fan motor  120  and engine fan  122  is drawn from the powertrain which can aid in retarding the vehicle&#39;s speed. The VCU  100  can also cause the secondary cooling system  108  to run at a higher speed to draw additional power from the powertrain. The secondary cooling system  108  can help alleviate any additional heat load this action might generate in the hydraulics  146  or other components. The temperature sensors  114 ,  130 ,  150  can be used to monitor the temperatures of the load components, and the VCU  100  can also activate and deactivate the parasitic loads based on these temperature readings. 
         [0024]      FIG. 2  shows an exemplary embodiment of a vehicle powertrain  200  which includes an engine  202 , a countershaft transmission  204 , and a drivetrain. The engine  202  is coupled to the countershaft transmission  204  through an upper power shaft  210 . The drivetrain includes multiple axles  220 ,  222 ,  224  coupled to the transmission  204  through multiple drive shafts  212 ,  214 ,  216 . The transmission  204  is coupled to the front axle  220  through the front drive shaft  212 , coupled to the mid axle  222  through the mid drive shaft  214  and coupled to the rear axle  224  through the rear drive shaft  216 . The mid axle  222  includes a through drive clutch coupling the rear axle  224  to the transmission  204 . In this embodiment, the engine  202  and countershaft transmission  204  transfer power through the drive shafts  212 ,  214  and  216  to each of the three axles  220 ,  224  and  226 . 
         [0025]    Under normal operating conditions, a vehicle with an exemplary powertrain like that shown in  FIG. 2 , may disengage the through clutch of the mid axle  222  that couples the rear axle  224  to the powertrain. Disengaging the through clutch reduces the parasitic losses through the rear axle  222 . In an overspeed condition, the vehicle control unit could reengage the through clutch or otherwise reengage a drive axle to increase the parasitic losses from the powertrain. If the vehicle control unit reconnects one or more drive axles before or during a vehicle overspeed condition, the additional power used by the reconnected drive axle(s) is a parasitic load on the powertrain which can aid in retarding the vehicle&#39;s speed. 
         [0026]    One or more of the axles shown in  FIG. 2  can include an axle cooling system that can also be used to draw power from the powertrain in an overspeed condition to aid with vehicle speed retardation. The axle cooling system can have multiple hydraulic pressure settings, for example, differential-lock mode (high parasitic load) and non-activation mode. If the vehicle control unit activates the differential-lock mode of an axle cooling system before or during a vehicle overspeed condition, the additional power used by the axle cooling system is drawn from the powertrain which can aid in retarding the vehicle&#39;s speed. 
         [0027]      FIGS. 3 and 4  show an example of a vehicle control unit activating a hydraulic pump to cause fluid flow over a relief valve which causes a parasitic load to aid with vehicle speed retardation.  FIGS. 3 and 4  show a simplified representation of a vehicle control unit (VCU)  300  coupled to a hydraulic circuit  302  that controls the movement of a cylinder  306 . The hydraulic circuit  302  includes the cylinder  306 , a spool  304  and a relief valve  308 . In  FIG. 3 , the spool  304  is positioned to reduce flow and pressure, thereby minimizing the parasitic losses on the powertrain due to the hydraulic circuit  302 .  FIG. 4  shows the same hydraulic circuit  302  except that the spool  304  is shuttled to a position that forces the cylinder  306  against its end stop, thereby increasing the pressure in the hydraulic circuit  302  and forcing fluid flow over the relief valve  308 , thereby increasing the parasitic losses on the powertrain. If the vehicle control unit  300  activates the hydraulic pump  302  as shown in  FIG. 4  before or during a vehicle overspeed condition, the additional power used for the high pressure and high flow caused by the hydraulic pump  302  is drawn from the powertrain which can aid in retarding the vehicle&#39;s speed. In this case almost all of the energy will be absorbed by the hydraulic fluid, and this energy can be dissipated through a hydraulic cooler. 
         [0028]    Some of the parasitic loads activated to draw power from the powertrain may generate heat. The vehicle control unit can also be coupled to one or more temperature sensors that monitor the temperature(s) of the affected component(s), such as temperature sensors  114 ,  130 ,  150  of  FIG. 1 . The vehicle control system can include the capability to switch off one or more parasitic load(s) when a particular temperature sensor indicates a temperature at or above an overheat threshold. The vehicle control system can also include the capability to reactivate the parasitic load(s) when the temperature sensor indicates the temperature has dropped below a lower load activation temperature threshold that is deemed safe for re-activation of the parasitic load. 
         [0029]      FIG. 5  shows an exemplary embodiment of a control method  500  that can be used by the vehicle control system for controlling parasitic loads to retard vehicle speed and avoid or regain control of an overspeed condition. The method  500  starts at block  502  and proceeds to block  504  where the system checks whether a first overspeed threshold has been exceeded. If the first overspeed threshold has not been exceeded then the system remains at block  504  and continues to check whether the first overspeed threshold has been exceeded. If the first overspeed threshold is exceeded then, at block  506 , throttle control is removed from the vehicle operator and taken over by the vehicle control system. From block  506 , control passes to block  508 . 
         [0030]    At block  508 , the system checks whether a second overspeed threshold has been exceeded, the second overspeed threshold being greater than the first overspeed threshold. If the second overspeed threshold has not been exceeded then, at block  510 , the system checks whether the first overspeed threshold is still exceeded. If the second overspeed threshold is exceeded then, at block  514 , the vehicle control system activates a transmission retarder, engine brakes and/or service brakes. From block  514  control passes to block  516 . 
         [0031]    At block  510 , if the first overspeed threshold is still exceeded then control passes back to block  508  to check whether the second overspeed threshold is exceeded. If the first overspeed threshold is no longer exceeded then control passes to block  512  where the system restores throttle control to the vehicle operator. From block  512 , control passes back to block  504 . 
         [0032]    At block  516 , the system checks whether a third overspeed threshold has been exceeded, the third overspeed threshold being greater than the second overspeed threshold. If the third overspeed threshold has not been exceeded then, at block  518 , the system checks whether the second overspeed threshold is still exceeded. If the third overspeed threshold is exceeded then, at block  522 , the vehicle control system activates one or more parasitic loads to take additional power from the powertrain. From block  522  control passes to block  524 . 
         [0033]    At block  518 , if the second overspeed threshold is still exceeded then control passes back to block  516  to check whether the third overspeed threshold is exceeded. If the second overspeed threshold is no longer exceeded then control passes to block  520  where the vehicle control system deactivates the transmission retarder, engine brakes and/or service brakes. From block  520 , control passes back to block  510 . 
         [0034]    At block  524  the system checks whether the third overspeed threshold is still exceeded. If the third overspeed threshold is still exceeded then the system remains at block  524  and continues to check whether the third overspeed threshold is still exceeded. If the third overspeed threshold is no longer exceeded then, at block  526 , the vehicle control system deactivates the one or more parasitic loads. From block  526 , control passes back to block  518 . 
         [0035]    The control system illustrated in  FIG. 5  utilizes three progressively higher overspeed thresholds and takes additional actions to end the overspeed condition. Alternative control systems could have more or less thresholds and could have different actions prior to or after activating the parasitic loads. Alternative control systems could also activate parasitic loads one at a time or several at a time based on additional overspeed thresholds or time exceeding a particular overspeed threshold. Those of skill in the art will recognize that a control system can have numerous other variations with different thresholds, speed retarding actions and timers. 
         [0036]      FIG. 6  illustrates an exemplary embodiment of a variation of the control system shown in  FIG. 5  that also checks for overheating conditions that could be caused by the parasitic loads. In this variation, the blocks of  FIG. 6  replace blocks  522  and  524  of  FIG. 5 . At block  516  of  FIG. 5 , if the third overspeed threshold is exceeded then one or more parasitic loads are activated and control passes to the routine of  FIG. 6 . 
         [0037]    At block  602  a parasitic load is activated, and then at block  604  the control system checks whether a load temperature associated with the parasitic load exceeds an overheat threshold temperature associated with the parasitic load. If the load temperature exceeds the overheat threshold temperature then control passes to block  606  where the parasitic load is deactivated, and then control passes to block  610 . If the load temperature does not exceed the overheat threshold temperature then control passes to block  608  to check whether the third overspeed threshold is still exceeded. 
         [0038]    At block  608 , if the third overspeed threshold is still exceeded then the system returns to block  604  to check the overheat threshold. If the third overspeed threshold is no longer exceeded then control passes to block  526  of  FIG. 5  where the vehicle control system deactivates the one or more parasitic loads, and control continues as described above with regard to  FIG. 5 . 
         [0039]    At block  610  the control system checks whether the load temperature has fallen below a load activation threshold temperature associated with the parasitic load. If the load temperature has fallen below the load activation threshold temperature, then control passes to block  602  where the parasitic load is reactivated. If the load temperature has not fallen below the load activation threshold temperature, then control passes to block  612  to check whether the third overspeed threshold is still exceeded. 
         [0040]    At block  612 , if the third overspeed threshold is still exceeded, then the system returns to block  610  to check the load activation threshold. If the third overspeed threshold is no longer exceeded then control passes to block  526  of  FIG. 5  where the vehicle control system deactivates the one or more parasitic loads, and control continues as described above with regard to  FIG. 5 . 
         [0041]    The routine shown in  FIG. 6  can be implemented for one or more parasitic loads together where all of the parasitic loads are activated at block  602  and all of the parasitic loads are deactivated at block  606  based on one or more load temperatures. Alternatively, the routine shown in  FIG. 6  can be implemented for each of the parasitic loads separately where each parasitic load has an associated overheat threshold and activation threshold. In this latter case, only the load with an associated load temperature exceeding the overheat threshold is deactivated at block  606  and the other loads remain active; and only the formerly overheated load with the associated load temperature going below the activation threshold is reactivated at block  602 . In this latter case all of the parasitic loads are activated before entering the routine of  FIG. 6 . In yet another alternative embodiment, the loads can be grouped into sets of loads with associated overheat thresholds and activation thresholds to deactivate and reactivate each set of loads. Those of skill in the art will recognize additional contemplated variations for the exemplary control systems illustrated of  FIGS. 5 and 6 . 
         [0042]    While exemplary embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.