Patent Application
20090322101
The present invention relates to a system and a method for cranking and starting an engine in a vehicle.
A conventional light-duty vehicle engine is typically started at the beginning of a trip and remains active through the duration or length of the trip. The engine starting event draws a significant amount of electrical energy or power over a relatively short period of time ranging from approximately 0.3 seconds for a warm engine, to over 2 seconds for a very cold engine. Generally, a direct current (DC) electric motor powered by a single 12-volt battery is used to start the engine. Such a motor draws maximum amount of electrical current at its stall speed, with the electrical current decreasing as the speed of the motor increases. A typical 12-volt battery provides maximum current and minimum voltage during the initial portion of the starting event.
Before the engine of a conventional vehicle is started, the auxiliary electrical loads in the vehicle are powered by the 12-volt battery. Thus, all of the auxiliary loads experience a reduced voltage supply during the initial portion of the engine starting event. In some cases, this transient voltage reduction or voltage sag can cause a potentially noticeable or perceptible change in the performance of the auxiliary loads, such as a decrease in light intensity from incandescent lighting. Once the engine starts, the engine-driven generator produces the necessary electrical power for energizing the auxiliary loads, and may also recharge the 12-volt battery.
One method of reducing fuel consumption in a conventional vehicle is to shut off the fuel supply to the engine whenever the engine is not needed for supplying propulsive power. However, this method requires repeated engine restarts during a given trip, such as each time the vehicle is stationary at a stop light between end points of the trip. Additionally, the power delivered by the engine-driven generator to the auxiliary loads will be reduced to zero as the engine is shut off. The power required for powering the auxiliary loads is supplied by the 12-volt battery or by another power source if the vehicle is so equipped.
In some vehicles, the electrical power needed for restarting the engine is provided by a second battery which powers an alternative starting motor. For example, a belted alternator/starter utilizes a combined starter/generator as a secondary engine starting device in place of a conventional engine-driven generator. By using separate batteries to provide electrical power for the auxiliary loads and the secondary engine starting device, the electrical voltage supplied to the auxiliary loads is generally unaffected during the engine starting event, generally minimizing any customer-perceptible changes in performance of the auxiliary system. However, duplicate batteries contribute significant weight while consuming valuable packaging space within the vehicle.
In other light-duty systems, a single vehicle battery and starting device are always used for starting the engine. The generator is unchanged from that of the conventional vehicle. An electronic device known as a DC-DC converter takes electrical power supplied by the battery, regardless of the battery voltage, and produces a stable DC output voltage that is supplied to specific auxiliary loads, which could otherwise exhibit a change in performance during a transient voltage fluctuation during the engine starting event.
Accordingly, a vehicle is provided having an engine, a starter motor, an energy storage system (ESS), and a supercapacitor module. When the engine is stopped, the ESS exclusively powers an auxiliary system aboard the vehicle, such as one or more sets of wipers, and/or interior/exterior lights, but the ESS itself does not exclusively power the starter motor during an engine cranking and starting event. Instead, the starter motor is initially powered at least primarily and potentially exclusively using the supercapacitor module. After the initial power for the starter motor has been drawn from the supercapacitor module, the starter motor may be connected to the ESS if conditions warrant.
To ensure proper charging and recharging of the supercapacitor module, the starter motor is connected to the supercapacitor module only during starting of the engine. Once the engine is rotating without the aid of the starter motor, the starter motor is disconnected from the supercapacitor module. One means for connecting and disconnecting the starter motor is an electrical switch, or a starter solenoid which is generally an integral part of a starter motor assembly in a conventional vehicle, although it is not necessarily so. Recharging the supercapacitor module can be accomplished at times other than during active engine starting. Charging of the supercapacitor module may be performed by the ESS, the generator, and/or another special-purpose charging device. In the event that the supercapacitor module and the ESS are both providing power to the starter motor during engine starting, there will be short periods of low current demand by the starter motor, during which the ESS may temporarily provide short term limited or partial recharging of the supercapacitor module.
One type of DC-DC converter is a boost converter. This device can be used to increase the level of voltage supplied from the ESS or from the generator to the supercapacitor module during charging, thus storing a relatively higher voltage level within the supercapacitor module than might otherwise be possible absent use of such a converter.
In a sufficiently cold ambient temperature environment, the power required to start an engine is significantly greater than the power required in a warm environment. It is possible that energy is drawn from the supercapacitor module so quickly that the voltage of the supercapacitor module drops significantly, possibly below that of the ESS before the engine has started. During this condition, the supercapacitor module can be placed in electrical parallel with the ESS using a contactor or switch when the voltage stored in the capacitor drops below a threshold during extended cranking. In one embodiment, the supercapacitor module can be charged to approximately 125 to 140 percent of the voltage level of the ESS. In another embodiment, the ESS is a 12-volt battery, and the voltage provided by the supercapacitor module prior to engine cranking and starting is approximately 15 to 17 volts. In general, the DC-DC converter can be controlled in a manner to deliver a limited amount of power to the supercapacitor module, and thus may or may not be operated during engine cranking. The appropriate type of DC-DC converter should be used depending on the voltage of the ESS, the voltage of the generator, and the voltage of the supercapacitor module.
A method for preventing voltage sag in an auxiliary system of a vehicle having an engine, a generator, a starter motor, a DC-DC converter, and an energy storage system (ESS) includes disconnecting a supercapacitor module from the starter motor when the engine is running, and then charging the supercapacitor module using the ESS, the generator, and/or the DC-DC converter until a cranking support voltage stored in the supercapacitor module equals a predetermined target voltage. If the target voltage is greater than the voltage of the ESS and the generator, then only the DC-DC converter is used to further charge the supercapacitor module above the voltage level provided by the ESS and the generator.
The method includes detecting a commanded cranking and starting of the engine, which when detected is followed by the rapid connection of the module to the starter motor. The starter motor is initially energized exclusively by the supercapacitor module for a predetermined minimum amount of time. If the engine has not started when the predetermined minimum amount of time has passed, then the voltages of supercapacitor module and the ESS are measured and compared. If the voltage of the supercapacitor module is less than the ESS, then a switch is closed to connect the supercapacitor module and the ESS in parallel. At times when the starter motor is powered exclusively by the supercapacitor module, the auxiliary system is powered only by the ESS. At times when both of the supercapacitor module and the ESS are used to power the starter motor, they both provide power to the auxiliary system.
The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.
Referring to the drawings, wherein like reference numbers refer to like components, and beginning with
The electrical system 50 further includes an energy storage system (ESS) 13 which can be configured as a rechargeable battery device or another suitable energy storage device. The ESS 13 is configured for powering or energizing one or more auxiliary systems (AUX) 40 and sensors 19a, 19b, as will be described below with reference to
Within the system 50, the ESS 13 is electrically connected to a supercapacitor module (SCM) 65 via a DC-DC converter 22 of the type known in the art. Exemplary embodiments of each of the module 65 and the DC-DC converter 22 are described below with reference to
When the engine 12 is running or operational, the ESS 13 and the generator 14 may each provide power to the auxiliary systems 40 and the DC-DC converter 22, or the generator 14 may exclusively provide power for the auxiliary systems 40. When the generator 14 is exclusively powering the auxiliary systems 40 and the DC-DC converter 22, the generator 14 may also be used for recharging the ESS 13. In one embodiment, a second electrical switch (Sw2) 60 is connected in electrical parallel with the DC-DC converter 22. This second switch 60 may be of the same general type as the first switch 32, and is electrically controlled to be either open or closed by a control signal 90 enforced or applied by the controller 24.
The controller 24 includes a cranking support algorithm 100, and is in electrical communication with the first and second switches 32 and 60, respectively, the DC-DC converter 22, the engine 12 via the auxiliary systems 40, the ESS 13, and the module 65. The controller 24 can also be programmed and/or configured to include a hybrid control module, an engine control module, a transmission control module, a motor/generator control module, and/or any necessary electronic drives or power electronics circuits, as well as the algorithm 100, as described below and as shown in
During the initial time period of cranking and starting of the engine 12, the controller 24 enforces the signal 91 to close the first switch 32, and does not enforce the signal 90 to close the second switch 60, thus leaving the second switch 60 in an open state or condition. The controller 24 may or may not enforce a signal 92 to the DC-DC converter 22 to selectively supply power at any chosen level from the ESS 13 to the module 65. During the initial time period of cranking, energy is drawn exclusively from the module 65 when the DC-DC converter 22 is left in an “off” state or condition. During the initial time period of cranking, energy is drawn preferentially from the module 65 when the DC-DC converter 22 is controlled in an “on” state, and when the DC-DC converter 22 supplies less than half of the power required by the motor 41.
In general, the characteristics of a DC motor that is sized appropriately for cranking a vehicle engine such as the engine 12 are such that a support voltage (V2) of the module 65 is drawn lower than an auxiliary voltage (V1) of the ESS 13 during the initial portion of the cranking event. Once the initial portion of the cranking event is finished and the engine 12 is rotating at an average speed that is no longer generally increasing, the support voltage V2 of the module 65 may be greater than, equal to, or less than the auxiliary voltage V1 of the ESS 13. With the module 65 having a sufficiently large size, and with a cranking and starting event having a sufficiently short period, all or a majority of the power utilized by the motor 41 will come from the module 65. In this case, the support voltage V2 of the module 65 is reduced noticeably while the auxiliary voltage V1 of the ESS 13 is reduced marginally, if at all.
In an embodiment in which the DC-DC converter 22 is a boost-type or a buck-boost-type converter of an appropriate configuration generally well-known in the art, the support voltage V2 of the module 65 may be in excess of the auxiliary voltage V1 prior to cranking and starting the engine 12. During later portions of the cranking event and after the cranking event, the support voltage V2 may be less than the auxiliary voltage V1. Ideally, the support voltage V2 exclusively powers or energizes the motor 41 through the duration or interval required for fully starting the engine 12 during such normal or warm cranking conditions. However, as will be explained below, the auxiliary voltage V1 can be used under certain circumstances to assist the support voltage V2 as needed.
When the controller 24 determines that the cranking and starting of the engine 12 is complete, the controller 24 opens the first switch 32. Once the first switch 32 is open, the DC-DC converter 22 is allowed to recharge the module 65, i.e., one or more super-capacitive cells resident therein, to a sufficiently high voltage level. This level is referred to hereinafter as the target voltage level (VT) and is described below with reference to
Environmental conditions may be such that the ambient temperature and the temperature of the engine 12 may be extremely cold. In general, the time required to start a cold engine may be much longer than when the engine is warm. Likewise, the amount or level of energy required by a motor to crank a cold engine is much greater than the amount or level of energy required to start a warm engine. In these situations, the module 65 may not store sufficient energy for ensuring a successful engine start.
A provision is therefore made to allow the ESS 13 to deliver energy for starting the engine 12 once the energy level of the module 65 becomes sufficiently depleted. When conditions warrant, such as when outside temperatures and internal engine temperatures drop below the predetermined threshold temperature, which might be determined directly by sensing or measuring the outside temperature and/or the temperature of any engine coolant (not shown) using the sensor or sensors 19A, the second switch 60 is closed by the controller 24 in order to place the ESS 13 in electrical parallel with the module 65 to allow the relatively stable auxiliary voltage V1 from the ESS 13 to crank the engine 12 at a maximum possible speed. Once the engine 12 has started, the second switch 60 can again be opened.
Referring to
Referring to
Within the module 65, one or more supercapacitor cells rapidly deliver the required support voltage V2 to the motor 41 to fully crank and start the engine 12 (see
As used herein, and as will be understood by those of ordinary skill in the art, a capacitor is an electronic device having a pair of conductive plates which are in turn separated or spaced by a dielectric substance or material such as glass, ceramic, cellulose, fluorocarbon, air, or another suitable dielectric material. The term “supercapacitor” in particular refers to a specialized capacitor having a high relative measure of capacitance, defined as the magnitude of a stored charge per volt, i.e., Farads. A supercapacitor can differ from a standard capacitor in a number of ways, including in its use of particular types of electrodes or plates.
For example, the electrodes of a supercapacitor might include a metal oxide, various conductive polymers, or a high surface area activated carbon material in order to provide a sufficient total capacitance. In the exemplary embodiment of
The DC-DC converter 22 includes any necessary electronic circuit components needed to boost or increase the level of the auxiliary voltage V1 provided by the ESS 13 in order to produce and store a sufficiently increased level of support voltage V2 within the module 65. Such components can include, for example, a set of suitably configured transistors 45, e.g., a field-effect transistor such as MOSFET of the type known in the art, and/or diodes, a capacitor 49, and an inductive coil 43, as will be understood by those of ordinary skill in the art of DC-DC boost or buck-boost converters. The torque-speed envelope of any DC motor, such as the motor 41, is dependent upon the supply voltage energizing the DC motor. That is, the greater the supply voltage to the motor, the greater the amount of available torque at a given motor speed, as well as a maximum motor speed at no-load.
In the embodiment of
Still referring to
Referring to
Beginning with step 102, with the engine 12 off, the algorithm 100 ensures that the first and second switches 32 and 60 are both open, either by opening the switches 32 and 60, or by verifying that the switches 32 and 60 are already open. This may be accomplished by sending a signal or command to the switches 32 and/or 60 to open, or by sensing their position. Opening of the switches 32 and 60 includes any action which, for the first switch 32, breaks or disconnects the electrical connection between the motor 41 and the module 65, or for the second switch 60 which breaks the direct connection between the ESS 13 and the motor 41. The algorithm 100 then proceeds to step 104.
At step 104, the algorithm 100 compares the support voltage V2 in the module 65 to a stored threshold or target voltage (VT), and then charges the module 65 via the DC-DC converter 22 and the ESS 13 until the support voltage V2 is substantially equal to the target voltage (VT), i.e., within an allowable range of the target voltage (VT). The target voltage (VT) can be set, in one embodiment, to approximately 25 to 40 percent above the level of the ESS 13. For example, if the ESS 13 is a standard 12-volt battery, the target voltage (VT) can be set to approximately 15 to 17 volts. However, those of ordinary skill in the art will recognize that other target voltages (VT) can be used within the scope of the invention, depending on the particular design of the engine 12, the ESS 13, and/or the motor 41.
Additionally, the time required for charging and recharging a given capacitor of the module 65 is a function of the capacitance of each supercapacitor contained within the module 65, the stored voltage in each supercapacitor at the start of a recharge event, the current delivered by the DC-DC converter 22, and the target voltage (VT) to be achieved. In equation form, tcharge=C[Vf−Vi]/i, wherein C=total capacitance, Vf=final voltage, Vi=initial capacitor voltage, and i=the current delivered by the DC-DC converter 22 (see
At step 106, the algorithm 100 detects or otherwise determines whether an engine cranking and starting event has been presently initiated or commanded, such as by a detected depression of an accelerator pedal (not shown) within the vehicle 10. If engine cranking and starting has been initiated and detected, the algorithm 100 proceeds to step 108, otherwise algorithm 100 returns to step 104, repeating steps 104 and 106 until engine cranking has been detected.
At step 108, having determined at step 106 that engine cranking and starting have been initiated, the algorithm 100 closes the first switch 32. The second switch 60 remains in an open state. The algorithm 100 then proceeds to step 109.
At step 109, a variable te representing the amount of time which has elapsed since the start of cranking of the engine 12 is initialized or set to zero. Afterward, the motor 41 is powered exclusively by the support voltage V2 from the module 65 through the transient interval or duration required for cranking and starting the engine 12, so long as this duration is within a predetermined minimum threshold duration, or tmin. The algorithm 100 then proceeds to step 110.
At step 110, the algorithm 100 determines whether the engine 12 has started. If not, the algorithm 100 proceeds to step 111. Otherwise, the algorithm 100 proceeds to step 112.
At step 111, the present value for the elapsed time variable te (see step 109) is calculated or otherwise determined, after which the algorithm 100 proceeds to step 113.
At step 112, the switch 32 (Sw1) is opened. The algorithm 100 then proceeds to step 114.
At step 113, the value of te is compared to a calibrated minimum time value tmin. The algorithm 100 proceeds to step 117 when te exceeds the calibrated minimum time value (tmin), otherwise proceeding to step 115.
At step 114, the status of the second switch 60 is checked to determine if the second switch 60 is closed. If so, the algorithm 100 proceeds to step 116. If the second switch 60 is determined to be open, the algorithm 100 is finished.
At step 115, the support voltage V2 is compared to the auxiliary voltage V1. If the support voltage V2 exceeds the auxiliary voltage V1, the algorithm 100 proceeds to step 117, otherwise the algorithm 100 proceeds to step 117.
At step 116, the second switch 60 is opened. The algorithm 100 is then finished.
At step 117, the second switch 60 is closed, and the algorithm 100 proceeds to step 119.
At step 119, the position of the switch 32 (Sw1) is maintained, and the algorithm 100 continues with step 110.
While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims.
