Integrated starter alternator troller

• US 6,396,161 B1
• Filed: 04/17/2000
• Issued: 05/28/2002
• Est. Priority Date: 04/17/2000
• Status: Expired due to Fees

• Current Assignee: Remy Incorporated (BorgWarner Incorporated)
• Original Assignee: Delco Remy Int Inc.
• Inventors: Fulton, David A., Crecelius, David R.
• Primary Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US09/551,395
• Time in Patent Office: 771 Days
• Field of Search: 290/1 R,1 A,31,36 R,40 C 322/1 318/376
• US Class Current: 290/36.00R
• CPC Class Codes: B63H 2021/205 the second power unit being of the internal combustion engine type, or the like, e.g. a Diesel engine
• CPC Class Codes: B63H 2021/216 using electric control means
• CPC Class Codes: B63H 21/20 the vessels being powered by combinations of different types of propulsion units
• CPC Class Codes: B63H 21/21 Control means for engine or transmission, specially adapted for use on marine vessels
• CPC Class Codes: B63J 3/02 from propulsion power plant
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: Y02T 70/5236 Renewable or hybrid-electric solutions

Abstract

A marine integrated starter alternator troller device (ISAT) includes a stator portion and a rotor portion connected to a drive shaft. The ISAT is incorporated into an engine assembly power train which includes an internal combustion engine having a crankshaft connected to an electric clutch. The electric clutch is operable to connect or disconnect the drive shaft and the crankshaft. Thus, the ISAT may be connected to or disconnected from the crankshaft of the internal combustion engine. When connected to the engine by the electric clutch, the ISAT device is operable to receive electrical power from a battery and act as a cranking motor to provide starting torque to the internal combustion engine. The ISAT may also be driven by the internal combustion engine and act as a generator to provide power to re-charge the battery or drive other electrical devices. When disconnected from the engine by the electric clutch, the ISAT receives electrical power from the battery and acts as a trolling motor to drive a propeller. A transmission is connected between the ISAT and the propeller such that rotation of the ISAT spins the propeller at a number of forward and reverse speeds.

Claims

1. A propulsion system for a boat comprising:

a. an electro-mechanical device operable as an electric motor or an electric generator, the electro-mechanical device having a rotor connected to a drive shaft;

b. an internal combustion engine having a rotatable crankshaft releasably connected to the drive shaft;

c. a clutch in communication with the drive shaft and the crankshaft, the clutch for releasably connecting the drive shaft to the crankshaft and disconnecting the drive shaft from the crankshaft;

d. a propeller operable to rotate when driven by rotation of the rotor and the drive shaft; and

e. a controller operable to control the electric currents flowing in the electro-mechanical device and thereby cause the electro-mechanical device to operate as (i) a generator when the internal combustion engine is running, (ii) a starter motor that provides power to crank the internal combustion engine when the internal combustion engine is not running, or (iii) a trolling motor that provides power to rotate the drive shaft and the rotor.

2. The system of claim 1 wherein the clutch is an electric clutch.

3. The system of claim 1 wherein the electro-mechanical device comprises a rotor winding positioned upon the rotor and three phase stator windings positioned across an air gap from the rotor winding, the three phase stator windings connected to an active rectifier bridge, the active rectifier bridge being controlled by gate drivers and the gate drivers being controlled by the controller.

4. The system of claim 3 wherein the controller is operable to receive a start mode command for instructing the controller to operate the electro-mechanical device as a cranking motor.

5. The system of claim 4 wherein the controller is operable to receive a signal representing the speed of the rotor, such that when the rotor achieves a speed indicating that the internal combustion engine has fired, the controller operates the electro-mechanical device as a generator.

6. The system of claim 3 wherein the controller is operable to receive a electric propulsion mode command for instructing the controller to operate the electro-mechanical device as a motor to provide propulsion power for the boat.

7. The system of claim 6 wherein the electric propulsion mode command instructs the clutch to disconnect the crankshaft from the drive shaft.

8. The system of claim 3 wherein the controller uses an indirect vector control method to control the active rectifier bridge, the indirect vector control method comprising the steps of

a. determining a torque component of stator current;

b. determining a flux component of stator current;

c. transferring the torque component of stator current and the flux component of stator current from a synchronous reference frame to a stationary reference frame using vector rotation equations; and

d. transferring the torque component of stator current and the flux component of stator current in the stationary reference frame from two-phase flux and torque quantities to three-phase stator current quantities using two-phase to three-phase equations.

9. An electro-mechanical device for use with an internal combustion engine having a crankshaft, the electro-mechanical device comprising:

a. three phase stator windings;

b. a rotor having a rotor winding positioned across an air gap from the stator windings, the rotor having a drive shaft releasably connected to the crankshaft;

c. an active rectifier bridge connected to the three phase stator windings, the active rectifier bridge comprising a plurality of transistor switches;

d. a controller in communication with the active rectifier bridge, the controller operable to control the active rectifier bridge such that the electro-mechanical device operates in one of at least three modes, wherein

i. a first of the at least three modes causes the electro-mechanical device to operate as a starting motor to crank the internal combustion engine when the internal combustion engine is not in operation,

ii a second of the at least three modes causes the electro-mechanical device to operate as a generator during operation of the internal combustion engine, and

iii a third of the at least three modes causes the electro-mechanical device to operate as an electric motor to provide propulsion power for the boat.

10. The electro-mechanical device of claim 9 wherein the controller is connected to gate drivers which are connected to the active rectifier bridge, the controller controlling the active rectifier bridge by controlling the gate drivers.

11. The electro-mechanical device of claim 9 wherein the controller receives a start mode command from a command console instructing the controller to operate in the first of the at least three modes.

12. The electro-mechanical device of claim 11 wherein the controller begins operation in the first of the at least three modes upon receipt of an initiate start sequence command.

13. The electro-mechanical device of claim 9 wherein the controller receives a signal representative of rotor speed from a speed sensor and the controller operates in the second of the at least three modes when the rotor speed reaches a threshold indicating that the internal combustion engine has fired.

14. The electro-mechanical device of claim 9 wherein the controller receives an electric propulsion mode command from a command console instructing the controller to operate in the third of the at least three modes.

15. The electro-mechanical device of claim 14 wherein the drive shaft is disconnected from the crankshaft when the controller receives the electric propulsion mode command.

16. The electro-mechanical device of claim 9 wherein the controller uses an indirect vector control method to operate the electro-mechanical device in one of the at least three modes, the indirect vector control method comprising the steps of

a. determining a torque component of stator current;

b. determining a flux component of stator current;

c. transferring the torque component of stator current and the flux component of stator current from a synchronous reference frame to a stationary reference frame using vector rotation equations; and

d. transferring the torque component of stator current and the flux component of stator current in the stationary reference frame from two-phase flux and torque quantities to three-phase stator current quantities using two-phase to three-phase equations.

17. A method of operating an electro-mechanical device having a rotor and an active rectifier bridge, the active rectifier bridge electrically connected to a battery and a controller, the rotor releasably connected to an internal combustion engine, the rotor also connected to a propeller, the method comprising the steps of:

a. sending a first signal to the controller to operate the electro-mechanical device as a starting motor and, upon receipt of the first signal by the controller, controlling the active rectifier bridge such that the electro-mechanical device operates as a starting motor to crank the internal combustion engine;

b. sending a second signal to the controller to operate the electro-mechanical device as a generator, and upon receipt of the second signal by the controller, controlling the active rectifier bridge such that the electro-mechanical device operates as a generator driven by the internal combustion engine; and

c. sending a third signal to the controller to operate the electro-mechanical device as an electric motor, and upon receipt of the third signal by the controller, controlling the active rectifier bridge such that the electro-mechanical device operates as a propulsion motor.

18. The method of claim 17 further comprising the step of disconnecting the electro-mechanical device from the internal combustion engine when the third signal is sent to the controller.

19. The method of claim 18 wherein the controller activates a warning device when the battery voltage reaches a predetermined threshold during operation of the electro-mechanical device as the trolling motor.

20. The method of claim 17 wherein the controller uses an indirect vector control method to control the active rectifier bridge, the indirect vector control method comprising the steps of

a. determining a torque component of stator current;

b. determining a flux component of stator current;

c. transferring the torque component of stator current and the flux component of stator current from a synchronous reference frame to a stationary reference frame using vector rotation equations; and

d. transferring the torque component of stator current and the flux component of stator current in the stationary reference frame from two-phase flux and torque quantities to three-phase stator current quantities using two-phase to three-phase equations.