Electrical circuit for providing a reduced average voltage

• US 6,744,146 B2
• Filed: 09/05/2002
• Issued: 06/01/2004
• Est. Priority Date: 09/05/2002
• Status: Expired due to Term

• Current Assignee: BorgWarner Incorporated
• Original Assignee: Delco Remy America Inc (BorgWarner Incorporated)
• Inventors: Fulton, David A., Cai, William
• Primary Examiner(s): Ponomarenko, Nicholas
• Application Number:
  US10/234,113
• Publication Number:
  US 20040046393A1
• Time in Patent Office: 635 Days
• Field of Search: 290/30.R, 290/31, 290/36.R, 290/37.A, 290/38.A, 322/40, 123/339.16
• US Class Current: 290/37.00A
• CPC Class Codes: F02N 11/006 using a plurality of electric motors
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: F02N 11/0859 specially adapted to the type of the starter motor or integrated into it
• CPC Class Codes: F02N 11/0866 comprising several power sources, e.g. battery and capacitor or two batteries
• CPC Class Codes: F02N 11/087 Details of the switching means in starting circuits, e.g. relays or electronic switches
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: F02N 2011/0896 Inverters for electric machines, e.g. starter-generators

Abstract

Systems and methods of the invention may utilize integrated starter-alternator (ISA) electronics to drive a conventional DC starter coupled to a start-stop ISA system providing a voltage higher than that at which the starter is rated. The DC starter may cold crank an internal combustion engine, while a poly-phase starter alternator warn cranks the engine and converts mechanical energy to an AC current. The AC current may be converted to a DC current to provide charging functions. A reduced average voltage is provided to the DC starter and an adjustable-frequency alternating current may be provided to the starter alternator.

Claims

1. An electrical system comprising:

a direct current (DC) voltage source providing a first voltage;

an alternating current (AC) starter-alternator mechanism configured for warm cranking an engine and converting rotational energy from the engine into an AC current;

a starter mechanism, rated at a second voltage which is lower than the first voltage, for cold cranking the engine; and

a circuit coupled to the voltage source for;

providing the second voltage to the starter mechanism in response to a switch closing; and

in response to the switch opening, ceasing to provide the second voltage to the starter mechanism;

transferring energy from the DC voltage source to the AC starter-alternator mechanism; and

converting the AC current, converted from the engine by the starter-alternator, to a DC current in order to charge the voltage source.

2. The system of claim 1, wherein the circuit comprises at least one switching device.

3. The system of claim 1, wherein the AC starter-alternator mechanism includes n phases and wherein the circuit transfers energy by way of providing a set of n voltages substantially equal in magnitude and respectively displaced by a phase angle of 360°

/n.

4. The system of claim 3, wherein each of the n phases are coupled to at least one switching device residing in the circuit.

5. The system of claim 2, wherein the at least one switching device is arranged in a converter configuration.

6. The system of claim 4, wherein the at least one switching device is arranged in a converter configuration.

7. The system of claim 2 further comprising a control mechanism for controlling the at least one switching device.

8. The system of claim 7, wherein the control mechanism sets an adjustable frequency at which the energy is transferred from the DC voltage source to the AC starter-alternator mechanism.

9. The system of claim 2, wherein the at least one switching device includes at least one of a MOSFET, a JFET, a BJT, and a thyristor.

10. The system of claim 1, wherein the switch is a magnetic switch.

11. The system of claim 1, wherein the switch is a single pole single throw magnetic switch and wherein the circuit comprises at least diode coupled to said switch.

12. The system of claim 2, wherein the at least one switching device is cooled via a heat sink.

13. The system of claim 12, wherein the heat sink transfers heat from the switching device via at least one of conduction, convection, and radiation.

14. The system of claim 1, wherein the first voltage is 36V and the second voltage is 12V.

15. The system of claim 1, wherein the switch is closed and opened in response to at least one of a key-driven starter switch and a push button starter switch.

16. An electrical circuit comprising:

at least one switching device coupled to a direct current (DC) voltage source providing a first voltage;

a first terminal set coupled to a switch, the first terminal set comprising at least one terminal coupled to the at least one switching device; and

a second terminal set coupled to an AC load having at least one phase, the second terminal set comprising at least one terminal coupled to the at least one switching device,

wherein the at least one switching device is pulsed in response to the switch closing, thereby providing, via the first terminal set, a reduced average voltage from the DC voltage source to a DC device; and

wherein the at least one switch, in response to the switch opening, provides via the second terminal set, energy from the DC voltage source to the AC load.

17. The circuit of claim 16, wherein the AC load is a starter-alternator device for warm cranking an engine and converting rotational energy produced by the engine into an AC current.

18. The circuit of claim 17, wherein the circuit converts the AC current to a DC current and charges the DC voltage source.

19. The circuit of claim 16, wherein the DC device is a starter for cold cranking an engine.

20. The circuit of claim 16, wherein the AC load is an n-phase load and wherein the circuit provides energy to the n-phase load by way of providing a set of n voltages substantially equal in magnitude and respectively displaced by a phase angle of 360°

/n.

21. The circuit of claim 16, wherein the at least one switching device is arranged in a converter configuration.

22. The circuit of claim 16, wherein the at least one switching device includes at least one of a MOSFET, a JFET, a BJT, and a thyristor.

23. The circuit of claim 16 further comprising at least one heat sink for cooling the at least one switching device.

24. The circuit of claim 23, wherein the at least one heat sink transfers heat from the at least one switching device via at least one of conduction, convection, and radiation.

25. The circuit of claim 16, wherein the switch is a magnetic switch.

26. The circuit of claim 25, wherein the magnetic switch is a single pole single throw magnetic switch.

27. The circuit of claim 26 further comprising at least one diode coupled in series to the at least one terminal included in the first terminal set.

28. The circuit of claim 16, wherein the switch is activated by at least one of a key-driven starter switch and a push button starter switch coupled to the voltage source.

29. The circuit of claim 16, wherein the first voltage is 36V and the reduced average voltage is 12V.

30. The circuit of claim 16, wherein the reduced average voltage is at least one of a pulse width modulated, hysteretic, and a chopped voltage.

31. An electrical system comprising:

a voltage source providing a first voltage;

an electrical device requiring a second voltage lower than the first voltage;

an alternating current.(AC) machine, having at least one phase, for converting rotational energy from an engine into an AC current;

a circuit coupled to the voltage source, the AC machine, and a switch;

wherein the circuit;

causes, in response to the switch closing, a reduced average voltage substantially equivalent to the second voltage to be provided from the voltage source to the electrical device; and

in response to the switch opening, causes energy to be transferred from the voltage source to the AC machine and enables the voltage source to be charged via the AC current.

32. In a system having a voltage source providing a first voltage, a starter motor rated at a second voltage lower than the first voltage, a starter-alternator device, and an engine including a throttle and a clutch, a method comprising the steps of:

providing, in response to a user-controlled switch closing, a reduced average voltage substantially equal to the second voltage to the starter motor from the voltage source;

starting the engine via the starter motor;

providing, in response to the user controlled switch opening, the first voltage to the starter-alternator device from the voltage source;

charging the voltage source from the engine via the starter-alternator device;

stopping the engine after a predetermined period of time;

re-starting the engine via the starter-alternator device in response to a change in position of the throttle or clutch.

33. The method of claim 32, wherein providing the reduced average voltage to the starter motor from the voltage source comprises providing at least one of a pulse-width modulated and hysteretic voltage via at least one switching device.

34. The method of claim 32, wherein providing the first voltage to the starter-alternator device from the voltage source comprises providing a set of n voltages substantially equal in magnitude and respectively displaced by a phase angle of 360°

/n.

35. The method of claim 33, wherein providing the reduced average voltage to the starter motor comprises providing the reduced average voltage via at least one of a MOSFET, a JFET, a BJT, and a thyristor.

36. In a system having a voltage source supplying a first voltage, a DC device, and AC load having a plurality of phases, a method comprising the steps of:

providing a reduced average voltage from;

the voltage source to the DC device in response to a switch closing, wherein the reduced average voltage is lower than the first voltage; and

transferring a plurality of voltages substantially equal in magnitude, each displaced by a phase angle, to the AC load from the voltage source in response to the switch opening.

37. The method of claim 36, wherein the providing step comprises providing the reduced average voltage from the voltage source to a DC starter motor rated at 12 volts.

38. The method of claim 36, wherein the transferring step comprises transferring a plurality of voltages to a starter-alternator device operating at 36 volts.

39. The method of claim 36, wherein the providing step comprises providing the reduced average voltage to the DC device by way of pulsing at least one switching device.

40. The method of claim 36, wherein the switch is a magnetic switch.

41. The method of claim 40, wherein the switch closes and opens in response to a user turning a key.

42. The method of claim 40, wherein the switch closes and opens in response to a user pushing a button.