Electrical power system for vehicles requiring electrical power while the vehicle engine is not in operation

• US 7,145,788 B2
• Filed: 07/27/2004
• Issued: 12/05/2006
• Est. Priority Date: 07/27/2004
• Status: Active Grant

• Current Assignee: PACCAR Incorporated
• Original Assignee: PACCAR Incorporated
• Inventors: Plummer, Lew E.
• Primary Examiner(s): NGUYEN, MATTHEW VAN
• Application Number:
  US10/899,795
• Publication Number:
  US 20060023480A1
• Time in Patent Office: 861 Days
• Field of Search: 363/141, 363/144, 363/146, 180/54.1, 180/65.1, 180/68.5, 290/27, 290/28, 290/34, 290/36.R, 290/38.R, 290/40.R, 621/34, 621/48, 624/51
• US Class Current: 363/141
• CPC Class Codes: B60H 1/00271 HVAC devices specially adapted for particular vehicle parts or components and being connected to the vehicle HVAC unit
• CPC Class Codes: B60H 1/00278 for the battery arrangement of batteries B60R16/04
• CPC Class Codes: B60H 1/00378 for tractor or load vehicle cabins
• CPC Class Codes: B60L 1/02 to electric heating circuits
• CPC Class Codes: B60L 2210/20 AC to AC converters
• CPC Class Codes: B60L 58/25 by controlling the electric load
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility

Abstract

A system for supplying electrical power for use when the vehicle engine is shut down and configurations of long-haul trucks employing the system are disclosed. The power system is a battery bank contained within an insulated enclosure. The batteries are heated when the truck is in operation with the insulated enclosure maintaining battery temperature sufficient to provide high battery power capacity for an extended period after the vehicle is shut down. A large capacitor, rather than the batteries, provides current for starting the vehicle engine. A dc-to-dc converter controls the fully charged capacitor voltage and provides capacitor charging current even when the batteries have been discharged to a low-voltage condition. The disclosed long-haul truck configurations include a storage cooler that employs a phase-change medium that is thermally charged to a low temperature while the truck is in operation and is used to provide sleeper unit cooling air. Additional provision is made for heating the sleeper unit and for powering a coolant heater that can warm the truck engine block and truck fuel when the engine is shut down during cold weather.

Claims

1. An electrical power system for use in a vehicle that includes an engine equipped with a starter motor and an alternator for supplying electrical current while the vehicle engine is in operation, said electrical power system being operable for supplying power to equipment that is contained in the vehicle and that requires power during periods of time during which the vehicle engine is shut down, said electrical power system comprising:

an insulated enclosure;

a set of one or more batteries contained within said insulated enclosure;

an electrical heating element contained within said insulated enclosure for maintaining the temperature of said set of batteries at or near a predetermined temperature while the vehicle engine is in operation; and

circuitry for sensing the temperature of said set of batteries and for selectively supplying electrical power from the alternator of the vehicle to said electrical heating element when the vehicle engine is in operation, said circuitry supplying said electrical power from the vehicle alternator when the temperature of said set of batteries is below said predetermined temperature and interrupting the supply of electrical power from the vehicle alternator when the temperature of said set of batteries reaches said predetermined temperature.

2. The electrical power system of claim 1 wherein said circuitry for sensing the temperature of said set of batteries includes a temperature sensor in contact with at least one battery terminal of said set of batteries and a switching element for receiving electrical current from the vehicle alternator, said switching element electrically connecting current from the vehicle alternator to said electrical heating element when said temperature sensor indicates battery temperature below said predetermined temperature and interrupting the current from the vehicle alternator when said temperature sensor indicates that said battery temperature is at said predetermined temperature.

3. The electrical power system of claim 2 wherein said switching element is a relay and wherein said circuitry for sensing the temperature of said set of batteries includes circuitry for receiving a signal supplied by said temperature sensor and for energizing said relay when said temperature sensor indicates battery temperature below said predetermined temperature.

4. The electrical power system of claim 3 wherein the vehicle includes a voltage regulator connected to the vehicle alternator for establishing the voltage supplied to said set of batteries when the vehicle engine is in operation and wherein said circuitry for energizing said relay is included in the vehicle voltage regulator.

5. The electrical power system of claim 2 wherein the vehicle is equipped with dc power devices that are operable when the vehicle engine is not in operation and wherein said electrical power system further comprises a low voltage disconnect unit for disconnecting said set of batteries from at least a portion of the dc power devices when the terminal voltage of said set of batteries is at a first predetermined terminal voltage.

6. The electrical power system of claim 5 wherein said low voltage disconnect unit disconnects said set of batteries from at least a portion of said dc power devices when the terminal voltage of said set of batteries remains at or below a second predetermined terminal voltage for a predetermined period of time, said second predetermined terminal voltage being greater than said first predetermined terminal voltage and being less than the terminal voltage of said second set of batteries when said set of batteries is fully charged.

7. The electrical power system of claim 5 wherein the vehicle is equipped with ac powered devices that are operable when the vehicle engine is not in operation and wherein said electrical power system further comprises an inverter unit, said inverter unit being connected for receiving dc current from said set of batteries and for supplying ac power to said ac power devices.

8. The electrical power system of claim 2 wherein said electrical heating element is a resistive sheet material that exhibits flexibility that allows said resistive sheet material to be wrapped about said set of batteries.

9. The electrical power system of claim 1 further comprising a capacitor capable of storing electrical energy sufficient for powering the vehicle starter motor through a plurality of vehicle start cycles.

10. The electrical power system of claim 9 further comprising a dc-to-dc converter connected to said capacitor and to said set of batteries, said dc-to-dc converter having a predetermined output voltage for establishing the fully charged potential of said capacitor at a predetermined target voltage.

11. The electrical power system of claim 10 wherein said predetermined target voltage of said capacitor is less than the maximum output voltage of the vehicle alternator and is greater than the voltage of said set of batteries when the batteries are in a state of discharge.

12. The electrical power system of claim 11 wherein said dc-to-dc converter is an up/down converter operable to down covert the output voltage of the vehicle alternator to said target voltage of said capacitor when the vehicle alternator output voltage exceeds said capacitor target voltage, said up/down converter being further operable to up convert the voltage supplied by said set of batteries to said capacitor target voltage when the vehicle engine is shut down and the terminal voltage of said set of batteries is less than said capacitor target voltage.

13. The electrical power system of claim 12 further comprising circuitry for monitoring the dc current being supplied to said capacitor and de-energizing said dc-to-dc converter when the current is at a level that indicates that the capacitor is at said capacitor target voltage and for energizing said dc-to-dc converter when the capacitor terminal voltage falls below said capacitor target voltage.

14. The electrical system of claim 13 wherein said circuitry for monitoring the dc current being supplied to said capacitor and de-energizing said dc-to-dc converter is included in said dc-to-dc converter.

15. The electrical power system of claim 8 further comprising a capacitor capable of storing electrical energy sufficient for powering the vehicle starter motor through a plurality of vehicle start cycles.

16. The electrical power system of claim 15 further comprising a dc-to-dc converter connected to said capacitor and to said set of batteries, said dc-to-dc converter having a predetermined output voltage for establishing the fully charged potential of said capacitor at a predetermined target voltage.

17. The electrical power system of claim 16 wherein said predetermined target voltage of said capacitor is less than the maximum output voltage of the vehicle alternator and is greater than the voltage of said set of batteries when the batteries are in a state of discharge.

18. The electrical power system of claim 17 wherein said dc-to-dc converter is an up/down converter operable to down covert the output voltage of the vehicle alternator to said target voltage of said capacitor when the vehicle alternator output voltage exceeds said capacitor target voltage, said up/down converter being further operable to up convert the voltage supplied by said set of batteries to said capacitor target voltage when the vehicle engine is shut down and the terminal voltage of said set of batteries is less than said capacitor target voltage.

19. The electrical power system of claim 18 further comprising circuitry for monitoring the dc current being supplied to said capacitor and de-energizing the dc-to-dc converter when the current is at a level that indicates that the capacitor is at said capacitor target voltage and for energizing said dc-to-dc converter when the capacitor terminal voltage falls below said capacitor target voltage.

20. In a long-haul truck of the type that includes a sleeper unit and an engine having a starter motor and an alternator, the improvement comprising:

an electrical power system for supplying power when the engine of said long-haul truck is shut down, said electrical power system including a plurality of batteries connected in parallel with one another, said batteries being contained within an insulated enclosure and being thermally charged to a predetermined temperature when said long-haul truck is in operation; and

a cooling unit for supplying cooling air to said sleeper unit when said engine is shut down, said cooling unit including a phase change media that is thermally charged to a low temperature when said long-haul truck is in operation, said cooling unit further including a blower motor powered by said electrical power system when said cooling air is being supplied to said sleeper unit.

21. The long-haul truck of claim 20 wherein the improvement further comprises a capacitor electrically connected to the truck starter motor, said capacitor being capable of storing electrical energy sufficient for powering the starter motor through a plurality of engine start cycles without the starter motor being supplied electrical current from said plurality of batteries.

22. The improvement of claim 20 wherein said electrical power system includes a heating element for thermally charging said plurality of batteries to said predetermined temperature, said heating element being a resistive sheet material at least partially encompassing said plurality of batteries, said resistive sheet material being connected for receiving current supplied by the alternator of the long-haul truck when the long-haul truck is in operation.

23. The improvement of claim 22 wherein said electrical power system further comprises circuitry for sensing the temperature of said plurality of batteries, said circuitry including a temperature sensor positioned to sense the temperature of at least one battery of said plurality of batteries and a switching element for receiving current from the vehicle alternator, the switching element electrically connecting current from the vehicle alternator to said heating element when said temperature sensor indicates a battery temperature below said predetermined temperature and for interrupting the current from the vehicle alternator when said temperature sensor indicates that said battery temperature is at said predetermined temperature.

24. The improvement of claim 23 wherein said electrical power system further comprises an over temperature switch positioned to sense the temperature of said heating element, said over temperature switch interrupting current flow to said heating element in the event the temperature of said heating element exceeds a predetermined value.

25. The improvement of claim 21 wherein said electrical power system further comprises a dc-to-dc converter connected to said capacitor and to said plurality of batteries, said dc-to-dc converter having a predetermined output voltage for establishing the fully charged potential of said capacitor at a predetermined target voltage.

26. The improvement of claim 25 wherein said predetermined target voltage of said capacitor is less than the maximum output voltage of the alternator of the long-haul truck and is greater than the voltage of said plurality of batteries when the batteries are in a state of discharge.

27. The improvement of claim 26 wherein said dc-to-dc converter is an up/down converter operable to down convert the output voltage of the long-haul truck alternator to said target voltage of said capacitor when the long-haul truck alternator output voltage exceeds said capacitor target voltage, said up/down converter being further operable to up convert the voltage supplied by said set of batteries to said capacitor target voltage when the engine of the long-haul truck is shut down and the terminal voltage of said plurality of batteries is less than said capacitor target voltage.

28. The long-haul truck of claim 23 wherein the improvement further comprises a capacitor electrically connected to the truck starter motor, said capacitor being capable of storing electrical energy sufficient for powering the starter motor through a plurality of engine start cycles without the starter motor being supplied electrical current from said plurality of batteries.

29. The improvement of claim 28 wherein said electrical power system further comprises a dc-to-dc converter connected to said capacitor and to said plurality of batteries, said dc-to-dc converter having a predetermined output voltage for establishing the fully charged potential of said capacitor at a predetermined target voltage.

30. The improvement of claim 29 wherein said predetermined target voltage of said capacitor is less than the maximum output voltage of the alternator of the long-haul truck and is greater than the voltage of said plurality of batteries when the batteries are in a state of discharge.

31. The improvement of claim 30 wherein said dc-to-dc converter is an up/down converter operable to down convert the output voltage of the long-haul truck alternator to said target voltage of said capacitor when the long-haul truck alternator output voltage exceeds said capacitor target voltage, said up/down converter being further operable to up convert the voltage supplied by said set of batteries to said capacitor target voltage when the engine of the long-haul truck is shut down and the terminal voltage of said plurality of batteries is less than said capacitor target voltage.