Using a DC or AC generator as a starter with fault detection

• US 9,719,477 B2
• Filed: 12/09/2013
• Issued: 08/01/2017
• Est. Priority Date: 12/09/2013
• Status: Active Grant

• Current Assignee: Textron Inc
• Original Assignee: Textron Inc
• Inventors: Iyasere, Osahenrhunwen Erhun, Harper, Joseph Lowell
• Primary Examiner(s): LATHERS, KEVIN ANTHONY
• Application Number:
  US14/100,481
• Publication Number:
  US 20150159614A1
• Time in Patent Office: 1,331 Days
• Field of Search: 12317928
• CPC Class Codes: B60K 2006/268 Electric drive motor starts the engine, i.e. used as starter motor
• CPC Class Codes: B60K 6/46 Series type
• CPC Class Codes: B60L 2260/26 Transition between different drive modes
• CPC Class Codes: B60L 3/0061 relating to electrical machines
• CPC Class Codes: B60L 50/10 using propulsion power supplied by engine-driven generators, e.g. generators driven by combustion engines
• CPC Class Codes: B60W 20/50 Control strategies for responding to system failures, e.g. for fault diagnosis, failsafe operation or limp mode
• CPC Class Codes: B60W 2510/0638 Engine speed
• CPC Class Codes: B60W 2510/0657 Engine torque
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• CPC Class Codes: F02N 11/0851 characterised by means for controlling the engagement or disengagement between engine and starter, e.g. meshing of pinion and engine gear
• CPC Class Codes: F02N 11/0862 characterised by the electrical power supply means, e.g. battery
• CPC Class Codes: Y02T 10/62 Hybrid vehicles
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors

Abstract

A power generation and starting device for a utility vehicle having a battery source capable of storing electrical energy, a logic/driver module operably coupled to the battery source and capable of outputting power to a drive system of the utility vehicle, an internal combustion engine capable of outputting a mechanical driving force, and a generator system operably coupled to the internal combustion engine and electrically coupled to the logic/driver module. The generator system is capable of operating as a generator in response to the mechanical driving force of the internal combustion engine, thereby outputting electrical energy to the logic/driver module. The generator is further capable of operating as an electric motor in response to input of electrical energy from the logic/driver module to drive the internal combustion engine during startup of the internal combustion engine.

Claims

1. A power generation and starting system for a utility vehicle, said system comprising:

a battery source structured and operable to store electrical energy;

a logic/driver module operably coupled to said battery source, said logic/driver module structured and operable to output electrical energy to a drive system of the utility vehicle;

an internal combustion engine structured and operable to output a mechanical driving force; and

a generator operably coupled to said internal combustion engine and electrically coupled to said logic/driver module, said generator being structured and operable as a generator in response to said mechanical driving force of said internal combustion engine, thereby outputting electrical energy to said logic/driver module, said generator further being structured and operable to as an electric motor in response to input of electrical energy from said logic/driver module to drive said internal combustion engine during a starting sequence of said internal combustion engine, wherein

the logic/driver module is further structured and operable to detect potential operational failures of the internal combustion engine by monitoring a current draw of said generator during the starting sequence and terminating the starting sequence in response to detecting the current draw of said generator is outside a predetermined range, the current draw of said generator being outside of the predetermine range;

in an instance in which the current draw of said generator is less than a minimum value of the predetermined range of current draw, a current draw less than the minimum value being indicative of a potential operational failure of the internal combustion engine, and

in an instance in which the current draw of said generator is greater than a maximum value of the predetermined range of current draw, a current draw greater than the maximum value being indicative of a potential operational failure of the internal combustion engine.

2. The power generation and starting system according to claim 1 wherein said logic/driver module is structured and operable to output electrical energy to said generator to drive said internal combustion engine to a first predetermined revolutions per unit of time, said logic/driver module further being structured and operable to detect said internal combustion engine is at a second predetermined revolutions per unit of time that is greater than said first predetermined revolutions per unit of time whereby said logic/driver module ceases said outputting electrical energy to said generator.

3. The power generation and starting system according to claim 2 wherein said logic/driver module enables said generator to freely spin with said internal combustion engine following detection of said second predetermined revolutions per unit of time.

4. The power generation and starting system according to claim 1 wherein said logic/drive module controls the output of electrical energy by said battery source and the receipt of electrical energy by said battery source.

5. The power generation and starting system according to claim 1 wherein said internal combustion engine is responsive to a control input from said logic/driver module.

6. The power generation and starting system according to claim 1 wherein said generator is operably coupled to said internal combustion engine via a mechanical coupler.

7. The power generation and starting system according to claim 1 wherein said generator is an AC induction motor.

8. The power generation and starting system according to claim 1 wherein said generator is a brushless DC motor.

9. The power generation and starting system according to claim 1 wherein said generator is a frameless generator.

11. The power generation and starting system according to claim 1, wherein the potential engine operational failure is selected from the group consisting of a broken shaft and a broken rod.

12. The power generation and starting system according to claim 1, wherein the potential operational failure is selected from the group consisting of the internal combustion engine being seized and an obstruction preventing rotation of the internal combustion engine.

10. A method for starting an internal combustion engine of a utility vehicle, the utility vehicle comprising a battery source, the internal combustion engine, a generator mechanically coupled to the internal combustion engine, and a logic/drive module electrically and communicatively coupled to the battery source, the internal combustion engine and the generator, said method comprising:

initiating a starting sequence of the internal combustion engine by providing electrical energy from the battery source to the generator, via the logic/driver module, such that the generator rotates the internal combustion engine;

monitoring the current draw of the generator during the starting sequence, via the logic/driver module;

monitoring the rotational speed of the internal combustion engine during the starting sequence, via the logic/driver module; and

detecting potential operational failures of the internal combustion engine and terminating the starting sequence, via the logic/drive module, in response to detecting the current draw of the generator is outside a predetermined range, wherein the current draw is detected to be outside the predetermined range;

in an instance in which it is detected that the current draw of the generator is less than a minimum current draw value of the predetermined range, a current draw less than the minimum value being indicative of a potential operational failure of the internal combustion engine; and

in an instance in which it is detected that the current draw of the generator is greater than a maximum current draw value of the predetermined range, a current draw greater than the maximum value being indicative of a potential operational failure of the internal combustion engine.