System and methods for improved starting of combustion engines

• US 9,803,609 B2
• Filed: 04/21/2015
• Issued: 10/31/2017
• Est. Priority Date: 04/22/2014
• Status: Active Grant

• Current Assignee: UCAP Power, Inc.
• Original Assignee: Maxwell Technologies Incorporated (Tesla Inc.)
• Inventors: Setterberg, Ulf Carl Mikael, Cowperthwaite, Jeremy Michael, Brakley, Jeff
• Primary Examiner(s): Tso, Edward
• Assistant Examiner(s): Omar, Ahmed
• Application Number:
  US14/692,116
• Publication Number:
  US 20150300307A1
• Time in Patent Office: 924 Days
• Field of Search: 320104, 320166
• CPC Class Codes: F02N 11/04 the motors being associated with current generators
• 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 2011/0885 Capacitors, e.g. for additional power supply
• CPC Class Codes: F02N 2011/0888 DC/DC converters
• CPC Class Codes: F02N 2200/063 Battery voltage
• CPC Class Codes: H02J 1/10 Parallel operation of dc sources
• CPC Class Codes: H02J 7/1423 with multiple batteries
• CPC Class Codes: H02J 7/34 Parallel operation in networks using both storage and other dc sources, e.g. providing buffering H02J7/14 takes precedence

Abstract

This disclosure provides systems, methods and apparatus for a engine start system. In one aspect, the engine start system includes: a booster battery selectively connected in parallel with the primary batteries of the engine. The booster battery is disconnected when the battery voltage of the primary batteries is below a first target voltage. The booster battery is connected when the battery voltage of the primary batteries is at or above the second target voltage, or in response to an external input.

Claims

1. An engine start system, comprising:

a capacitor system comprising one or more capacitors;

one or more booster batteries connected in parallel with the capacitor system, the one or more booster batteries configured to be connected in parallel with a primary battery system of an engine;

a switch connected to the one or more booster batteries and configured to selectively control electrical communication between the one or more booster batteries and the primary battery system; and

a controller configured to detect a battery voltage of the primary battery system, the controller configured to;

move the switch to an open state and disconnect the one or more booster batteries from the primary battery system when the battery voltage is below a first target voltage;

move the switch from the open state to a closed state and connect the one or more booster batteries to the primary battery system when the battery voltage is at or above a second target voltage, and in response to an external input; and

after a predetermined period of time, return the switch from the closed state to the open state if the battery voltage is below the second target voltage, or maintain the switch in the closed state if the battery voltage is at or above the second target voltage.

2. The system of claim 1, wherein the first target voltage corresponds to a value of the battery voltage when the primary battery system is not being charged by an external power supply.

3. The system of claim 2, further comprising the external power supply, wherein the external power supply comprises a vehicle alternator.

4. The system of claim 1, wherein the second target voltage is between or including the approximate open circuit voltage of the primary battery system and the approximate output voltage of an alternator for a vehicle.

5. The system of claim 1, wherein the predetermined period of time is within a range of approximately 10 to 600 seconds.

6. The system of claim 1, wherein the predetermined period of time is determined based on a load of an electrical system of the engine start system.

7. The system of claim 1, wherein the external input comprises a user-activated switch.

8. The system of claim 1, wherein the first target voltage and second target voltage are approximately the same voltage.

9. The system of claim 1, wherein the first target voltage is greater than a voltage sufficient to activate a starter for an internal combustion engine.

10. The system of claim 1, further comprising at least one sensor configured to detect the battery voltage, the sensor configured to communicate the battery voltage to the controller.

11. The system of claim 1, further comprising an energy storage system, wherein the energy storage system comprises the capacitor system and the controller.

12. The system of claim 1 wherein the switch comprises one or more of a contactor, relay, DC/DC converter or transistor.

13. The system of claim 1, further comprising the primary battery system.

14. The system of claim 13, wherein the primary battery system is connected to a critical load of a vehicle.

15. A vehicle comprising the engine start system of claim 13.

16. A method of operating an engine start system, comprising:

providing one or more booster batteries connected in parallel with a capacitor system and a primary battery system;

detecting a battery voltage of the primary battery system;

disconnecting the one or more booster batteries from the primary battery system when the battery voltage is below a first target voltage;

connecting the one or more booster batteries to the primary battery system when the primary battery voltage is at or above a second target voltage, or in response to an external input;

disconnecting the one or more booster batteries from the primary battery system in response to the external input; and

after a predetermined period of time, disconnecting the one or more booster batteries from the primary battery system if the battery voltage is below the second target voltage, or connecting and maintaining the connection between the one or more booster batteries and the primary battery system if the battery voltage is at or above the second target voltage.

17. The method of claim 16, further comprising applying an external power from an external power source to the booster batteries and the primary battery system.

18. The method of claim 17, wherein applying an external power comprises applying external power from an alternator.

19. The method of claim 17, wherein the first target voltage corresponds to a value of the battery voltage when the external power is not applied.

20. The method of claim 16, wherein the second target voltage corresponds to a value between and including the approximate open circuit voltage of the primary battery system and the approximate output voltage of an alternator for a vehicle.

21. The method of claim 16, wherein the predetermined period of time is within a range of approximately 10 to 600 seconds.

22. The method of claim 16, wherein the predetermined period of time is determined based on a load of an electrical system of an engine.

23. The method of claim 16, wherein the external input comprises a user-activated switch.

24. The method of claim 16, wherein the first target voltage and second target voltage are approximately the same voltage.

25. The method of claim 16, wherein the first target voltage is greater than a voltage sufficient to activate a starter for an engine.

26. The method of claim 16, wherein detecting comprises detecting the battery voltage with a sensor and communicating the battery voltage to a controller.

27. The method of claim 16, wherein disconnecting and connecting comprise controlling one or more of a contactor, relay, DC/DC converter or transistor.

28. The method of claim 16, wherein disconnecting and connecting comprise controlling a switch connected between the one or more booster batteries and the primary battery system.

29. The method of claim 28, wherein controlling the switch comprises providing a control signal to the switch from an energy storage system, wherein the energy storage system comprises the capacitor system.