WO2016075616A2 - Aid module for electrically starting an internal combustion engine - Google Patents

Aid module for electrically starting an internal combustion engine Download PDF

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Publication number
WO2016075616A2
WO2016075616A2 PCT/IB2015/058664 IB2015058664W WO2016075616A2 WO 2016075616 A2 WO2016075616 A2 WO 2016075616A2 IB 2015058664 W IB2015058664 W IB 2015058664W WO 2016075616 A2 WO2016075616 A2 WO 2016075616A2
Authority
WO
WIPO (PCT)
Prior art keywords
accumulator
battery pack
processing
controlling unit
vehicle
Prior art date
Application number
PCT/IB2015/058664
Other languages
French (fr)
Other versions
WO2016075616A3 (en
Inventor
Guglielmo De Rosa
Original Assignee
Awelco Inc. Production S.P.A.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Awelco Inc. Production S.P.A. filed Critical Awelco Inc. Production S.P.A.
Publication of WO2016075616A2 publication Critical patent/WO2016075616A2/en
Publication of WO2016075616A3 publication Critical patent/WO2016075616A3/en

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Classifications

    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • F02N11/08Circuits or control means specially adapted for starting of engines
    • F02N11/0862Circuits or control means specially adapted for starting of engines characterised by the electrical power supply means, e.g. battery
    • F02N11/0866Circuits or control means specially adapted for starting of engines characterised by the electrical power supply means, e.g. battery comprising several power sources, e.g. battery and capacitor or two batteries
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01RMEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/36Arrangements for testing, measuring or monitoring the electrical condition of accumulators or electric batteries, e.g. capacity or state of charge [SoC]
    • G01R31/3644Constructional arrangements
    • G01R31/3647Constructional arrangements for determining the ability of a battery to perform a critical function, e.g. cranking
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • F02N11/04Starting of engines by means of electric motors the motors being associated with current generators
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • F02N11/08Circuits or control means specially adapted for starting of engines
    • F02N11/087Details of the switching means in starting circuits, e.g. relays or electronic switches
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • F02N11/12Starting of engines by means of mobile, e.g. portable, starting sets
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00Starting of engines by means of electric motors
    • F02N11/14Starting of engines by means of electric starters with external current supply
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/04Parameters used for control of starting apparatus said parameters being related to the starter motor
    • F02N2200/046Energy or power necessary for starting
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/06Parameters used for control of starting apparatus said parameters being related to the power supply or driving circuits for the starter
    • F02N2200/061Battery state of charge [SOC]
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/06Parameters used for control of starting apparatus said parameters being related to the power supply or driving circuits for the starter
    • F02N2200/062Battery current
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/06Parameters used for control of starting apparatus said parameters being related to the power supply or driving circuits for the starter
    • F02N2200/063Battery voltage
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/06Parameters used for control of starting apparatus said parameters being related to the power supply or driving circuits for the starter
    • F02N2200/064Battery temperature
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00Parameters used for control of starting apparatus
    • F02N2200/12Parameters used for control of starting apparatus said parameters being related to the vehicle exterior
    • F02N2200/122Atmospheric temperature
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02NSTARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2250/00Problems related to engine starting or engine's starting apparatus
    • F02N2250/02Battery voltage drop at start, e.g. drops causing ECU reset
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0047Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with monitoring or indicating devices or circuits
    • H02J7/0048Detection of remaining charge capacity or state of charge [SOC]
    • H02J7/0049Detection of fully charged condition
    • HELECTRICITY
    • H02GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02JCIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries
    • H02J7/0047Circuit arrangements for charging or depolarising batteries or for supplying loads from batteries with monitoring or indicating devices or circuits
    • H02J7/005Detection of state of health [SOH]

Definitions

  • the present invention concerns an aid module for electrically starting an internal combustion engine, that allows in a reliable, effective, simple and inexpensive way, that is comfortable for the user, to ensure the availability of electric current necessary to start an internal combustion engine of a motor vehicle even when the accumulator of the vehicle is discharged or inefficient.
  • the invention is illustrated with reference to an application of the aid module according to the invention to a motor vehicle, such as a motor vehicle intended to transport people or goods such as a car or a truck.
  • the aid module may be applied to electrically start internal combustion engines of whatever motor vehicle, for instance including motorcycles and boats, still remaining within the scope of the present invention.
  • starters which are usually electric starter, provided with an electric motor that is supplied by the accumulator of the motor vehicle that is connected to the electrical network of the latter to which electrical loads (such as lighting lamps and possible electronic equipments) of the vehicle are also connected.
  • electrical loads such as lighting lamps and possible electronic equipments
  • motorcycles also use an electric starter that, in the last decades, has replaced the traditional mechanical starter, and also many boats, especially large size ones, use electric starters.
  • a current generator (based on an alternator) converts (part of) the mechanical energy of the internal combustion engine into electric energy, recharging the accumulator of the vehicle through the electrical network of the latter and directly supplying at least part of the electrical loads of the vehicle; in this regard, the electrical loads of the vehicle are usually protected by valves or fuses.
  • the accumulator may be inefficient to start the internal combustion engine, i.e. it may be not capable to provide the energy (i.e. the electric current) necessary to the electric starter, because it is e low or maintenance of the same accumulator or of the electrical network has been neglected.
  • the accumulator may be low because the current generator is faulty or defective and during normal operation of the internal combustion engine it is not capable to recharge the accumulator, that hence discharges while supplying all the electrical loads of the vehicle, or because during a long stay, when the internal combustion engine is off, the user leaves some electrical loads of the vehicle operating and, hence, supplied by the accumulator, as it happens for instance in the case where the user parks a motor vehicle leaving the headlights on.
  • a lack of proper maintenance of the accumulator may lead to an interruption of one of the cells with which the accumulator is provided, while a lack of maintenance of the electrical network of the vehicle may cause, during a long stay wherein the internal combustion engine is off, a possible current leakage of the electrical network of the vehicle to discharge the accumulator and/or to prevent the accumulator from providing the energy necessary to the electric starter.
  • an object of the present invention to allow in a reliable, effective, simple and inexpensive way that is comfortable for the user, to ensure the availability of electric current necessary to start an internal combustion engine of a motor vehicle even when the accumulator of the vehicle is discharged or inefficient.
  • an aid module for electrically starting an internal combustion engine of a motor vehicle comprising a battery pack having a positive terminal, that is connected to power switching means in turn configured to be connected to a positive terminal of an accumulator of a vehicle, and a negative terminal configured to be connected to a negative terminal of the accumulator, wherein said power switching means is configured to selectively connect the positive terminal of the battery pack to a positive terminal of the accumulator of the vehicle under the control of a processing and controlling unit, the aid module further comprising sensing means connected to the battery pack and to the processing and controlling unit and configured to be connected to the positive terminal of the accumulator, wherein said sensing means is configured to make detections of an operational state of the battery pack, as well as of the operational state of the accumulator and of a current generator configured to be actuated by the internal combustion engine of the vehicle, wherein said sensing means is configured to provide the processing and controlling unit with the detections made, wherein the processing and controlling unit is configured to recognise, on the basis
  • the processing and controlling unit is configured to control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator, whereby the battery pack provides the current necessary to the electric starter of the vehicle, and
  • the processing and controlling unit is configured to control said power switching means so as to partly derive a current generated by the current generator towards the positive terminal of the battery pack, whereby the battery pack is recharged.
  • said sensing means may be selected from the group comprising voltage sensors, wherein at least one voltage sensor is optionally made through a connection of a circuit node to a voltage input of the processing and controlling unit, and current sensors.
  • said sensing means may be configured to be connected to one or more with which the vehicle is provided configured to detect an operational state of the accumulator and/or of the current generator, whereby said sensing means comprises one or more connections from outputs of said one or more sensors with which the vehicle is provided to voltage inputs of the processing and controlling unit or comprises an interface of connection to a CAN bus of the vehicle configured to transmit information related to an operational state of the accumulator and/or of the current generator to digital inputs of the processing and controlling unit.
  • said sensing means may be configured to make detections of an ambient temperature to provide the processing and controlling unit with the temperature detections made, the processing and controlling unit being configured to activate heating means for heating the battery pack when the detected temperature is lower than a minimum threshold.
  • the battery pack may comprise a plurality of lithium cells.
  • the battery pack may comprise a plurality of N main cells and one or more backup cells, each one of said N main cells and of said one or more backup cells being provided with a respective switch configured connect in series the respective cell between the positive and negative terminals of the battery pack or to disconnect the respective cell from the positive and negative terminals of the battery pack, wherein the voltage across the positive and negative terminals of the battery pack is equal to a nominal voltage of the accumulator when N operating cells selected from the group comprising said N main cells and said one or more backup cells are connected in series, wherein a current sensor and a voltage sensor are associated to each one of said N main cells and of said one or more backup cells configured to make detections of an operational state of the respective cell, the processing and controlling unit being configured to receive the detections of the current sensor and of the voltage sensor associated to each one of said N main cells and of said one or more backup cells and to identify, on the basis of them, operating cells and defective cells, the processing and controlling unit being configured to control the switches with which said N main cells
  • the module may further comprise a photovoltaic cell unit configured to generate electric energy, to which said sensing means are also connected which are configured to make detections of its operational state and to provide the processing and controlling unit with such detections, the photovoltaic cell unit being connected to said power switching means, the processing and controlling unit being configured to recognise, on the basis of the received detections of the operational state of the photovoltaic cell unit, when the photovoltaic cell unit delivers electric energy so as to control said power switching means such that the photovoltaic cell unit recharges the battery pack or, when the latter is fully charged, the accumulator.
  • a photovoltaic cell unit configured to generate electric energy
  • said sensing means are also connected which are configured to make detections of its operational state and to provide the processing and controlling unit with such detections
  • the photovoltaic cell unit being connected to said power switching means
  • the processing and controlling unit being configured to recognise, on the basis of the received detections of the operational state of the photovoltaic cell unit, when the photovoltaic cell unit delivers electric energy so as
  • the processing and controlling unit may be connected to a visual and/or acoustic signalling unit, comprising a display and/or a buzzer, wherein the processing and controlling unit is configured to control the signalling unit so as to provide information about the operational state of the accumulator and/or of the aid module and/or of the current generator.
  • said power switching means may comprise:
  • a first three-terminal power switch module one of which is a gate terminal controlling the operation of the same first switch module
  • first switch module is connected in series to the battery pack and the second switch module is connected, through the first switch module, in series to the battery pack and is configured to be connected in series to a parallel connection between current generator and accumulator of the vehicle, wherein said sensing means may comprise:
  • a first current transducer configured to measure a first current entering or exiting from the accumulator
  • a second current transducer configured measure a second current entering or exiting from the battery pack and flowing through the first switch module
  • connection to a circuit node interposed between the first and the second switch modules and that provides a voltage at the positive terminal of the battery pack, and a connection configured to be connected to the positive terminal of the accumulator of the vehicle,
  • the processing and controlling unit receives detections of the voltage at the positive terminal of the battery pack, of the voltage at the accumulator, of the first current and of the second current, the processing and controlling unit being configured to control, on the basis of such detections, the first switch module and the second switch module, through the respective gate terminals, so that the first switch module is configured to let current flow from the battery pack to the accumulator when the first switch module receives an enable signal at its gate terminal, and that the second switch module is configured to let the second portion of the current flow towards battery pack when it receives an enable signal at its gate terminal.
  • the processing and controlling unit may be supplied by the battery pack or by a dedicated battery or is configured to be supplied by the current generator or by the accumulator of the vehicle.
  • the processing and controlling unit may comprise a the microprocessor.
  • said sensing means may be further connected to said power switching means and may be configured to make detections of an operational state of said power switching means and to provide the processing and controlling unit with such detections, the processing and controlling unit being configured to control said power switching means also in function of such detections, optionally compensating a possible deterioration or inefficiency of said power switching means.
  • the processing and controlling unit may be configured to recognise that, when during an attempt of electrically starting the internal combustion engine a voltage across the accumulator drops in a range of reduction at starting by at least one first percentage reduction threshold with respect to a voltage across the accumulator before the attempt of starting, the accumulator is not capable to deliver the current necessary to the electric starter of the vehicle, wherein the processing and controlling unit is optionally configured to control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator only in the case where it recognises that the accumulator is not capable to deliver the current necessary to the electric starter of the vehicle after a second attempt of electrically starting the internal combustion engine out of two consecutive attempts distant by not more than a predetermined time range, more optionally not longer than 20 seconds.
  • the module may further comprise a button connected to the processing and controlling unit, wherein the processing and controlling unit is configured to recognise that, when the button is operated, the accumulator is not capable to deliver the current necessary to the electrical starter of the vehicle, and to recognise that an attempt of starting the internal combustion engine is in progress when the detections received from said sensing means detects a change of the load connected to the battery pack and the processing and controlling unit is configured to consequently control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator, whereby the battery pack delivers the current necessary to the electric starter of the vehicle, wherein the processing and controlling unit is optionally configured to consequently control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator so as to make the battery pack deliver a limited initial current, more optionally equal to 10 Amperes, for a preliminary time range, more optionally equal to 1 minute, starting from the instant when the button is operated.
  • the processing and controlling unit is configured to recognise that, when the button is operated
  • an accumulator comprising a plurality of housings, each housing being configured to house a cell, wherein one of said housings houses an aid module as previously described, each of the other housings housing a respective cell.
  • the present invention concerns an aid module for electrically starting an internal combustion engine that is configured to detect that, during an attempt of starting the internal combustion engine, the accumulator of the vehicle cannot provide the energy necessary to the electric starter, whereby in this case the aid module delivers the electric current necessary to the electric starter, because the battery pack with which it is provided is optionally capable to deliver a maximum current of at least 200 A, more optionally at least 500 A, still more optionally at least 800 A, even more optionally at least 1000 A, and it optionally has a capacity of at least 7 Ah (Ampere-hour), more optionally at least 20 Ah, still more optionally at least 40 Ah, even more optionally at least 90 Ah, still even more optionally at least 150 Ah.
  • Ah Ampere-hour
  • the aid module according to the invention is configured such that the battery pack with which it is provided is charged during the operation of the internal combustion engine taking part of the current generated by the current generator that recharges also the accumulator of the vehicle and supplies the electrical loads of the vehicle as well; optionally, some embodiments of the aid module according to the invention are portable and the battery pack with which it is provided is rechargeable even through the mains.
  • the aid module according to the invention comprises a special battery pack, advantageously a lithium battery pack, that increases its reliability.
  • some embodiments of the aid module according to the invention increase their reliability by being provided with a battery pack also comprising one or more backup cells capable to automatically replace in real time possible defective cells of the battery pack, thanks to continuous controls of the cell efficiency which allows to ascertain and isolate possible damaged cells to replace with the backup ones.
  • Figure 1 shows a block diagram of a first embodiment of the aid module according to the invention
  • Figure 2 shows a circuit diagram of a second embodiment of the aid module according to the invention
  • Figure 3 shows a circuit diagram of a third embodiment of the aid module according to the invention.
  • Figures 4a and 4b show a battery pack of a third embodiment of the aid module according to the invention in a first and second configuration, respectively.
  • a first embodiment of the aid module according to the invention applied to a vehicle provided with an accumulator 210 having a positive terminal 212 and a negative terminal 214 connected to circuit ground, wherein the terminals 212 and 214 of the accumulator 210 are connected to the electrical network of the vehicle that particularly comprises a switch 220 connecting the positive terminal 212 of the accumulator 210 to the electric starter 240 of the vehicle when the internal combustion engine (not shown) of the vehicle is not yet operating and the user attempts to start the same internal combustion engine
  • the switch 220 is shown in a configuration in which the positive terminal 212 of the accumulator 210 is disconnected from the electric starter 240 of the vehicle); moreover, the positive terminal 212 of the accumulator 210 is connected to the current generator Gl configured to be actuated by the internal combustion engine and, hence, to generate an electric current when the internal combustion engine is operating.
  • the aid module 100 comprises a battery pack 110 the positive terminal 112 of which is connected to power switching means 120 in turn configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle; the negative terminal 114 of the battery pack 110 is configured to be connected to the circuit ground of the electrical network of the vehicle (i.e. to the negative terminal 214 of the accumulator 210 of the vehicle).
  • the battery pack 110 is optionally capable to deliver a maximum current of at least 200 A, more optionally at least 500 A, still more optionally at least 800 A, even more optionally at least 1000 A, and it optionally has a capacity of at least 7 Ah (Ampere-hour), more optionally at least 20 Ah, still more optionally at least 40 Ah, even more optionally at least 90 Ah, still even more optionally at least 150 Ah.
  • the battery pack 110 is formed by a plurality of lithium cells.
  • the power switching means 120 is configured to selectively connect the positive terminal 112 of the battery pack 110 to the positive terminal 212 of the accumulator 210 of the vehicle (and to the current generator Gl) of the vehicle under the control of a processing and controlling unit 130, for instance comprising a the microprocessor.
  • the processing and controlling unit 130 is advantageously supplied by the battery pack 110 (alternatively it could be supplied by an autonomous dedicated battery or even by the accumulator 210 or by the current generator Gl of the vehicle).
  • the aid module 100 further comprises sensing means 140 connected to the battery pack 110 and to the processing and controlling unit 130 and configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle.
  • the sensing means 140 is configured to detect the operational state of the battery pack 110 of the aid module 110, as well as the operational state of the accumulator 210 and of the current generator Gl of the vehicle and to provide the processing and controlling unit 130 with (the signals of) such detections.
  • the sensing means 140 comprises voltage sensors, which may be also made through a simple connection of a specific circuit node to a voltage input of the processing and controlling unit 130 (that is hence configured to read the node voltage through this connection at its own input), and/or current sensors; in particular, the sensing means 140 may be configured to be connected to sensors, already present in the vehicle to which the aid module 100 is applied, for the detection of the operational state of the accumulator 210 and of the current generator Gl of the vehicle, and in this case it may be assumed that the sensing means 140 comprises specific connections from the outputs of such sensors already present in the vehicle to voltage inputs of the processing and controlling unit 130, or it comprises an interface of connection to the CAN bus of the vehicle that transmits specific information related to the operational state of the accumulator 210 and/or of the current generator Gl to corresponding digital inputs of the processing and controlling unit 130.
  • the sensing means 140 comprises voltage sensors, which may be also made through a simple connection of a specific circuit node to a voltage input of the processing and controlling unit
  • the sensing means comprising an interface of connection to the CAN bus of the vehicle also detects other parameters, for instance the ambient temperature (that could be also autonomously detected by the aid module through its own temperature sensor) in order to activate a preliminary heating of the battery pack 110 (heating that is advantageous in the case where the latter comprises lithium cells) and/or of other electronic or mechanical components of the aid module and/or of the vehicle (e.g. the internal combustion engine) through heating means, optionally electrically heating components.
  • aid module may have the sensing means 140 that is further connected to the power switching means 120 and that is configured to detect the operational state of the power switching means 120 and to provide the processing and controlling unit 130 with (the signals of) such detections, such that the processing and controlling unit 130 is configured to control the power switching means 120 also in function of such detections (for instance by compensating a possible deterioration or inefficiency of performance of the power switching means 120).
  • the processing and controlling unit 130 is configured to control the power switching means 120 on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140.
  • the processing and controlling unit 130 is configured to recognise when an attempt of starting the internal combustion engine is in progress and the accumulator 210 is not capable to deliver the current necessary to the electric starter 240 of the vehicle, and in this case it controls the power switching means 120 so as to connect (through the same power switching means 120) the positive terminal 112 of the battery pack 110 to the positive terminal 212 of the accumulator 210 of the vehicle and, consequently, through the switch 220, to the electric starter 240 of the vehicle.
  • the processing and controlling unit 130 is configured to recognise when the internal combustion engine is operating and the current generator Gl of the vehicle properly operates, and in this case it controls the power switching means 120 so as to partly derive the current generated by the current generator Gl towards the positive terminal 112 of the battery pack 110 (the current generated by the generator Gl is partly derived so as not to interfere with the proper operation of the electrical loads which must be in any case also supplied by the generator Gl), whereby the battery pack 110 is recharged by a current limited by the power switching means 120 properly controlled by the processing and controlling unit 130 such that the battery pack 110 does not discharge on the accumulator 210 when the latter is not fully charged.
  • the processing and controlling unit 130 may be configured to control the power switching means 120 so as to partly derive the current generated by the current generator Gl towards the positive terminal of the vehicle (for instance by properly modulating the control of the switching means 120).
  • the battery pack 110 may comprise a plurality of main cells, one or more backup cells, and a switch for each (main or main) cell capable to connect in series or disconnect the respective cell between the positive and negative terminals 112 and 114, so that the voltage across the positive and negative terminals 112 and 114 of the battery pack 110 is equal to the nominal voltage of the accumulator 210 (initially, the cells connected in series are all and only those of the plurality of main cells).
  • the detections i.e.
  • the processing and controlling unit 130 is configured to recognise when a cell among those which are connected in series between the positive and negative terminals 112 and 114 of the battery pack 110 (initially, the cells connected in series are all and only those of the plurality of main cells) and which contribute to the nominal voltage is defective (e.g.
  • the aid module 100 further comprises a photovoltaic cell unit SPl configured to generate electric energy, to which the sensing means 140 is also connected and that is configured to detect its operational state, which photovoltaic cell unit SPl is connected to the power switching means 120; in particular, on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured to recognise when the photovoltaic cell unit SPl is delivering electric energy so as to control the power switching means 120 such that the photovoltaic cell unit SPl recharges the battery pack 110 or, if the latter is fully charged, the accumulator 210.
  • a photovoltaic cell unit SPl configured to generate electric energy, to which the sensing means 140 is also connected and that is configured to detect its operational state, which photovoltaic cell unit SPl is connected to the power switching means 120; in particular, on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured
  • the presence of the photovoltaic cell unit SPl that is useful in the case where the vehicle to which the aid module is applied remains in a stay for a long period (i.e. with the internal combustion engine not operating) or with the current generator Gl not operating, is an optional component, and other embodiments of the aid module according to the invention may be devoid of such a photovoltaic cell unit SP1.
  • the processing and controlling unit 130 is connected to a visual and/or acoustic signalling unit 150, comprising a display (possibly coinciding with a display or dashboard of the vehicle) and/or a buzzer (possibly coinciding with a speaker of the vehicle), wherein the processing and controlling unit 130 is configured to control the signalling unit 150 so as to inform the user about the operational state of the accumulator 210 and/or of the aid module 100, for instance to inform the user that the starting has been possible through the intervention of the aid module 100.
  • a visual and/or acoustic signalling unit 150 comprising a display (possibly coinciding with a display or dashboard of the vehicle) and/or a buzzer (possibly coinciding with a speaker of the vehicle)
  • the processing and controlling unit 130 is configured to control the signalling unit 150 so as to inform the user about the operational state of the accumulator 210 and/or of the aid module 100, for instance to inform the user that the starting has been possible through the intervention of the
  • Figure 2 shows a second embodiment of the aid module according to the invention, indicated with the reference numeral 200, applied to a vehicle the accumulator 210 and the current generator Gl of which are shown.
  • the aid module 200 comprises a first current transducer Al configured to measure a first current entering or exiting from the accumulator 210, and a second current transducer A2 configured to measure a second current entering or exiting from the battery pack 110 of the aid module 200.
  • such first current measured by the first current transducer Al may consist of a fraction of the current generated by the current generator Gl, which fraction enters the accumulator 210 of the vehicle to recharge it when the internal combustion engine and the generator Gl properly operate (in this regard, it is a fraction of the current generated by the current generator Gl, since the whole generated current also supplies the electrical loads of the vehicle and may also recharge the battery pack 110 of the aid module 200), or such first current may consist of the current exiting from the accumulator 210 of the vehicle that is delivered to the electric starter when the internal combustion engine does not yet operate and/or to the electrical loads of the vehicle when the internal combustion engine does not yet operate or the generator Gl does not operate properly;
  • such second current measured by the second current transducer A2 may consist of a fraction of the current generated by the current generator Gl, which fraction enters the battery pack 110 formed by the four cells CI, C2, C3 and C4 to recharge it when the internal combustion engine and the generator Gl operate properly (also in this case
  • the aid module 200 also comprises a photovoltaic cell unit SP1 configured to recharge primarily the four cells CI, C2, C3 and C4 of the battery pack 110 and then, when the cells of the latter are charged, the accumulator 210 of the vehicle.
  • a photovoltaic cell unit SP1 configured to recharge primarily the four cells CI, C2, C3 and C4 of the battery pack 110 and then, when the cells of the latter are charged, the accumulator 210 of the vehicle.
  • the aid module 200 further comprises a first three-terminal power switch module Tl, one of which is the gate terminal Tl-G controlling the operation of the same switch module Tl, wherein the first switch module Tl optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal Tl-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal Tl-G); the first switch module Tl is connected in series to the battery pack 110, whereby the second current transducer A2 is configured to measure the current flowing across the same.
  • the first switch module Tl optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal Tl-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal Tl-G); the first switch module Tl is connected in series to the battery pack 110, whereby the second current transducer A2 is configured to measure
  • the aid module 200 also comprises a second three-terminal power switch module T2, one of which is the gate terminal T2-G controlling the operation of the same switch module T2, wherein the second switch module T2 optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal T2-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal T2-G); the second switch module T2 is connected (indirectly, through the first switch module Tl) in series to the battery pack 110 and is configured to be connected in series to the parallel connection between current generator Gl and accumulator 210 of the vehicle.
  • the second switch module T2 optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal T2-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal T2-G); the second switch module T2 is connected (indirectly, through the first switch module T
  • the processing and controlling unit (indicated with the reference numeral 130 for the aid module of Figure 1) comprises a the microprocessor M, connected to a buzzer SI, that receives all the detections of the operational state of the aid module 200 and of the accumulator 210 and of the current generator Gl which are necessary to the proper control of the aid module 200; namely, such detections concern the voltage of the photovoltaic cell unit SP1, the voltage of the cells CI, C2, C3 and C4 of the battery pack 110, the voltage of the accumulator 210 of the vehicle, the first current detected by the first transducer Al and the second current detected by the second transducer A2.
  • the microprocessor M is configured to control the first switch module Tl and the second switch module T2, through the respective gate terminals Tl-G and T2-G, as well as the buzzer SI, for instance notifying the user that the starting has been possible through the intervention of the aid module 200.
  • the power switching means (indicated with the reference numeral 120 for the aid module of Figure 1) of the aid module 200 of Figure 2 comprise the first and second switch modules Tl and T2
  • the sensing means (indicated with the reference numeral 140 for the aid module of Figure 1) of the aid module 200 of Figure 2 comprise the first and second transducers Al and A2, as well as the connection to the circuit node Nl interposed between the two switch modules Tl and T2 (providing the voltage at the positive terminal 112 of the battery pack 110) and the connection configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle.
  • the first switch module Tl when receiving an enable signal at its own gate terminal Tl-
  • G from the microprocessor M is configured to let the current flow from the four cells CI, C2, C3 and C4 of the battery pack 110 (through the internal diode of the second switch module T2) to the accumulator 210 that, consequently, will be capable to provide the electric starter (not shown) of the internal combustion engine of the vehicle with the current necessary to the starting.
  • the second switch module T2 when receiving an enable signal at its own gate terminal T2-G from the microprocessor M, is configured to let the (second portion of) charging current flow from the current generator Gl (through the internal diode of the first switch module Tl) to the four cells CI, C2, C3 and C4 of the battery pack 110.
  • the microprocessor M constantly monitors the value of the voltage of the accumulator 210 of the vehicle (through the connection to the positive terminal 212) and of the input and output currents of the same accumulator 210 (through the first current transducer Al).
  • a 12 Volt accumulator 210 of a motor vehicle with internal combustion engine off having a charge not sufficient to electrically start the internal combustion engine has a voltage approximately ranging from 3 to 12 Volt.
  • the accumulator 210 has not sufficient energy to start the engine and the voltage across it (i.e. the voltage at the positive terminal 212 with respect to circuit ground) will instantly drop by at least 30% in less than 1 second with respect to the voltage before the attempt of starting.
  • the voltage across it i.e. the voltage at the positive terminal 212 with respect to circuit ground
  • the voltage across it will instantly drop by at least a first (minimum) percentage reduction threshold (that may be different from 30%) with respect to the voltage before the attempt of starting, which first percentage reduction threshold is higher than a second (maximum) percentage reduction threshold that occurs for the voltage across the accumulator when the user attempts to start the internal combustion engine and the accumulator 210 has a charge sufficient to provide the energy necessary to the electric starter (in the case of a 12 Volt accumulator 210 of a car or truck such second percentage reduction threshold is equal to about 20%) in a reduction period at starting that may be different from the period shorter than 1 second (period that is valid for a 12 Volt accumulator 210).
  • the current generator Gl of the vehicle does not deliver any current to the accumulator 210 and the first current transducer Al does not detect any current flow.
  • the microprocessor M is configured to recognise that the vehicle has not been started and, consequently, to enter an alert state. In the case where the user attempts to start again within a predetermined time range (e.g.
  • the voltage of the accumulator 210 reduces again by at least 30% (in the general case such voltage reduces again below the first percentage reduction threshold) with respect to the initial value (ranging from 3 to 12 Volt in the case of accumulator 210 for cars and trucks, initial value to which the voltage of the accumulator 210 is returned at the end of the preceding start attempt) in the reduction period at starting
  • the microprocessor M is configured to recognise that the voltage across the accumulator 210 dropped again by at least 30% (in the general case where such voltage dropped below the first percentage reduction threshold) in a reduction period at starting and to activate, consequently, the first switch module Tl permitting the flow (through the internal diode of the second switch module T2) of the current necessary to the starting from the four cells CI, C2, C3 and C4 of the battery pack 110 to the accumulator 210.
  • the microprocessor M is configured to exit from the alert state (in fact, at the next attempt of starting the accumulator 210 of the vehicle could have been replaced or recharged, whereby it is preferable that the microprocessor M repeats the recognition of the - In efficiency of the accumulator 210).
  • the current generator Gl delivers the current for recharging the accumulator 210 of the vehicle (assuming that the generator Gl operates properly).
  • the microprocessor M is configured to monitor the charge state of the accumulator through the first current transducer Al and the connection to the positive terminal 212 of the accumulator 210 (that provides the voltage thereof).
  • the microprocessor M is advantageously configured to control the buzzer SI notifying the user that the starting has been possible through the intervention of the aid module 200.
  • the first current transducer Al does not detect any current flow
  • the second current transducer A2 continues to detect flow of current (delivered by the battery pack 110) necessary to supply the electrical loads of the vehicle while the internal combustion engine is operating, and, on the basis of such detections of the two current transducers Al and A2, the microprocessor M is advantageously configured to control the buzzer SI notifying the user that the current generator Gl has a malfunction.
  • the microprocessor M is configured to modulate the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2, whereby the microprocessor M is configured to limit the current charging the battery pack 110 so as not to disturb the correct supply to all the electrical loads of the vehicle during the operation of the internal combustion engine and the possible recharge of the accumulator 210.
  • the microprocessor M may be configured to allow the battery pack 110 and the accumulator 210 to be simultaneously recharged, possibly giving priority to recharging the battery pack 110 (which is allowed to receive a higher current through an appropriate control of the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2 and of the detection of the voltage at the positive terminal 112 of the battery pack 110).
  • the microprocessor M could be configured to first allow the accumulator 210 to be fully charged and then the battery pack 110 to be recharged. In this case, only when the microprocessor M recognises that the accumulator 210 is charged (on the basis of the detection of the first input current of the accumulator 210 made by the first current transducer Al and of the detection of the voltage at the positive terminal 212 of the accumulator 210), the microprocessor M is configured to activate and modulate the second switch module T2 so as to permit recharging of the four cells CI, C2, C3 and C4 of the battery pack 110 as long as these are not fully charged.
  • the microprocessor M is configured to modulate the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2, whereby the microprocessor M is configured to limit the current recharging the battery pack 110 so as not to disturb the correct supply to all the electrical loads of the vehicle during the operation of the internal combustion engine.
  • the microprocessor is no more capable to recognise any voltage drop below the first percentage reduction threshold (that, in case of 12 Volt accumulator 210 of a car or truck is equal to 30%) with respect to the initial voltage when the user attempts to start the internal combustion engine.
  • FIG. 3 shows a third embodiment of the aid module according to the invention, indicated with the reference numeral 300, differing from the aid module 200 of Figure 2 in that it comprises a button 160 connected (via cable or wireless) to the microprocessor M.
  • a user is immediately capable to recognise the case where the accumulator 210 is interrupted, damaged or completely discharged (i.e. the voltage at the positive terminal 212 is equal to 0 Volt), since in such case no electrical load is supplied by the accumulator 210, not even those which are usually observed or heard by a user (e.g., in the case of a car or truck, interior lights, dashboard lights or dashboard instruments). Once he has recognised such a condition, the user operates (e.g.
  • the button 160 and the microprocessor M is configured to consequently control the first switch module Tl so as to allow delivery of a limited initial current necessary to supply the electrical loads of the vehicle, for instance equal to 10 Amperes, from the battery pack 110 (through the internal diode of the second switch module T2) for a preliminary time range (for instance equal to 1 minute); in particular, in the case where the accumulator 210 is completely discharged but it is not interrupted nor damaged, such limited initial current delivered by the battery pack 110 will also begin to recharge the accumulator 210.
  • the microprocessor M could be also configured to signal through the buzzer SI the end of such preliminary time range.
  • the current and voltage sensing means with which the module 300 is provided namely, the connection to the circuit node Nl and the second current transducer A2
  • the microprocessor M is configured to consequently control the first switch module Tl so as to allow delivery of the current necessary to the electric starter.
  • the accumulator 210 is efficient, i.e. it is sufficiently charged for providing the electric energy necessary to the electric starter of the internal combustion engine, as mentioned above the voltage across it would drop at maximum by a second percentage reduction threshold (in case of a 12 Volt accumulator 210 of a car or truck such second percentage reduction threshold is equal to about 20%) with respect to the voltage before the attempt of starting in a reduction period at starting (in case of a 12 Volt accumulator 210 of a car or truck such reduction period at starting is shorter than 1 second), whereby on the basis of the detection of such voltage (through the connection to the positive terminal 212 of the accumulator 210) the microprocessor M, of both aid module 200 and aid module 300 shown in Figures 2 and 3, is configured to recognise that the accumulator 210 is efficient and, hence, it does not need any intervention.
  • a second percentage reduction threshold in case of a 12 Volt accumulator 210 of a car or truck such second percentage reduction threshold is equal to about 20%
  • the current generator Gl of the vehicle delivers current towards the accumulator 210 and the first current transducer Al detects that there is a recharging current flow from the generator Gl to the accumulator 210.
  • the microprocessor M is configured to recognise that, with internal combustion engine started, the generator Gl operates correctly.
  • the microprocessor M is configured to recharge the battery pack 110 and/or the accumulator 210.
  • FIGS 4a and 4b show a battery pack 110 of a fourth embodiment of the aid module according to the invention in a first and second configurations, respectively.
  • the battery pack 110 of Figure 4 comprises four main cells, indicated with the reference signs CI, C2, C3 and C4, and one backup cell CR.
  • Each cell is provided with a respective switch, respectively Wl, W2, W3, W4 and WR, capable to connect in series or disconnect the respective cell between the positive and negative terminals 112 and 114 of the battery pack 110; in the battery pack 110 of Figure 4, it is necessary to connect in series four cells to ensure that the voltage across the positive and negative terminals 112 and 114 of the battery pack 110 is equal to the nominal voltage of the accumulator of the vehicle.
  • a current sensor and a voltage sensor are associated to each cell, which are configured to detect the operational state of the related cell.
  • the processing and controlling unit of the aid module receives the detections from the current and voltage sensors associated to each cell of the battery pack 110 and, on the basis of such detections, it is configured to control the switches with which each cell of the battery pack 110 is provided.
  • the processing and controlling unit of the aid module recognises that all the cells CI, C2, C3, C4 and CR of the battery pack 110 operate correctly and, consequently, it controls the switches Wl, W2, W3, W4 and WR so as to connect in series between the positive and negative terminals 112 and 114 of the battery pack 110 the four main cells CI, C2, C3 and C4 and to disconnect the backup cell CR, whereby only the four main cells CI, C2, C3 and C4 contribute to the nominal voltage of the battery pack 110.
  • the processing and controlling unit of the aid module controls the recharging of all the five cells CI, C2, C3, C4 and CR of the battery pack 110, including the backup cell CR.
  • the processing and controlling unit of the aid module recognises that one of the main cells, specifically cell C2, has become defective
  • the processing and controlling unit is configured to control the respective switch W2 so as to disconnect the defective cell C2 and to control the switch WR of the backup cell CR so as to connect it in series to the other cells CI, C3 and C4 between the positive and negative terminals 112 and 114 of the battery pack 110, as shown in the second configuration of Figure 4b.
  • the four cells CI, C3, C4 and CR contribute to the nominal voltage of the battery pack 110, whereby, in case of intervention of the aid module, such four cells CI, C3, C4 and CR will provide the electric energy necessary to the electric starter of the internal combustion engine.
  • the processing and controlling unit of the aid module controls the recharging only of the four operating cells CI, C3, C4 and CR of the battery pack 110, excluding the defective cell C2.
  • the processing and controlling unit may notify the user, through a visual and/or acoustic signalling unit 150, that cell C2 is defective, so as to allow its replacement.
  • the aid module according to the invention may be installed on a vehicle both in the factory where the vehicle is produced and by retrofitting already existing vehicles.
  • further embodiments of the aid module according to the invention may be made with components having a minimum size, so that the size of the whole module is equal to that of a cell of a traditional (e.g. lead) accumulator of a vehicle, whereby the aid module could be housed within a housing for such a traditional cell.
  • the accumulator comprising a plurality of housings for single cells, wherein one of such housings houses the aid module, whereas the other housings house respective cells, is part of the present invention.
  • the aid module according to the invention may be portable, whereby such a portable aid module is applicable to a vehicle and removable from the same once that it has permitted to start the respective internal combustion engine.
  • the battery pack of the portable aid module may be recharged even through the mains and a usual rectifier and regulator stage, with which the aid module is optionally provided, configured to rectify the AC current of the mains and to output a regulated current adequate to recharge the battery pack of the portable aid module; the processing and controlling unit is configured to control the recharging process by means of the mains.

Abstract

Aid module (100; 200; 300) for electrically starting an internal combustion engine of a motor vehicle, comprising a battery pack (110), connected to power switching means (120; T1, T2) in turn configured to be connected to an accumulator (210) of a vehicle, and sensing means (140; A1, A2) connected to the battery pack (110) and to the processing and controlling unit (130; M) and configured to be connected to the accumulator (210), wherein said sensing means (140; A1, A2) is configured to make detections of a n operational state of the battery pack (110), as well as of the operational state of the accumulator (210) and of a current generator (Gl) configured to be actuated by the internal combustion engine of the vehicle, wherein the processing and controlling unit (130; M) is configured to recognise, on the basis of the detections received from said sensing means (140): - when an attempt of starting the internal combustion engine is in progress and the accumulator (210) is not capable to deliver a current necessary to an electric starter (240) of the vehicle and consequently the processing and controlling unit (130; M) is configured to control said power switching means (120) so that the battery pack (110) provides the current necessary to the electric starter (240) of the vehicle, and - when the internal combustion engine of the vehicle is operating a nd the current generator (G1) operates properly a nd consequently the processing and controlling u nit (130; M) is configured to control said power switching means (120) so that the battery pack (110) is recharged.

Description

AID MODULE FOR ELECTRICALLY STARTING AN INTERNAL COMBUSTION ENGINE
The present invention concerns an aid module for electrically starting an internal combustion engine, that allows in a reliable, effective, simple and inexpensive way, that is comfortable for the user, to ensure the availability of electric current necessary to start an internal combustion engine of a motor vehicle even when the accumulator of the vehicle is discharged or inefficient.
In the following of the present description, the invention is illustrated with reference to an application of the aid module according to the invention to a motor vehicle, such as a motor vehicle intended to transport people or goods such as a car or a truck. However, it must be considered that the aid module may be applied to electrically start internal combustion engines of whatever motor vehicle, for instance including motorcycles and boats, still remaining within the scope of the present invention.
It is known that most motor vehicles are provided with an internal combustion engine that, when off, needs to be started. To this end, starters are used which are usually electric starter, provided with an electric motor that is supplied by the accumulator of the motor vehicle that is connected to the electrical network of the latter to which electrical loads (such as lighting lamps and possible electronic equipments) of the vehicle are also connected. In this regard, most motorcycles also use an electric starter that, in the last decades, has replaced the traditional mechanical starter, and also many boats, especially large size ones, use electric starters. Once that the internal combustion engine has been started, a current generator (based on an alternator) converts (part of) the mechanical energy of the internal combustion engine into electric energy, recharging the accumulator of the vehicle through the electrical network of the latter and directly supplying at least part of the electrical loads of the vehicle; in this regard, the electrical loads of the vehicle are usually protected by valves or fuses.
However, in the normal use of the motor vehicle, the accumulator may be inefficient to start the internal combustion engine, i.e. it may be not capable to provide the energy (i.e. the electric current) necessary to the electric starter, because it is e low or maintenance of the same accumulator or of the electrical network has been neglected. In particular, the accumulator may be low because the current generator is faulty or defective and during normal operation of the internal combustion engine it is not capable to recharge the accumulator, that hence discharges while supplying all the electrical loads of the vehicle, or because during a long stay, when the internal combustion engine is off, the user leaves some electrical loads of the vehicle operating and, hence, supplied by the accumulator, as it happens for instance in the case where the user parks a motor vehicle leaving the headlights on. Moreover, a lack of proper maintenance of the accumulator may lead to an interruption of one of the cells with which the accumulator is provided, while a lack of maintenance of the electrical network of the vehicle may cause, during a long stay wherein the internal combustion engine is off, a possible current leakage of the electrical network of the vehicle to discharge the accumulator and/or to prevent the accumulator from providing the energy necessary to the electric starter.
In the prior art, some solutions to such problem have been developed, such as those described in documents US 5448152 A, US 5418444 A, US 5637978 A, US 6321707 Bl, US 2002/0195995 Al, US 2004/0119338 Al, US 2004/0227492 Al and EP 2159409 A2 which teach the use of one or more auxiliary batteries which are used in case of malfunction or inefficiency of the main accumulator of the vehicle.
However, even such solutions suffer from some drawbacks: they are complex and not completely reliable solutions, many of which require a manual intervention, and consequently they are not effective, simple, inexpensive, and they are not even comfortable for the user.
It is, therefore, an object of the present invention to allow in a reliable, effective, simple and inexpensive way that is comfortable for the user, to ensure the availability of electric current necessary to start an internal combustion engine of a motor vehicle even when the accumulator of the vehicle is discharged or inefficient.
It is specific subject matter of the present invention an aid module for electrically starting an internal combustion engine of a motor vehicle, comprising a battery pack having a positive terminal, that is connected to power switching means in turn configured to be connected to a positive terminal of an accumulator of a vehicle, and a negative terminal configured to be connected to a negative terminal of the accumulator, wherein said power switching means is configured to selectively connect the positive terminal of the battery pack to a positive terminal of the accumulator of the vehicle under the control of a processing and controlling unit, the aid module further comprising sensing means connected to the battery pack and to the processing and controlling unit and configured to be connected to the positive terminal of the accumulator, wherein said sensing means is configured to make detections of an operational state of the battery pack, as well as of the operational state of the accumulator and of a current generator configured to be actuated by the internal combustion engine of the vehicle, wherein said sensing means is configured to provide the processing and controlling unit with the detections made, wherein the processing and controlling unit is configured to recognise, on the basis of the detections received from said sensing means:
- when an attempt of starting the internal combustion engine is in progress and the accumulator is not capable to deliver a current necessary to an electric starter of the vehicle and consequently the processing and controlling unit is configured to control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator, whereby the battery pack provides the current necessary to the electric starter of the vehicle, and
- when the internal combustion engine of the vehicle is operating and the current generator properly operates and consequently the processing and controlling unit is configured to control said power switching means so as to partly derive a current generated by the current generator towards the positive terminal of the battery pack, whereby the battery pack is recharged.
According to another aspect of the invention, said sensing means may be selected from the group comprising voltage sensors, wherein at least one voltage sensor is optionally made through a connection of a circuit node to a voltage input of the processing and controlling unit, and current sensors.
According to a further aspect of the invention, said sensing means may be configured to be connected to one or more with which the vehicle is provided configured to detect an operational state of the accumulator and/or of the current generator, whereby said sensing means comprises one or more connections from outputs of said one or more sensors with which the vehicle is provided to voltage inputs of the processing and controlling unit or comprises an interface of connection to a CAN bus of the vehicle configured to transmit information related to an operational state of the accumulator and/or of the current generator to digital inputs of the processing and controlling unit.
According to an additional aspect of the invention, said sensing means may be configured to make detections of an ambient temperature to provide the processing and controlling unit with the temperature detections made, the processing and controlling unit being configured to activate heating means for heating the battery pack when the detected temperature is lower than a minimum threshold.
According to another aspect of the invention, the battery pack may comprise a plurality of lithium cells.
According to a further aspect of the invention, the battery pack may comprise a plurality of N main cells and one or more backup cells, each one of said N main cells and of said one or more backup cells being provided with a respective switch configured connect in series the respective cell between the positive and negative terminals of the battery pack or to disconnect the respective cell from the positive and negative terminals of the battery pack, wherein the voltage across the positive and negative terminals of the battery pack is equal to a nominal voltage of the accumulator when N operating cells selected from the group comprising said N main cells and said one or more backup cells are connected in series, wherein a current sensor and a voltage sensor are associated to each one of said N main cells and of said one or more backup cells configured to make detections of an operational state of the respective cell, the processing and controlling unit being configured to receive the detections of the current sensor and of the voltage sensor associated to each one of said N main cells and of said one or more backup cells and to identify, on the basis of them, operating cells and defective cells, the processing and controlling unit being configured to control the switches with which said N main cells and said one or more backup cells are provided so as to disconnect possible defective cells and to charge, when the internal combustion engine of the vehicle is operating and the current generator properly operates, all the operating cells.
According to an additional aspect of the invention, the module may further comprise a photovoltaic cell unit configured to generate electric energy, to which said sensing means are also connected which are configured to make detections of its operational state and to provide the processing and controlling unit with such detections, the photovoltaic cell unit being connected to said power switching means, the processing and controlling unit being configured to recognise, on the basis of the received detections of the operational state of the photovoltaic cell unit, when the photovoltaic cell unit delivers electric energy so as to control said power switching means such that the photovoltaic cell unit recharges the battery pack or, when the latter is fully charged, the accumulator.
According to another aspect of the invention, the processing and controlling unit may be connected to a visual and/or acoustic signalling unit, comprising a display and/or a buzzer, wherein the processing and controlling unit is configured to control the signalling unit so as to provide information about the operational state of the accumulator and/or of the aid module and/or of the current generator. According to a further aspect of the invention, said power switching means may comprise:
a first three-terminal power switch module, one of which is a gate terminal controlling the operation of the same first switch module,
- and a second three-terminal power switch module, one of which is a gate terminal controlling the operation of the same second switch module,
wherein the first switch module is connected in series to the battery pack and the second switch module is connected, through the first switch module, in series to the battery pack and is configured to be connected in series to a parallel connection between current generator and accumulator of the vehicle, wherein said sensing means may comprise:
a first current transducer configured to measure a first current entering or exiting from the accumulator,
a second current transducer configured measure a second current entering or exiting from the battery pack and flowing through the first switch module,
- a connection to a circuit node interposed between the first and the second switch modules and that provides a voltage at the positive terminal of the battery pack, and a connection configured to be connected to the positive terminal of the accumulator of the vehicle,
whereby the processing and controlling unit receives detections of the voltage at the positive terminal of the battery pack, of the voltage at the accumulator, of the first current and of the second current, the processing and controlling unit being configured to control, on the basis of such detections, the first switch module and the second switch module, through the respective gate terminals, so that the first switch module is configured to let current flow from the battery pack to the accumulator when the first switch module receives an enable signal at its gate terminal, and that the second switch module is configured to let the second portion of the current flow towards battery pack when it receives an enable signal at its gate terminal.
According to an additional aspect of the invention, the processing and controlling unit may be supplied by the battery pack or by a dedicated battery or is configured to be supplied by the current generator or by the accumulator of the vehicle.
According to another aspect of the invention, the processing and controlling unit may comprise a the microprocessor.
According to a further aspect of the invention, said sensing means may be further connected to said power switching means and may be configured to make detections of an operational state of said power switching means and to provide the processing and controlling unit with such detections, the processing and controlling unit being configured to control said power switching means also in function of such detections, optionally compensating a possible deterioration or inefficiency of said power switching means.
According to an additional aspect of the invention, on the basis of the detections received from said sensing means, the processing and controlling unit may be configured to recognise that, when during an attempt of electrically starting the internal combustion engine a voltage across the accumulator drops in a range of reduction at starting by at least one first percentage reduction threshold with respect to a voltage across the accumulator before the attempt of starting, the accumulator is not capable to deliver the current necessary to the electric starter of the vehicle, wherein the processing and controlling unit is optionally configured to control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator only in the case where it recognises that the accumulator is not capable to deliver the current necessary to the electric starter of the vehicle after a second attempt of electrically starting the internal combustion engine out of two consecutive attempts distant by not more than a predetermined time range, more optionally not longer than 20 seconds.
According to another aspect of the invention, the module may further comprise a button connected to the processing and controlling unit, wherein the processing and controlling unit is configured to recognise that, when the button is operated, the accumulator is not capable to deliver the current necessary to the electrical starter of the vehicle, and to recognise that an attempt of starting the internal combustion engine is in progress when the detections received from said sensing means detects a change of the load connected to the battery pack and the processing and controlling unit is configured to consequently control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator, whereby the battery pack delivers the current necessary to the electric starter of the vehicle, wherein the processing and controlling unit is optionally configured to consequently control said power switching means so as to connect the positive terminal of the battery pack to the positive terminal of the accumulator so as to make the battery pack deliver a limited initial current, more optionally equal to 10 Amperes, for a preliminary time range, more optionally equal to 1 minute, starting from the instant when the button is operated.
It is further specific subject matter of the present invention an accumulator comprising a plurality of housings, each housing being configured to house a cell, wherein one of said housings houses an aid module as previously described, each of the other housings housing a respective cell.
The advantages offered by the aid module according to the invention are evident.
In fact, the present invention concerns an aid module for electrically starting an internal combustion engine that is configured to detect that, during an attempt of starting the internal combustion engine, the accumulator of the vehicle cannot provide the energy necessary to the electric starter, whereby in this case the aid module delivers the electric current necessary to the electric starter, because the battery pack with which it is provided is optionally capable to deliver a maximum current of at least 200 A, more optionally at least 500 A, still more optionally at least 800 A, even more optionally at least 1000 A, and it optionally has a capacity of at least 7 Ah (Ampere-hour), more optionally at least 20 Ah, still more optionally at least 40 Ah, even more optionally at least 90 Ah, still even more optionally at least 150 Ah.
The aid module according to the invention is configured such that the battery pack with which it is provided is charged during the operation of the internal combustion engine taking part of the current generated by the current generator that recharges also the accumulator of the vehicle and supplies the electrical loads of the vehicle as well; optionally, some embodiments of the aid module according to the invention are portable and the battery pack with which it is provided is rechargeable even through the mains.
Optionally, the aid module according to the invention comprises a special battery pack, advantageously a lithium battery pack, that increases its reliability.
Moreover, some embodiments of the aid module according to the invention increase their reliability by being provided with a battery pack also comprising one or more backup cells capable to automatically replace in real time possible defective cells of the battery pack, thanks to continuous controls of the cell efficiency which allows to ascertain and isolate possible damaged cells to replace with the backup ones.
The present invention will be now described, by way of illustration and not by way of limitation, according to its preferred embodiments, by particularly referring to the Figures of the annexed drawings, in which:
Figure 1 shows a block diagram of a first embodiment of the aid module according to the invention;
Figure 2 shows a circuit diagram of a second embodiment of the aid module according to the invention;
Figure 3 shows a circuit diagram of a third embodiment of the aid module according to the invention; and
Figures 4a and 4b show a battery pack of a third embodiment of the aid module according to the invention in a first and second configuration, respectively.
In the Figures identical reference numerals will be used for alike elements.
With reference to Figure 1, it may be observed that a first embodiment of the aid module according to the invention, indicated with the reference numeral 100, applied to a vehicle provided with an accumulator 210 having a positive terminal 212 and a negative terminal 214 connected to circuit ground, wherein the terminals 212 and 214 of the accumulator 210 are connected to the electrical network of the vehicle that particularly comprises a switch 220 connecting the positive terminal 212 of the accumulator 210 to the electric starter 240 of the vehicle when the internal combustion engine (not shown) of the vehicle is not yet operating and the user attempts to start the same internal combustion engine (in Figure 1, the switch 220 is shown in a configuration in which the positive terminal 212 of the accumulator 210 is disconnected from the electric starter 240 of the vehicle); moreover, the positive terminal 212 of the accumulator 210 is connected to the current generator Gl configured to be actuated by the internal combustion engine and, hence, to generate an electric current when the internal combustion engine is operating.
The aid module 100 comprises a battery pack 110 the positive terminal 112 of which is connected to power switching means 120 in turn configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle; the negative terminal 114 of the battery pack 110 is configured to be connected to the circuit ground of the electrical network of the vehicle (i.e. to the negative terminal 214 of the accumulator 210 of the vehicle). The battery pack 110 is optionally capable to deliver a maximum current of at least 200 A, more optionally at least 500 A, still more optionally at least 800 A, even more optionally at least 1000 A, and it optionally has a capacity of at least 7 Ah (Ampere-hour), more optionally at least 20 Ah, still more optionally at least 40 Ah, even more optionally at least 90 Ah, still even more optionally at least 150 Ah. Advantageously, the battery pack 110 is formed by a plurality of lithium cells. The power switching means 120 is configured to selectively connect the positive terminal 112 of the battery pack 110 to the positive terminal 212 of the accumulator 210 of the vehicle (and to the current generator Gl) of the vehicle under the control of a processing and controlling unit 130, for instance comprising a the microprocessor. In particular, the processing and controlling unit 130 is advantageously supplied by the battery pack 110 (alternatively it could be supplied by an autonomous dedicated battery or even by the accumulator 210 or by the current generator Gl of the vehicle).
The aid module 100 further comprises sensing means 140 connected to the battery pack 110 and to the processing and controlling unit 130 and configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle. In particular, the sensing means 140 is configured to detect the operational state of the battery pack 110 of the aid module 110, as well as the operational state of the accumulator 210 and of the current generator Gl of the vehicle and to provide the processing and controlling unit 130 with (the signals of) such detections. Optionally, the sensing means 140 comprises voltage sensors, which may be also made through a simple connection of a specific circuit node to a voltage input of the processing and controlling unit 130 (that is hence configured to read the node voltage through this connection at its own input), and/or current sensors; in particular, the sensing means 140 may be configured to be connected to sensors, already present in the vehicle to which the aid module 100 is applied, for the detection of the operational state of the accumulator 210 and of the current generator Gl of the vehicle, and in this case it may be assumed that the sensing means 140 comprises specific connections from the outputs of such sensors already present in the vehicle to voltage inputs of the processing and controlling unit 130, or it comprises an interface of connection to the CAN bus of the vehicle that transmits specific information related to the operational state of the accumulator 210 and/or of the current generator Gl to corresponding digital inputs of the processing and controlling unit 130. In this regard, other embodiments of the aid module according to the invention may have that the sensing means comprising an interface of connection to the CAN bus of the vehicle also detects other parameters, for instance the ambient temperature (that could be also autonomously detected by the aid module through its own temperature sensor) in order to activate a preliminary heating of the battery pack 110 (heating that is advantageous in the case where the latter comprises lithium cells) and/or of other electronic or mechanical components of the aid module and/or of the vehicle (e.g. the internal combustion engine) through heating means, optionally electrically heating components. Other embodiments of the aid module according to the invention may have the sensing means 140 that is further connected to the power switching means 120 and that is configured to detect the operational state of the power switching means 120 and to provide the processing and controlling unit 130 with (the signals of) such detections, such that the processing and controlling unit 130 is configured to control the power switching means 120 also in function of such detections (for instance by compensating a possible deterioration or inefficiency of performance of the power switching means 120).
The processing and controlling unit 130 is configured to control the power switching means 120 on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140. In particular, on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured to recognise when an attempt of starting the internal combustion engine is in progress and the accumulator 210 is not capable to deliver the current necessary to the electric starter 240 of the vehicle, and in this case it controls the power switching means 120 so as to connect (through the same power switching means 120) the positive terminal 112 of the battery pack 110 to the positive terminal 212 of the accumulator 210 of the vehicle and, consequently, through the switch 220, to the electric starter 240 of the vehicle. Moreover, on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured to recognise when the internal combustion engine is operating and the current generator Gl of the vehicle properly operates, and in this case it controls the power switching means 120 so as to partly derive the current generated by the current generator Gl towards the positive terminal 112 of the battery pack 110 (the current generated by the generator Gl is partly derived so as not to interfere with the proper operation of the electrical loads which must be in any case also supplied by the generator Gl), whereby the battery pack 110 is recharged by a current limited by the power switching means 120 properly controlled by the processing and controlling unit 130 such that the battery pack 110 does not discharge on the accumulator 210 when the latter is not fully charged. Optionally, when it recognises that the internal combustion engine is operating and the current generator Gl of the vehicle properly operates, the processing and controlling unit 130 may be configured to control the power switching means 120 so as to partly derive the current generated by the current generator Gl towards the positive terminal of the vehicle (for instance by properly modulating the control of the switching means 120).
Moreover, as it will be shown later with reference to Figure 4, the battery pack 110 may comprise a plurality of main cells, one or more backup cells, and a switch for each (main or main) cell capable to connect in series or disconnect the respective cell between the positive and negative terminals 112 and 114, so that the voltage across the positive and negative terminals 112 and 114 of the battery pack 110 is equal to the nominal voltage of the accumulator 210 (initially, the cells connected in series are all and only those of the plurality of main cells). On the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured to recognise when a cell among those which are connected in series between the positive and negative terminals 112 and 114 of the battery pack 110 (initially, the cells connected in series are all and only those of the plurality of main cells) and which contribute to the nominal voltage is defective (e.g. interrupted or malfunctioning) and to control the switches of the cells of the battery pack so as to replace the defective cell with an efficient cell among those which in that moment are not connected in series between the positive and negative terminals 112 and 114 of the battery pack 110 (initially, an efficient cell among said one or more backup cells), whereby the defective cell is disconnected from the positive and negative terminals 112 and 114 and the cell replacing the latter is connected in series between the positive and negative terminals 112 and 114 of the battery pack 110. Advantageously, when the internal combustion engine is operating and the current generator Gl of the vehicle properly operates, all the both main and backup cells, which are not defective are recharged.
Moreover, the aid module 100 further comprises a photovoltaic cell unit SPl configured to generate electric energy, to which the sensing means 140 is also connected and that is configured to detect its operational state, which photovoltaic cell unit SPl is connected to the power switching means 120; in particular, on the basis of the detections (i.e. of the signals of the detections) received from the sensing means 140, the processing and controlling unit 130 is configured to recognise when the photovoltaic cell unit SPl is delivering electric energy so as to control the power switching means 120 such that the photovoltaic cell unit SPl recharges the battery pack 110 or, if the latter is fully charged, the accumulator 210. The presence of the photovoltaic cell unit SPl, that is useful in the case where the vehicle to which the aid module is applied remains in a stay for a long period (i.e. with the internal combustion engine not operating) or with the current generator Gl not operating, is an optional component, and other embodiments of the aid module according to the invention may be devoid of such a photovoltaic cell unit SP1.
In the aid module 100 of Figure 1, the processing and controlling unit 130 is connected to a visual and/or acoustic signalling unit 150, comprising a display (possibly coinciding with a display or dashboard of the vehicle) and/or a buzzer (possibly coinciding with a speaker of the vehicle), wherein the processing and controlling unit 130 is configured to control the signalling unit 150 so as to inform the user about the operational state of the accumulator 210 and/or of the aid module 100, for instance to inform the user that the starting has been possible through the intervention of the aid module 100.
Figure 2 shows a second embodiment of the aid module according to the invention, indicated with the reference numeral 200, applied to a vehicle the accumulator 210 and the current generator Gl of which are shown. It may be observed that the aid module 200 comprises a first current transducer Al configured to measure a first current entering or exiting from the accumulator 210, and a second current transducer A2 configured to measure a second current entering or exiting from the battery pack 110 of the aid module 200. By way of example, such first current measured by the first current transducer Al may consist of a fraction of the current generated by the current generator Gl, which fraction enters the accumulator 210 of the vehicle to recharge it when the internal combustion engine and the generator Gl properly operate (in this regard, it is a fraction of the current generated by the current generator Gl, since the whole generated current also supplies the electrical loads of the vehicle and may also recharge the battery pack 110 of the aid module 200), or such first current may consist of the current exiting from the accumulator 210 of the vehicle that is delivered to the electric starter when the internal combustion engine does not yet operate and/or to the electrical loads of the vehicle when the internal combustion engine does not yet operate or the generator Gl does not operate properly; still by way of example, such second current measured by the second current transducer A2 may consist of a fraction of the current generated by the current generator Gl, which fraction enters the battery pack 110 formed by the four cells CI, C2, C3 and C4 to recharge it when the internal combustion engine and the generator Gl operate properly (also in this case, it is a fraction of the current generated by the current generator Gl since the whole generated current also supplies the electrical loads of the vehicle and may also recharge the accumulator 210 of the vehicle), or such second current may consist of the current exiting from the battery pack 110 that is delivered to the electric starter when the internal combustion engine does not yet operate and the accumulator is inefficient.
The aid module 200 also comprises a photovoltaic cell unit SP1 configured to recharge primarily the four cells CI, C2, C3 and C4 of the battery pack 110 and then, when the cells of the latter are charged, the accumulator 210 of the vehicle.
The aid module 200 further comprises a first three-terminal power switch module Tl, one of which is the gate terminal Tl-G controlling the operation of the same switch module Tl, wherein the first switch module Tl optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal Tl-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal Tl-G); the first switch module Tl is connected in series to the battery pack 110, whereby the second current transducer A2 is configured to measure the current flowing across the same.
The aid module 200 also comprises a second three-terminal power switch module T2, one of which is the gate terminal T2-G controlling the operation of the same switch module T2, wherein the second switch module T2 optionally comprises a MOSFET or an IGBT connected in parallel (between the two terminals different from the gate terminal T2-G) to an internal diode (so as to allow current to flow in both directions between such two terminals different from the gate terminal T2-G); the second switch module T2 is connected (indirectly, through the first switch module Tl) in series to the battery pack 110 and is configured to be connected in series to the parallel connection between current generator Gl and accumulator 210 of the vehicle.
The processing and controlling unit (indicated with the reference numeral 130 for the aid module of Figure 1) comprises a the microprocessor M, connected to a buzzer SI, that receives all the detections of the operational state of the aid module 200 and of the accumulator 210 and of the current generator Gl which are necessary to the proper control of the aid module 200; namely, such detections concern the voltage of the photovoltaic cell unit SP1, the voltage of the cells CI, C2, C3 and C4 of the battery pack 110, the voltage of the accumulator 210 of the vehicle, the first current detected by the first transducer Al and the second current detected by the second transducer A2. On the basis of such detections, the microprocessor M is configured to control the first switch module Tl and the second switch module T2, through the respective gate terminals Tl-G and T2-G, as well as the buzzer SI, for instance notifying the user that the starting has been possible through the intervention of the aid module 200.
In particular, the power switching means (indicated with the reference numeral 120 for the aid module of Figure 1) of the aid module 200 of Figure 2 comprise the first and second switch modules Tl and T2, while the sensing means (indicated with the reference numeral 140 for the aid module of Figure 1) of the aid module 200 of Figure 2 comprise the first and second transducers Al and A2, as well as the connection to the circuit node Nl interposed between the two switch modules Tl and T2 (providing the voltage at the positive terminal 112 of the battery pack 110) and the connection configured to be connected to the positive terminal 212 of the accumulator 210 of the vehicle.
The first switch module Tl, when receiving an enable signal at its own gate terminal Tl-
G from the microprocessor M, is configured to let the current flow from the four cells CI, C2, C3 and C4 of the battery pack 110 (through the internal diode of the second switch module T2) to the accumulator 210 that, consequently, will be capable to provide the electric starter (not shown) of the internal combustion engine of the vehicle with the current necessary to the starting.
The second switch module T2, when receiving an enable signal at its own gate terminal T2-G from the microprocessor M, is configured to let the (second portion of) charging current flow from the current generator Gl (through the internal diode of the first switch module Tl) to the four cells CI, C2, C3 and C4 of the battery pack 110.
In the following, the operating modes of the aid module 200 of Figure 2 are illustrated, similar modes being valid for the other embodiments of the aid module according to the invention.
The microprocessor M constantly monitors the value of the voltage of the accumulator 210 of the vehicle (through the connection to the positive terminal 212) and of the input and output currents of the same accumulator 210 (through the first current transducer Al). In this regard, a 12 Volt accumulator 210 of a motor vehicle with internal combustion engine off having a charge not sufficient to electrically start the internal combustion engine has a voltage approximately ranging from 3 to 12 Volt. At the moment when the user attempts to start the internal combustion engine, the accumulator 210 has not sufficient energy to start the engine and the voltage across it (i.e. the voltage at the positive terminal 212 with respect to circuit ground) will instantly drop by at least 30% in less than 1 second with respect to the voltage before the attempt of starting. Obviously, in the general case of accumulators having voltage different from 12 Volt and/or used in motor vehicles different from cars and trucks, in the case where the accumulator 210 has not sufficient energy to start the engine, the voltage across it (i.e. the voltage at the positive terminal 212 with respect to circuit ground) will instantly drop by at least a first (minimum) percentage reduction threshold (that may be different from 30%) with respect to the voltage before the attempt of starting, which first percentage reduction threshold is higher than a second (maximum) percentage reduction threshold that occurs for the voltage across the accumulator when the user attempts to start the internal combustion engine and the accumulator 210 has a charge sufficient to provide the energy necessary to the electric starter (in the case of a 12 Volt accumulator 210 of a car or truck such second percentage reduction threshold is equal to about 20%) in a reduction period at starting that may be different from the period shorter than 1 second (period that is valid for a 12 Volt accumulator 210).
If the internal combustion engine has not been started, then the current generator Gl of the vehicle does not deliver any current to the accumulator 210 and the first current transducer Al does not detect any current flow. On the basis of these detections, the microprocessor M is configured to recognise that the vehicle has not been started and, consequently, to enter an alert state. In the case where the user attempts to start again within a predetermined time range (e.g. 20 seconds), the voltage of the accumulator 210 reduces again by at least 30% (in the general case such voltage reduces again below the first percentage reduction threshold) with respect to the initial value (ranging from 3 to 12 Volt in the case of accumulator 210 for cars and trucks, initial value to which the voltage of the accumulator 210 is returned at the end of the preceding start attempt) in the reduction period at starting, the microprocessor M is configured to recognise that the voltage across the accumulator 210 dropped again by at least 30% (in the general case where such voltage dropped below the first percentage reduction threshold) in a reduction period at starting and to activate, consequently, the first switch module Tl permitting the flow (through the internal diode of the second switch module T2) of the current necessary to the starting from the four cells CI, C2, C3 and C4 of the battery pack 110 to the accumulator 210. Differently, in the case where the user does not attempt any further starting within said predetermined time range (e.g. 20 seconds), then the microprocessor M is configured to exit from the alert state (in fact, at the next attempt of starting the accumulator 210 of the vehicle could have been replaced or recharged, whereby it is preferable that the microprocessor M repeats the recognition of the - In efficiency of the accumulator 210).
Once the vehicle has been started, the current generator Gl delivers the current for recharging the accumulator 210 of the vehicle (assuming that the generator Gl operates properly). In this case, the microprocessor M is configured to monitor the charge state of the accumulator through the first current transducer Al and the connection to the positive terminal 212 of the accumulator 210 (that provides the voltage thereof).
At the same time, the microprocessor M is advantageously configured to control the buzzer SI notifying the user that the starting has been possible through the intervention of the aid module 200. Moreover, in the case where the current generator Gl has a malfunction, the first current transducer Al does not detect any current flow, whereas the second current transducer A2 continues to detect flow of current (delivered by the battery pack 110) necessary to supply the electrical loads of the vehicle while the internal combustion engine is operating, and, on the basis of such detections of the two current transducers Al and A2, the microprocessor M is advantageously configured to control the buzzer SI notifying the user that the current generator Gl has a malfunction.
Once that it has recognised that the current generator Gl operates correctly, the microprocessor M is configured to modulate the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2, whereby the microprocessor M is configured to limit the current charging the battery pack 110 so as not to disturb the correct supply to all the electrical loads of the vehicle during the operation of the internal combustion engine and the possible recharge of the accumulator 210. In particular, the microprocessor M may be configured to allow the battery pack 110 and the accumulator 210 to be simultaneously recharged, possibly giving priority to recharging the battery pack 110 (which is allowed to receive a higher current through an appropriate control of the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2 and of the detection of the voltage at the positive terminal 112 of the battery pack 110).
Alternatively, the microprocessor M could be configured to first allow the accumulator 210 to be fully charged and then the battery pack 110 to be recharged. In this case, only when the microprocessor M recognises that the accumulator 210 is charged (on the basis of the detection of the first input current of the accumulator 210 made by the first current transducer Al and of the detection of the voltage at the positive terminal 212 of the accumulator 210), the microprocessor M is configured to activate and modulate the second switch module T2 so as to permit recharging of the four cells CI, C2, C3 and C4 of the battery pack 110 as long as these are not fully charged. In particular, the microprocessor M is configured to modulate the second switch module T2 on the basis of the detection of the second input current of the battery pack 110 made by the second current transducer A2, whereby the microprocessor M is configured to limit the current recharging the battery pack 110 so as not to disturb the correct supply to all the electrical loads of the vehicle during the operation of the internal combustion engine.
Differently from the case illustrated above where the accumulator 210 has a charge that is not sufficient to electrically start the internal combustion engine, wherein nevertheless the accumulator 210 has a detectable voltage, if the accumulator 210 is interrupted, damaged or completely discharged (i.e. the voltage at the positive terminal 212 is equal to 0 Volt), the microprocessor is no more capable to recognise any voltage drop below the first percentage reduction threshold (that, in case of 12 Volt accumulator 210 of a car or truck is equal to 30%) with respect to the initial voltage when the user attempts to start the internal combustion engine. Figure 3 shows a third embodiment of the aid module according to the invention, indicated with the reference numeral 300, differing from the aid module 200 of Figure 2 in that it comprises a button 160 connected (via cable or wireless) to the microprocessor M. A user is immediately capable to recognise the case where the accumulator 210 is interrupted, damaged or completely discharged (i.e. the voltage at the positive terminal 212 is equal to 0 Volt), since in such case no electrical load is supplied by the accumulator 210, not even those which are usually observed or heard by a user (e.g., in the case of a car or truck, interior lights, dashboard lights or dashboard instruments). Once he has recognised such a condition, the user operates (e.g. by pressing or lifting or sliding) the button 160 and the microprocessor M is configured to consequently control the first switch module Tl so as to allow delivery of a limited initial current necessary to supply the electrical loads of the vehicle, for instance equal to 10 Amperes, from the battery pack 110 (through the internal diode of the second switch module T2) for a preliminary time range (for instance equal to 1 minute); in particular, in the case where the accumulator 210 is completely discharged but it is not interrupted nor damaged, such limited initial current delivered by the battery pack 110 will also begin to recharge the accumulator 210. The microprocessor M could be also configured to signal through the buzzer SI the end of such preliminary time range. When the button 160 is operated, as soon as the user attempts to start the internal combustion engine, the current and voltage sensing means with which the module 300 is provided (namely, the connection to the circuit node Nl and the second current transducer A2) detects a change of the load connected to the battery pack 110 due to the attempt of starting and, already at the first attempt of starting, the microprocessor M is configured to consequently control the first switch module Tl so as to allow delivery of the current necessary to the electric starter.
Differently from what illustrated above, in the case where the accumulator 210 is efficient, i.e. it is sufficiently charged for providing the electric energy necessary to the electric starter of the internal combustion engine, as mentioned above the voltage across it would drop at maximum by a second percentage reduction threshold (in case of a 12 Volt accumulator 210 of a car or truck such second percentage reduction threshold is equal to about 20%) with respect to the voltage before the attempt of starting in a reduction period at starting (in case of a 12 Volt accumulator 210 of a car or truck such reduction period at starting is shorter than 1 second), whereby on the basis of the detection of such voltage (through the connection to the positive terminal 212 of the accumulator 210) the microprocessor M, of both aid module 200 and aid module 300 shown in Figures 2 and 3, is configured to recognise that the accumulator 210 is efficient and, hence, it does not need any intervention. Then, when the internal combustion engine of the vehicle is started without the intervention of the aid module 200 or 300, the current generator Gl of the vehicle delivers current towards the accumulator 210 and the first current transducer Al detects that there is a recharging current flow from the generator Gl to the accumulator 210. On the basis of these detections, the microprocessor M is configured to recognise that, with internal combustion engine started, the generator Gl operates correctly. As previously explained, when the generator Gl, the microprocessor M is configured to recharge the battery pack 110 and/or the accumulator 210.
Figures 4a and 4b show a battery pack 110 of a fourth embodiment of the aid module according to the invention in a first and second configurations, respectively. In particular, the battery pack 110 of Figure 4 comprises four main cells, indicated with the reference signs CI, C2, C3 and C4, and one backup cell CR. Each cell is provided with a respective switch, respectively Wl, W2, W3, W4 and WR, capable to connect in series or disconnect the respective cell between the positive and negative terminals 112 and 114 of the battery pack 110; in the battery pack 110 of Figure 4, it is necessary to connect in series four cells to ensure that the voltage across the positive and negative terminals 112 and 114 of the battery pack 110 is equal to the nominal voltage of the accumulator of the vehicle. A current sensor and a voltage sensor (not shown in Figure 4) are associated to each cell, which are configured to detect the operational state of the related cell. The processing and controlling unit of the aid module receives the detections from the current and voltage sensors associated to each cell of the battery pack 110 and, on the basis of such detections, it is configured to control the switches with which each cell of the battery pack 110 is provided.
In the first configuration shown in Figure 4a, the processing and controlling unit of the aid module recognises that all the cells CI, C2, C3, C4 and CR of the battery pack 110 operate correctly and, consequently, it controls the switches Wl, W2, W3, W4 and WR so as to connect in series between the positive and negative terminals 112 and 114 of the battery pack 110 the four main cells CI, C2, C3 and C4 and to disconnect the backup cell CR, whereby only the four main cells CI, C2, C3 and C4 contribute to the nominal voltage of the battery pack 110. This entails that, in case of intervention of the aid module due to the fact that the accumulator of the vehicle is inefficient and is not capable to provide the electric energy necessary to the electric starter of the internal combustion engine, the four main cells CI, C2, C3 and C4 provide such energy. Then, during the operation of the internal combustion engine, the processing and controlling unit of the aid module controls the recharging of all the five cells CI, C2, C3, C4 and CR of the battery pack 110, including the backup cell CR.
In the case where the processing and controlling unit of the aid module recognises that one of the main cells, specifically cell C2, has become defective, the processing and controlling unit is configured to control the respective switch W2 so as to disconnect the defective cell C2 and to control the switch WR of the backup cell CR so as to connect it in series to the other cells CI, C3 and C4 between the positive and negative terminals 112 and 114 of the battery pack 110, as shown in the second configuration of Figure 4b. In such second configuration, the four cells CI, C3, C4 and CR contribute to the nominal voltage of the battery pack 110, whereby, in case of intervention of the aid module, such four cells CI, C3, C4 and CR will provide the electric energy necessary to the electric starter of the internal combustion engine. Then during the operation of the internal combustion engine, the processing and controlling unit of the aid module controls the recharging only of the four operating cells CI, C3, C4 and CR of the battery pack 110, excluding the defective cell C2. Advantageously, the processing and controlling unit may notify the user, through a visual and/or acoustic signalling unit 150, that cell C2 is defective, so as to allow its replacement. The aid module according to the invention may be installed on a vehicle both in the factory where the vehicle is produced and by retrofitting already existing vehicles.
Moreover, further embodiments of the aid module according to the invention may be made with components having a minimum size, so that the size of the whole module is equal to that of a cell of a traditional (e.g. lead) accumulator of a vehicle, whereby the aid module could be housed within a housing for such a traditional cell. In this case, also the accumulator comprising a plurality of housings for single cells, wherein one of such housings houses the aid module, whereas the other housings house respective cells, is part of the present invention.
Furthermore, other embodiments of the aid module according to the invention may be portable, whereby such a portable aid module is applicable to a vehicle and removable from the same once that it has permitted to start the respective internal combustion engine. I n this case, the battery pack of the portable aid module may be recharged even through the mains and a usual rectifier and regulator stage, with which the aid module is optionally provided, configured to rectify the AC current of the mains and to output a regulated current adequate to recharge the battery pack of the portable aid module; the processing and controlling unit is configured to control the recharging process by means of the mains.
The preferred embodiments of this invention have been described and a number of variations have been suggested hereinbefore, but it should be understood that those skilled in the art can make other variations and changes without so departing from the scope of protection thereof, as defined by the attached claims.

Claims

1. Aid module (100; 200; 300) for electrically starting an internal combustion engine of a motor vehicle, comprising a battery pack (110) having a positive terminal (112), that is connected to power switching means (120; Tl, T2) in turn configured to be connected to a positive terminal (212) of an accumulator (210) of a vehicle, and a negative terminal (114) configured to be connected to a negative terminal (214) of the accumulator (210), wherein said power switching means (120) is configured to selectively connect the positive terminal (112) of the battery pack (110) to a positive terminal (212) of the accumulator (210) of the vehicle under the control of a processing and controlling unit (130; M), the aid module (100; 200; 300) further comprising sensing means (140; Al, A2) connected to the battery pack (110) and to the processing and controlling unit (130; M) and configured to be connected to the positive terminal (212) of the accumulator (210), wherein said sensing means (140; Al, A2) is configured to make detections of an operational state of the battery pack (110), as well as of the operational state of the accumulator (210) and of a current generator (Gl) configured to be actuated by the internal combustion engine of the vehicle, wherein said sensing means (140; Al, A2) is configured to provide the processing and controlling unit (130; M) with the detections made, wherein the processing and controlling unit (130; M) is configured to recognise, on the basis of the detections received from said sensing means (140):
- when an attempt of starting the internal combustion engine is in progress and the accumulator (210) is not capable to deliver a current necessary to an electric starter
(240) of the vehicle and consequently the processing and controlling unit (130; M) is configured to control said power switching means (120) so as to connect the positive terminal (112) of the battery pack (110) to the positive terminal (212) of the accumulator (210), whereby the battery pack (110) provides the current necessary to the electric starter (240) of the vehicle, and
- when the internal combustion engine of the vehicle is operating and the current generator (Gl) operates properly and consequently the processing and controlling unit (130; M) is configured to control said power switching means (120) so as to partly derive a current generated by the current generator (Gl) towards the positive terminal (112) of the battery pack (110), whereby the battery pack (110) is recharged.
2. Aid module (100; 200; 300) according to claim 1, characterised in that said sensing means (140) is selected from the group comprising voltage sensors, wherein at least one voltage sensor is optionally made through a connection of a circuit node to a voltage input of the processing and controlling unit (130; M), and current sensors.
3. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that said sensing means (140) is configured to be connected to one or more with which the vehicle is provided configured to detect an operational state of the accumulator (210) and/or of the current generator (Gl), whereby said sensing means (140) comprises one or more connections from outputs of said one or more sensors with which the vehicle is provided to voltage inputs of the processing and controlling unit (130; M) or comprises an interface of connection to a CAN bus of the vehicle configured to transmit information related to an operational state of the accumulator (210) and/or of the current generator (Gl) to digital inputs of the processing and controlling unit (130; M).
4. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that said sensing means (140) is configured to make detections of an ambient temperature to provide the processing and controlling unit (130; M) with the temperature detections made, the processing and controlling unit (130; M) being configured to activate heating means for heating the battery pack (110) when the detected temperature is lower than a minimum threshold.
5. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that the battery pack (110) comprises a plurality of lithium cells.
6. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that the battery pack (110) comprises a plurality of N main cells (CI, C2, C3, C4) and one or more backup cells (CR), each one of said N main cells (CI, C2, C3, C4) and of said one or more backup cells (CR) being provided with a respective switch (Wl, W2, W3, W4, WR) configured connect in series the respective cell (CI, C2, C3, C4) between the positive and negative terminals (112, 114) of the battery pack (110) or to disconnect the respective cell (CI, C2, C3, C4) from the positive and negative terminals (112, 114) of the battery pack (110), wherein the voltage across the positive and negative terminals (112, 114) of the battery pack (110) is equal to a nominal voltage of the accumulator (210) when N operating cells selected from the group comprising said N main cells (CI, C2, C3, C4) and said one or more backup cells (CR) are connected in series, wherein a current sensor and a voltage sensor are associated to each one of said N main cells (CI, C2, C3, C4) and of said one or more backup cells (CR) configured to make detections of an operational state of the respective cell, the processing and controlling unit (130; M) being configured to receive the detections of the current sensor and of the voltage sensor associated to each one of said N main cells (CI, C2, C3, C4) and of said one or more backup cells (CR) and to identify, on the basis of them, operating cells and defective cells, the processing and controlling unit (130; M) being configured to control the switches (Wl, W2, W3, W4, WR) with which said N main cells (CI, C2, C3, C4) and said one or more backup cells (CR) are provided so as to disconnect possible defective cells and to charge, when the internal combustion engine of the vehicle is operating and the current generator (Gl) operates properly, all the operating cells.
7. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that it further comprises a photovoltaic cell unit (SP1) configured to generate electric energy, to which said sensing means (140) are also connected which are configured to make detections of its operational state and to provide the processing and controlling unit (130; M) with such detections, the photovoltaic cell unit (SP1) being connected to said power switching means (120), the processing and controlling unit (130; M) being configured to recognise, on the basis of the received detections of the operational state of the photovoltaic cell unit (SP1), when the photovoltaic cell unit (SP1) delivers electric energy so as to control said power switching means (120) such that the photovoltaic cell unit (SP1) recharges the battery pack (110) or, when the latter is fully charged, the accumulator (210).
8. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that the processing and controlling unit (130; M) is connected to a visual and/or acoustic signalling unit (150), comprising a display and/or a buzzer, wherein the processing and controlling unit (130; M) is configured to control the signalling unit (150) so as to provide information about the operational state of the accumulator (210) and/or of the aid module (100) and/or of the current generator (Gl).
9. Aid module (200; 300) according to any one of the preceding claims, characterised in that said power switching means comprises:
a first three-terminal power switch module (Tl), one of which is a gate terminal (Tl-G) controlling the operation of the same first switch module (Tl),
and a second three-terminal power switch module (T2), one of which is a gate terminal (T2-G) controlling the operation of the same second switch module (T2),
wherein the first switch module (Tl) is connected in series to the battery pack (110) and the second switch module (T2) is connected, through the first switch module (Tl), in series to the battery pack (110) and is configured to be connected in series to a parallel connection between current generator (Gl) and accumulator (210) of the vehicle, wherein said sensing means comprises:
a first current transducer (Al) configured to measure a first current entering or exiting from the accumulator (210),
a second current transducer (A2) configured measure a second current entering or exiting from the battery pack (110) and flowing through the first switch module (Tl), a connection to a circuit node (Nl) interposed between the first and the second switch modules (Tl, T2) and that provides a voltage at the positive terminal (112) of the battery pack (110), and
a connection configured to be connected to the positive terminal (212) of the accumulator (210) of the vehicle,
whereby the processing and controlling unit (M) receives detections of the voltage at the positive terminal (112) of the battery pack (110), of the voltage at the accumulator (210), of the first current and of the second current, the processing and controlling unit (M) being configured to control, on the basis of such detections, the first switch module (Tl) and the second switch module (T2), through the respective gate terminals (Tl-G, T2-G), so that the first switch module (Tl) is configured to let current flow from the battery pack (110) to the accumulator (210) when the first switch module (Tl) receives an enable signal at its gate terminal (Tl-G), and that the second switch module (T2) is configured to let the second portion of the current flow towards battery pack (110) when it receives an enable signal at its gate terminal (T2-G).
10. Aid module (100; 200; 300) according to any one of the preceding claims, characterised in that the processing and controlling unit (130; M) is supplied by the battery pack (110) or by a dedicated battery or is configured to be supplied by the current generator (Gl) or by the accumulator (210) of the vehicle.
11. Aid module (200; 300) according to any one of the preceding claims, characterised in that the processing and controlling unit (130; M) comprises a the microprocessor.
12. Aid module (200; 300) according to any one of the preceding claims, characterised in that said sensing means (140) is further connected to said power switching means (120) and is configured to make detections of an operational state of said power switching means (120) and to provide the processing and controlling unit (130; M) with such detections, the processing and controlling unit (130; M) being configured to control said power switching means (120) also in function of such detections, optionally compensating a possible deterioration or inefficiency of said power switching means.
13. Aid module (200; 300) according to any one of the preceding claims, characterised in that, on the basis of the detections received from said sensing means (140), the processing and controlling unit (130; M) is configured to recognise that, when during an attempt of electrically starting the internal combustion engine a voltage across the accumulator (210) drops in a range of reduction at starting by at least one first percentage reduction threshold with respect to a voltage across the accumulator (210) before the attempt of starting, the accumulator (210) is not capable to deliver the current necessary to the electric starter (240) of the vehicle, wherein the processing and controlling unit (130; M) is optionally configured to control said power switching means (120) so as to connect the positive terminal (112) of the battery pack (110) to the positive terminal (212) of the accumulator (210) only in the case where it recognises that the accumulator (210) is not capable to deliver the current necessary to the electric starter (240) of the vehicle after a second attempt of electrically starting the internal combustion engine out of two consecutive attempts distant by not more than a predetermined time range, more optionally not longer than 20 seconds.
14. Aid module (200; 300) according to any one of the preceding claims, characterised in that it further comprises a button (160) connected to the processing and controlling unit (130; M), wherein the processing and controlling unit (130; M) is configured to recognise that, when the button (160) is operated, the accumulator (210) is not capable to deliver the current necessary to the electrical starter (240) of the vehicle, and to recognise that an attempt of starting the internal combustion engine is in progress when the detections received from said sensing means (140) detects a change of the load connected to the battery pack (110) and the processing and controlling unit (130; M) is configured to consequently control said power switching means (120) so as to connect the positive terminal (112) of the battery pack (110) to the positive terminal (212) of the accumulator (210), whereby the battery pack (110) delivers the current necessary to the electric starter (240) of the vehicle, wherein the processing and controlling unit (130; M) is optionally configured to consequently control said power switching means (120) so as to connect the positive terminal (112) of the battery pack (110) to the positive terminal (212) of the accumulator (210) so as to make the battery pack (110) deliver a limited initial current, more optionally equal to 10 Amperes, for a preliminary time range, more optionally equal to 1 minute, starting from the instant when the button (160) is operated.
15. Accumulator comprising a plurality of housings, each housing being configured to house a cell, wherein one of said housings houses an aid module (100; 200; 300) according to any one of claims 1 to 14, each of the other housings housing a respective cell.
PCT/IB2015/058664 2014-11-10 2015-11-10 Aid module for electrically starting an internal combustion engine WO2016075616A2 (en)

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ITRM2014A000660 2014-11-10

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