System, method, and power delivery system for starting an engine

Abstract

A system, method, and power delivery system for starting an engine. The system includes a secondary energy storage system (SESS) and a control system. The SESS is configured to be disposed on a vehicle and conductively connected to a primary battery and a starting device of the vehicle via a switching device. The control system is configured to, during a starting operation, control the switching device to close a conductive path to release current from the SESS to power the starting device and thereby rotate an engine shaft. The control system is configured to, after the starting operation is completed, control the switching device to open the conductive path and prevent current from being released from the SESS.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application is related to and claims priority to U.S. Provisional Application No. 63 / 133,103 filed on December 31, 2020, the entire contents of which are incorporated by reference into this application. Technical Field

[0003] The subject matter of the present application describes embodiments related to internal combustion engine starting operations, and more particularly, to systems, methods, and power delivery systems for starting a vehicle engine. Background Art

[0004] In some vehicles, such as conventional diesel-electric locomotives, the internal combustion engine is used to mechanically drive a synchronous generator that provides current to multiple alternating current (AC) traction motors, the rotors of which are coupled to the vehicle's various axle wheelsets through reduction gearing for propelling the vehicle on the route. The generator typically includes a main three-phase traction AC generator, the rotor of which is mechanically coupled to the output shaft of the engine. When excitation current is supplied to the field winding on the rotating rotor, an AC voltage is generated in the three-phase armature windings on the AC generator stator. These voltages are rectified to produce a direct current (DC) voltage with controlled amplitude, which is then applied to one or more pulse width modulation (PWM) inverters, which control the effective frequency of the AC power supplied to the armature windings of the AC traction motors. The effective AC excitation frequency produced by the inverter controls the speed of the AC motor, and the power is controlled by pulse width modulation of the AC waveform.

[0005] When the vehicle is initially started from an off or stopped state with the engine, an onboard battery (referred to herein as a primary battery) may be used to provide power for starting the engine during a cranking operation. The primary battery is typically connected to provide direct current to an inverter, and the inverter is operated to convert the direct current to frequency-controlled alternating current. The inverter that receives the direct current from the primary battery may be one of the PWM inverters that provide alternating current to the traction motor, or it may be a separate inverter dedicated to the cranking operation. The inverter is connected in circuit to a synchronous generator, which operates as a motor to rotate the output shaft of the engine for starting. During the cranking operation, the rotor of a generator (e.g., an alternator) that is mechanically coupled to the output shaft (e.g., a crankshaft) of the engine rotates the output shaft to start the engine.

[0006] Initially, a relatively high rotor output torque (and current in the stator windings) is required to start turning the crankshaft. As the rotor accelerates from a stationary state, less torque (and current) is required, and the fundamental frequency of the load current increases with the engine speed (rpm). During the starting operation, the inverter provides the machine with current of appropriately varying amplitude and frequency until the engine is self-sustaining, meaning that the crankshaft rotates at a speed that equals or exceeds the minimum speed that can maintain normal engine operating conditions.

[0007] Vehicles typically use primary batteries to provide electrical energy to the motor to drive the starting operation. However, if the primary battery is partially or completely exhausted, the electrical energy provided by the primary battery may not be sufficient to successfully start the engine. For example, primary batteries are typically used to power multiple non-propulsion or auxiliary loads, such as lights, electronic devices (such as radios, computers, sensors, display devices, speakers, etc.), environmental control systems or heating, ventilation, air conditioning (Heating Ventilation and Air Conditioning, HVAC) systems and / or similar devices. For example, if the primary battery powers one or more auxiliary loads for a long period of time after the vehicle completes the journey and shuts down the engine, the charge state of the primary battery may be significantly reduced when the engine needs to be restarted. The exhausted primary battery may not be able to release (e.g., supply) enough current to provide enough torque to rotate the engine shaft. In addition, the voltage in the primary battery may drop to a level that the primary battery cannot maintain other loads (such as control electronics), which may have secondary effects. If the primary battery fails to successfully start the engine, remedial measures may have to be taken, such as jumpstarting the engine and / or charging the primary battery with an external power source, both of which may cause delays.

[0008] Even if a primary battery is able to complete the starting task, over time, the starting load will degrade the health of the primary battery and shorten its life. For example, the starting load can cause the primary battery to undergo deep discharge cycles, where the available electrical energy stored in the primary battery often drops to less than 30% capacity, less than 20% capacity, or even less than 10% capacity. Deep discharge cycles can shorten the life of the primary battery. A system and method may be needed to improve the reliability of the starting operation and reduce the load burden on the primary battery. A system and method may be needed that is different from those currently available. Summary of the invention

[0009] In one or more embodiments, a system for starting an engine is provided, the system comprising a secondary energy storage system (SESS) and a control system. The SESS is configured to be disposed on a vehicle and conductively connected to a primary battery and a starting device of the vehicle via a switching device. The control system is configured to control the switching device to close a conductive path during a starting operation to release current from the SESS to power the starting device and thereby rotate an engine shaft. The control system is configured to control the switching device to disconnect the conductive path and prevent current from being released from the SESS after the starting operation is completed.

[0010] In one or more embodiments, a method (e.g., for starting an engine) is provided, the method comprising: during a starting operation, controlling a switch device via a control system to close a conductive path to release current from a SESS to power a starting device of a vehicle to rotate an engine shaft. The SESS is configured to be disposed on the vehicle and conductively connected to a primary battery and the starting device via the switch device. The method comprises controlling the switch device via the control system to open the conductive path and prevent current from being released from the SESS after the starting operation is completed.

[0011] In one or more embodiments, a power delivery system is provided, the power delivery system comprising an engine, an alternator, a primary battery, a SESS and a control system. The engine comprises an engine shaft and the engine is configured to be disposed on a vehicle. The alternator is mechanically coupled to the engine shaft. The primary battery is conductively connected to the alternator via at least a first switching device. The SESS is conductively connected to the alternator via at least a second switching device. The control system is configured to close the second switching device during a starting operation to establish a conductive path between the SESS and the alternator for supplying current from the SESS to power the alternator to rotate the engine shaft. The control system is also configured to open the second switching device to disconnect the conductive path after the starting operation is completed. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The subject matter of the present invention may be understood by reading the following description of non-limiting embodiments and by referring to the accompanying drawings, in which:

[0013] Figure 1 A power transmission system provided on a vehicle according to one embodiment is shown;

[0014] Figure 2 is a graph depicting strong battery properties during a successful start-up operation;

[0015] Figure 3 is a graph depicting properties of a first depleted battery during a failed starting operation;

[0016] Figure 4 is a graph depicting properties of a second depleted battery during a failed starting operation;

[0017] Figure 5 is a circuit diagram showing a starting system according to an embodiment;

[0018] Figure 6 is a diagram showing a method according to an embodiment of the present invention. Figure 5 Circuit diagram of the starting system;

[0019] Figure 7 is a circuit diagram showing a starting system according to an embodiment;

[0020] Figure 8 A starting system according to an alternative embodiment is shown;

[0021] Fig. 9 It is a balancing scheme that can be used to balance the voltage within multiple battery cells of a secondary energy storage system (SESS);

[0022] Fig.10 is a circuit diagram showing a starting system according to an embodiment;

[0023] Fig.11 is a circuit diagram showing a starting system according to an embodiment;

[0024] Fig.12 is a circuit diagram showing a starting system according to an embodiment;

[0025] Fig.13 depicts a circuit diagram showing a starting system according to another embodiment;

[0026] Fig.14 depicts a circuit diagram showing a starting system according to another embodiment;

[0027] Fig.15 shows a power delivery system according to an embodiment; and

[0028] Fig.16 is a flowchart of a method for starting an engine according to an embodiment. DETAILED DESCRIPTION

[0029] The embodiments described in the present application relate to a system and method for starting a vehicle internal combustion engine. The system and method include a backup electric energy storage system, which is separate from the primary battery of the vehicle and is dedicated to starting use. The backup electric energy storage system is referred to as SESS in the present application. The SESS may include a battery cell, a capacitor, or a combination of a battery cell and a capacitor. The SESS may be dedicated to starting use because the starting load (for example, the motor that rotates the engine shaft during the starting operation) may be one of the few loads or the only load powered by the SESS. Although the SESS may be dedicated to starting use, the SESS may not be the only power source for powering all starting operations. For example, as described in the present application, the SESS may be controlled to supplement the primary battery during the starting operation, to alternate with the primary battery when performing multiple starting operations, or to perform all starting tasks exclusively. Because the SESS is dedicated to the starting operation (which rarely occurs when the engine is restarted from a shutdown state), the SESS may be dormant for a period of time in a (fully) charged state. In one or more embodiments, the SESS is electrically isolated from the electrical load and power source, and the SESS is in a dormant state to avoid current consumption and maintain a state of charge over time. The SESS can be electrically connected to other devices only under a few specific conditions, such as providing current to power a starting operation, providing current to power a control system when the primary battery cannot be used (e.g., due to being in a depleted state), and receiving current during a charging operation of the SESS. The SESS and the associated control system that controls the flow of current into and out of the SESS can be implemented in existing vehicles that already have primary batteries.

[0030] In one or more embodiments, monitoring is used to allocate the roles of the primary battery and the SESS during the starting operation and the charging operation. For example, a control system associated with the SESS can monitor one or more properties or conditions of the primary battery and the SESS, and can control which power source is used to power each starting operation based at least in part on the monitored properties and program instructions for interpreting and responding to the monitored properties. Therefore, the starting system and method described in the present application can modify the starting operation and / or the charging operation based on the monitored conditions of the primary battery and the SESS.

[0031] By providing a SESS as a backup power source and maintaining the SESS in a relatively high power state of charge (e.g., fully charged or at least 80% of power), the starting system and method disclosed in the present application can improve the reliability of the starting operation and reduce the load burden of the primary battery. For example, the SESS combines with the primary battery or replaces the primary battery to power the starting load to ensure that sufficient voltage and current are provided to start the engine. Even if the primary battery is exhausted due to aging, health problems, or the auxiliary load consumes power for a long time after the engine is shut down, the SESS can be controlled to intervene and provide sufficient power to successfully start the engine. Therefore, the vehicle can be reliably controlled to start and run as planned, with almost no risk of delays caused by the exhaustion of the primary battery.

[0032] Figure 1 A power delivery system 100 is shown disposed on a vehicle 102 according to an embodiment. The power delivery system 100 includes an internal combustion engine 104, an alternator 106, a field shunt resistor 108, one or more inverters 110, one or more traction motors 112, a switch device 114, a primary battery 116, a secondary energy storage system (SESS) 118, and one or more non-propulsion or auxiliary loads 120. The components of the power delivery system are electrically connected to each other by conductive elements (e.g., power cables, wires, switch devices, etc.). In one embodiment, the engine is a diesel engine that burns diesel fuel to rotate an output shaft 122 or crankshaft. The alternator is mechanically connected to the output shaft of the engine and generates electrical energy using the mechanical energy of the output shaft. The alternator is electrically connected to the field shunt resistor. The electrical energy from the alternator is direct current (DC) provided to one or more inverters. The one or more inverters convert the direct current into alternating current (AC) and provide the AC to one or more traction motors. The traction motors are mechanically coupled to the axles and wheels 124 of the vehicle through connecting rods. The traction motors convert the received AC power into mechanical energy, which forces the axles and wheels 124 to rotate to propel the vehicle systems. Other types of vehicles, such as watercraft and aircraft, may have propellers for propulsion rather than axles and wheels.

[0033] Starting an engine from a stopped state typically requires electric rotation of the engine output shaft, which is referred to as a starting operation. Typically, a primary battery is the only source of electrical energy for powering the starting engine. For example, a switch gear 114 including a switching device and associated circuits may be controlled to establish a closed conductive path 126 to release current from the primary battery to one or more inverters. The current released from the primary battery may be direct current; and the one or more inverters may convert the direct current into alternating current, which is then provided to an alternator. In the illustrated embodiment, the alternator is a starting device that converts electrical energy into mechanical energy during a starting operation for rotating the shaft of the engine. In this case, the alternator operates as a motor. In an alternative embodiment, the power delivery system includes a starting device for starting the engine that is separate from the alternator. When the vehicle is stationary and the engine is turned off, the primary battery may continue to provide current to non-propulsion loads, which may include lights, radios, speakers, computers, display devices, instruments, sensors, air conditioning components, and the like. The power consumption of the primary battery by the non-propulsion loads may deplete the primary battery to a level that risks the primary battery failing to successfully start the engine during a subsequent starting process.

[0034] The SESS is present in the power delivery system to support the primary battery, at least in terms of starting operations. For example, if it is determined that the primary battery is depleted beyond a threshold level, the switch device can establish a second closed conductive path 128 to release current from the SESS to one or more inverters and then to the alternator for powering the starting load. Alternatively, the SESS can be the preferred or priority power source for powering the starting load, and the primary battery can be controlled to support or supplement the SESS when necessary based on monitored conditions.

[0035] Figure 1 The vehicles shown in can be independent vehicle systems or components of a vehicle system including multiple vehicles. In one embodiment, the vehicle is a rail vehicle, such as a locomotive. The rail vehicle can be mechanically coupled to one or more other rail vehicles to define a train that travels together along a route (e.g., rails). In another example, the vehicle can be an off-road vehicle that travels on a road or path. For example, the vehicle can be a truck (e.g., a highway semi-trailer, a mining truck, a logging truck, etc.). In other embodiments, the vehicle can be another type of vehicle, such as an automobile, a ship, an aircraft, etc. The vehicle can be directly controlled or can be guided only by another vehicle in the vehicle system.

[0036] Figure 22 is a graph 200 depicting strong battery properties during a successful starting operation. A first portion 202 of a vertical axis 204 of the graph represents battery voltage, while a second portion 206 of the vertical axis represents battery current. A horizontal axis 208 represents time. The graph includes a first curve 210 representing battery voltage over time, a second curve 212 representing battery current over time, and a third curve 214 representing engine speed over time. The curves 210, 212 refer to properties of a single battery, such as Figure 1 A primary battery 116 is shown, whose controlled discharge current provides power for the starting operation.

[0037] At time T0, power is supplied to the electric engine starter, and at time T1, the engine begins to accelerate. Powering the engine starter causes the battery voltage to drop from 65V in the figure to 45V. As the voltage drops, the battery starting current soars from 0 amps (amps, A) to 1200A. It should be noted that the voltage and current values ​​are only examples and are not used to limit the battery. After the engine begins to accelerate, the battery voltage gradually increases and the battery starting current gradually decreases. The peak battery current of 1200A is sufficient to provide the engine torque that meets the demand; even at a low point of 45V, the battery voltage can be maintained high enough to support the starting control system and keep the engine accelerating. Engine combustion begins at time T2, and the power to the electric starter is cut off at time T3. Figure 2 The starting operation is successful. The starting operation extends from time T0 to time T3, and its duration can be between 5 seconds and 45 seconds. Optionally, the duration of the starting operation can be between 10 seconds and 30 seconds.

[0038] Figure 3 2 is a graph 220 depicting properties of a first depleted battery during a failed starting operation. A battery may be considered depleted if it has a state of charge and / or energy capacity below a preferred range associated with a successful start. For example, the state of charge may be 60%. The graph has a battery voltage curve 222 and a battery starting current curve 224. The battery has a starting voltage of 63V, which is below the starting voltage of 63V. Figure 2 The battery begins to discharge current to supply power to the electric engine starter at time T0. Since the battery is in a depleted state, the battery starting current cannot rise to Figure 2 The level reached by the battery (e.g., 1200 A) is insufficient to provide the required torque to overcome engine friction, resulting in the engine starting operation failing at time T1.

[0039] Figure 4 is a graph 240 depicting properties of a second depleted battery during a failed starting operation. Figure 4 The battery in the Figure 3 The battery depicted in Figure 2 has more degradation. For example, Figure 4The battery in may have a state of charge of about 30%. The graph has a battery voltage curve 242 and a battery starting current curve 244. The battery has a state of charge of about 30%. Figure 3 The battery in the same starting voltage is 63V. The battery starts to release current to power the electric engine starter at time T0. Since the battery is in a depleted state, the voltage is Figure 2 and 3 The battery in drops even more, reaching a level below the threshold control minimum voltage level 246. The excessive voltage drop results in aborted start at time T1.

[0040] A starting system according to one or more embodiments described herein can detect when a primary battery is in a depleted state, e.g. Figure 3 and Figure 4 The depleted state shown in the figure can be detected by the SESS, and the primary battery can be supplemented or replaced by the SESS to perform the starting task to ensure a successful start. In other words, the starting system can selectively use the SESS to provide a reliable start.

[0041] Figure 5 is a circuit diagram showing a starting system 300 according to an embodiment. The starting system 300 is configured to supply power to a starting load 302, which represents a starting device that rotates an engine shaft of an internal combustion engine to start the engine. The starting device may be a device that is separate from the engine and mechanically connected to the engine shaft, such as a crankshaft or a drive shaft. The starting device receives power in the form of electrical energy or pneumatic energy and converts the received power into mechanical energy to force the engine shaft to rotate, especially when the engine is not running. For example, the starting load may represent Figure 1 The alternator 106 is shown to start the engine 104. The starting system 300 may be provided on a vehicle or vehicle system.

[0042] The starting system 300 includes a secondary energy storage system (SESS) 304, a switching device 310, one or more sensors 312, and a control system 306. The starting system also includes a primary battery 316 of the vehicle and a starting load, which can be a starting device such as an alternator, an electric motor, an air starter motor, etc. The primary battery can represent Figure 1 The control system controls the SESS and the charge and discharge of the primary battery. The control system includes a controller 308 having one or more processors 318 and a non-volatile computer-readable storage medium, referred to as a memory device 320 in this application.

[0043] The SESS is electrically connected to the primary battery 316 via a conductive element that defines a conductive path. The conductive element 316 may include a wire, a trace in a circuit board, and / or the like. In the illustrated embodiment, the SESS and the primary battery are connected in parallel. The SESS and the primary battery are each selectively electrically connected to the starting load through different corresponding switching devices. The controller selectively operates the switching devices. For example, the controller may actuate Figure 5 The controller may include a first switching device ("Cb") 310A in the SESS to close (e.g., establish) a conductive path from the SESS to the starting load. The first switching device is also referred to herein as a SESS discharge switch. Once the conductive path is established, current may be released from the SESS to power the starting load. For example, when the conductive path is closed to establish a closed circuit, current may be immediately released from the SESS. The controller may open the SESS discharge switch Cb to disconnect (e.g., turn off) the conductive path and prevent current from being released from the SESS. For example, once it is determined that the starting operation is completed (e.g., successfully), the controller may open the SESS discharge switch Cb to disconnect the circuit and electrically isolate the SESS from the starting load. Similarly, the controller may actuate Figure 5 The second switch device ("Cp") 310B in the circuit closes the second conductive path from the primary battery to the starting load, releasing current from the primary battery to power the starting load. The second switch device is also referred to as a primary discharge switch in this application.

[0044] The SESS may include one or more battery cells, one or more capacitors, or a combination of one or more battery cells and one or more capacitors. In one embodiment, the SESS includes a plurality of battery modules 314 electrically connected in series with each other. Each battery module 314 may include one or more corresponding battery cells. Connecting multiple battery modules in series may increase the voltage of the SESS without requiring large and bulky batteries. The SESS in the illustrated embodiment has five battery modules, but in other embodiments the SESS may have more or less than five battery modules. For example, each battery module of the SESS may be smaller in size (e.g., smaller in volume) than a primary battery. Even though, in general, the size of the SESS may be smaller than that of a primary battery, the weight of a primary battery may be at least 1000 pounds. Relative to a SESS having only battery cells, the presence of capacitors in the SESS may further reduce the size of the SESS because the unit energy storage capacity of the capacitor may be smaller than that of the battery cell. The current (or charge) capacity of each battery cell in the SESS may be smaller than that of the primary battery. For example, even though, in general, the primary battery current capacity may be greater than that of the SESS; due to the reduced capacity, the SESS may reach a specified state of charge faster than the primary battery during charging. The voltage of the SESS may be lower than that of the primary battery. The lower voltage of the SESS may be beneficial during charging.

[0045] The one or more sensors of the starting system are configured to monitor one or more properties or characteristics of the primary battery, the SESS, or both the primary battery and the SESS. In the illustrated embodiment, a first sensor 312A is positioned on or near the primary battery to monitor the properties of the primary battery, and a second sensor 312B is positioned on or near the SESS to monitor the properties of the SESS. The sensors may include current sensors, voltage sensors, temperature sensors, and / or the like. Although Figure 5 Two sensors are shown, including one sensor that monitors the primary battery and one sensor that monitors the SESS, but the starting system may optionally include a different sensor arrangement. For example, at least two different sensors, such as a voltage sensor, a current sensor, and / or a temperature sensor, may monitor the primary battery, and at least two other sensors may monitor the SESS. In other embodiments, the sensor may monitor only the primary battery or may monitor only the SESS instead of monitoring one or more properties of both. The controller may be communicatively connected to the one or more sensors via a wired or wireless communication path. For example, the controller may receive a sensor signal generated by the sensor and determine the properties of the primary battery and / or the SESS based on an analysis of the sensor signal.

[0046] The controller can be connected to the switching device, including the SESS and the primary discharge switch, via a wired or wireless communication path. For example, the controller can generate a control signal transmitted to a specific switching device to control the state of the specific switching device. The switching device can be an electromechanical relay or contactor configured to withstand relatively high current and voltage along the circuit. The relay can have a solenoid, which converts the electrical energy of the control signal received from the controller into mechanical energy, which moves the contacts in the relay to the junction to establish conduction, and moves away from the junction to block conduction. In another embodiment, the switching device can be a solid-state switch (e.g., a solid-state relay). Different from the electromechanical relay using coils, magnetic fields, springs and mechanical contacts, the solid-state switch utilizes the electrical and optical properties of solid-state semiconductors without moving parts. The solid-state switch can also avoid the risk of arcing when switching between open and closed states. Based on the relatively high energy density (or load) conducted by the circuit, the starting system can also include a solid-state ground fault scheme. In another embodiment, the switching device can be an optical switch. The optical switch itself provides electrical isolation. For example, each switching device may include an insulated-gate bipolar transistor (IGBT), MOSFET, or other transistor with an optical interface (e.g., an isolated input from an LED to a photoreceptor, or other optical isolator control input interface) to eliminate electrical noise and interference risks. Figure 5The switching devices in the SESS include switching devices Cp, Cb, BS+, BS-, and a charging relay associated with each battery cell of the SESS.

[0047] The controller represents a hardware circuit that may include and / or may be connected to one or more processors 318 (e.g., one or more microprocessors, integrated circuits, microcontrollers, field programmable gate arrays, etc.). The controller may include and / or be connected to a tangible and non-transitory computer-readable storage medium (e.g., memory) 320. For example, the memory may store program instructions (e.g., software) executable by one or more processors to perform the operations of the controller described herein, such as the distribution of responsibilities between the primary battery and the SESS for powering the starting load and the operation of charging the SESS. Additionally or alternatively, the memory may store various information, such as a log or record of sensor data generated by one or more sensors, a log or record of starting operations, and / or the like.

[0048] The circuit of the starting system may optionally include additional circuit devices. For example, the circuit may include one or more resistors 322. In the illustrated embodiment, one resistor 322A is a charging resistor arranged along a charging circuit (or path) 324 extending from a primary battery to a SESS. When the primary battery charges the SESS by releasing current along the charging circuit, the charging resistor 322A can passively limit the current provided to the SESS to avoid damaging the SESS or associated circuits and devices. The charging resistor may have a relatively low resistance, such as 1 ohm. The circuit may also include various balancing resistors 322B associated with different battery cells of the SESS. The resistance of the balancing resistor may be greater than the charging resistor. In a non-limiting example, each balancing resistor has a resistance of 100 ohms. The balancing resistor can be used to relatively evenly distribute the series voltage between multiple batteries during the charging operation.

[0049] In one or more embodiments, the SESS is dedicated to the starting operation, so that the controller will not use the SESS to power non-starting loads under normal circumstances. For example, the SESS can be charged to a specified state of charge, such as a state of charge between 80% and 100%, and then the SESS is electrically isolated by the controller. The specified state of charge can optionally be at least 90%. The controller can electrically isolate the SESS by opening the third switching device 310C and the SESS discharge switch Cb. The third switching device is referred to as a charging switch in this application. Opening the charging switch can turn off or disconnect the conductive path between the primary battery and the SESS, also referred to as a charging circuit in this application, and opening the SESS discharge switch Cb can disconnect the conductive path between the SESS and the starting load. The SESS is in the electrically isolated state when there is no closed conductive path connected to the SESS due to the switch position. When the SESS is electrically isolated, the charge state can remain relatively unchanged, except for minimal leakage that occurs over time. For example, the SESS may not have any floating voltage applied. The SESS can be controlled to remain dormant in the charging state until the controller uses the SESS to power one or more loads.

[0050] Under normal operating conditions, the controller may maintain the SESS in an electrically isolated state, except during a starting operation, during a control assist mode when the primary battery is depleted and unable to power the control system, and / or during a charging operation in which the SESS receives and stores current. During a starting operation, the controller may activate the SESS from a dormant state by closing the SESS discharge switch Cb, which establishes a closed conductive path from the SESS to the starting load. During a charging operation, the controller may close the charging switch 310C to close the conductive path along the charging circuit from the primary battery to the SESS (e.g., close the charging circuit).

[0051] Optionally, even if the SESS is dedicated to starting operations, the controller can be configured to requisition the SESS to power one or more non-starting loads under special circumstances, such as when the controller determines that the primary battery cannot provide sufficient power to auxiliary loads (such as control systems) that are considered high priority. For example, the SESS can be used as a backup power source for the primary battery to power security critical loads (such as control instruments, vehicle monitoring sensors, computing devices, etc.). In one embodiment, if the primary battery is sufficiently depleted, one or more computing devices on the vehicle that include the controller (such as computers, vehicle-mounted workstations, servers, etc.) may shut down due to lack of power. In the control assist mode, an external input can be provided to actuate a switching device to enable the SESS to power critical loads including the computing device that includes the controller. The external input can be provided by a user input device, such as a button on a control panel, a disconnect switch on a circuit breaker, etc. Figure 6 As described in.

[0052] In one or more embodiments, the controller determines the distribution of responsibilities for powering the starting operation based at least in part on monitored properties of the primary battery and / or SESS. Typically, the SESS is fully charged, but the primary battery may be depleted due to powering the auxiliary load. In one or more embodiments, the primary battery is designated as the default power source for the starting operation. If the sensor signals received from one or more sensors indicate that both the primary battery and the SESS are strong, the default controller can use the primary battery to power the starting load. The determination of "strong" can represent a healthy energy storage device with at least a threshold state of charge, such as but not limited to at least 60%, 70%, or at least 80% of the charge capacity, or at least a threshold amount of electrical energy available for discharge to the starting load. The controller can evaluate the strength of the primary battery by monitoring the voltage drop during a high current consumption event (e.g., an engine starting operation or an engine pre-lubrication operation). The controller can establish a closed conductive path from the primary battery to the starting load by closing the switching devices BS-, BS+, and Cp to release current from the primary battery to power the starting load. The controller may maintain other switching devices (e.g., SESS discharge switch Cb, charging switch, etc.) in an open circuit, non-conducting state to keep the SESS isolated from the primary battery and the starting load when the primary battery is powering the starting load. When the primary battery is powering the starting load, the controller may monitor the properties of the primary battery.

[0053] If the properties of the primary battery indicate that the primary battery is low or depleted during the starting operation, the controller may, as an exception, utilize the SESS to assist in powering the starting load. The controller may select a SESS based on the primary battery voltage dropping beyond a specified control minimum voltage level (e.g., Figure 4 246), decreases at a faster rate than expected, etc. to determine that the primary battery is low or exhausted. In a non-limiting example, the minimum voltage level can be 55V. Optionally, the controller can determine that the primary battery is low or exhausted based on other attributes, such as the current released from the primary battery is less than a specified current level, fails to soar as expected, or detects a primary battery temperature exceeding a specified threshold temperature. Battery voltage drop during loading is another way to identify weak batteries. In this case, the controller can use the SESS to support the primary battery to ensure that sufficient power is provided to successfully start the engine. The SESS can support the primary battery by closing the SESS discharge switch Cb by the controller while keeping the primary discharge switch Cp in a closed state, which causes the primary battery and the SESS to release current to the circuit at the same time to power the starting load.

[0054] In another option, the controller may block the current released from the primary battery by opening the primary discharge switch Cp before closing the SESS discharge switch Cb to start discharging from the SESS. For example, the controller may optionally control the switch devices in a break-before-make operation sequence to keep the primary battery discharge separate from the SESS discharge, ensuring that the starting load is powered by only one power source at a time.

[0055] Optionally, even if the primary battery is deemed healthy and can successfully power an upcoming starting operation, the controller may sometimes select the SESS to power the starting operation instead of the primary battery as a periodic health check of the SESS. For example, starting operations may be relatively infrequent because the vehicle may be parked for a long time without starting the engine between trips where all or most loads are disconnected. In particular, if the primary battery is the default starting power source, the SESS may be dormant for a long time. To ensure that the SESS is healthy and fully functional, the controller may periodically use the SESS to power the starting operation, such as once a week or month, once every five or ten starting operations, etc. The controller may also track the time elapsed since the last SESS-powered starting operation began, and in response to determining that the elapsed time exceeds a specified time interval, such as a week or a month, select the SESS to power the next starting operation. In the periodic health check of using the SESS to power the starting load, the primary battery can support the SESS when necessary to ensure a successful starting operation.

[0056] Now returning to the start of the starting operation, if on the other hand, the sensor signal received from one or more sensors indicates that one of the primary battery or the SESS is low or depleted, the controller may select the stronger of the two energy storage systems to power the starting operation. For example, if the attribute indicates that the SESS has more electrical energy available to power the starting load than the primary battery, the controller may select the SESS to power the starting load instead of the primary battery. Therefore, the controller turns off one or more switching devices and closes the SESS discharge switch Cb and the SESS discharge switch Cb. Figure 5 The controller may be configured to control the individual switching devices associated with the battery cells of the SESS to discharge from the SESS without discharging from the primary battery. During the starting operation, if necessary, the controller may enlist the primary battery to assist the SESS based on the monitored properties of the SESS. For example, if the controller determines that the SESS is degrading, the controller may begin discharging from the primary battery to supplement or replace the current discharged by the SESS.

[0057] In another example, if the sensor signal indicates that both the primary battery and the SESS are low or exhausted, the controller may select both the primary battery and the SESS to power the starting load. For example, the controller may close both the primary discharge switch and the SESS discharge switches Cp, Cb to simultaneously release current from the primary battery and the SESS to the circuit to power the starting load.

[0058] In the above example, the primary battery is the default energy storage system for powering the starting load. In an alternative embodiment, the SESS is designated as the default energy storage system for starting the engine. Therefore, if both the primary battery and the SESS are considered robust, the controller can use the SESS to power the starting operation, and can use the primary battery to support the SESS as needed. For example, after determining that the SESS is robust, the controller can control the switch device to disconnect the primary battery from the SESS (or maintain a disconnected state) and block (or continuously block) the primary battery from providing current to power the starting load. The controller can then control the switch device to electrically connect the SESS to the starting load to release current from the SESS to power the starting load. After the starting operation is completed, the controller can control the primary discharge switch and the SESS discharge switches Cp and Cb to achieve or maintain an open position to disconnect the starting load from the primary battery and the SESS.

[0059] In addition to reducing the risk of starting failure, incorporating a SESS as described herein to assist starting may have a beneficial effect on the primary battery. For example, the primary battery life may be extended due to the reduced starting burden. In addition, a SESS for starting may enable the vehicle to reduce the size and capacity of the primary battery because the primary battery may no longer require the ability to independently provide high current for starting. Alternatively, the primary battery selected for the application may be a deep discharge type with longer life expectancy characteristics because it does not need to have a high discharge capability.

[0060] Figure 6 326 is a circuit diagram illustrating a starting system 300 according to an embodiment. In the illustrated embodiment, the starting system includes a user input device 330 that an operator uses to manually electrically connect the SESS 304 to various loads on the vehicle at least temporarily to power one or more loads during the control assist mode. The loads may include a starting load 302, a shed control load 328, and a base load 332. Figure 5 The control system including the controller shown in FIG. 1 is within the shedding control load. For example, the shedding control load includes a computing device, circuit, etc. for controlling the operation of the starting system, including current transmission between the load, the primary battery 316 and the SESS 304.

[0061] As described above, unless used to support the starting operation, the SESS is usually dormant in the charging state. The primary battery is usually used to power most loads, including the control load and the basic load under shedding. The starting load may require significantly more power than the control load under shedding. For example, a successful start may require about 1000A, while the control load may only use about 20A to 30A. Usually, even in a state where it is attenuated and cannot start the engine independently, the primary battery has enough power to power the control load including the controller. However, the primary battery may be exhausted to a state where it is basically "completely dead" and cannot even power the relatively insignificant control load. In this case, the computing device containing the controller may be shut down and the controller will not be able to operate. The controller in an inoperable state cannot control the current flowing through the circuit by actuating the switching device. For example, although the SESS can be charged, the controller cannot close the SESS discharge switch 310A to establish a conductive path from the SESS to the load.

[0062] In the illustrated embodiment, the user input device is an electromechanical device that can be manually actuated to electrically connect the SESS to one or more loads on the vehicle. Actuating the user input device closes the SESS discharge switch to establish a conductive path for supplying current from the SESS to at least the detached control load including the controller. The user input device can be a circuit breaker having a button, lever, physical switch, toggle, knob, etc., which is used to selectively manually actuate the circuit breaker. The button, lever, switch, toggle, knob, etc. can be disposed on a control panel of the vehicle.

[0063] In one embodiment, when the user input device is manually actuated (e.g., by pressing a button), the user input device automatically closes the SESS discharge switch 310A and opens the primary discharge switch 310B. Thus, the primary battery is electrically disconnected from the load, and the SESS is electrically connected to the load. Alternatively, the user input device can be designed to open the primary discharge switch before closing the SESS discharge switch. Disconnecting the primary battery avoids circulating current and ensures that current from the SESS will be delivered to the control load that needs power most, rather than being diverted to charge the primary battery. Manual actuation of the user input device initiates a control assist mode of the starting system.

[0064] During the control assist mode, the SESS (through the SESS discharge switch) provides current to power the control load under detachment, thereby enabling the controller to function and operate normally. For example, a computing device including the controller can be started. Once it becomes operational, the controller can determine that the starting system is in control assist mode and is powered by the SESS based on the state of the switching device and / or the state of the primary battery. When the controller is operational, the controller can reaffirm control of the switching device to control the current flowing through the circuit. The next step is to perform a starting operation to attempt to start the engine. The controller can automatically indicate the execution of the starting operation in response to the actuation of the user input device. Alternatively, the starting operation can be initiated exclusively using the second user input device. In this way, when the primary battery is exhausted and the control load is powered by the SESS, the user can actuate the first user input device, and then the user can actuate the second user input device to send a signal for the starting operation.

[0065] In one embodiment, when in control assist mode, the controller may utilize the SESS to power all or at least a portion of the starting operation due to the condition of the primary battery. The controller may limit the use of the SESS for starting to extend the useful life of the SESS. As described above, starting can be difficult for energy storage devices and can reduce capacity and shorten life. One of the limitations or constraints intended to reduce the risk of damage to the SESS may be to apply a starting limit during each given time period. For example, the controller may limit the SESS to only engage in one or two starting operations per day. After the starting operation using the SESS is completed, the controller may, at the storage device (e.g., Figure 5 A log or record of detailed information stored in the memory of the control system.

[0066] If the limit has been reached, the next time a start operation is requested within the same time period, the controller determines based on the memory that the limit has been reached. As a result, the controller prohibits the SESS from participating in the start operation. For example, the controller can open the SESS discharge switch to disconnect the conductive path and isolate the SESS. The limit can protect the SESS from degradation caused by repeated start attempts. Another limit or constraint can be that the charge state in the SESS is at least a specified threshold. For example, the threshold can be 70%, 80%, etc. of the charge capacity. The controller can monitor the charge state of the SESS based on at least one of the sensors. If the charge in the SESS is less than the threshold, the controller prohibits the SESS from participating in the start operation. If any limit or constraint as required is not met (for example, the start limit has been reached), the controller can notify the user that the start operation will not be performed. For example, the controller can generate a control signal that causes an output device such as a smart phone, a computer, a vehicle display, an audio speaker, etc. to alert the user. The alarm or notification can be a text message displayed on a graphical user interface, an audio message emitted from a speaker, etc.

[0067] If all restrictions or constraints are met, the controller can control the switching device to cause the SESS to supply current to the starting load during the starting operation. For example, the controller can close Figure 6 The controller may further include a switch device BJ+ in the control assist mode (referred to herein as the starting load switch) to provide a conductive path from the SESS to the starting load. Alternatively, the controller may maintain the primary discharge switch 310B in an open, non-conductive state during the starting operation so that only the SESS is powering the starting operation. For example, in the control assist mode, the primary battery will be in a depleted or at least weakened state, so the primary battery is unlikely to provide much assistance for starting before the primary battery can be charged. Alternatively, the controller may close the primary discharge switch so that the primary battery supplies current to the starting load while the SESS is supplying current through the SESS discharge switch 310A.

[0068] If the starting operation is successful when starting the engine, the engine can be used to charge the primary battery and the controller can switch back to the normal operating mode. In the normal operating mode, the primary battery is used to power most (if not all) of the vehicle loads. For example, the controller can open the SESS discharge switch to disconnect the electrical connection between the SESS and the load and the primary battery, and can close the primary discharge switch. After a specified amount of time has accumulated after the actuation of the user input device, the controller can switch from the SESS that powers the load to the primary battery that powers the load. The specified amount of time can be in the order of minutes, such as ten minutes. The SESS is taken offline again to extend the service life of the SESS. In this way, the SESS is used to provide the necessary backup power for the vehicle for a limited time.

[0069] Because the user input device is a manually operated electromechanical device, the user can actuate the user input device even when the primary battery is in a healthy state of charge. In one embodiment, the circuit may include a disconnect switch device that substantially disconnects the user input device when the disconnect switch device is activated by receiving a specific voltage. Therefore, if the starting system is in a normal operating mode, the controller can direct a sufficient amount of power to the disconnect switch device to make the user input device inoperable (e.g., disconnected from the circuit). In the event of a power outage due to exhaustion of the primary battery, the disconnect switch can be automatically activated, causing the user input device to become operable to close the SESS discharge switch upon manual actuation, as described above. In another embodiment, the user input device can always be connected to the circuit and be operable. Therefore, each time a manual input is received, the user input device can close the SESS discharge switch within a specified time period (e.g., 10 seconds). In order to prevent repeated manual actuation, the controller can generate a control signal to notify the user to modify the user behavior (e.g., stop pressing the button).

[0070] In one or more embodiments, the SESS may be charged by a primary battery. For example, when the SESS is depleted after a starting operation, the controller may charge the SESS by closing the charging switch 310C, thereby establishing a closed conductive path between the primary battery and the SESS along the charging circuit. The current is discharged from the primary battery to the SESS. The charging circuit may include a charging resistor 322A, which passively limits the current supplied from the charging circuit of the SESS during the charging operation. In the illustrated embodiment, the charging resistor has a relatively high resistance (e.g., high impedance) to extend battery life and simplify the charging circuit. Since the SESS may be rarely used / discharged, the charging rate may be relatively slow, which is more beneficial to battery health than a higher current level. In the illustrated embodiment, the charging resistor has a resistance of 1 ohm, but may have a different resistance in another embodiment. Before starting the charging operation, the controller may analyze the sensor signal from the sensor to ensure that the voltage of the primary battery is greater than the SESS. Optionally, the charging circuit may include a diode that only allows current to flow from the primary battery to the SESS. The diode may block the conduction of current from the SESS to the primary battery.

[0071] The controller may monitor the properties of the SESS during charging and may also monitor the duration of charging since the start of the charging operation. Once the controller determines that the SESS has reached a specified fully charged state based on voltage, charge state, etc., the controller may open the charging switch 310C to disconnect the conductive path along the charging circuit and block the release of current from the primary battery to the SESS. Optionally, the controller may be configured to open the charging relay before the SESS achieves a fully charged state in response to the charging duration exceeding a specified time limit, such as two hours, four hours, etc. The specified time limit may be used to prevent overcharging and / or component damage in the event of a sensor failure. The controller may also be configured to terminate the charging operation early by opening the charging relay, disconnecting the resistor and the SESS from the primary battery in response to a voltage difference determined between the primary battery and the SESS exceeding a specified threshold. For example, an excessively large voltage difference may cause thermal stress to the charging resistor and may damage the resistor.

[0072] In one embodiment, the controller may charge the SESS using overvoltage while charging the primary battery. For example, while the primary battery is being charged, the controller may monitor properties of the primary battery, such as voltage, current, temperature, and / or the like. In response to determining that the voltage of the primary battery exceeds a specified threshold voltage, such as but not limited to 65V, the controller may close a charging relay along the charging circuit to establish a closed conductive path from the host device to the SESS. Thereby, excess current is released from the primary battery to the SESS to charge the SESS. Optionally, the controller may wait until the primary battery is fully charged before closing the charging relay to direct the overcurrent to the SESS, rather than simultaneously with the charging of the primary battery. The controller may also charge the SESS with an excess current in response to determining that the primary battery is receiving current at an excessive rate.

[0073] In order to extend the battery life, a charging strategy can be deployed to avoid charging at high battery temperatures. For example, the controller can receive a sensor signal from a temperature sensor (e.g., sensor 312A) that monitors the temperature of the primary battery. The controller can determine the temperature of the primary battery based on the sensor signal received from the temperature sensor. If the temperature of the primary battery is at or above a specified threshold temperature, the controller can prevent the primary battery from charging until the temperature of the primary battery drops below the threshold temperature. Non-limiting examples of threshold temperatures may include 200°C (392°F), 300°C (572°F), etc. In one embodiment, the controller may also not charge the SESS when the primary battery temperature is too high. For example, in a circuit configuration in which the SESS is charged with electrical energy provided by a primary battery, during a period when the primary battery temperature is too high (equal to or above a specified temperature threshold), removing the load that charges the SESS from the primary battery can extend the life of the primary battery.

[0074] In alternative embodiments, the controller may still charge the SESS during periods when the primary battery temperature is too high, particularly in circuit configurations where the charging current is not provided by the primary battery. For example, the controller may direct the charging current to bypass the primary battery and enter the SESS.

[0075] Optionally, during periods when the primary battery temperature is too high, the controller can use the SESS as the default power source for engine starting operations. If a starting operation occurs when the primary battery temperature is too high, the primary battery can only be used as a backup battery for the SESS to provide power when the SESS decays.

[0076] Optionally, the controller may receive a sensor signal indicating an ambient temperature in the surrounding environment. In response to the ambient temperature being greater than a threshold ambient temperature, the controller may avoid charging the SESS to extend SESS battery life. The threshold ambient temperature may be selected based on characteristics of the SESS. Non-limiting examples of the threshold ambient temperature include 40°C (104°F), 50°C (122°F), etc.

[0077] The controller may terminate charging of the SESS by opening the charging switch 310C to block conduction along the charging circuit. The controller may maintain the SESS in an electrically disconnected and charging state until the next mission cycle. By using the primary battery and the existing charging system to charge the SESS, no additional hardware is required to install and operate the starting system, other than the SESS and associated circuitry not already present on the vehicle. For example, the SESS may not require a separate charger system or device other than the charger used with the main device.

[0078] Figure 7 3 is a circuit diagram showing a starting system 350 according to an embodiment. The starting system 350 is similar to the Figure 5 and Figure 6 The starting system 300 shown. In the illustrated embodiment, the SESS includes a first string 356 and a second string 358 of one or more battery cells 314. The first and second strings are arranged in parallel with each other and in parallel with the primary battery 316. In the illustrated embodiment, each of the first and second strings includes five battery cells arranged in series, but in other embodiments may have as few as one or more than five battery cells. In addition, the first string may have a different number of battery cells than the second string or one or more battery cells of different types or sizes. Optionally, at least one of the first string and the second string may include at least one capacitor.

[0079] The starting system 350 can be configured to charge and discharge a first string of the SESS independently relative to a second string of the SESS, and vice versa. For example, the control system includes a first charging switch 360A and a first discharging switch 362A (Cb1) associated with the first string, and a second charging switch 360B and a second discharging switch 362B (Cb2) associated with the second string. The control system closes the first charging switch to charge the first string with current released from the primary battery, and closes the second charging switch to charge the second string. The control system closes the first discharging switch Cb1 to release current from the first string to power the starting load 302, and closes the second discharging switch Cb2 to power the starting load with current released from the second string. In the illustrated embodiment, the charging circuit 364 includes a first charging resistor 366A electrically connected to the first string and a second charging resistor 366B electrically connected to the second string. In other embodiments, the SESS may include more than three strings of batteries and / or capacitors connected in parallel.

[0080] Figure 8 380 according to an alternative embodiment. In the starting system 380, a secondary energy storage system (SESS) 382 may be connected in series with the primary battery 316, rather than Figures 5 to 7The SESS 382 may include two or more battery cells 384 connected in series with each other. The starting system may have multiple chargers 386, with each battery cell 384 having a different associated charger.

[0081] Fig. 9 390 is a balancing scheme that can be used to balance the voltage within a plurality of battery cells 392 of a secondary energy storage system (SESS) 394. The SESS in the illustrated embodiment includes three battery cells and two capacitors 396. Four switching devices 398 can be controlled by a controller to balance the power between the battery cells. Optionally, the SESS may not be balanced.

[0082] Fig.10 is a circuit diagram showing a starting system 400 according to an embodiment. The starting system 400 may be similar to Figure 5 The starting system 300 is shown. Optionally, the secondary energy storage system (SESS) 402 of the starting system includes one or more supercapacitors 404 instead of Figure 5 The battery string is shown. The SESS may include a light emitting diode (LED) 406 associated with a supercapacitor. Fig.10 The circuit shown is similar to Figure 5 The circuit, therefore Figure 5 The description of how the starting system operates is applicable to Fig.10 Starting system in.

[0083] Fig.11 4 is a circuit diagram showing a starting system 420 according to an embodiment. The addition of parallel diodes 430B and 430C ensures that the highest voltage applied to the primary battery during the most recent charge of the primary battery is retained across the ultracapacitor and applied during the next engine start. Retaining the highest voltage from the last charge across the ultracapacitor so that the voltage is applied during the next start operation ensures that sufficient energy (e.g., maximum available energy) is provided for the next start operation. Fig.12 4 is a circuit diagram showing a starting system 440 according to another embodiment. The starting systems 420 and 440 are similar to Fig.10 The starting system 400 shown in FIG. 4 is different from the starting system 400 shown in FIG. 4 in that the starting system 420 and the starting system 440 include a diode 430 for providing a unidirectional current flow along the conductive path. For example, both starting systems include an RC diode 430A for blocking current conduction to the battery charger, and a charging diode 430B arranged along the charging circuit path 432 for blocking current conduction from the SESS 434 to the primary battery 316. Fig.12 The starting system also includes Fig.11 The additional switching device BJx 438 is not present in the described starting system. Fig.11 and12 The starting system in can be similar to Fig.10 The starting system and Figure 5 The starting system in the EV engine is operated in a controller that can determine when and how long to supply the energy stored in the supercapacitor for engine starting. The two systems are similar in that the primary battery charger can boost the energy stored in the capacitor by retaining the maximum voltage of the charger, which is usually applied during the primary battery bulk charge. The high-voltage energy retained by the capacitor can be used during the subsequent engine start.

[0084] Fig.13 and 14 Depicted are circuit diagrams showing various starting systems 450 , 460 according to other embodiments.

[0085] Fig.15 FIG. 5 shows a power transmission system 500 according to an embodiment. The power transmission system 500 may be similar to Figure 1 The power delivery system 100 shown in the figure is similar to the power delivery system 100, and similar components are labeled the same for comparison. In the illustrated embodiment, the engine 104 can be started using a starting device 506 that is separate from the alternator 106. For example, the starting device 506 can be an air starter motor that is mechanically connected to the engine shaft. The air starter motor is pneumatically connected to the valve 504 and the compressed air tank 502 through a pipe or hose 508. The compressed air tank stores compressed air, which is supplied to the air starter motor through the valve and the hose, and the air starter motor rotates the engine shaft during the starting operation. The compressed air tank may have an associated motor for compressed air. In one embodiment, when the engine is pre-operated, the air in the tank is compressed and stored. Then, when the engine is shut down, the stored compressed air can be selectively supplied to the air starter motor through the hose. The air starter motor converts the compressed air into mechanical energy to start the engine. Optionally, when the engine is shut down, the primary battery 116 and / or the SESS 118 can be controlled by a controller to start air compression, and the compressed air is supplied to the air starter motor for starting operation. For example, the SESS can release current to a motor integrated into a compressed air tank to power the compression and storage of air in the tank. The pneumatic system allows a continuous low-power source to provide high-power pulses to start the engine. The motor associated with the compressed air tank can represent Figure 5 The starting load 302 is shown in FIG.

[0086] Fig.16 600 is a flow chart of a method for starting an engine according to an embodiment. The various steps of the method can be Figure 5 The method may include more than one processor 318 of the controller 308. Fig.16 Additional steps shown, less than Fig.16The steps shown and / or Fig.16 In step 602, a sensor signal is received. The sensor signal may be generated by one or more sensors monitoring a primary battery and / or a secondary energy storage system (SESS). The sensor signal indicates one or more properties or parameters of the primary battery and / or the SESS, such as voltage, current, temperature, and / or the like.

[0087] In step 604, it is determined whether to use the SESS to power the starting load, which refers to one or more external components used to power the shaft of the internal combustion engine to rotate during engine starting. The determination can be made based on the sensor signal. For example, if the SESS has a higher voltage than the primary battery or more electrical energy available for starting, the SESS can be selected, so that the process proceeds to step 606. In another example, if the sensor signal indicates that the primary battery voltage is below a specified threshold, the SESS is selected. In another embodiment, the SESS can be designated as the default energy storage device to power the starting load, so the process proceeds to step 606. The SESS can also be selected due to periodic health testing to check whether the SESS is healthy and fully functional.

[0088] At step 606, a closed conductive path is established from the SESS to the starting load by a switching device. The switching device may be controlled by one or more processors. Current may be released from the SESS along the closed conductive path to power the starting load. Optionally, the SESS may be controlled by the switching device and the processor to remain electrically isolated except: (i) during a starting operation, and (ii) during a charging operation in which the SESS receives current. Optionally, before establishing the closed conductive path from the SESS to the starting load, the switching device may be controlled to electrically disconnect the primary battery from the SESS and the starting load, thereby preventing the primary battery from releasing current during the starting operation.

[0089] During the starting operation, the starting device of the vehicle is powered by the current released from the SESS to rotate the shaft of the internal combustion engine at step 608. The starting device may be an alternator operating in motor mode, an air starter motor, etc.

[0090] At step 610, after the start-up operation is completed, the switching device is controlled to open the closed conductive path and block the release of additional current from the SESS.

[0091] Returning to the decision of step 604, if it is determined that the primary battery will be used to power the starting load, the process proceeds to step 612. At step 612, a second closed conductive path from the primary battery to the starting load is established by the switching device. During the starting operation, the current discharged from the primary battery to the second closed conductive path powers the starting device. At step 614, during the starting operation, the starting device of the vehicle is powered by the current discharged from the primary battery to rotate the shaft of the engine.

[0092] In step 616, it is determined whether the primary battery should be supplemented with the SESS during the starting operation. For example, if the sensor signal indicates that the primary battery is decaying and may not be able to provide sufficient power to successfully start the engine, it may be determined to use the SESS as a backup power source to supplement the primary battery or replace the primary battery. If the answer is "yes", the process proceeds to step 606 and a (first) closed conductive path is established, which may cause the primary battery and the SESS to release current simultaneously to power the starting load. On the other hand, if the answer in step 616 is "no", the process proceeds to step 618. The primary battery continues to provide current until the starting operation is completed. In step 618, after the starting operation is completed, the second closed conductive path is disconnected by the switching device and blocks the release of additional current from the primary battery.

[0093] Optionally, the method may include a charging step for replenishing the electrical energy stored in the SESS. For example, the method may include: passively limiting the current provided to the SESS via a resistor on a charging circuit during a charging operation, the charging circuit electrically connecting the SESS to the primary battery. In response to a voltage difference between the primary battery and the SESS exceeding a specified threshold, the method includes controlling the switching device to disconnect the resistor.

[0094] Optionally, the method includes monitoring a duration of a charging operation initiated when a closed conductive path is established on a charging circuit between the primary battery and the SESS, and in response to the duration exceeding a specified time limit, controlling the switching device to disconnect a second closed conductive path between the primary battery and the SESS.

[0095] Optionally, during a charging operation, in response to determining based on the sensor signal that the voltage of the primary battery exceeds a specified threshold voltage, the method includes establishing a closed conductive path along the charging circuit between the primary battery and the SESS via a switching device controlled by one or more processors to discharge excess current from the primary battery to the SESS.

[0096] In one or more embodiments, a starting system is provided, the starting system comprising a secondary energy storage system (SESS) and a control system. The SESS is configured to be disposed on a vehicle and conductively connected to a primary battery and a starting device of the vehicle via a switching device. The control system is configured to control the switching device to close a conductive path during a starting operation to release current from the SESS to power the starting device and thereby rotate an engine shaft. The control system is configured to control the switching device to disconnect the conductive path and prevent current from being released from the SESS after the starting operation is completed.

[0097] Optionally, the control system is configured to control the switch device to maintain the SESS in an electrically isolated state except in response to actuation of the user input device during a starting operation, during a charging operation of the SESS, and for a specified period of time after receiving power from the SESS.

[0098] Optionally, the SESS includes one or more battery modules. The one or more battery modules of the SESS may include a plurality of battery modules connected in series. Optionally, the SESS includes one or more capacitors.

[0099] Optionally, the starting system further comprises a starting device, which is an alternator on the vehicle. During the starting operation, current is supplied from the SESS to the alternator. Optionally, the starting system further comprises a starting device, which is an air starter motor powered by compressed air to rotate the engine shaft during the starting operation.

[0100] Optionally, the primary battery and the SESS are electrically connected in parallel. Alternatively, the primary battery and the SESS are electrically connected in series.

[0101] Optionally, the control system is configured to, during the starting operation, control the switching device to electrically disconnect the primary battery from the SESS and prevent the primary battery from powering the starting device. The control system may be configured to control the switching device to prevent the primary battery from powering the starting device before closing the conductive path from the SESS to power the starting device.

[0102] Optionally, the control system is configured to control the switch device to close the second conductive path during a starting operation so that the primary battery and the SESS simultaneously power the starting device.

[0103] Optionally, the starting system includes a user input device, the user input device being electromechanically connected to a first switch device and a second switch device of the switch device. Manual actuation of the user input device controls the first switch device to connect the SESS to the control system to power the control system, and controls the second switch device to disconnect the primary battery from the control system.

[0104] Optionally, the control system further comprises one or more sensors configured to monitor the voltage of the primary battery. During the starting operation, the control system may be configured to control the switch device to close the conductive path so that the SESS powers the starting device in response to determining that the voltage of the primary battery is below a specified threshold and / or that the voltage of the primary battery has excessively dropped during a previous starting operation based on sensor signals generated by the one or more sensors.

[0105] Optionally, the control system is configured to control the switching device to close the conductive path during a starting operation so that the SESS supplies power to the starting device as a regular health check of the SESS.

[0106] Optionally, the control system is configured to, in response to determining that the SESS has more electrical energy available to power the starting device than the primary battery, control the switching device to close the conductive path so that the SESS powers the starting device.

[0107] Optionally, the SESS is electrically connected to the primary battery via a charging circuit. The charging circuit includes a resistor configured to passively limit a charging current provided to the SESS during a charging operation. In response to a voltage difference between the primary battery and the SESS exceeding a specified threshold, the control system may be configured to control the switching device to disconnect the resistor. The charging circuit may include a diode configured to block current from being conducted from the SESS to the primary battery.

[0108] Optionally, the control system is configured to monitor the duration of a charging operation involving the discharge of current from the primary battery along the charging circuit to the SESS. The control system is configured to control the switching device to disconnect the charging circuit and prevent the discharge of current from the primary battery in response to the duration exceeding a specified time limit.

[0109] Optionally, the control system further comprises one or more sensors configured to monitor the voltage of the primary battery. The control system may be configured to, in response to the voltage of the primary battery exceeding a specified threshold voltage during the charging operation, control the switch device to close the conductive path from the primary battery to the SESS to discharge excess current from the primary battery to the SESS.

[0110] In one or more embodiments, a method for starting an engine is provided, the method comprising: during a starting operation, controlling a switch device via a control system to close a conductive path to release current from a SESS to power a starting device of a vehicle to rotate an engine shaft. The SESS is configured to be disposed on the vehicle and conductively connected to a primary battery and a starting device via a switch device. The method comprises: controlling the switch device to open the conductive path and prevent current from being released from the SESS after the starting operation is completed.

[0111] Optionally, the method further comprises: controlling the switching device to keep the SESS in an electrically isolated state except during a starting operation, and controlling the switching device to keep the SESS in an electrically isolated state except during a charging operation of the SESS.

[0112] Optionally, the method further comprises: during the starting operation, controlling the switch device to disconnect the electrical connection between the primary battery and the SESS and prevent the primary battery from powering the starting device. The method may also comprise: before closing the conductive path for releasing current from the SESS, controlling the switch device to prevent current from being released from the primary battery.

[0113] Optionally, the method further comprises: during a starting operation, controlling the switching device to close the second conductive path to allow the primary battery and the SESS to release current to the starting device.

[0114] Optionally, the method further includes receiving a sensor signal generated by one or more sensors monitoring the primary battery. During the starting operation, in response to the control system determining based on the sensor signal that the voltage of the primary battery is below a specified threshold and / or that the primary battery voltage has excessively dropped during a previous starting operation, the switch device can be controlled to close the conductive path to release current from the SESS.

[0115] Optionally, the method further comprises: passively limiting a current provided to the SESS via a resistor on a charging circuit during a charging operation, the charging circuit electrically connecting the SESS to the primary battery. In response to a voltage difference between the primary battery and the SESS exceeding a specified threshold, the method may comprise: controlling the switching device to disconnect the resistor.

[0116] Optionally, the method further comprises: monitoring the duration of a charging operation involving current release from the primary battery along the charging circuit to the SESS, and in response to the duration exceeding a specified time limit, controlling the switching device to disconnect the charging circuit and prevent current release from the primary battery.

[0117] Optionally, the method further includes: receiving a sensor signal generated by one or more sensors monitoring the primary battery. In response to determining that the voltage of the primary battery exceeds a specified threshold voltage during the charging operation based on the sensor signal, the method may include: controlling the switching device to close the charging circuit between the primary battery and the SESS to discharge excess current from the primary battery to the SESS.

[0118] In one or more embodiments, a power delivery system is provided, the power delivery system comprising an engine, an alternator, a primary battery, a SESS, and a control system. The engine comprises an engine shaft and is configured to be disposed on a vehicle. The alternator is mechanically coupled to the engine shaft. The primary battery is conductively connected to the alternator via at least a first switching device. The SESS is conductively connected to the alternator via at least a second switching device. The control system is configured to close the second switching device to establish a conductive path between the SESS and the alternator for supplying current by the SESS during a starting operation, thereby powering the alternator to rotate the engine shaft. The control system is also configured to open the second switching device to disconnect the conductive path after the starting operation is completed.

[0119] Optionally, the primary battery is electrically connected to the control system via a first switching device, and the SESS is electrically connected to the control system via a second switching device. The power delivery system includes a user input device electromechanically connected to the first switching device and the second switching device. Manual actuation of the user input device controls closing the second switching device and opening the first switching device to supply current from the SESS to power the control system for a specified amount of time. Optionally, the control system is configured to open the second switching device and close the first switching device after a specified amount of time from manual actuation of the user input device to electrically connect the primary battery to the control system, so that the primary battery powers the control system instead of the SESS powering the control system.

[0120] As used in this application, the terms "processor" and "computer" and related terms, such as "processing means", "computing means" and "controller" may not be limited to those integrated circuits known in the art as computers, but may refer to microcontrollers, microcomputers, programmable logic controllers (PLC), field programmable gate arrays, and application-specific integrated circuits, as well as other programmable circuits. Suitable memory may include, for example, computer-readable media. Computer-readable media may be, for example, random-access memory (RAM), computer-readable non-volatile media such as flash memory. The term "non-volatile computer-readable medium" means a tangible computer-based device that implements short-term and long-term storage of information (such as computer-readable instructions, data structures, program modules and submodules, or other data in any device). Therefore, the methods described herein may be encoded as executable instructions embodied in tangible, non-temporary computer-readable media (including but not limited to storage devices and / or memory devices). When executed by a processor, these instructions cause the processor to perform at least a portion of the methods described herein. As such, the term may include tangible computer-readable media, including but not limited to non-transitory computer storage devices, including but not limited to volatile and non-volatile media, and removable and non-removable media such as firmware, physical and virtual storage, CD-ROMs, DVDs, and other digital sources such as a network or the Internet.

[0121] Unless the context clearly dictates otherwise, the singular forms "a", "an" and "the" include plural references. "Optional" or "optionally" means that the event or situation described subsequently may or may not occur, and the description may include situations where the event occurs and situations where it does not occur. As used herein throughout the specification and claims, approximate language may be applied to modify any quantitative representation, which may allow for variation without causing a change in the basic function associated therewith. Therefore, the value modified by a term or terms such as "about", "substantially" and "roughly" may not be limited to the specified exact value. In at least some cases, approximate language may correspond to the precision of an instrument for measuring a value. Here and throughout the specification and claims, range limitations may be combined and / or interchanged, and such ranges may be identified and include all sub-ranges contained therein, unless otherwise indicated by context or language.

[0122] This written description uses examples to disclose embodiments, including the best mode, and to enable a person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The claims define the patentable scope of the disclosure, and include other examples that occur to a person skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A system for starting an engine, comprising: a secondary energy storage system configured to be disposed on a vehicle and conductively connected to a primary battery and a starting device of the vehicle via a switching device; as well as a control system configured to control the switching device to close the conductive path during a starting operation to release current from the secondary energy storage system to power the starting device to rotate an engine shaft of the engine, and In response to the starting operation successfully starting the engine, the switch device is controlled to disconnect the secondary energy storage system from the primary battery and the starting device, thereby preventing current from being released from the secondary energy storage system to the primary battery and the starting device.

2. The system according to claim 1, wherein: The control system is configured to control the switching device to maintain the secondary energy storage system in an electrically isolated state, except during the starting operation in response to actuation of the user input device, during a charging operation of the secondary energy storage system, and during a control assist mode, in which power is received from the secondary energy storage system.

3. The system of claim 1 further comprising the starting device being an alternator on the vehicle, and during the starting operation, current is provided from the secondary energy storage system to the alternator.

4. The system of claim 1 further comprising the starting device being an air starting motor powered by compressed air to rotate the engine shaft during the starting operation.

5. The system according to claim 1, wherein: The control system is configured to: in response to the starting operation successfully starting the engine, when the engine is running and the secondary energy storage system is in an electrically isolated state, control the switching device to allow the primary battery to release current to power one or more electrical loads of the vehicle.

6. The system according to claim 1, wherein: The primary battery and the secondary energy storage system are electrically connected in series.

7. The system according to claim 1, wherein: The control system is configured to control the switch device to electrically disconnect the primary battery from the secondary energy storage system and prevent the primary battery from powering the starting device during the starting operation.

8. The system according to claim 1, wherein: The control system is configured to: during the starting operation, control the switch device to close the second conductive path so that the primary battery and the secondary energy storage system simultaneously power the starting device.

9. The system of claim 1, further comprising a user input device electromechanically connected to a first switching device and a second switching device of the switching devices, in, Manual actuation of the user input device controls the first switch device to connect the secondary energy storage system to the control system to power the control system and controls the second switch device to disconnect the primary battery from the control system.

10. The system according to claim 1, wherein: The control system further includes one or more sensors configured to monitor a voltage of the primary battery; and The control system is configured to: in response to determining that the voltage of the primary battery is lower than a specified threshold and / or that the voltage of the primary battery has dropped excessively during a last starting operation based on a sensor signal generated by the one or more sensors, control the switching device to close the conductive path so that the secondary energy storage system powers the starting device.

11. The system according to claim 1, wherein: The control system is configured to, in response to determining that the secondary energy storage system has more electrical energy than the primary battery available to power the starting device, control the switching device to close the conductive path so that the secondary energy storage system powers the starting device.

12. The system of claim 1, wherein: The control system is configured to: monitoring the duration of a charging operation involving a discharge of current from the primary battery along a charging circuit to the secondary energy storage system; and In response to the duration exceeding a specified time limit, the switching device is controlled to disconnect the charging circuit and prevent current from being discharged from the primary battery.

13. The system of claim 1, wherein: The control system further includes one or more sensors configured to monitor a voltage of the primary battery; and The control system is configured to, in response to a voltage of the primary battery exceeding a specified threshold voltage during a charging operation, control the switching device to close a conductive path from the primary battery to the secondary energy storage system to discharge excess current from the primary battery to the secondary energy storage system.

14. A method for starting an engine, comprising: During a starting operation, controlling one or more switching devices via a control system to close a conductive path to release current from a secondary energy storage system to power a starting device of the vehicle to rotate an engine shaft of the engine, the secondary energy storage system being configured to be disposed on the vehicle and conductively connected to a primary battery and the starting device via the one or more switching devices; as well as In response to the starting operation successfully starting the engine, the control system controls the one or more switching devices to disconnect the electrical connection between the secondary energy storage system and the primary battery and the starting device, thereby preventing current from being released from the secondary energy storage system to the primary battery and the starting device.

15. The method according to claim 14, further comprising: During the starting operation, at least a first switching device among the one or more switching devices is controlled to electrically disconnect the primary battery from the secondary energy storage system to prevent the primary battery from powering the starting device.

16. The method according to claim 14, further comprising: During the starting operation, at least a second switching device among the one or more switching devices is controlled to close a second conductive path so that the primary battery and the secondary energy storage system simultaneously supply power to the starting device.

17. The method according to claim 14, further comprising: receiving sensor signals generated by one or more sensors monitoring the primary battery; Wherein, during the starting operation, in response to the control system determining, based on the sensor signal, that the voltage of the primary battery is lower than a specified threshold and / or that the voltage of the primary battery has dropped excessively during the last starting operation, the one or more switching devices are controlled to close the conductive path to release current from the secondary energy storage system.

18. A power delivery system for starting an engine, comprising: an engine, including an engine shaft, the engine being configured to be disposed on a vehicle; an alternator mechanically coupled to the engine shaft; a primary battery conductively connected to the alternator via at least a first switching device; A secondary energy storage system secondary energy storage system conductively connected to the alternator via at least a second switching device and conductively connected to the primary battery via at least a third switching device; as well as The control system is configured as: during a starting operation, closing the second switching device to establish a conductive path between the secondary energy storage system and the alternator for supplying current from the secondary energy storage system to power the alternator to rotate the engine shaft; as well as In response to the starting operation successfully starting the engine, the second switch device is opened and (i) the third switch device is opened or (ii) the third switch device is maintained in an open state to electrically isolate the secondary energy storage system relative to the primary battery and the AC generator, thereby preventing current from being released from the secondary energy storage system to the primary battery and the AC generator.

19. The power transmission system of claim 18, wherein: The primary battery is electrically connected to the control system through the first switch device, and the secondary energy storage system is electrically connected to the control system through the second switch device; The power delivery system further includes a user input device electromechanically connected to the first switching device and the second switching device; Manual actuation of the user input device closes the second switching device and opens the first switching device to supply current from the secondary energy storage system to power the control system for a specified amount of time.

20. The power transmission system of claim 19, wherein: The control system is configured to open the second switch device and close the first switch device to electrically connect the primary battery to the control system after a specified amount of time after the user input device is manually actuated, so that the primary battery powers the control system instead of the secondary energy storage system.

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