Pump system having a motor and a pump controller

Abstract

A vehicle pump system having an electronic control unit (ECU) for operating the pump system includes a pump assembly including a motor and a pump controller having a command input in communication with the vehicle's ECU. The pump controller is configured to determine whether the command input of the pump controller is selectively connected to the vehicle's ECU. The pump controller is operable in at least two modes, including a first mode and a second mode. The first mode utilizes a valid pulse width modulation (PWM) input received from the ECU when the pump controller is in communication with the ECU. The second mode utilizes a discrete digital input to control the speed of the pump assembly when the pump controller is not in communication with the ECU.

Description

[Technical Field]

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 to U.S. patent application Ser. No. 17 / 884,123, filed Aug. 9, 2022, the contents of which are incorporated herein by reference in their entirety.

[0002] The present invention relates to a pump system having a pump controller, and more particularly to a pump controller having a control circuit with multi-function commands. [Background technology]

[0003] This section merely provides background information related to the present invention and may not constitute prior art.

[0004] Typically, in a vehicle, a pump controller operates pumps installed in the fuel system and / or coolant system. In particular, the pump is typically driven by a motor (e.g., a brushless direct current (BLDC) motor). For example, a BLDC motor has a rotor that rotates by sequentially switching electromagnetic coils disposed in a stator. In a BLDC motor, the rotation speed is controlled by detecting the magnetic pole position of the rotor. That is, the relative position between the magnetic rotor and the stator windings is detected by the speed electromotive force generated in the stator windings of the BLDC motor. By assuming or acquiring the relative position between the rotor and the stator windings, the rotation speed of the BLDC motor is controlled accordingly. Summary of the Invention [Problem to be solved by the invention]

[0005] A motor installed in a fuel pump system or a coolant pump system is typically controlled by a vehicle's ECU. The control is performed to adjust the speed of a pump having the motor in response to a pulse-width modulation (PWM) signal from the vehicle's electronic control unit (ECU). The vehicle's ECU communicates with multiple controllers to operate various systems in the vehicle. In particular, the vehicle's ECU communicates with a pump controller to operate the motor to adjust the speed of a pump in the vehicle's fuel pump system or coolant pump system. In conventional pump controllers, additional hardware or wiring systems are typically required in the pump assembly to implement the pump controller's function of adjusting the pump speed, which increases cost and weight. [Means for solving the problem]

[0006] The present invention relates to a pump system comprising a pump assembly and a pump controller for adjusting the speed of the pump according to a command input to a pump controller circuit. According to one embodiment of the present invention, a vehicle pump system having an electronic control unit (ECU) for operating the pump system includes a pump assembly including a motor and a pump controller having a command input in communication with the vehicle's ECU. The pump controller is configured to determine whether the command input of the pump controller is selectively connected to the vehicle's ECU. The pump controller is operable in at least two modes, including a first mode and a second mode. The first mode utilizes a valid pulse-width modulation (PWM) input received from the ECU when the pump controller is in communication with the ECU. The second mode utilizes a discrete digital input to control the speed of the pump assembly when the pump controller is not in communication with the ECU.

[0007] According to a further embodiment of the present invention, when the pump controller determines that the command input of the pump controller is not connected to the vehicle's ECU, the pump controller is configured to use a discrete digital input to regulate the speed of the pump having the motor to a constant value. The pump controller is configured to regulate the speed of the pump having the motor to a constant low speed when the command input of the pump controller is left unconnected. The pump controller is configured to regulate the speed of the pump having the motor to a constant high speed when the command input of the pump controller is connected to ground. Some end users, particularly for aftermarket use or when replacing a pump controller, may not have access to a PWM output or simply not want to implement variable speed control. Therefore, end users may configure the pump controller in multiple configurations, i.e., for variable speed PWM control or for discrete pump speed control (high or low). The systems and controllers described herein allow end users to ignore traditional PWM commands and use the same PWM wiring to set the pump to either a statistically high or low speed.

[0008] According to a further embodiment of the present invention, when the pump controller determines that a command input of the pump controller is connected to the vehicle's ECU to detect a valid PWM input, the pump controller is configured to use the valid PWM input as a frequency cycle or a duty cycle, and upon receiving the valid PWM input, the pump controller is configured to adjust the speed of the pump having a motor in accordance with the frequency cycle or the duty cycle.

[0009] According to a further embodiment of the present invention, the pump system further comprises a relay switch connected to the pump controller for power supply.

[0010] Further details and advantages will become apparent from the accompanying drawings, which are provided herein for illustrative purposes and are not intended to limit the scope of the invention, as set forth in the detailed description below.

[0011] For a more detailed understanding of the present invention, various forms thereof will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0012] The drawings in this specification are for illustrative purposes only and are not intended to limit the scope of the present invention in any way. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a plan view of a pump assembly in accordance with an exemplary embodiment of the present invention. [Figure 2] FIG. 2 is a wiring diagram of a pump system having the pump assembly of FIG. [Figure 3] 3 and 3A are circuit schematic diagrams of the pump controller in the pump assembly of FIG. [Figure 4] FIG. 4 is a logic flow diagram of the pump controller of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0014] The following description is merely exemplary in nature and is not intended to limit the invention or its application or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.

[0015] The present invention relates to a pump assembly used in a fuel system and / or a cooling system of a vehicle. As an example, FIG. 1 shows a fuel pump assembly 10 mounted on a vehicle (not shown) and powered by an on-board battery system. The pump assembly 10 described in the present invention may also be used in a cooling system of the vehicle. As shown in FIG. 1 , for example, the pump assembly 10 includes a pump 12 and a motor (e.g., a brushless DC (BLDC) motor) 14 housed integrally in a cylindrical housing 16. The pump 12 further includes an impeller 22, a pump casing 18, and a pump cover 20, all fixedly housed in the bottom of the housing 16. The pump casing 18 and the pump cover 20 are both fixed to the housing 16 by caulking or press fitting, thereby forming a pump chamber therebetween. The impeller 22 is rotatably supported in the pump chamber. The impeller 22 is fixedly connected to a shaft 24 of the BLDC motor 14.

[0016] In FIG. 1 , for example, a BLDC motor 14 is a motor driven by a five-phase armature winding. The BLDC motor 14 includes a cylindrical stator 26 fixedly accommodated in a housing 16 and a magnetic rotor 28 rotatably supported in the housing 16. The lower end of a shaft 24 is rotatably supported by a first bearing 29. The first bearing 29 is fixed to a first bearing holder 31 in the pump casing 18. The upper end of the shaft 24 is rotatably supported by a second bearing 32. The second bearing 32 is held by a second bearing holder 33 fixedly accommodated in the housing 16. The pump 12 further includes a pump controller 34. The pump controller 34 controls the supply of power to the armature winding in the stator 26 and adjusts the pump speed. In the example shown in FIG. 1 , the pump controller 34 is disposed at the upper end of the shaft 24. In other embodiments of the present invention, pump controller 34, including microcontroller 48 and memory 50, may be located anywhere on pump 12 (see FIG. 2).

[0017] When the impeller 22 of the pump 12 is driven by the BLDC motor 14, for example, fuel in a fuel tank (not shown) is sucked into a pump chamber through an inlet port (not shown) and is then pumped out from an outlet port (not shown) of the pump chamber into the interior space of the housing 16. The fuel that has flowed into the housing 16 flows through the gap between the magnetic rotor 28 and the stator 26 and is supplied to an injector (not shown) through an outlet port 36.

[0018] FIG. 2 shows a wiring block diagram of the pump system 11, which includes a pump controller 34. The pump controller 34 communicates with a vehicle's (not shown) electronic control unit (ECU) 38 and adjusts the speed of the BLDC motor 14 to control the pump 12 according to the ECU's instructions. As shown in FIG. 2, the pump controller 34 is connected to the BLDC motor 14 in the fuel pump 12 via a wiring configuration 40 to control the speed of the pump 12. To ensure efficient communication between the BLDC motor 14 in the fuel pump 12 and the pump controller 34, the wiring configuration 40 between the pump controller 34 and the BLDC motor 14 must be simple and reliably connected. Therefore, the wiring configuration 40 must be robust and failure-free. For example, a soldering method for the wiring configuration 40 is typically used to connect the wires together. Furthermore, the end-to-end resistance of any phase wire is less than 100 mΩ to reduce the risk of failure in pump performance.

[0019] In FIG. 2, the pump controller 34 is further connected to an electrically operated relay switch 42. Typically, the relay switch 42 uses an electromagnet (coil) to operate an internal mechanical switching mechanism (contacts). The relay switch 42 is widely used throughout the vehicle's electrical system. Furthermore, the switching circuit of the relay switch 42 does not require high-current-rated switches or cables, thereby reducing cost and weight. The relay switch 42 may be located anywhere in the vehicle to efficiently transfer power to the electrical accessories it controls. For example, as shown in FIG. 2, the relay switch 42 may be located near the fuel pump 12 with the pump controller 34 to control the BLDC motor 14.

[0020] In FIG. 2, the relay switch 42 is a five-pin relay used to switch power between two circuits. As shown in FIG. 2, the five-pin relay switch has two pins (85, 86) for controlling the coil and three pins (30, 87, 87A) for switching power between the two circuits. These pins include a normally open connection pin and a normally closed connection pin. For example, when the coil is activated, power switches from the normally closed connection pin to the normally open connection pin. The two circuits (terminals 87, 87a) have a common terminal (30), and when the relay is in a standby state, terminal 87a is connected to terminal 30 (see FIG. 2). Furthermore, when the relay is energized, terminal 87 is connected to terminal 30, but is not connected to both terminals (87, 87a) simultaneously.

[0021] Furthermore, as shown in FIG. 2, the coil connected between the two pins (85, 86) requires +12V to be supplied to terminal 86 and grounded via terminal 85. The allowable current of the high current circuit is typically in the range of 25 A to 40 A. When pump controller 34 and relay switch 42 are installed in an aftermarket vehicle, terminal 30 is further connected to the battery and terminal 86 is connected to the OEM harness so that pump controller 34 can control the pump assembly in the aftermarket vehicle.

[0022] As shown in FIG. 2 , the pump controller 34 further includes a ground input 43 connected to ground and a command input 44 that receives a pulse-width modulated (PWM) signal from the vehicle's ECU 38. The command input 44 is utilized to adjust the speed of the pump 12 as an additional function of the pump controller 34. Typically, an effective pulse-width modulated (PWM) signal is used in combination with a transfer function to simply command the pump speed (i.e., the speed of the BLDC motor) or open-loop voltage within a predetermined range. In the present invention, the command input 44 of the pump controller 34 is selectively connected to an output 46 of the vehicle's ECU 38 to control the pump assembly 10. Furthermore, the command input 44 of the pump controller 34 is selectively connected to ground so that the pump controller 34 can adjust the speed of the pump 12 in the pump assembly 10 without the need for additional hardware or wiring systems. An effective PWM signal is typically provided by the vehicle's ECU 38 to achieve variable speed control of the BLDC motor 14. However, some end users may not have access to the output 46 of the ECU 38, or may simply not want to implement variable speed control with an active PWM signal. Instead, the end user may want to selectively connect the command input 44 to provide stepped pump speed control as an additional feature of the pump 12.

[0023] In FIG. 2, the output 46 of the ECU 38 may be connected to the command input 44 of the pump controller 34. A valid PWM signal from the vehicle's ECU 38 is transmitted via a connection line between the pump controller 34 and the ECU 38. As described above, when a valid PWM signal is transmitted, the pump speed is controlled according to the transfer function output, typically resulting in a pump speed that corresponds to the provided transfer function. According to an exemplary embodiment of the present invention, the command input 44 of the pump controller 34 may be connected to ground or left unconnected to control the pump assembly 10 with additional functionality. When the connection line between the output 46 of the ECU 38 and the command input 44 is disconnected and the command input 44 is left unconnected, the internal circuitry of the pump controller 34 pulls up the input command to a high voltage level (i.e., the base of transistor T103 is pulled up to Vbatt; see FIG. 3). The pump controller 34 interprets the input command as "maximum speed" for the pump assembly 10 and operates the pump 12 at a constant maximum speed. This is defined as one of additional functionality that is realized without the need for additional hardware or wiring systems.

[0024] When the connection line between the command input 44 of the pump controller 34 and the output 46 of the ECU 38 is disconnected and the command input 44 is connected to ground, the internal circuitry of the pump controller 34 pulls the input command to a low voltage level (i.e., the base of the transistor (T103) is pulled to ground; see FIG. 3 ). The pump controller 34 interprets the input command as a “low speed” for the pump assembly 10 and operates the pump 12 at a constant minimum speed. This is defined as another of the additional functions. Therefore, the additional function of the pump assembly 10 in the present invention allows the pump controller 34 to ignore the active PWM signal and statistically set the fuel pump 12 to a constant high or low speed using the same hardware, including the wiring configuration 40. Furthermore, the pump controller generally sets the fuel pump to any constant speed, including high and low. As mentioned above, pump controllers 34 with additional functions, such as a discrete command with any static speed of the pump, can also be used in aftermarket vehicles. In another approach, the pump controller 34 of the present invention may be utilized in a vehicle cooling system.

[0025] 3 and 3A are schematic diagrams of the pump controller 34 circuit, which includes a microcontroller 48. In FIGS. 3 and 3A, when the output 46 of the vehicle's ECU 38 is connected to the command input 44 (i.e., when a valid PWM signal is sent to the pump controller 34 via the command input 44), the pump controller 34 converts the signal amplitude to 5V and sends this signal amplitude as an input to the pump controller 34 to control the pump assembly 10. In FIGS. 3 and 3A, when a valid PWM signal is sent, the pump controller 34 uses the input (i.e., register counter input (RA4)) as a frequency cycle or duty cycle so that the speed of the pump 12 is adjusted according to the frequency cycle or duty cycle. If the pump controller does not detect a valid PWM signal, it decides to ignore the register counter input (RA4) and uses it as a discrete digital input. As shown in FIGS. 2, 3, and 3A, when the command input 44 is left unconnected, the base of the transistor (T103) is pulled up to Vbatt. This state is seen as a logic low to the register counter input (RA4), instructing the pump 12 to run at its maximum speed or at a constant high speed (e.g., greater than 50% of its maximum speed). Additionally, if command input 44 is connected to ground, the base of transistor T103 is pulled down to ground. This state is seen as a logic high to the register counter input (RA4), instructing the pump 12 to run at its minimum speed or at a constant low speed (e.g., less than 50% of its maximum speed).

[0026] FIG. 4 shows a flowchart 100 of the pump controller 34 according to an exemplary embodiment of the present invention. In step 102, the pump controller 34 determines whether a valid PWM input (signal) from the vehicle's ECU 38 is detected at the command input 44. If a valid PWM input (signal) from the vehicle's ECU 38 is detected at step 104, the pump controller 34 uses the input (signal) as a frequency cycle or duty cycle and controls the pump speed according to the frequency cycle of the duty cycle. If a valid PWM signal from the ECU 38 is not detected at step 106, the pump controller 34 determines whether the command input 44 of the controller 34 is left unconnected or connected to ground. If the command input 44 of the controller 34 is left unconnected at step 108, the pump controller 34 adjusts the pump speed to a constant low or minimum speed. If the command input 44 of the controller 34 is connected to ground at step 110, the pump controller 34 adjusts the pump speed to a constant high or maximum speed. Thus, in the present invention, the pump controller 34 of the pump assembly 10 can control additional functions, such as any static speed of the pump 12, without additional hardware or wiring systems.

[0027] The methods, devices, processors, modules, engines, and logic described above can be implemented in a variety of ways and with various combinations of hardware and software. For example, all or part of these implementations may be circuitry including an instruction processor (e.g., a central processing unit (CPU), microcontroller, or microprocessor), an application specific integrated circuit (ASIC), a programmable logic device (PLD) or field programmable gate array (FPGA), or the like, circuitry including discrete logic or other circuit components (including analog circuit components, digital circuit components, or both), or any combination thereof. The circuitry may include discrete interconnected hardware components, or may be integrated on a single integrated circuit die, or may be distributed across multiple integrated circuit dies, or may be implemented as a multi-chip module (MCM) including multiple integrated circuit dies within a common package.

[0028] The circuitry further includes or has access to instructions that are executed by the circuitry. The instructions are stored in or on a tangible, non-transitory storage medium, such as flash memory, random access memory (RAM), read-only memory (ROM), erasable programmable read-only memory (EPROM), or a magnetic or optical disk, such as a compact disc read-only memory (CD-ROM), hard disk drive (HDD), other magnetic or optical disk, or other machine-readable medium. An article of manufacture, e.g., a computer program product, includes a storage medium and instructions stored in or on the medium that, when executed by circuitry in a device, cause the device to perform any of the processes described or illustrated above.

[0029] The implementation may be distributed as circuitry across multiple system components, e.g., multiple processors and memories, and may include multiple distributed processing systems, if desired. Parameters, databases, and other data structures may be stored and managed separately, incorporated into a single memory or database, logically and physically organized in various ways, and implemented in various ways as data structures such as linked lists, hash tables, arrays, records, objects, or implicit storage mechanisms. Programs may be implemented in various ways, including as parts (e.g., subroutines) within a single program, as separate programs, distributed across multiple memories and processors, or implemented in a library, such as a shared library (e.g., a dynamic link library (DLL)). For example, a DLL stores instructions that cause circuitry to perform any of the processes described or illustrated above.

[0030] The foregoing description of various aspects of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Numerous modifications or variations are possible in light of the above teachings. The described form was chosen and described to provide the best explanation of the principles of the invention and its practical application, thereby enabling those skilled in the art to utilize the invention in various forms, with various modifications, suited to the particular uses intended. All such modifications and variations are within the scope of the invention, as determined by the following claims, when interpreted in accordance with the breadth to which they are fairly, legally, and equitably entitled.

Claims

1. 1. A pump system for a vehicle having an electronic control unit (ECU) for operating the pump system, comprising: a pump assembly including a motor; a pump controller having a command input in communication with the vehicle ECU; Equipped with the pump controller is configured to determine whether the command input of the pump controller is selectively connected to the ECU of the vehicle; the pump controller is operable in at least two modes including a first mode and a second mode; the first mode utilizes a valid pulse width modulation (PWM) input received from the ECU when the pump controller is in communication with the ECU; The second mode utilizes a discrete digital input to control the speed of the pump assembly when the pump controller is not in communication with the ECU.

2. 2. The pump system of claim 1, wherein the pump controller is configured to use the discrete digital input to regulate the speed of the pump having the motor to a constant value when the pump controller determines that the command input unit of the pump controller is not connected to the ECU of the vehicle.

3. 3. The pump system of claim 2, wherein the pump controller is configured to regulate the speed of the pump having the motor to a constant low speed when the command input of the pump controller remains disconnected.

4. 3. The pump system of claim 2, wherein the pump controller is configured to regulate the speed of the pump having the motor to a constant high speed when the command input of the pump controller is connected to ground.

5. 2. The pump system of claim 1, wherein the pump controller is configured to use the valid PWM input as a frequency cycle or a duty cycle when the pump controller determines that the command input of the pump controller is connected to the ECU of the vehicle to detect the valid PWM input.

6. 6. The pump system of claim 5, wherein the pump controller receiving the valid PWM input is configured to adjust the speed of the pump having the motor according to the frequency cycle or the duty cycle.

7. 10. The pump system of claim 1, further comprising a relay switch connected to the pump controller for power supply.

8. 1. A method for controlling a pump system in communication with a vehicle electronic control unit (ECU), comprising: providing a pump assembly having a motor and a pump controller having a command input; determining whether the command input unit is connected; generating an output signal according to the determined connection of the command input, wherein when the pump controller is connected to the ECU, the output signal is based on a valid pulse width modulation (PWM) input, and when the pump controller is not connected to the ECU, the output signal is based on a discrete digital input; adjusting the speed of the pump having the motor in accordance with the input; A method comprising:

9. The step of determining connection of the command input unit of the pump controller includes: determining that the ECU of the vehicle is connected; determining that the device remains unconnected; determining that the device is connected to ground; 9. The method of claim 8, comprising:

10. 10. The method of claim 9, wherein the pump controller utilizes the discrete digital input if it is determined to remain unconnected.

11. 11. The method of claim 10, further comprising the step of adjusting the speed of the pump with the motor to a constant low speed.

12. 10. The method of claim 9, wherein the pump controller is configured to utilize the discrete digital input if the pump controller is determined to be connected to ground.

13. 13. The method of claim 12, further comprising the step of regulating the speed of the pump having the motor at a constant high speed.

14. 10. The method of claim 9, wherein the pump controller utilizes the valid PWM input if it is determined to be connected to the vehicle's ECU.

15. 15. The method of claim 14, further comprising adjusting the speed of the pump having the motor according to a frequency cycle or a duty cycle from the valid PWM input.

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