System and method for protecting from power generation instability because of belt-slip

Abstract

A system includes a prime mover drivably coupled to a belt-driven electric machine. An electronic control system is configured to detect belt slip and / or undervoltage conditions and protect electric loads connected to the electric machine in response to the same.

Description

SYSTEM AND METHOD FOR PROTECTING FROM POWER GENERATION INSTABILITY BECAUSE OF BELT-SLIPCROSS-REFERENCE TO RELATED APPLICATION:

[0001] The present application claims priority to, and the benefit of the filing date of, U.S. Provisional Application No. 63 / 677,451 filed July 31, 2024, which is incorporated herein by reference.TECHNICAL FIELD

[0002] The present application relates generally to power generation systems for prime movers that drive electric machines, and more particularly, but not exclusively, to systems and methods for providing protection from power generation instability of electric machines driven by prime movers.BACKGROUND

[0003] Internal combustion engines may utilize a motor and / or a generator to provide start-stop control of the engine, to generate electricity for storage, and / or to use in powering electrical loads. The motor and / or generator can be drivably coupled to the internal combustion engine with a drive belt. However, if the drive belt slips, power generation instability, undervoltage conditions, improper charging of energy storage devices, and other issues can be created. Existing approaches suffer from a number of disadvantages, shortcomings, and unmet needs. There remains a significant need for the unique apparatuses, methods, systems, and techniques disclosed herein.DISCLOSURE OF EXAMPLE EMBODIMENTS

[0004] For the purposes of clearly, concisely, and exactly describing example embodiments of the present disclosure, the manner, and process of making and using the same, and to enable the practice, making and use of the same, reference will now be made to certain example embodiments, including those illustrated in the figures, and specific language will be used to describe the same. It shall nevertheless be understood that no limitation of the scope of the invention is thereby created, and that the invention includes and protects such alterations, modifications, and further applications of the example embodiments as would occur to one skilled in the art.SUMMARY

[0005] A number of embodiments relate to prime movers that operate in conjunction with an electric machine drivably coupled to the prime mover with a drive belt. Belt slip conditions and / or undervoltage conditions are detected during operation of the prime mover and electric machine. Systems and methods are disclosed for protecting a load connected to the electric machine from power generation instability during belt-slip and / or undervoltage conditions. In an embodiment, electric aftertreatment heater loads are protected power generation instability of the electric machine in response to belt-slip and / or undervoltage conditions.

[0006] This summary is provided to introduce a selection of concepts that are further described below in the illustrative embodiments. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter. Further embodiments, forms, objects, features, advantages, aspects, and benefits shall become apparent from the following description and drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] FIG. l is a schematic block diagram of a system with a prime mover and a belt-driven electric machine.

[0008] FIG. 2 is a flow diagram of one embodiment of a method for protecting one or more electric loads from power generation instability of the electric machine.DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

[0009] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, any alterations and further modifications in the illustrated embodiments, and any further applications of the principles of the invention as illustrated therein as would normally occur to one skilled in the art to which the invention relates are contemplated herein.

[0010] With the systems and methods such as those shown in FIGs. 1-2, control strategies for a control apparatus and method for a system 10 that includes a prime mover 12 and an electric machine 14 are disclosed. The prime mover 12 may provide output power to propel a vehicle and / or to provide output power in a stationary application, such as a generator or equipment. The prime mover 12 drives operation of the electric machine 14 with a drive belt 16. The control strategies may be implemented to protect one or more loads connected to the electric machine 14 from power generation instability during undervoltage and / or belt slip conditions.

[0011] With reference to FIG. 1, a system 10 is shown that includes a prime mover 12 and an electric machine 14. Electric machine 14 is drivably coupled to prime mover 12 with drive belt 16. In an embodiment, prime mover 12 includes an output shaft 18 with a gear, pulley, wheel, etc. coupled to drive belt 16. Electric machine 14 includes an input shaft 20 with a gear, pulley, wheel, etc. coupled to drive belt 16 and rotatably drivable via drive belt 16 by rotation of output shaft 18.

[0012] In an embodiment, prime mover 12 is an internal combustion engine, and electric machine 14 is a motor-generator operable to output electric power to power an electric load. The internal combustion engine embodiment includes an intake 22, one or more cylinders 24 that each include a piston (not shown) and form combustion chambers therein to combust an air and fuel mixture, and an exhaust 26 to receive the combustion products from the one or more cylinders 24. Exhaust 26 includes an aftertreatment system 28 that is configured to receive the exhaust and treat the exhaust for emissions reduction. Exhaust 26 may also include one or more electrical loads, such as an electric heater 30 operable to increase a temperature of the exhaust so that aftertreatment system 28 operates more effectively.

[0013] In the illustrated embodiment, prime mover 12 is shown with one cylinder 24, but any number and arrangement of cylinders 24 are contemplated, and system 10 is not limited to the number and arrangement shown in FIG. 1. Each cylinder 24 typically includes a piston slidably disposed in a combustion chamber, at least one intake valve to admit intake flow from intake 22, and at least one exhaust valve to release exhaust gases produced from combustion to exhaust 26.

[0014] Electric heater 30 in exhaust 26 is connected to electric machine 14. Electric heater 30 is an example of an electric load that the operated by electric machine 14. Other types of electric loads are also contemplated and not precluded. In the illustrated example, electric heater 30 is operable via electrical energy from electric machine 14 to heat the exhaust from cylinders 2. In an embodiment, electric machine 14 is operable to supply voltage / power to electric heater 30 continuously in response to a temperature increase condition of the exhaust except when disabled due to belt slip and / or undervoltage conditions exist, as discussed further below.

[0015] Aftertreatment system 28 can be connected downstream of electric heater 30. The aftertreatment system 28 may include, for example, three way catalysts (TWC), oxidation devices (DOC), particulate removing devices (DPF, CDPF), constituent absorbers or reducers (SCR, AMOX, LNT), reductant systems, and other components if desired.

[0016] In an embodiment, system 10 is controlled by an electronic control system (ECS) 50 to control the operational status of electric machine 14 and heater 30. Electric machine 14 responds to control commands from ECS 50 and / or to an electronic controller 52 of ECS 50 to selectively start, stop, and / or derate electric power from electric machine 14 to power electric loads, such as electric heater 30. In the illustrated embodiment, only one electric heater 30 is shown, but it should be understood that the electric load can be comprised of more than one electric loads and / or more than one electric heater 30.

[0017] System 10 includes one or more prime mover sensors 60 operably connected to ECS 50 to provide signals indicative of one or more of the prime mover operating parameters, such as engine speed, shaft speed, torque output, etc. In addition, system 10 includes one or more electric machine sensors 62 connected to ECS 50 to provide signals indicative of one or more electric machine operating parameters, such as machine speed, output power, output current, output voltage, temperature, etc. In addition, system 10 is configured to derive one or more operating parameters from sensors 60 and / or sensors 62, such as a belt slip condition of drive belt 16 between prime mover 12 and electric machine 14. It shall be appreciated that sensors 60and / or sensors 62 may be physical sensors, virtual sensors, or representative of values derived from one or more other physical and / or virtual sensors.

[0018] ECS 50 is configured to implement and / or output control commands to control operation of the electric machine 14 either directly or to a controller of electric machine 14. The control commands can be, for example, on-off commands to start / stop electric machine 14, output power commands to derate an electric power output from electric machine 14 to electric heater 30, and / or commands to selectively engage and disengage the connection between electric machine 14 and prime mover 12, such as be actuating and deactuating a clutch. It shall be appreciated that FIG. 1 depicts control relationships between the foregoing components conceptually and that various communications hardware and protocols may be utilized to implement, such as one or more controller area networks (CAN) or other communications components.

[0019] The ECS 50 can be implemented in any of a number of ways that combine or distribute the control function across one or more control units in various manners. The ECS 50 includes one or more programmable microprocessors or microcontrollers of a solid-state, integrated circuit type, and one or more non-transitory memory media configured to store instructions executable by the one or more microprocessors or microcontrollers. The ECS 50 may execute operating logic that defines various control, management, and / or regulation functions. This operating logic may be in the form of dedicated hardware, such as a hardwired state machine, analog calculating machine, programming instructions, and / or a different form as would occur to those skilled in the art.

[0020] The ECS 50 may be provided as a single component or a collection of operatively coupled components; and may be comprised of digital circuitry, analog circuitry, or a hybrid combination of both of these types. When of a multi-component form, the ECS 50 may have one or more components remotely located relative to the others in a distributed arrangement. The ECS 50 can include multiple processing units arranged to operate independently, in a pipeline processing arrangement, in a parallel processing arrangement, or the like. It shall be further appreciated that the ECS 50 and / or any of its constituent components may include one or more signal conditioners, modulators, demodulators, Arithmetic Logic Units (ALUs), Central Processing Units (CPUs), limiters, oscillators, control clocks, amplifiers, signal conditioners, filters, format converters, communication ports, clamps, delay devices, memory devices, Analogto Digital (A / D) converters, Digital to Analog (D / A) converters, and / or different circuitry or components as would occur to those skilled in the art to perform the desired communications.

[0021] Referring to FIG. 2, a method 200 is shown for operating system 10 using prime mover 12, electric machine 14, and electric heater 30. Method 200 can be implemented in ECS 50 and / or in electronic controller 52 in response to signal s / outputs from sensors 60 and / or 62, prime mover 12 operating parameters, electric machine 14 operating parameters, belt slip operating parameters including belt slip detection of drive belt 16, and / or undervoltage detection operating parameters.

[0022] Method 200 includes an operating parameter data step 202 executed during operation of prime mover 12 and electric machine 14. Data step 202 retrieves or calculates the available power to the electric loads, such as the available power to electric heater 30, before a derate condition occurs. In an embodiment, a derate condition occurs due to undervoltage of electric machine 14 and / or due to a belt slip condition of drive belt 16.

[0023] Method 200 continues at an operation step 204 to calculate the derate in electric power from electric machine 14 based on belt slippage of drive belt 16 and / or undervoltage conditions of electric machine 14. Based on the calculation(s) from operation step 204, a second operating parameter data step 206 includes or retrieves the available power to the electric load, such as the available power to electric heater 30, after the power derate due to undervoltage and / or belt slippage conditions.

[0024] Method 200 continues at conditional 208 to determine if the difference in the available electric power from operating parameter data steps 202, 206 is greater than a calibrated threshold. In an embodiment, the calibrated threshold corresponds to a protection limit for the electric load that protects the electric load from undervoltage and / or power generation instability conditions. If conditional 208 is NO, method 200 returns to continue to monitor for electric power derating during operation of prime mover 12 and electric machine 14 due to belt slip and / or undervoltage conditions.

[0025] If conditional 208 is YES, method 200 continues at operation 210 to start a timer. The time monitors the elapsed time in which the power derate occurs. Method 200 continues while the timer is operating at conditional 212 to determine if the time recorded by the timer exceeds a calibrated threshold. The calibrated threshold is set to avoid indicating faults for momentary power derates.

[0026] If conditional 212 is NO, method 200 returns to continue to monitor for the elapsed time that conditional 208 remains YES, or may return to data step 202 if conditional 208 is NO. If conditional 212 is YES, then method 200 continues at operation step 214 to set a fault. The fault provides, for example, a system diagnostic that the reduction in the electric load induced by ECS 50 and the persistence in the electric load reduction is excessive and system repairs are needed to protect against failure conditions.

[0027] In an embodiment, method 200 includes operating prime mover 12 while drivably coupled to electric machine 14 with drive belt 16. Method 200 includes monitoring drive belt 16 for belt-slip and / or monitoring electric machine 14 for undervoltage. Method 200 includes detecting a belt-slip condition of drive belt 16 and / or an undervoltage condition of electric machine 14 and initiating one or more power instability protection operations for an electric load, such as electric heater 30, coupled to electric machine 14 in response to detecting the beltslip condition and / or the undervoltage condition.

[0028] In an embodiment, method 200 includes derating an electric power available to electric load 30 from electric machine 14 in response to initiating one or more power instability protection operations. In an embodiment, method 200 includes outputting the fault in response to derating the electric power more than a calibrated threshold for a threshold amount of time.

[0029] In an embodiment, method 200 includes derating electric power to the electric load, such as electric heater 30, coupled to electric machine 14 to reduce the belt slip condition and / or the undervoltage condition in response to initiating the one or more power instability protection operations. In an embodiment, method 200 includes determining a difference between the electric power to the electric load before the derate and the electric power to the electric load after the derate.

[0030] In an embodiment, method 200 includes determining the difference in the electric power before and after derate exceeds a calibrated threshold and outputting a fault in response to the determination. In an embodiment, method 200 includes determining the difference exceeds the calibrated threshold for a threshold amount of time before outputting the fault.

[0031] In an embodiment, ECS 50 includes an apparatus such as electronic controller 52 for protecting an electric load from power generation instability of electric machine 14 drivably coupled to prime mover 12 with drive belt 16. The electronic controller 52 includes a processorand a memory coupled to the processor. The memory includes instructions encoded on a non- transitory computer readable medium.

[0032] In an embodiment, the instructions when executed cause the processor of electronic controller 52 to monitor the drive belt 16 for belt-slip conditions and / or electric machine 14 for undervoltage conditions; detect a belt-slip condition of the drive belt 16 and / or an undervoltage condition of electric machine 14; and initiate one or more power instability protection operations for the electric load coupled to electric machine 14 in response to detecting the belt-slip condition and / or the undervoltage condition.

[0033] In an embodiment, the instructions encoded on the non-transitory computer readable medium cause the processor of electronic controller 52 to derate an electric power to the electric load from electric machine 14 in response to detecting the belt-slip condition and / or the undervoltage condition that initiates the one or more power instability protection operations.

[0034] In an embodiment, the instructions encoded on the non-transitory computer readable medium cause the processor to determine a difference between the electric power before the derate and after the derate exceeds a calibrated threshold; determine an amount of time the difference exceeds the calibrated threshold; and output a fault in response to the amount of time exceeding a threshold amount of time.

[0035] Any technique for detecting, measuring, determining, and / or calculating undervoltage and / or belt slip conditions is contemplated. For example, in one embodiment belt slip conditions are detected by determining a difference between a speed of prime mover 12 and a speed of electric machine 12 differ from one another by more than a normal operational amount.

[0036] Various aspects of the present disclosure are contemplated. In one aspect of the present disclosure, a system for generating power is provided. The system includes a prime mover including an output shaft, an electric machine drivably couple to the output shaft with a drive belt, and one or more electrical loads coupled to the electric machine. The system also includes a controller configured to detect a belt-slip condition of the drive belt and / or an undervoltage condition of the electric machine. The controller is further configured to initiate one or more power generation instability operations in response to detecting the belt-slip condition and / or the undervoltage condition.

[0037] In an embodiment, the controller is configured to output a fault in response to the powergeneration instability operations reducing an electric power to the electric loads more than a threshold amount for a threshold amount of time.

[0038] In an embodiment, the one or more power generation instability operations include the controller derating an electric power available to the one or more electric loads from the electric machine.

[0039] In an embodiment, the prime mover is an internal combustion engine that includes an aftertreatment system configured to receive an exhaust output from the internal combustion engine. The one or more electric loads include an electric heater operable to heat the exhaust output.

[0040] In an embodiment, the one or more power instability protection operations includes the controller derating an electric power to the one or more electric loads from the electric machine in response to detecting the one or more of the belt-slip condition and the undervoltage condition.

[0041] In a further embodiment, the controller is configured to determine a difference between the electric power before the derate and the electric power after the derate in response to initiating the one or more power generation instability protection operations.

[0042] In yet a further embodiment, the controller is configured to determine an amount of time that the difference exceeds a calibrated threshold. In still a further embodiment, the controller is configured to output a fault in response to the amount of time exceeding a time threshold.

[0043] In an embodiment, the electric machine is a motor-generator.

[0044] According to another aspect of the present disclosure, a method for operating a prime mover drivably coupled to an electric machine with a drive belt is disclosed. The method includes monitoring the drive belt for belt-slip and monitoring the electric machine for undervoltage; detecting a belt-slip condition of the drive belt and / or an undervoltage condition of the electric machine; and initiating one or more power instability protection operations for an electric load coupled to the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition.

[0045] In an embodiment, the method includes derating an electric power available to the electric load from the electric machine in response to initiating one or more power instability protection operations.

[0046] In a further embodiment, the method includes outputting a fault in response to derating the electric power more than a calibrated threshold for a threshold amount of time.

[0047] In an embodiment, the method includes derating electric power to the electric load coupled to the electric machine to reduce the belt slip condition and / or the undervoltage condition in response to initiating the one or more power instability protection operations.

[0048] In a further embodiment, the electric load is a heater operable to heat exhaust gas in an aftertreatment system coupled to the prime mover.

[0049] In yet a further embodiment, the method includes determining a difference between the electric power to the electric load before the derate and the electric power to the electric load after the derate.

[0050] In still a further embodiment, the method includes determining the difference exceeds a calibrated threshold and outputting a fault in response to the determination.

[0051] In still yet a further embodiment, the method includes determining the difference exceeds the calibrated threshold for a threshold amount of time before outputting the fault.

[0052] According to another aspect of the present disclosure, an apparatus for protecting an electric load from power generation instability of an electric machine drivably coupled to a prime mover with a drive belt is provided. The apparatus includes an electronic controller including a processor and a memory coupled to the processor, the memory including instructions encoded on a non-transitory computer readable medium. The instructions when executed cause the processor to monitor the drive belt for a belt-slip conditions and the electric machine for an undervoltage condition; detect the belt-slip condition of the drive belt and / or the undervoltage condition of the electric machine; and initiate one or more power instability protection operations for an electric load coupled to the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition.

[0053] In an embodiment, the instructions encoded on the non-transitory computer readable medium cause the processor to derate an electric power to the electric load from the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition that initiates the one or more power instability protection operations.

[0054] In an embodiment, the instructions encoded on the non-transitory computer readable medium cause the processor to determine a difference between the electric power before the derate and after the derate exceeds a calibrated threshold; determine an amount of time thedifference exceeds the calibrated threshold; and output a fault in response to the amount of time exceeding a threshold amount of time.

[0055] According to another aspect of the present disclosure, a method for operating an internal combustion engine that includes a belt-driven motor-generator is provided. The method includes determining a target condition associated with the turbocharger compressor during operation of the internal combustion engine; and operating the electric compressor in response to the target condition of the turbocharger compressor.

[0056] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only certain exemplary embodiments have been shown and described and that all changes and modifications that come within the spirit of the inventions are desired to be protected.

[0057] It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention, the scope being defined by the claims that follow. In reading the claims, it is intended that when words such as “a,” “an,” “at least one,” or “at least one portion” are used there is no intention to limit the claim to only one item unless specifically stated to the contrary in the claim. When the language “at least a portion” and / or “a portion” is used the item can include a portion and / or the entire item unless specifically stated to the contrary.

Claims

What is claimed is:

1. A system for generating power, the system comprising: a prime mover including an output shaft; an electric machine drivably couple to the output shaft with a drive belt; one or more electrical loads coupled to the electric machine; and a controller configured to detect a belt-slip condition of the drive belt and / or an undervoltage condition of the electric machine, the controller further configured to initiate one or more power generation instability operations in response to detecting the belt-slip condition and / or the undervoltage condition.

2. The system according to claim 1, wherein the controller is configured to output a fault in response to the power generation instability operations reducing an electric power to the electric loads more than a threshold amount for a threshold amount of time.

3. The system according to claim 1, wherein the one or more power generation instability operations include the controller derating an electric power available to the one or more electric loads from the electric machine.

4. The system according to claim 1, wherein: the prime mover is an internal combustion engine that includes an aftertreatment system configured to receive an exhaust output from the internal combustion engine; and the one or more electric loads include an electric heater operable to heat the exhaust output.

5. The system according to claim 1, wherein the one or more power instability protection operations includes the controller derating an electric power to the one or more electric loads from the electric machine in response to detecting the one or more of the belt-slip condition and the undervoltage condition.

6. The system according to claim 5, wherein the controller is configured to determine a difference between the electric power before the derate and the electric power after the derate in response to initiating the one or more power generation instability protection operations.

7. The system according to claim 6, wherein the controller is configured to determine an amount of time that the difference exceeds a calibrated threshold.

8. The system according to claim 7, wherein the controller is configured to output a fault in response to the amount of time exceeding a time threshold.

9. The system according to claim 1, wherein the electric machine is a motor-generator.

10. A method for operating a prime mover drivably coupled to an electric machine with a drive belt, the method comprising: monitoring the drive belt for belt-slip and monitoring the electric machine for undervoltage; detecting a belt-slip condition of the drive belt and / or an undervoltage condition of the electric machine; and initiating one or more power instability protection operations for an electric load coupled to the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition.

11. The method according to claim 10, further comprising derating an electric power available to the electric load from the electric machine in response to initiating one or more power instability protection operations.

12. The method according to claim 11, further comprising outputting a fault in response to derating the electric power more than a calibrated threshold for a threshold amount of time.

13. The method according to claim 10, further comprising derating electric power to the electric load coupled to the electric machine to reduce the belt slip condition and / or theundervoltage condition in response to initiating the one or more power instability protection operations.

14. The method according to claim 13, wherein the electric load is a heater operable to heat exhaust gas in an aftertreatment system coupled to the prime mover.

15. The method according to claim 13, further comprising determining a difference between the electric power to the electric load before the derate and the electric power to the electric load after the derate.

16. The method according to claim 15, further comprising determining the difference exceeds a calibrated threshold and outputting a fault in response to the determination.

17. The method according to claim 16, further comprising determining the difference exceeds the calibrated threshold for a threshold amount of time before outputting the fault.

18. An apparatus for protecting an electric load from power generation instability of an electric machine drivably coupled to a prime mover with a drive belt, the apparatus comprising: an electronic controller including a processor and a memory coupled to the processor, the memory including instructions encoded on a non-transitory computer readable medium, the instructions when executed cause the processor to: monitor the drive belt for a belt-slip conditions and the electric machine for an undervoltage condition; detect the belt-slip condition of the drive belt and / or the undervoltage condition of the electric machine; and initiate one or more power instability protection operations for an electric load coupled to the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition.

19. The apparatus according to claim 18, wherein the instructions encoded on the non- transitory computer readable medium cause the processor to:derate an electric power to the electric load from the electric machine in response to detecting the belt-slip condition and / or the undervoltage condition that initiates the one or more power instability protection operations.

20. The apparatus according to claim 18, wherein the instructions encoded on the non- transitory computer readable medium cause the processor to: determine a difference between the electric power before the derate and after the derate exceeds a calibrated threshold; determine an amount of time the difference exceeds the calibrated threshold; and output a fault in response to the amount of time exceeding a threshold amount of time.

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