Alternator Control System Optimizing Fuel Consumption via Battery State Feedback
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Solution Overview
Problem
Current alternator electronic control systems in vehicles face challenges in accurately predicting and managing electric loads, leading to inefficient energy use, increased emissions, and reduced battery life due to complex and approximate efficiency index calculations that do not consider battery state of charge.
Innovation Solution
An alternator electronic control system incorporating an Intelligent State Battery sensor, body computer, and Intelligent Alternator Module, which dynamically estimates electric loads and adjusts the alternator's control current based on real-time battery state parameters and vehicle operational states to optimize torque and reduce energy waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the alternator electronic control system calculates the efficiency index based on the working point of the internal combustion engine, then the alternator can be controlled to reduce fuel consumption, but the calculation becomes complex and approximate because it does not accurately predict current requirements from varying electric vehicle loads and battery voltage
Solution Approach 1:
The control system continuously monitors actual battery voltage and current draw, comparing these measurements against predicted values. This feedback loop allows the system to refine its efficiency calculations in real-time, correcting for variations in electric loads and battery characteristics that were not predictable using only engine working point data.
Solution Approach 2:
The system pre-calculates efficiency maps based on engine operating conditions before actual operation. These pre-computed efficiency indices are stored and then adjusted during runtime based on actual battery state measurements, combining offline preparation with online refinement to achieve both computational efficiency and accuracy.
2Device complexity
If the alternator control system only considers the torque pattern of the internal combustion engine, then the control implementation is simplified, but the battery state of charge is not considered causing progressive discharging over time
Solution Approach 1:
The control system integrates multiple functions into a single controller: it monitors both engine torque requirements and battery state of charge, manages alternator output accordingly, and maintains adequate battery charging levels. This multi-functional approach handles both engine performance and battery reliability within one control architecture.
Solution Approach 2:
The system dynamically adjusts alternator control based on real-time battery state of charge measurements. When battery charge drops below thresholds, the system automatically increases alternator output to recharge the battery, even if this temporarily increases engine load. This dynamic response ensures long-term battery health while maintaining overall system efficiency.
3Duration of action of stationary object
If the alternator control current is adjusted dynamically based on real-time battery state parameters, then battery life is extended and energy waste is reduced, but the control system complexity increases with additional sensors and processing
Solution Approach 1:
The control system uses the vehicle's existing communication networks and microcontroller units to perform battery state monitoring and alternator control. Rather than requiring completely new hardware, the system leverages available resources in the vehicle's electrical architecture, adding only minimal dedicated sensors and integration logic.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces energy waste, improves engine performance, extends battery life, and decreases emissions by accurately managing alternator torque and energy consumption, achieving a 2-3% reduction in fuel consumption on the NEDC cycle.
Implementation Method 1
the alternator is a vehicle electrical device which is rotated by the internal combustion engine
Implementation Method 2
measuring a series of battery state parameters comprising an internal battery temperature, a state of charge, a battery voltage and a battery current
Data Source
AI summary
Automotive electrical system for a motor vehicle comprising an internal combustion engine of a motor vehicle; the electric vehicle system comprising a series of electric vehicle loads, an electric battery, and an alternator generating a supply voltage of the electric vehicle loads and of the electric battery; the alternator comprising an inductive electric circuit adapted to be crossed by an electric control current; the electric vehicle system comprises an alternator electronic control system configured so as to determine a series of battery parameters (pam_bat) indicating the state of operation of the electric battery; determine at least a first vehicle parameter indicating the acceleration of the motor vehicle; determine the operative state of the internal combustion engine; determine an electric regulation voltage according to the operative engine station, to the vehicle parameter and to the battery parameters; vary an electric control current circulating in the inductive electric circuit of the alternator according to the electric regulation voltage.