Alternator Control System With Relay Feedback Switch
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Solution Overview
Problem
Existing alternator systems with remote sense capabilities for maintaining battery charge face risks of component damage due to potential failures in the feedback loop, which can lead to unsafe voltage levels if the feedback circuit is compromised.
Innovation Solution
An alternator control system that includes a switch on the internal feedback line, an adjustable voltage source, and an external feedback line connected to a battery monitor, allowing the controller to selectively vary the voltage input to the internal output voltage regulator to maintain a pre-set voltage at the battery, while automatically reverting to internal feedback in case of external feedback loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an external wire is added to provide remote sense capability for accurate battery voltage feedback, then voltage measurement precision is improved, but system reliability deteriorates due to additional failure mechanisms in the feedback loop
Solution Approach 1:
The patent introduces a relay as an intermediary component that selectively connects or disconnects the external feedback wire from the voltage regulator. This allows the system to use the external wire for accurate voltage measurement when needed, while being able to disconnect it to prevent failure propagation. The relay acts as a mediator that enables the benefits of external sensing without permanently committing the system to the reliability risks of a continuous external feedback path.
Solution Approach 2:
The patent makes the feedback path dynamic by using a relay that can switch between internal and external feedback sources. This dynamic configuration allows the system to adapt its feedback path based on operational needs and component health status. The ability to dynamically change the feedback source provides both the measurement precision of external sensing and the reliability of having an internal backup path.
2Device complexity
If the feedback loop is compromised in a remote sense system, then system simplicity is maintained, but harmful effects occur due to unsafe voltage levels that can destroy components
Solution Approach 1:
The patent implements beforehand cushioning by providing an internal feedback path that serves as a protective backup before external feedback failure can cause harm. The relay is configured to automatically or manually switch to the internal feedback path when external feedback is compromised, preventing the harmful effect of uncontrolled voltage rise. This prior preparation of an alternative path cushions the system against the potential damage from feedback loop failure.
Solution Approach 2:
The patent employs dual feedback paths (internal and external) with the relay enabling selective switching between them. This feedback redundancy ensures that if one feedback path fails or provides incorrect information, the other path can take over to maintain proper voltage regulation. The system thus maintains its ability to detect and respond to voltage conditions even when one feedback mechanism is compromised.
3Reliability
If internal feedback is used to maintain constant voltage output, then system reliability is improved by eliminating external failure points, but adaptability deteriorates as the system cannot respond to environmental conditions or line losses
Solution Approach 1:
The patent makes the feedback system universal by designing it to accept multiple feedback sources (internal and external) through the relay switching mechanism. The same voltage regulator can operate in different modes depending on which feedback path is active. This multi-functionality allows the system to maintain the reliability of internal feedback while gaining the adaptability of external feedback for environmental compensation and line loss correction when conditions require it.
Data Source
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Figure 3~4
AI summary
An alternator control system (40) and method for an alternator (30) having an internal output voltage regulator (16) that measures and regulates the charging voltage through an internal feedback line (18) characterized by a switch (42) on the internal feedback line; an adjustable voltage source (46) connected to the internal output voltage regulator; an external feedback line (22) configured to be connected to measure a condition of a battery (14) receiving the charging voltage at the battery; and a controller (44) connected to receive a signal corresponding to the condition of the battery over the external feedback line, and in response thereto, selectively open the switch, and selectively actuate the adjustable voltage source to selectively vary the voltage input to the internal output voltage regulator, thereby causing the internal output voltage regulator to signal the alternator to correspondingly vary the output voltage so that a voltage reaching the battery is at a pre-set value.