Engine Starter Control for Stall Prevention
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Solution Overview
Problem
Conventional engine control systems often fail to prevent engine stalls effectively, as they rely on varying engine torque output and load management, which are not always sufficient to maintain engine speed and prevent stalling.
Innovation Solution
A control system and method that utilize a starter assembly to supply torque to the engine at low speeds by selectively activating the starter motor and adjusting its rotational speed to synchronize with the engine's crankshaft, thereby preventing engine stalls by maintaining engagement until the engine reaches a predetermined speed or desired RPM.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional engine control systems vary engine torque output and load management to prevent stalls, then engine operation is maintained under normal conditions, but the systems fail to prevent engine stalls effectively at low speeds
Solution Approach 1:
The starter motor is designed to perform dual functions: traditional engine starting and low-speed operation assistance. The control system enables the starter motor to engage with the flywheel at low engine speeds (above stalling threshold but below normal operating RPM) to provide torque support, preventing engine stalls during idle or low-load conditions without requiring separate dedicated components
Solution Approach 2:
The system dynamically adjusts starter motor activation based on real-time engine speed monitoring. The control system continuously monitors engine RPM and selectively engages the starter motor only when engine speed falls below a predetermined threshold, disengages when threshold is exceeded, creating adaptive response to varying operational conditions to prevent stalls while maintaining normal operation
2Reliability
If the starter motor is selectively activated to increase engine rotational speed, then engine stalls are prevented, but additional complexity is introduced to the control system
Solution Approach 1:
The control system implements a feedback mechanism by continuously monitoring engine speed through existing sensors and using this information to control starter motor activation. When engine speed drops below the predetermined threshold, the control system automatically engages the starter motor; when speed exceeds the threshold, it disengages the starter motor, creating a closed-loop control system that prevents stalls through real-time responsiveness
Solution Approach 2:
The system utilizes existing engine components and sensors to monitor and control starter motor operation. The control system leverages the engine's own speed feedback to determine when starter assistance is needed, making the system self-regulating without requiring external intervention or complex additional sensing infrastructure
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
The system effectively prevents engine stalls by ensuring the engine receives additional torque at low speeds, synchronizing rotational speeds, and reducing the difference between current and desired engine RPM, thus maintaining engine operation and avoiding stalling conditions.
Implementation Method 1
A control system and method that utilize a starter assembly to supply torque to the engine at low speeds by selectively activating the starter motor and adjusting its rotational speed
Implementation Method 2
adjusting its rotational speed to synchronize with the engine's crankshaft, thereby preventing engine stalls by maintaining engagement until the engine reaches a predetermined speed or desired RPM
Data Source
AI summary
A control system for an engine including a starter may include a speed determination module that determines a first rotational speed of the engine during a run period contiguously following a period of starting the engine using the starter, and a speed control module that, when the first rotational speed falls below a predetermined speed greater than zero during the run period, selectively activates the starter to increase the first rotational speed. The speed control module may selectively activate the starter by selectively adjusting, based on the first rotational speed, a second rotational speed of a motor drive of the starter that supplies torque for cranking the engine and subsequently selectively engaging one of the motor drive and a first rotational member of the starter rotationally driven by the motor drive with a second rotational member of the engine. A related method is also provided.