On-Board Starting Module Using Super Capacitors for Engine Cranking
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Solution Overview
Problem
Vehicles with lead acid batteries often face starting issues due to battery weakness, especially in delivery trucks and boats, as the batteries lose charge over time and are further drained by frequent engine restarts, leading to unreliable engine cranking and the need for external recharging.
Innovation Solution
An on-board engine starting module equipped with a housing, a bank of super capacitors, a DC converter, control logic, and an isolation switch, which stores charge from the vehicle's electrical system and releases it to assist the battery in starting the engine when weak, and recharges once the alternator is operational.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lead acid battery is used to start the engine, then the battery can store electrical energy, but the battery loses charge over time and becomes too weak to start the engine reliably
Solution Approach 1:
The patent combines a super capacitor bank with the existing lead acid battery system. The super capacitor bank is electrically connected in parallel with the battery, creating a hybrid energy storage system. This merging allows the super capacitor to provide high current bursts for engine starting while the battery handles steady-state electrical loads, resolving the reliability issue without completely replacing the battery infrastructure.
Solution Approach 2:
The super capacitor bank serves multiple functions: it provides auxiliary starting power when the battery is weak, captures regenerative braking energy in hybrid vehicles, and supplies power during engine idle periods when the alternator is not running. This multi-functionality addresses the energy loss problem by making the system more versatile in energy management.
2Productivity
If the battery is frequently discharged to start the engine multiple times, then the engine can be restarted, but the battery becomes completely depleted and requires external recharging
Solution Approach 1:
The super capacitor bank is designed to automatically recharge itself from the alternator when the engine is running. During engine operation, the alternator charges the super capacitor bank, which then becomes available for the next starting cycle. This self-service capability eliminates the need for external recharging services and allows continuous engine restarts without time loss.
Solution Approach 2:
The super capacitor bank is pre-charged during engine operation before a starting event is needed. This preliminary charging action ensures that when engine starting is required, the super capacitor is already ready to provide immediate high current, eliminating the need for external recharging and enabling quick engine restarts.
3Reliability
If a larger battery is used to provide more starting power, then the battery can handle more crank cycles, but the battery weight and size increase
Solution Approach 1:
The patent changes the electrical parameters of the energy storage system by introducing super capacitors with high capacitance values (e.g., 6,000 Farads per capacitor). This parameter change allows the system to deliver high current pulses for engine starting without requiring a proportionally larger battery, thus maintaining reliability while avoiding excessive weight increase from battery alone.
Solution Approach 2:
The system uses a composite energy storage architecture combining super capacitors and lead acid batteries. Each component contributes its strengths: super capacitors provide high power density for starting, while batteries provide high energy density for steady-state operation. This composite approach achieves the required cranking power without the weight penalty of a single oversized battery.
4Loss of energy
If the engine is allowed to idle to save battery life, then battery charge is preserved, but carbon emissions increase due to regulatory restrictions
Solution Approach 1:
The super capacitor bank enables continuous engine operation without idle periods. By providing auxiliary starting power, the system allows the engine to remain running during stop-and-go delivery operations rather than shutting down and restarting. This continuity of useful action preserves battery charge while eliminating the harmful emissions associated with frequent cold starts and idle regulations.
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
Enables reliable engine starting even when the battery is dead, reduces the need for external recharging, and maintains the super capacitors' charge through the alternator, ensuring efficient power transfer and extended vehicle operation.
Implementation Method 1
a bank of super capacitors, which stores charge from the vehicle's electrical system and releases it to assist the battery in starting the engine when weak
Implementation Method 2
a DC converter, which transforms voltage from the vehicle's electrical system to charge the super capacitors
Implementation Method 3
recharges once the alternator is operational
Data Source
AI summary
A starting module for a vehicle is provided. The starting module is configured to reside on-board the vehicle, and is used to start an engine associated with the vehicle in the event the battery on the vehicle is too weak to crank the engine. The engine starting module first comprises a housing. The housing resides proximate the vehicle battery and holds a plurality of super capacitors. The super capacitors reside within the housing, in series, and are electrically in parallel with the vehicle battery. The super capacitors store charge received from the electrical system of the vehicle. The starting module also includes control logic. The control logic controls the release of energy from the super capacitors. The engine starting module also comprises an isolation switch, which is configured to move between open and close positions in response to signals from the control logic.