Retrofit Engine Start/Stop Control via Standalone Microcontroller
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing engine start/stop systems require invasive modifications and are costly, leading to increased complexity and risk of warranty issues, while failing to efficiently manage idle times, resulting in fuel wastage, emissions, and maintenance challenges, especially in intermittent use scenarios and harsh weather conditions.
Innovation Solution
A retrofit engine start/stop control system utilizing a programmable logic controller with sensors for engine block, ambient air temperature, and battery voltage monitoring, allowing for programmable start/stop and idle control without requiring integration with proprietary engine control units, enabling efficient engine management and reduced idle times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If engine start/stop systems are integrated into OEM ECU systems, then start/stop functionality is achieved, but system complexity and development costs increase
Solution Approach 1:
The system separates the start/stop control functionality from the OEM ECU by using a standalone microcontroller unit that independently monitors engine parameters and controls engine starting/stopping without requiring integration into the proprietary ECU system. This segmentation eliminates the need for complex integration while maintaining full automation of start/stop operations.
2Extent of automation
If substantial mechanical modifications are made to engines, then start/stop control is achieved, but reliability and warranty coverage are compromised
Solution Approach 1:
The system uses an intermediary microcontroller unit that interfaces with the engine's existing electrical system through standard connectors and wiring harnesses, rather than requiring direct mechanical modifications to the engine block or internal components. This intermediary approach enables start/stop control while preserving engine integrity and warranty coverage.
3Temperature
If engines are idled in harsh cold weather, then operating temperature is maintained, but fuel consumption and emissions increase
Solution Approach 1:
The system incorporates pre-heating elements and insulation measures that are activated before the engine is started in cold weather, and maintains minimal idle operation only when absolutely necessary. The microcontroller monitors ambient temperature and engine coolant temperature to determine the minimum required idle time, reducing unnecessary fuel consumption while ensuring the engine reaches operating temperature efficiently.
4Productivity
If engines are idled for extended periods, then operational readiness is maintained, but maintenance requirements and wear increase
Solution Approach 1:
The system continuously monitors engine parameters including coolant temperature, oil pressure, and runtime hours through sensors connected to the microcontroller. Based on this feedback, the system dynamically adjusts idle duration and timing to maintain operational readiness while minimizing engine wear and maintenance requirements. The controller can extend idle time when conditions warrant and reduce it when not necessary, optimizing the balance between readiness and maintenance.
Data Source
AI summary
A system and method for retrofit engine start/stop control system for an air starter equipped internal combustion engine includes a circuit to energize and air control value, an air pressure sensor, a programmable logic controller, an engine block temperature sensor to measure an external engine temperature, an ambient temperature sensor, an ignition circuit connector, a battery voltage sensor, and an engine speed sensor. The programmable logic controller is configured to start the engine when at least one of the pressure of the compressed gas tank, an external engine block temperature, an ambient air temperature, and a battery output voltage fall below a predefined threshold value for startup.