Starter Motor Test Bench Simulation Unit for Combustion Engine Dynamics
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Solution Overview
Problem
Existing test benches for starter motors using electrical dynamometers struggle to accurately simulate the deterministic temporal profile of combustion engines, leading to time-shifting and unrealistic loads, which can cause damage to the starter motor and render the test bench unusable for real testing.
Innovation Solution
A simulation unit with a mathematical model of the combustion engine is implemented to determine a new load nominal value at each scanning time point, ensuring the regulation is based on the current state of the combustion engine, and the electrical dynamometer's moment of inertia is matched to the real engine's to account for random temporal variations and mechanical dynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a predefinable test characteristic is used to regulate the electrical dynamometer, then the testing process is simplified and can be repeated, but time-shifting occurs between the theoretical characteristic and actual operation leading to unrealistic loads and potential damage to the starter motor
Solution Approach 1:
The patent transitions from a static, predefinable test characteristic to a dynamic regulation approach where the test characteristic is continuously adapted based on actual measured values. The control unit dynamically adjusts the dynamometer's load profile in real-time during each test run, allowing the system to respond to actual temporal variations in the starter motor-combustion engine system while maintaining efficient automated testing.
Solution Approach 2:
The patent implements a feedback mechanism where actual measured values from the starter motor operation are continuously fed back to the control unit. The control unit compares these actual values with the test characteristic and dynamically adjusts the dynamometer regulation accordingly. This closed-loop feedback system eliminates time-shifting issues by continuously synchronizing the test profile with actual system behavior, ensuring realistic load conditions without sacrificing testing efficiency.
2Device complexity
If the electrical dynamometer is regulated according to a fixed test characteristic, then the test setup is simple and cost-effective, but the random temporal variations in the electromechanical system cause time-shifting and unrealistic operational conditions
Solution Approach 1:
The patent employs dynamic regulation of the electrical dynamometer where the test characteristic is not fixed but continuously adapted during operation. The control unit adjusts the dynamometer's load profile in real-time based on actual measured values, enabling the system to accommodate random temporal variations in the starter motor-combustion engine electromechanical system. This dynamic approach maintains relatively simple test bench hardware while significantly improving test accuracy by eliminating time-shifting between theoretical and actual operation.
3Adaptability or versatility
If a predefinable test characteristic is removed and reset for each test run, then the system can be quickly reconfigured, but the deterministic profile fails to account for random temporal variations causing blocking motor conditions and excessive starter current
Solution Approach 1:
The patent implements continuous feedback control where actual measured values from the starter motor operation are constantly monitored and fed back to the control unit. This feedback mechanism enables the test profile to adapt in real-time to random temporal variations in the electromechanical system, preventing blocking motor conditions and excessive starter current by dynamically adjusting the dynamometer load to match actual system behavior rather than following a rigid predefinable profile.
Solution Approach 2:
The patent transforms the static, removable test characteristic into a dynamic, continuously adapting test profile. The control unit dynamically adjusts the dynamometer regulation during each test run based on actual measured values, allowing the system to adapt to random temporal variations without requiring removal or reconfiguration of the test profile. This dynamic adaptability eliminates unrealistic loads while maintaining system versatility.
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 approach enhances the precision and reliability of the test bench by avoiding time-shifting and simulating realistic operational conditions, reducing the risk of damage and making the test bench suitable for representative testing of starter motors.
Implementation Method 1
an electrical dynamometer (3), in particular a permanently magnetic excited synchronous motor, which is connected to the starter motor (2) and simulates a combustion engine
Implementation Method 2
In a simulation unit (20) in which a mathematical model of the combustion engine is implemented, actual values of the operation of the electrical dynamometer (3) at each scanning time point of the regulation measured using the mathematical model
Implementation Method 3
a regulator (21) for regulating the electrical dynamometer (3)... a new load nominal value is determined that is fed to the regulator (21)
Implementation Method 4
the electrical dynamometer's moment of inertia is matched to the real engine's to account for random temporal variations and mechanical dynamics
Data Source
AI summary
To enable testing of a starter motor on a test bench with an electrical dynamometer as a replacement for a real combustion engine, a simulation unit (20) is used in which a mathematical model of the combustion engine is implemented, and the simulation unit (20) determines a new load setpoint (ns, Ts) using the mathematical model from measured actual values (φi, ni, Ti) of the operation of the electrical dynamometer (3) at every scanning time point of a regulation, which new load setpoint (ns, Ts) is fed to the regulator (21) of the electrical dynamometer.