Supercapacitor Array On-Demand Voltage Boost for Engine Start
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Solution Overview
Problem
Existing techniques for charging supercapacitor arrays in engine starting applications are not ideal for maximizing energy extraction and can impact the operational lifetime, as they often hold the array at a constant voltage during warm conditions and experience self-discharge during cold conditions, leading to unpredictable voltage availability during engine starts.
Innovation Solution
A charger system that modifies the voltage of supercapacitor cells on-demand by receiving a bump-up command to temporarily increase the voltage from a first holding voltage to a higher start-up voltage, using a DC-DC converter and control module to manage the charging current, thereby ensuring maximum voltage availability during engine starts without significantly reducing the array's lifetime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the supercapacitor array is held at a constant voltage during warm conditions, then the cell lifetime is extended, but the energy extraction capability is reduced
Solution Approach 1:
The patent applies dynamics by transitioning from a static constant voltage holding strategy to a dynamic on-demand voltage boosting strategy. The charger controller dynamically adjusts the supercapacitor array voltage based on real-time detection of engine start conditions, providing high voltage only when needed for engine cranking while maintaining lower voltage during normal operation to preserve cell lifetime.
Solution Approach 2:
The patent changes the voltage parameter dynamically based on operational conditions. During warm conditions and normal operation, the supercapacitor array is held at a lower constant voltage to extend cell lifetime. Upon detection of engine start conditions (cold temperature, low battery voltage), the controller bumps up the voltage to the maximum rated voltage to maximize energy extraction for engine cranking.
2Loss of energy
If the charger is shut down during cold temperatures after charging the supercapacitor array to max rated voltage, then the quiescent draw from the battery is reduced, but the self-discharge causes unpredictable voltage availability
Solution Approach 1:
The patent implements feedback control through a charger controller that continuously monitors system conditions including battery voltage, supercapacitor array voltage, and temperature. Based on this feedback, the controller intelligently manages the charging process and determines when to bump up the voltage to maximum rated voltage, ensuring reliable voltage availability while minimizing unnecessary charging cycles and quiescent draw.
Solution Approach 2:
The supercapacitor array serves itself by providing on-demand high voltage output for engine cranking without requiring continuous charger intervention. The array maintains its charge and automatically delivers maximum voltage when engine start conditions are detected, eliminating the need for the charger to remain active and reducing quiescent battery draw.
3Use of energy by moving object
If the voltage of the supercapacitor array is increased to max rated voltage during cold temperatures, then the energy storage is maximized, but the cell degradation accelerates
Solution Approach 1:
The patent employs periodic action by implementing intermittent voltage boosting rather than continuous high voltage maintenance. The charger bumps up the supercapacitor array voltage to maximum rated voltage only periodically when engine start conditions are detected (cold temperature combined with low battery voltage), rather than maintaining maximum voltage continuously, thereby maximizing energy storage when needed while limiting cumulative stress on the cells.
Solution Approach 2:
The system performs preliminary detection of engine start conditions (temperature and battery voltage thresholds) before initiating the voltage bump-up sequence. This preliminary action allows the controller to prepare and execute the voltage increase only when truly necessary, avoiding unnecessary high-voltage exposure that would accelerate cell degradation while ensuring energy is available when needed.
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 on-demand voltage boost maximizes energy extraction from the supercapacitor array during engine starts, minimizing the impact on its operational lifetime and ensuring reliable voltage availability across varying temperatures, thus enhancing the system's efficiency and reliability.
Implementation Method 1
a DC-DC converter configured to convert a DC battery power received from a DC battery to a DC charging current for output to the arrangement of supercapacitor cells
Implementation Method 2
a supercapacitor array connected to the charger to receive the DC charging current therefrom and comprising a plurality of supercapacitor cells
Data Source
AI summary
A system for starting an internal combustion engine includes a battery system, a charger to receive DC battery power from the battery system and convert the power to a DC charging current, a supercapacitor array having a plurality of supercapacitor cells connected to the charger to receive the DC charging current therefrom, and a motor starter to start the internal combustion engine responsive to a DC input from the supercapacitor array. The charger modifies a voltage of the supercapacitor cells in an on-demand fashion, with the charger programmed to provide DC charging current to the supercapacitor array to hold the supercapacitor cells at a first voltage, receive a bump-up command indicative of an upcoming engine start and, responsive to receiving the bump-up command, provide DC charging current to the supercapacitor array to increase a voltage of the supercapacitor cells temporarily to a second voltage higher than the first voltage.