Ultracapacitor Stop-Start System for Vocational Vehicles

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Solution Overview

Problem

Stop-start systems for vocational vehicles face design challenges, including battery and starter motor limitations, integration issues due to multiple manufacturers, and the need for large batteries to power auxiliary equipment, leading to inefficiencies and high costs.

Innovation Solution

A stop-start fuel saving system utilizing a low storage capacity, rapid recharge, high cycle life electric energy storage device, such as ultracapacitors, that powers both integral and peripheral equipment, with a generator to recharge the energy storage device by restarting the engine, allowing for flexible power demand and reduced energy storage capacity requirements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional battery and starter motor are used in a stop-start system, then the system can be implemented, but the battery and starter motor cannot handle repeated stop-start cycles

Engineering Contradiction:

Improvebattery and starter motor durabilityVSAvoidnumber of stop-start cycles

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the electrical parameters by using a capacitor bank instead of a conventional battery, providing high surge current capability for repeated engine starts while maintaining system reliability through the capacitor's ability to handle frequent charge-discharge cycles

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the conventional battery-based electrical storage system with a capacitor-based electrical storage system, leveraging the capacitor's superior ability to deliver high current pulses for engine starting while withstanding repeated cycling

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If a large battery is used to power auxiliary equipment during engine-off periods, then auxiliary equipment can operate, but the energy storage capacity and weight increase significantly

Engineering Contradiction:

Improveauxiliary equipment operation capabilityVSAvoidbattery weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of moving object

Solution Approach 1:

The patent segments the power delivery function into two parts: the capacitor bank handles high-power auxiliary equipment operation during brief engine-off periods, while the engine-generator system recharges the capacitor and provides sustained power for longer duration needs, eliminating the need for a single large heavy battery

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent creates a multi-functional power system where the capacitor bank serves both as a start-stop energy source and as a power supply for auxiliary equipment, while the engine-generator provides both vehicle propulsion and capacitor recharging functions

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Quantity of substance

If the engine is restarted frequently to recharge the energy storage device, then the energy storage capacity can be reduced, but the engine wear and fuel consumption increase

Engineering Contradiction:

Improveenergy storage capacityVSAvoidfuel consumption

Core Design Contradiction:

Quantity of substanceVSLoss of energy

Solution Approach 1:

The patent implements periodic engine operation where the engine is restarted only when the capacitor bank charge drops below a threshold level, creating a regular cycling pattern that maintains adequate charge reserves while minimizing unnecessary restarts and associated fuel consumption

Inventive Principle:

Principle #19Periodic action

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 enables efficient operation of vocational vehicles with frequent stops and auxiliary equipment, reducing energy storage needs, weight, and cost, while providing extended operational capabilities and flexibility, including powering external equipment without increasing storage capacity.

Implementation Method 1

low storage capacity, rapid recharge, high cycle life electric energy storage device, such as ultracapacitors

Methodology Applied

Scientific EffectCapacitance: Capacitance

Implementation Method 2

a generator to recharge the energy storage device by restarting the engine

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS10875519B2Expanded functionality stop-start fuel saving system for vocational vehicles

Publication Date: 2020.12.29 14156048 CANADA INC

AI summary

An engine stop-start fuel saving system for a vocational vehicle propelled by a conventional internal combustion engine and powertrain. The system uses a low storage capacity, rapid recharge, high cycle life electric energy storage device, such as an ultracapacitor. The system also includes a generator that is coupled to the engine and that is connected to recharge the electric energy storage device, as well as a motor that is powered by the energy storage device and that is coupled to the engine. The system also includes a controller that can activate the motor to restart the engine when it is stopped, and engage the generator to recharge the electric energy storage device, and that can subsequently stop the engine again when the electric energy storage device has reached a threshold charge level. The electric energy storage device also powers at least one of: integral vehicle equipment; peripheral vehicle equipment; or an electrical outlet circuit with a socket for external plugin equipment.