Reserve power system for a power consumption device in an internal combustion engine system

According to one embodiment, an electrical power management system for an internal combustion engine system with a power consumption device includes a battery and a supercapacitor. The battery is coupleable in electrical power providing communication with the power consumption device. The supercapacitor is coupleable in electrical power providing communication with the power consumption device.

FIELD

This disclosure relates generally to internal combustion engine systems, and more particularly to providing reserve power to an internal combustion engine system using a supercapacitor.

BACKGROUND

Modern internal combustion engines are controlled by an engine control module (ECM). Generally, the ECM controls the operation of the internal combustion engine, as well various sub-systems operatively coupled to the internal combustion engine. The ECM can receive multiple inputs, process the inputs, and transmit multiple outputs. The outputs are received by one or more components of the internal combustion engine and associated systems, which respond in accordance to the received outputs to achieve desired results.

The ECM is powered by an electrical power source. Often, the internal combustion engine forms part of a vehicle and the electrical power source is a battery of the vehicle. Under some circumstances, power from the vehicle battery to the ECM may be either temporarily or permanently disrupted. For example, some internal combustion engines are equipped with a battery disconnect switch (e.g., kill switch) that can be actuated by a user to prevent the flow of power from the vehicle battery to the ECM. Additionally, some operations of an engine may degrade the performance of the vehicle battery such that the ability of the battery to deliver power to the ECM is limited or lost. As an example, the high current needs of a starter motor of the engine during a cranking operation of the engine may significantly drain power from the battery.

Disruption of power to the ECM can cause the ECM to reset, which may lead to lost data, damaged data, and disabling of one or more of the components of the internal combustion engine. Because data stored on the ECM may be required for necessary operations of the engine, such as the storage and transfer of signals and messages, as well as for servicing and warranty needs, preservation of the data management and engine control functionality of the ECM is important.

SUMMARY

The subject matter of the present application has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available electrical power management systems for internal combustion engines. For example, some currently available electrical power management systems provide back-up power batteries that are used to power components of an internal combustion engine when a dedicated vehicle battery fails or inadequately provides power to the components. Unfortunately, back-up power batteries are complex, bulky, and require robust harnesses to support the batteries in a vehicle. Because space within a vehicle is limited, the back-up batteries of conventional engine systems are undesirable. Additionally, back-up batteries fail to provide quick bursts of energy required by some engine components. Accordingly, the subject matter of the present application has been developed to provide methods, systems, and apparatus for managing electrical power in an internal combustion engine system that overcomes at least some shortcomings of the prior art.

According to one embodiment, an electrical power management system for an internal combustion engine system with a power consumption device includes a battery and a supercapacitor. The battery can be coupled to the power consumption device to provide electrical power to the power consumption device. The supercapacitor can be coupled in electrical power providing communication with the power consumption device.

In some implementations, the electrical power management system further includes a power arbitration module that receives electrical power from the battery and the supercapacitor. The power arbitration module also provides electrical power to the power consumption device. Additionally, the power arbitration module can be configured to selectively provide electrical power to the power consumption device from one or both of the battery and supercapacitor. The power arbitration module may selectively provide electrical power to the power consumption device from only the supercapacitor based on a condition of the battery. According to some implementations, the electrical power management system also includes a battery disconnect switch, where the power arbitration module selectively provides electrical power to the power consumption device from only the supercapacitor when the battery disconnect switch is activated. The power arbitration module can selectively provide electrical power to the power consumption device from only the supercapacitor during an engine cranking event of the internal combustion engine. Further, the power arbitration module may selectively provide electrical power to the power consumption device from both the battery and the supercapacitor during an engine cranking event of the internal combustion engine.

According to certain implementations, the electrical power management system includes a recharger that selectively provides electrical power to the supercapacitor. The recharger can be separate from the battery.

In some implementations of the electrical power management system, the power consumption device is an engine control module. The electrical power management system can further include a switch module that receives power from the supercapacitor and a power condition module that receives power from the battery. The switch module is configured to selectively transmit power from the supercapacitor to the engine control module based on a condition of the battery determined by the power condition module. The power condition module can be configured to selectively transmit power from the battery to the engine control module.

In yet certain implementations of the electrical power management system, the battery is non-selectively coupled in electrical power providing communication with the power consumption device, and the supercapacitor is selectively coupled in electrical power providing communication with the power consumption device. The power consumption device can be a starter motor. The supercapacitor can be selectively coupled in electrical power providing communication with the starter motor during an engine cranking event of the internal combustion engine.

According to some implementations of the electrical power management system, the battery and supercapacitor are in parallel. In yet some implementations, the battery is not in electrical power receiving communication with another component of the internal combustion engine system.

According to another embodiment, an internal combustion engine system includes an internal combustion engine and a power consumption device coupled to the internal combustion engine. The engine system also includes a battery that is selectively or non-selectively electrically coupled to the power consumption device. Additionally, the engine system includes a supercapacitor that is selectively electrically coupled to the power consumption device. The supercapacitor is in parallel with the battery.

In some implementations, the internal combustion engine system further includes a switch module. The supercapacitor is selectively electrically coupled to the power consumption device via the switch module. The switch module electrically couples the supercapacitor to the power consumption device during a power loss event and electrically decouples the supercapacitor from the power consumption device when a power loss event is not occurring.

According to some implementations, the internal combustion engine system also includes an arbitration module. The battery and supercapacitor are selectively electrically coupled to the power consumption device via the arbitration module. In one implementation, the arbitration module selectively electrically couples the battery, supercapacitor, or both in electrical power providing communication with the power consumption device based on predetermined data.

In yet another embodiment, a method for managing the electrical power within an internal combustion engine system includes providing electrical power to a power consumption device of the internal combustion engine system via a battery. The method also includes selectively providing electrical power to the power consumption device of the internal combustion engine system via a supercapacitor in parallel with the battery.

According to certain implementations, the method further includes selectively switching between providing electrical power to the power consumption device of the internal combustion engine system via the battery and providing electrical power to the power consumption device of the internal combustion engine system via the supercapacitor based on an operating condition of the internal combustion engine system.

DETAILED DESCRIPTION

FIG. 1depicts one embodiment of an internal combustion engine system100. The main components of the engine system100include an internal combustion engine110and a power consumption device120. The internal combustion engine110can be a compression-ignited internal combustion engine, such as a diesel fueled engine, or a spark-ignited internal combustion engine, such as a gasoline fueled engine. The power consumption device120can be any of various devices that consume electrical power or require electrical power for operation. Further, the power consumption device120can be directly or indirectly coupled to the engine to electronically, electrically, mechanically, or otherwise control operation of the engine.

In one embodiment, the power consumption device120is an engine control module (ECM). As described above, electrical power received by the ECM is utilized to electronically control the operation of the internal combustion engine, as well various sub-systems operatively coupled to the internal combustion engine. The ECM can receive multiple electronic inputs, process the inputs, and transmit multiple outputs. The outputs are received by one or more components of the internal combustion engine and associated systems, which respond in accordance to the received outputs to achieve desired results.

In yet some embodiments, the power consumption device120is a starter motor used to mechanically crank (e.g., rotate) the engine110during a start-up of the engine. Electrical power received by the starter motor is converted into mechanical power to crank a driveshaft of the engine via a flywheel or other power transfer mechanism. The starter motor can be any of various types of electric motors known in the art. During the start-up of the engine, the starter motor consumes a significant amount of electrical power in order to crank the driveshaft.

The power consumption device120can be any of various other devices or systems of an internal combustion engine system100or associated vehicle that consume electrical power during operation of the system. For example, in some implementations, the power consumption device120may be an auxiliary system of a vehicle, such as a vehicle electronics system (e.g., radio, dash displays, power windows/seats, etc.), external head and tail lamp system, A/C system, and the like.

Electrical power can be supplied to the power consumption device120from a dedicated power source130in electrical power providing communication with the power consumption device via one or more electrical transmission lines. The dedicated power source130forms part of an electrical power management system102of the engine system100. The dedicated power source130can be an automotive rechargeable battery that is recharged during operation of the engine system100by an alternator or similar power generator. Although not shown, the dedicated power source130may be a battery coupled to the engine system100via a harness or mount, which can be bulky and heavy in some cases. Due to the bulk and weight associated with automotive batteries and the harnesses required for such batteries, in certain implementations, the power management system102does not include auxiliary batteries for recharging the battery. In this manner, space normally reserved for auxiliary batteries dedicated solely for recharging main batteries, and the associated harnesses required to mount the batteries to the engine system, is available for other components of the engine system100. Moreover, weight savings is achieved without the added weight from such auxiliary batteries and associated harnesses.

It is recognized that in some implementations, the dedicated power source130may include two or more batteries in parallel. Although multiple batteries may be used in combination to provide power to the power consumption device, in certain implementations, no one battery is used to recharge another battery.

According to some implementations, the power consumption device120may require a steady, smaller amount of electrical power during operation, such as with an ECM. In yet some implementations, the power consumption device120may require frequent or infrequent pulses of large amounts of energy, such as with a starter motor. The dedicated power source130should be capable of storing and supplying enough electrical power to accommodate such electrical power demands.

Under certain operating conditions, which include electrical power demands at any given time, the power storage condition of the battery, and/or the activation of electrical power kill switches, the dedicated power source130may be incapable of storing and supplying an adequate level or duration of electrical power to meet the demands of the power consumption device120. Accordingly, the electrical power management system102of the engine system100includes a supercapacitor140that is communicable in electrical power providing communication with the power consumption device120via one or more electrical transmission lines. The supercapacitor140is in parallel with the dedicated power source130. In some implementations, electrical power is supplied to the power consumption device120from both the dedicated power source130and the supercapacitor140. For example, power from the supercapacitor140can be combined with power from the dedicated power source130to electrically power the power consumption device120. However, in other embodiments, such as when the dedicated power source130is unable to supply power to the power consumption device120, the supercapacitor140is utilized to supply power to the power consumption device in place of the dedicated power source. In such embodiments, electrical power supply to the power consumption device120can be switched between the dedicated power source130and the supercapacitor140.

The supercapacitor140can be any of various supercapacitors known in the art. As defined herein, the supercapacitor140can be considered an ultracapacitor, electric double-layer capacitor, pseudocapacitor, or hybrid capacitor. Generally, the supercapacitor140is an electrochemical capacitor or energy storage component that stores electrical energy using a certain electrochemical construction. The supercapacitor140may have one or more capacitive cells each of which includes two collectors, two electrodes, a separator, and an electrolyte. The electrodes are made from materials having a relatively high surface area compared to conventional capacitors and the electrolytes are made from relative thin electrolytic dielectrics compared to conventional capacitors. This electrochemical construction allows the supercapacitor140to achieve capacitances that are several orders of magnitude higher than conventional capacitors. Additionally, supercapacitors provide much higher energy densities compared to conventional capacitors and much higher power densities than electrochemical batteries, such as the dedicated power source130. Accordingly, the size of the supercapacitor140can be significantly smaller than a conventional automotive battery, yet provide even more power output than the battery. Moreover, supercapacitors take less time to charge/discharge, and have longer life cycles with negligible degradation, on the order of one million life cycles, compared to electrochemical batteries. Therefore, the supercapacitor140acts as a power source for the power consumption device120, and may provide both the steady, smaller amount of electrical power during operation, as well as the pulses of large amounts of energy. Additionally, supercapacitors can provide a higher percentage of their charge at low temperatures compared to batteries.

In some implementations, the supercapacitor140can be two or more supercapacitors individually or collectively electrically coupled with the power consumption device120. Multiple supercapacitors may be electrically coupled together in series or in parallel. Additionally, in some implementations, power output from a group of multiple supercapacitors can be selectively switched between individual supercapacitors of the group as desired.

The electrical power management system102includes a charger150in electrical power providing communication with the supercapacitor140. The charger150can be the dedicated power source130or a dedicated charging device, such as an alternator. In some implementations, the charger150can be an auxiliary battery. The charger150is configured to recharge the supercapacitor140after the supercapacitor has lost a threshold amount of electrical power to the power consumption device120, or the electrical power stored by the supercapacitor150has reached a minimum threshold amount of stored electrical power.

According to another embodiment shown inFIG. 2, an internal combustion engine system200includes an engine110, a power consumption device120, and an electrical power management system202. The electrical power management system202manages the delivery of electrical power to the power consumption device120. Electrical power is supplied to the power consumption device120from at least one power source as determined by an arbitration module210based on one or more inputs220. The power source includes a battery132, which can be an automotive battery, and one or more supercapacitors140. The battery132and supercapacitor140are independently electrically coupled to respective electrical switches of the arbitration module210. The arbitration module210includes logic that when executed controls the actuation of the switches and, correspondingly, the distribution of electrical power from the battery132, supercapacitor140, or both to the power consumption device120. The logic may include predetermined data, such as look-up tables, against which one or more of the inputs220may be compared. Based on the comparison, the arbitration module210selectively actuates one or both of the switches to electrically couple the battery132, supercapacitor140, or both in power providing communication with the power consumption device120. In some implementations, because the battery can be a dedicated power source, such as a conventional automotive battery, the arbitration module210may be configured generally to maintain closed (e.g., non-selectively close) the electrical circuit between the battery132and the power consumption device120, and selectively close the electrical circuit between the supercapacitor140and the power consumption device as needed. Based on the foregoing, the supercapacitor140acts as a backup or reserve power source to supplement or replace the power provided by the battery132based on the inputs220.

In one embodiment, the input220is a condition or power storage capability of the battery132. The condition of the battery132may be based on a physical or virtual sensor that detects one or more characteristics of the battery. As the condition of the battery132degrades beyond a threshold level, the arbitration module210may be configured to close the physical switch between the supercapacitor140and the power consumption device120, which facilitates the flow of electrical power from the supercapacitor to the power consumption device. Additionally, as the condition of the battery132degrades beyond a threshold level, the arbitration module210may be configured to open or maintain closed the physical switch between the battery132and the power consumption device120, which prevents or maintains the flow of electrical power from the battery to the power consumption device.

According to another embodiment, the input220is an operating condition of the engine system200, such as an engine start-up or cranking event. When the input220indicates the initiation of an engine start-up event, the arbitration module210may close the physical switch between the supercapacitor140and the power consumption device120, which allows the flow of electrical power from the supercapacitor to the power consumption device. Additionally, when the input220indicates the initiation of an engine start-up event, the arbitration module210may open or maintain closed the physical switch between the battery132and the power consumption device120.

Furthermore, according to yet another embodiment, the input220is the status of a battery disconnect switch (e.g., electrical power kill switch) that when activated cuts off power to the power consumption device120from the battery132. When the input220indicates the battery disconnect switch has been activated, the arbitration module210may close the physical switch between the supercapacitor140and the power consumption device120, which allows the flow of electrical power from the supercapacitor to the power consumption device.

Referring toFIG. 3, according to one embodiment, an internal combustion engine system300includes an engine110, a starter motor310, and an electrical power management system302. The electrical power management system302manages the delivery of electrical power to the starter motor310. Electrical power is non-selectively supplied to the starter motor310from a battery132of the system302. In other words, the battery132of the system302acts as a dedicated electrical power source for the starter motor310to provide electrical power to the starter motor310, independently of a supercapacitor140of the system302, when demanded by the starter motor310. The supercapacitor140is electrically coupled with a switch module320of the electrical power management system302. The switch module320includes a physical switch.

The switch module320is operable to actuate the physical switch to close an electrical circuit and allow electrical power providing communication between the supercapacitor140and the starter motor310. In some implementations, the switch module320actuates the physical switch based on input from an ECM330of the internal combustion engine system300. The ECM330controls operations of the engine system330, such as the activation of the starter motor310during an engine start-up or cranking event. Additionally, the ECM330is configured to control the switch module320to close the electrical circuit between the supercapacitor140and the starter motor310in cooperation with activating the starter motor310. In this manner, the ECM330controls the switch module320to provide electrical power from the supercapacitor140to the starter motor310to power the starter motor310during an engine start-up event. In certain implementations, the ECM330controls the switch module320to provide electrical power from the supercapacitor140to the starter motor310to power the starter motor310during an engine start-up event regardless of the condition of the battery132. Accordingly, the electrical power management system302is operable to supplement the electrical powering needs of the starter motor310with power from the supercapacitor140. Providing electrical power from the supercapacitor140in this manner also allows a developer or manufacturer of the engine system to select a smaller battery132, as the battery is typically sized to provide the required power at low operating temperatures.

Referring toFIG. 4, according to one embodiment, an internal combustion engine system400includes an engine110, an ECM410, and an electrical power management system402. The electrical power management system402manages the delivery of electrical power to the ECM410. Electrical power is selectively delivered to the ECM410from a battery132of the system302, a supercapacitor140of the system302, or both.

The battery132is coupled to a power condition module420of the electrical power management system402. The power condition module420is configured to determine a condition or power storage capability of the battery132. In certain implementations, the power condition module420receives input440. The input440may be output values from virtual and/or physical sensors that detect one or more sensed characteristics of the battery132. Additionally, or alternatively, the input440may be the status of a battery disconnect switch (not shown). Based on the input440, the power condition module420determines a condition or status of the battery132and determines whether to electrically couple the battery132to the ECM410(e.g., via a physical switch). For example, if the condition of the battery is significantly degraded, or the battery disconnect switch has been activated, the power condition module420may electrically decouple the battery132and the ECM410.

The supercapacitor140is electrically coupled with a switch module430of the electrical power management system402. The switch module430includes a physical switch. The switch module430is operable to actuate the physical switch to close an electrical circuit and allow electrical power providing communication between the supercapacitor140and the ECM410. In some implementations, the switch module430actuates the physical switch based on input received from the power condition module420. The input from the power condition module420may include the current condition or status of the battery132or operating condition of the engine system400determined by the power condition module420.

In one implementation, the input from the power condition module420includes the storage capacity or storage level of the battery132determined by the power condition module420. The switch module430is configured to electrically couple the supercapacitor140and the ECM410if a storage condition of the battery132falls below a threshold value. The threshold value may be associated with an estimation of the electrical power needs of the engine system400based on operating conditions of the engine system. In other words, should the battery132fail or come close to failing to provide sufficient electrical power to power the ECM410, the switch module430electrically couples the supercapacitor140and the ECM such that power to the ECM410is not interrupted or likely to be interrupted. By mitigating or preventing power supply interruptions to the ECM410, the loss of data saved on the ECM and/or the loss of controls for operation of the engine system400is mitigated or prevented.

In another implementation, the input from the power condition module420may be the status of a battery kill switch. If the status of the battery kill switch is active, the switch module430electrically couples the supercapacitor140and the ECM410such that power to the ECM410is not interrupted or likely to be interrupted.

Referring toFIG. 5, a method500for managing the electrical power within an internal combustion engine system is shown according to one embodiment. The steps of the method500can be executed by one or more of the components or modules of the engine systems described above in certain implementations. The method500begins by providing electrical power to a power consumption device via a battery at510. The power consumption device can be an ECM, starter motor, and/or other device. Further, the battery can be an automotive battery dedicated for providing electrical power to components of the engines system. The method500further includes determining operating conditions of the internal combustion engine system at520. The operating conditions can include any of various operating conditions, such as power storage conditions of the battery, status of a battery kill switch, activation of a starter motor, and the like. If the operating conditions do not meet an associated threshold (e.g., minimum threshold) at530, then the method500ends. However, if the operating conditions meet the associated threshold at530, then the method500proceeds to provide electrical power to the power consumption device via a supercapacitor at540. In other words, when the battery will not or may not provide enough electrical power to operate the power consumption device (e.g., power storage condition falls below minimum threshold, battery kill switch is activated, starter motor is activated, etc.), the method500replaces or supplements the power from the battery with power from a supercapacitor to ensure power to the electrical power device is sufficient and uninterrupted.

The schematic flow chart diagrams and method schematic diagrams described above are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of representative embodiments. Other steps, orderings and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the methods illustrated in the schematic diagrams.

Additionally, the format and symbols employed are provided to explain the logical steps of the schematic diagrams and are understood not to limit the scope of the methods illustrated by the diagrams. Although various arrow types and line types may be employed in the schematic diagrams, they are understood not to limit the scope of the corresponding methods. Indeed, some arrows or other connectors may be used to indicate only the logical flow of a method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of a depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown.

The computer readable medium may also be a computer readable signal medium. A computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electrical, electro-magnetic, magnetic, optical, or any suitable combination thereof. A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport computer readable program code for use by or in connection with an instruction execution system, apparatus, or device. Computer readable program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, Radio Frequency (RF), or the like, or any suitable combination of the foregoing