Description:TECHNICAL FIELD
Embodiments disclosed herein relate to monitoring the operation of fans in vehicles, and more particularly to Smart Power Control Modules (SPCMs) for monitoring and controlling the fans in vehicles.
BACKGROUND
Vehicles comprise one or more cooling fan assemblies. If the vehicle is an Internal Combustion Engine (ICE) vehicle, the fan can be a radiator fan. If the vehicle is an electric vehicle, the fan can be used for cooling the batteries present in the vehicle.
Currently, Smart Power Control Modules (SPCMs) are used to control the fan assembly by providing power to operate the fan assembly. FIG. 1 depicts a system, wherein the SPCM is controlling the fan assembly, based on signals received from a vehicle Electronic Control Unit (ECU). The SPCM can also monitor the operation of the fan assembly, by checking if the fan assembly is operating or not.
In some scenarios (such as water ingestion), the fan assembly may not operate temporarily. This can lead to the vehicle heating up and shutting down (if the vehicle is an ICE vehicle) or the batteries being damaged due to overheating (if the vehicle is an EV). However, the SPCMs are unable to detect such restricted conditions of the fan.
OBJECTS
The principal object of embodiments herein is to disclose methods and Smart Power Control Modules (SPCMs) for monitoring and controlling the fan assemblies in vehicles by using sensed peak current to detect restricted operating condition of the fan assemblies, when operating at low operating frequencies.
These and other aspects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating at least one embodiment and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.
BRIEF DESCRIPTION OF FIGURES
Embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
FIG. 1 depicts a system, wherein the SPCM is controlling the fan assembly, based on signals received from a vehicle Electronic Control Unit (ECU), according to prior arts;
FIG. 2 depicts a system for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein;
FIG. 3 depicts an example current signal provided to the fan assembly (203), wherein the frequency of the current signal is 100Hz with a 30% duty cycle (i.e., on time of 3ms of a total pulse width of 10ms), and a peak duration of 100s, according to embodiments as disclosed herein;
FIG. 4 is a flowchart depicting a process for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein; and
FIG. 5 is an example flowchart depicting a process for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein.
DETAILED DESCRIPTION
The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
The embodiments herein achieve methods and Smart Power Control Modules (SPCMs) for monitoring and controlling the fan assemblies in vehicles. Referring now to the drawings, and more particularly to FIGS. 2 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
FIG. 2 depicts a system for monitoring and controlling the fan assembly in a vehicle. The vehicle, as disclosed herein, can be a vehicle equipped with at least one of an Internal Combustion Engine (ICE) (i.e., an ICE vehicle) or one or more electric batteries (i.e., an EV or a hybrid vehicle). The system (200), as depicted, comprises a Smart Power Control Module (SPCM) (201), at least one Electronic Control Unit (ECU) (202), and one or more fan assemblies (203). The SPCM (201) and the ECU (202) can be connected to each other using a suitable communication link, such as, but not limited to, a Local Interconnect Network (LIN), a Controller Area Network (CAN), and so on, thereby forming a closed loop system. The SPCM (201) can provide power to the fan assembly (203), wherein the provided power can be used by the fan assembly (203) for operation. The SPCM (201) can also sense the peak current, being drawn by the fan assembly (203), wherein the sensed peak current can be used to determine the current operation status of the fan assembly (203). The operation status of the fan assembly (203) can be normal operations (i.e., the fan assembly (203) is working normally, as per the vehicle specifications/design), restricted operations (i.e., the fan assembly (203) is not working temporarily), and no operation (i.e., the fan assembly (203) is not working) (which can be due to a fault, blockage, or lack of input power supply).
The SPCM (201) can operate at low frequencies. In an embodiment herein, the SPCM (201) can operate at frequencies in terms of Hertz (Hz). In an example herein, the SPCM (201) can operate at 100Hz  60Hz. FIG. 3 depicts an example current signal provided to the fan assembly (203), wherein the frequency of the current signal is 100Hz with a 30% duty cycle (i.e., an on time of 3ms of a total pulse width of 10ms), and a peak duration of 100s.
The SPCM (201) can further comprise a Motor Control Unit (MCU) (201A), and a power device (201B). The power device (201B) can be at least one of a Metal-Oxide-Semiconductor Field-Effect Transistor (MOSFET), a Gallium Nitride (GaN) High-Electron-Mobility Transistor (HEMT), a GaN Field Effect Transistor (FET), an Insulated-Gate Bipolar Transistor (IGBT), or any other device capable of acting as a power device. The power device (201B) can provide power (in the form of a Pulse Width Modulation (PWM) wave) to the fan assembly (203), based on instructions received from the MCU (201A) and/or the ECU (202).
The ECU (202) can provide inputs to the SPCM (201), such as instructions to operate/not operate the fan assembly (203), the frequency and duty cycle at which the fan assembly (203) is to operate at, and so on. In an example herein, the ECU (202) can instruct the SPCM (201) to operate the fan assembly (203) at 100Hz with a 30% duty cycle (as depicted in the example in FIG. 3). In an example herein, the ECU (202) can instruct the SPCM (201) to operate the fan assembly (203) at 100Hz with a 50% duty cycle (i.e., an on time of 5ms of a total pulse width of 10ms). In an example herein, the ECU (202) can instruct the SPCM (201) to operate the fan assembly (203) at 100Hz with an 80% duty cycle (i.e., an on time of 8ms of a total pulse width of 10ms).
After a delay of a pre-determined first time period (for eliminating inrush current (if any)), the MCU (201A) can determine the input duty cycle at pre-defined time intervals. This enables the MCU (201A) to avoid sensing the peak current at a transition of the duty cycle; i.e., the duty cycle is in a steady state.
On determining the duty cycle, the MCU (201A) can sense the peak current at the fan assembly at pre-defined sensing time intervals. In an example herein, the MCU (201A) senses the peak current every 10ms. The MCU (201A) can determine an average current value from the sensed peak current over a pre-defined time period, based on the current duty cycle. The MCU (201A) can determine the average current value (I_avg) as the duty cycle percentage divided by a factor (which can vary with the application; in an example herein, consider that the factor is 100) and multiplied with the average of the sensed peak currents; i.e., as follows:
I=((I_1+I_2+⋯.I_N))⁄N
I_avg=((duty cycle)⁄100)*I
In an example herein, consider that the current duty cycle is 30%. The MCU (201A) senses the peak current every 10ms over a 100ms time period, thereby resulting in 10 sensed current value samples. The MCU (201A) determines the average current value (I_avg) as:
I=((I_1+I_2+⋯.I_10))⁄10
I_avg=(0.3)*I
In an example herein, consider that the current duty cycle is 30%. The MCU (201A) senses the peak current as 80A every 10ms over a 100ms time period, thereby resulting in 10 sensed current value samples of 80A each. The MCU (201A) determines the average current value (I_avg) as:
I=((80+80+80+80+80+80+80+ 80+80+80))⁄10
I=80
I_avg=(0.3)*80
I_avg=24
The MCU (201A) can compare I_avg with a master threshold value to check if I_avg is greater than the master threshold value for a pre-defined second time period. If I_avg is greater than the master threshold value for the pre-defined second time period, the MCU (201A) can consider that the fan assembly (203) is in a restricted condition and can cut power supply to the fan assembly (203), thereby turning the fan assembly (103) OFF.
The MCU (201A) can compare the I_avg with the master threshold value to check if the I_avg is greater than the master threshold value for a pre-defined third time period at a pre-defined checking interval for a plurality of consecutive cycles. If the I_avg is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles, then the MCU (201A) can cut off the power supply to the fan assembly (103) permanently and provide an alert to a user of the vehicle over the LIN; such as an alert on the instrument console, an alert on the dashboard, an alert on a user device, and so on. The alert can be at least one of an audio alert and a visual alert. If the I_avg is not greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles, then the MCU (201A) can resume power supply to the fan assembly (203).
The master threshold value can depend on the type of vehicle, vehicle characteristics, and so on. An initial master threshold value can be configured by a manufacturer of the vehicle. The initial master threshold value can be recalibrated, as the vehicle is running under pre-defined conditions. In an example scenario, consider that the vehicle is running continuously in X,Y,Z duty cycles for a minimum running time (for example, 3 minutes), the initial master threshold value for a particular duty cycle can be reset as the average peak power over the minimum running time for that particular duty cycle.
FIG. 4 is a flowchart depicting a process for monitoring and controlling the fan assembly in a vehicle. After a delay of a pre-determined first time period (for eliminating inrush current (if any)), and determining that the duty cycle is steady (i.e., not in transition), in step 401, the MCU (201A) senses the peak current at pre-defined sensing time intervals. In step 402, the MCU (201A) converts the sensed peak current over a pre-defined time period to the average current value (I_avg), based on the current duty cycle as follows:
I=((I_1+I_2+⋯.I_N))⁄N
I_avg=((duty cycle)⁄100)*I
In step 403, the MCU (201A) compares the I_avg with the master threshold value to check if I_avg is greater than the master threshold value for a pre-defined second time period. If the I_avg is greater than the master threshold value for the pre-defined second time period, in step 404, the MCU (201A) considers that the fan assembly (203) is in a restricted condition and cuts the power supply to the fan assembly (203), thereby turning the fan assembly (103) OFF.
The MCU (201A) compares the I_avg with the master threshold value to check if the I_avg is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles. If the I_avg is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles, then the MCU (201A) cuts off the power supply to the fan assembly (103) permanently and provides an alert to a user of the vehicle over the LIN. If the I_avg is not greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles, then the MCU (201A) resumes power supply to the fan assembly (203). In an embodiment herein, the pre-defined third time period can depend on the application and can vary based on the application. In an embodiment herein, the pre-defined checking interval can depend on the application and can vary based on the application. In an embodiment herein, the number of consecutive cycles can depend on the application and can vary based on the application. The various actions in method 400 may be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in FIG. 4 may be omitted.
FIG. 5 is an example flowchart depicting a process for monitoring and controlling the fan assembly in a vehicle. After a delay of a pre-determined first time period (for eliminating inrush current (if any)), and determining that the duty cycle is steady (i.e., not in transition), in step 501, the MCU (201A) senses the peak current every 10ms. In step 502, the MCU (201A) converts the sensed peak current over 100ms to the average current value (I_avg), based on the current duty cycle (30%) as follows:
I=((I_1+I_2+⋯.I_10))⁄10
I_avg=(0.3)*I
In step 503, the MCU (201A) compares the I_avg with the master threshold value to check if I_avg is greater than the master threshold value for 5 seconds. If the I_avg is greater than the master threshold value for 5 seconds, in step 504, the MCU (201A) considers that the fan assembly (203) is in a restricted condition and cuts the power supply to the fan assembly (203), thereby turning the fan assembly (103) OFF.
The MCU (201A) compares the I_avg with the master threshold value to check if the I_avg is greater than the master threshold value for 5 seconds every 5 minutes for 3 consecutive cycles. If the I_avg is greater than the master threshold value for 5 seconds every 5 minutes for 3 consecutive cycles, then the MCU (201A) cuts off the power supply to the fan assembly (103) permanently and provides an alert to a user of the vehicle over the LIN. If the I_avg is not greater than the master threshold value for 5 seconds every 5 minutes for 3 consecutive cycles (as per the current application), then the MCU (201A) resumes power supply to the fan assembly (203). The various actions in method 500 may be performed in the order presented, in a different order or simultaneously. Further, in some embodiments, some actions listed in FIG. 5 may be omitted.
The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of embodiments and examples, those skilled in the art will recognize that the embodiments and examples disclosed herein can be practiced with modification within the scope of the embodiments as described herein.
, Claims:We claim,
1. A method (400) for controlling a fan assembly (203) in a vehicle at low frequencies, the method comprising:
sensing, by a Smart Power Control Module (SPCM) (201), a peak current at the fan assembly (203) at pre-defined sensing time intervals;
determining, by the SPCM (201), an average current value from the sensed peak currents over a pre-defined time period and a current duty cycle; and
cutting off power supply, by the SPCM (201), to the fan assembly (203) if the average current value is greater than a master threshold value.
2. The method, as claimed in claim 1, wherein the method comprises the SPCM (201) sensing the peak current after a delay of a pre-determined first time period.
3. The method, as claimed in claim 1, wherein the method comprises the SPCM (201) sensing the peak current, when the duty cycle is in a steady state.
4. The method, as claimed in claim 1, wherein the method comprises the SPCM (201) determining the average current value as the duty cycle percentage divided by a factor and multiplied with the average of the sensed peak currents.
5. The method, as claimed in claim 1, wherein the method further comprises:
comparing the average current value with the master threshold value, by the SPCM (201), to check if the average current value is greater than the master threshold value for a pre-defined third time period at a pre-defined checking interval for a plurality of consecutive cycles;
cutting off power supply, by the SPCM (201), to the fan assembly (201) permanently and providing an alert to a user of the vehicle, if the average current value is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles; and
resuming power supply to the fan assembly (203), by the SPCM (201), if the average current value is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles.
6. A system (200) for controlling a fan assembly (203) in a vehicle at low frequencies, the system comprising:
at least one Electronic Control Unit (ECU) (202);
at least one fan assembly (203); and
a Smart Power Control Module (SPCM) (201),
wherein the SPCM (201) is configured for:
sensing a peak current at the fan assembly (203) at pre-defined sensing time intervals;
determining an average current value from the sensed peak currents over a pre-defined time period and a current duty cycle; and
cutting off power supply to the fan assembly (203) if the average current value is greater than a master threshold value.
7. The system, as claimed in claim 6, wherein the SPCM (201) is configured for sensing the peak current after a delay of a pre-determined first time period.
8. The system, as claimed in claim 6, wherein the SPCM (201) is configured for sensing the peak current, when the duty cycle is in a steady state.
9. The system, as claimed in claim 6, wherein the SPCM (201) is configured for determining the average current value as the duty cycle percentage divided by a factor and multiplied with the average of the sensed peak currents.
10. The system, as claimed in claim 6, wherein the SPCM (201) is further configured for:
comparing the average current value with the master threshold value to check if the average current value is greater than the master threshold value for a pre-defined third time period at a pre-defined checking interval for a plurality of consecutive cycles;
cutting off power supply to the fan assembly (201) permanently and providing an alert to a user of the vehicle, if the average current value is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles; and
resuming power supply to the fan assembly (203), if the average current value is greater than the master threshold value for the pre-defined third time period at the pre-defined checking interval for the plurality of consecutive cycles.