Description:TECHNICAL FIELD
[001] 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 the vehicles.
BACKGROUND
[002] 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 and Heating, Ventilation, and Air Conditioning (HVAC) present in the vehicle.
[003] 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.
[004] In some scenarios (such as water ingestion), the fan assembly may get loaded and take high current from battery which leads to motor coil failure. Then, compressor of the HVAC is loaded, which can lead to further failures. However, the SPCMs are unable to detect such restricted conditions of the fan.
OBJECTS
[005] 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 high operating frequencies.
[006] 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
[007] Embodiments herein are illustrated in the accompanying drawings, through out 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:
[008] 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;
[009] FIG. 2 depicts a system for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein;
[0010] FIG. 3 depicts an example current signal provided to the fan assembly, according to embodiments as disclosed herein;
[0011] FIGs. 4A, 4B, and 4C are flowcharts depicting a process for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein; and
[0012] FIGs. 5A, 5B, and 5C depict an example flowchart depicting a process for monitoring and controlling the fan assembly in a vehicle, according to embodiments as disclosed herein.
DETAILED DESCRIPTION
[0013] 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.
[0014] 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 5C, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0015] Embodiments herein sense the current to detect a restricted condition (such as, but not limited to, water wade, lock condition and other restricted conditions) of a fan motor present in a vehicle. Embodiments herein protect the fan motor from failure by temporarily shutting down supply to the motor during the restricted condition(s). On sensing restricted condition(s), embodiments herein control compressor motor operation to prevent any thermal incidents of the fan motors. High frequency of the operation results in optimised energy consumption and improves the energy performance.
[0016] 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).
[0017] The SPCM (201) can operate at high frequencies. In an embodiment herein, the SPCM (201) can operate at frequencies in terms of KiloHertz (KHz). In an example herein, the SPCM (201) can operate at 10 ? 0.5KHz. FIG. 3 depicts an example current signal provided to the fan assembly (203), wherein the frequency of the current signal is 10KHz.
[0018] 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).
[0019] 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.
[0020] Consider that the continuous current is at a high frequency. In an example herein, the continuous current is at 10KHz (as depicted in FIG. 3). The MCU (201A) can sense the current at first pre-defined time periods. In an example herein, the MCU (201A) can sense the current at 100ms intervals.
[0021] If average value of the sensed current exceeds a master threshold current value over a second time period, the MCU (201A) determines that the fan assembly (203) is in a restricted condition and cuts off power supply to the fan assembly (203). The MCU (201A) resumes power supply to the fan assembly (203) only on the current becoming normal or the issue causing the restricted condition is corrected.
[0022] FIGs. 4A, 4B, and 4C are flowcharts depicting a process for monitoring and controlling the fan assembly in a vehicle. Consider that the SPCM (201) is turned ON. Consider that the input frequency of the current to the system (200) is a lower frequency, which is converted to a higher frequency PWM current signal. Consider that the duty cycle is a pre-defined percentage; for example, 30%, 50%, 80%, and so on. In step 401, the MCU (201A) senses the current at the first pre-defined time periods. In step 402, the MCU (201A) averages the sensed current (avg) over the second pre-defined time period. In step 403, the MCU (201A) checks if the average current value (avg) is greater than a master threshold current value (by a first pre-defined percentage (A%) and less than a second pre-defined percentage (B%)) in a stable duty cycle for at least a third pre-defined time period.
[0023] If the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least the third pre-defined time period, in step 404, the MCU (201A) determines that the fan assembly (203) is in a restricted condition, cuts off the PWM current signal to the fan assembly (203) (thereby turning OFF the fan assembly (203)) for a fourth period of time, and resumes sensing the current.
[0024] If the average current value (avg) is not greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least the third pre-defined time period, in step 405, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for at least the third pre-defined time period. If the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for at least the third pre-defined time period, in step 406, the MCU (201A) determines that the fan assembly (203) is in a restricted condition, cuts off the PWM current signal to the fan assembly (203) (thereby turning OFF the fan assembly (203)) for the fourth period of time, and resumes the current sensing after the fourth period of time.
[0025] In step 407, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least a fifth pre-defined time period. If the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least the fifth pre-defined time period, in step 408, the MCU (201A) cuts off the PWM current signal to the fan assembly (203) for a sixth period of time and resumes sensing the current. These steps (405, 407, 408) are repeated till the average current value (avg) is less than the master threshold current value.
[0026] In step 409, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value by less than the second pre-defined percentage (B%) in a stable duty cycle for at least the third pre-defined time period. If the average current value (avg) is greater than the master threshold current value by less than the second pre-defined percentage (B%) in a stable duty cycle for at least the third pre-defined time period, in step 410, the MCU (201A) cuts off the PWM current signal to the fan assembly (203) for a seventh period of time and resumes sensing the current after the seventh period of time. The MCU (201A) continues the cycle (steps 401 onwards) for at least a pre-defined number of cycles. If the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for the pre-defined number of cycles, the MCU (201A) performs a continuous ON of the fan assembly (203) for an external fuse blow.
[0027] A and B can depend on the current duty cycle of the PWM current signal. 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 FIGs. 4A, 4B, and 4C may be omitted.
[0028] FIGs. 5A, 5B, and 5C depict an example flowchart depicting a process for monitoring and controlling the fan assembly in the vehicle. Consider that the SPCM (201) is turned ON. Consider that the input frequency to the system (200) is 100HZ, which is converted to a 10KHz PWM current signal. Consider that the duty cycle is a pre-defined percentage; for example, 30%, 50%, 80%, and so on. In step 501, the MCU (201A) senses the current every 10?s. In step 502, the MCU (201A) averages the sensed current (avg) every 100ms. In step 503, the MCU (201A) checks if the average current value (avg) is greater than a master threshold current value (by a first pre-defined percentage (A%) and less than a second pre-defined percentage (B%)) in a stable duty cycle for at least 5 seconds.
[0029] If the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for 5 seconds, in step 504, the MCU (201A) determines that the fan assembly (203) is in a restricted condition, cuts off the PWM current signal to the fan assembly (203) (thereby turning OFF the fan assembly (203)) for 2 minutes, and resumes sensing the current.
[0030] If the average current value (avg) is not greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least 5 seconds, in step 505, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for at least the third pre-defined time period. If the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for at least 5 seconds, in step 506, the MCU (201A) determines that the fan assembly (203) is in a restricted condition, cuts off the PWM current signal to the fan assembly (203) (thereby turning OFF the fan assembly (203)) for 2 minutes, and resumes the current sensing after 2 minutes.
[0031] In step 507, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least 1 minute. If the average current value (avg) is greater than the master threshold current value (by the first pre-defined percentage (A%) and less than the second pre-defined percentage (B%)) in a stable duty cycle for at least 1 minute, in step 508, the MCU (201A) cuts off the PWM current signal to the fan assembly (203) for 2 minutes and resumes sensing the current. These steps (505, 507, 508) are repeated till the average current value (avg) is less than the master threshold current value.
[0032] In step 509, the MCU (201A) checks if the average current value (avg) is greater than the master threshold current value by less than the second pre-defined percentage (B%) in a stable duty cycle for at least 5 seconds. If the average current value (avg) is greater than the master threshold current value by less than the second pre-defined percentage (B%) in a stable duty cycle for at least 5 seconds, in step 510, the MCU (201A) cuts off the PWM current signal to the fan assembly (203) for 5 seconds and resumes sensing the current after the 5 seconds. The MCU (201A) continues the cycle (steps 501 onwards) for at least 3 cycles. If the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for 3 cycles, the MCU (201A) performs a continuous ON of the fan assembly (203) for an external fuse blow.
[0033] A and B can depend on the current duty cycle of the PWM current signal. 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 FIGs. 5A, 5B, and 5C may be omitted.
[0034] The embodiments disclosed herein can be implemented through at least one software program running on at least one hardware device and performing network management functions to control the network elements. The network elements shown in FIG. 2 include blocks which can be at least one of a hardware device, or a combination of hardware device and software module.
[0035] The embodiment disclosed herein describes methods and Smart Power Control Modules (SPCMs) for monitoring and controlling the fan assemblies in vehicles. Therefore, it is understood that the scope of the protection is extended to such a program and in addition to a computer readable means having a message therein, such computer readable storage means contain program code means for implementation of one or more steps of the method, when the program runs on a server or mobile device or any suitable programmable device. The method is implemented in at least one embodiment through or together with a software program written in e.g., Very high speed integrated circuit Hardware Description Language (VHDL) another programming language, or implemented by one or more VHDL or several software modules being executed on at least one hardware device. The hardware device can be any kind of portable device that can be programmed. The device may also include means which could be e.g., hardware means like e.g., an ASIC, or a combination of hardware and software means, e.g., an ASIC and an FPGA, or at least one microprocessor and at least one memory with software modules located therein. The method embodiments described herein could be implemented partly in hardware and partly in software. Alternatively, the invention may be implemented on different hardware devices, e.g., using a plurality of CPUs.
[0036] 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 spirit and scope of the embodiments as described herein.
, Claims:We claim,
1. A system (200) for controlling a fan assembly (203) in a vehicle, 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 to:
sense an input Pulse Width Modulation (PWM) current signal at a first pre-defined time period, wherein the input Pulse Width Modulation (PWM) current signal is a high frequency signal; and
cut off power supply to the fan assembly (203), on determining that average value of the sensed current over a second time period exceeds a master threshold current value.
2. The system, as claimed in claim 1, wherein the Smart Power Control Module (SPCM) (201) is configured to resume power supply to the fan assembly (203), on at least one of the sensed current becoming normal or an issue causing a restricted condition is corrected.
3. The system, as claimed in claim 1, wherein the Smart Power Control Module (SPCM) (201) is configured to:
sense the input Pulse Width Modulation (PWM) current signal at the first pre-defined time period;
average the sensed current over the second pre-defined time period;
on determining that the average current value is greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period,
cut off the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for a fourth period of time, and resume sensing the current;
determine if the average current value is greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least a fifth pre-defined time period; and
cut off the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for a sixth period of time and resume sensing the current; and
on determining that the average current value is not greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period,
determine if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
cut off the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for the fourth period of time, and resume sensing the current after the fourth period of time, if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
determine if the average current value is greater than the master threshold current value by less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
cut off the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for the seventh period of time, and resume sensing the current after the seventh period of time, if the average current value is greater than the master threshold current value by less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
determine if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for a pre-defined number of cycles; and
perform a continuous ON of the fan assembly (203) for an external fuse blow, if the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for a pre-defined number of cycles.
4. A method (400) for controlling a fan assembly (203) in a vehicle, the method comprising:
sensing, by a Smart Power Control Module (SPCM) (201), an input Pulse Width Modulation (PWM) current signal at a first pre-defined time period, wherein the input Pulse Width Modulation (PWM) current signal is a high frequency signal; and
cutting off power supply, by the Smart Power Control Module (SPCM) (201), to a fan assembly (203), on determining that average value of the sensed current over a second time period exceeds a master threshold current value.
5. The method, as claimed in claim 4, wherein the method comprises resuming, by the Smart Power Control Module (SPCM) (201), power supply to the fan assembly (203), on at least one of the sensed current becoming normal or an issue causing a restricted condition is corrected.
6. The method, as claimed in claim 4, wherein the method comprises:
sensing, by the Smart Power Control Module (SPCM) (201), the input PWM current signal at the first pre-defined time period;
averaging, by the Smart Power Control Module (SPCM) (201), the sensed current over the second pre-defined time period;
on determining that the average current value is greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period,
cutting off, by the Smart Power Control Module (SPCM) (201), the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for a fourth period of time, and resume sensing the current;
determining, by the Smart Power Control Module (SPCM) (201), if the average current value is greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least a fifth pre-defined time period; and
cutting off, by the Smart Power Control Module (SPCM) (201), the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for a sixth period of time and resume sensing the current; and
on determining that the average current value is not greater than the master threshold current value by the first pre-defined percentage and less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period,
determining, by the Smart Power Control Module (SPCM) (201), if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
cutting off, by the Smart Power Control Module (SPCM) (201), the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for the fourth period of time, and resume sensing the current after the fourth period of time, if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
determining, by the Smart Power Control Module (SPCM) (201), if the average current value is greater than the master threshold current value by less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
cutting off, by the Smart Power Control Module (SPCM) (201), the Pulse Width Modulation (PWM) current signal to the fan assembly (203) for the seventh period of time, and resume sensing the current after the seventh period of time, if the average current value is greater than the master threshold current value by less than the second pre-defined percentage in a stable duty cycle for at least the third pre-defined time period;
determining, by the Smart Power Control Module (SPCM) (201), if the average current value is greater than the master threshold current value by the second pre-defined percentage in a stable duty cycle for a pre-defined number of cycles; and
performing, by the Smart Power Control Module (SPCM) (201), a continuous ON of the fan assembly (203) for an external fuse blow, if the average current value (avg) is greater than the master threshold current value by the second pre-defined percentage (B%) in a stable duty cycle for a pre-defined number of cycles.