Claims:
1. A method (200) for monitoring operational life of a starter motor (2) of an internal combustion engine (3) of a vehicle, the method (200) comprising:
determining (201), by an electronic control unit (ECU) (1), increase in speed of the internal combustion engine (3) within a defined time period during each operation of the starter motor (2) for cranking of the internal combustion engine (3);
evaluating (202), by the ECU (1), a total number of cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the internal combustion engine (3), based on the determination;
cumulating (203), by the ECU (1), the total number of cranks performed by the starter motor (2); and
indicating (204), by the ECU (1), an alert signal through an indication unit (10) when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor (2);
wherein, the alert signal is indicative of the operational life of the starter motor (2).

2. The method (200) as claimed in claim 1, wherein evaluating the total number of cranks by the ECU (1) includes determining both successful cranks and unsuccessful cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the internal combustion engine (3).

3. The method (200) as claimed in claim 2, wherein the crank is identified as the successful crank when the internal combustion engine (3) is cranked by the starter motor (2) to a predetermined speed within the defined time period.

4. The method (200) as claimed in claim 2, wherein the crank is identified as the unsuccessful crank when the internal combustion engine (3) is not cranked by the starter motor to the predetermined speed within the defined time period.

5. The method (200) as claimed in claim 3, wherein the predetermined speed is an idle speed of the internal combustion engine (3).

6. The method (200) as claimed in claim 1, wherein the ECU (1) is configured to store the cumulated number of cranks in a memory unit associated with the ECU (1).

7. The method (200) as claimed in claim 1, wherein the defined time period ranges from 1 second to 10 seconds.

8. A system (100) for monitoring operational life of a starter motor (2) of an internal combustion engine (3) of a vehicle, the system (100) comprising:
an electronic control unit (ECU) (1) associated with the internal combustion engine (3) and the starter motor (2) of the vehicle, wherein the ECU (1) is configured to,
determine increase in speed of the internal combustion engine (3) within a defined time period during each operation of the starter motor (2) for cranking of the internal combustion engine (3);
evaluate a total number of cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the internal combustion engine (3), based on the determination;
cumulate the total number of cranks performed by the starter motor (2); and
indicate an alert signal through an indication unit (10) when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor (2);
wherein, the alert signal is indicative of the operational life of the starter motor (2).

9. The system (100) as claimed in claim 8, wherein evaluating the total number of cranks by the ECU (1) includes determining both successful cranks and unsuccessful cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the internal combustion engine (3).

10. The system (100) as claimed in claim 9, wherein the crank is identified as the successful crank when the internal combustion engine (3) is cranked by the starter motor (2) to a predetermined speed within the defined time period.

11. The system (100) as claimed in claim 9, wherein the crank is identified as the unsuccessful crank when the internal combustion engine (3) is not cranked by the starter motor to the predetermined speed within the defined time period.

12. The system (100) as claimed in claim 10, wherein the predetermined speed is an idle speed of the internal combustion engine (3).

13. The system (100) as claimed in claim 8, wherein the ECU (1) is configured to store the cumulated number of cranks in a memory unit associated with the ECU (1).

14. The system (100) as claimed in claim 8, wherein the defined time period ranges from 1 second to 10 seconds.

15. A vehicle comprising a system (100) for monitoring operational life of a starter motor (2) of an internal combustion engine (3) of a vehicle as claimed in claim 8.
, Description:TECHNICAL FIELD
[001] Present disclosure, in general, relates to the field of automobiles. Particularly, but not exclusively, the present disclosure relates to operation of a starter motor for an internal combustion engine of a vehicle. Further, embodiments of the present disclosure relate to a system for monitoring operational life of the starter motor of the internal combustion engine and a method thereof.

BACKGROUND OF THE DISCLOSURE
[002] Most internal combustion engines (simply referred to as ‘engine’ hereinafter), employed in vehicles, are equipped with a starter motor (also referred to as ‘cranking motor’ or simply as ‘starter’) to provide initial rotation (crank) such that the engine begins to operate on its own power. The starter motors employed in the vehicles are generally mounted on the engine’s gearbox housing and may be positioned such that a driving gear of the starter motor may be meshed/unmeshed with an operational gear or a flywheel of the engine based on requirement.

[003] Generally, vehicle manufacturers and/or (Original Equipment Manufacturers) OEM’s provide warranty period on purchaser of the starter motor, where based on such warranty period the starter motor shall be repaired or replaced without any cost to the purchaser in case the starter motor fails within a specified warranty period. Such specified warranty period is usually defined in terms of at least one of days, months, and years from date of purchase of the starter motor and/or the vehicle. Also, the specified warranty period may also be defined in terms of distance covered by the vehicle, which may be quantified in terms of kilometers/miles covered from the date of installation of the starter motor and/or the vehicle.

[004] A drawback associated with providing such warranty period, i.e., in terms of time and/or distance, is that actual usage of the starter motor is not considered. In some applications of the starter motor, such as, but not limited to, those employed in public transport vehicles, garbage collection vehicles used in municipalities, shuttle vehicles and the like, number of cranks performed per kilometer is considerably higher in comparison with starter motors employed in other type of vehicles. In such vehicles requiring higher number of cranks or frequent cranks, the starter motor usually fails before the warranty period specified by manufacturer, due to above average usage of the starter motor. Further, the starter motors performing frequent and repetitive cranking, may be energized for a prolonged period of time, which may result in thermal failure of the starter motor or windings within the starter motor. In such conditions, the manufacturer and/or the OEM may incur losses, in spite of the starter motor providing sufficient number of cranks during its operational life. Further, in such vehicles requiring higher number of cranks per kilometer, providing warranty in terms of time and distance may not be feasible.

[005] The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional configuration of starter motor cranking systems of the engine.

SUMMARY OF THE DISCLOSURE

[006] One or more shortcomings of the conventional assemblies and arrangements are overcome by a system for monitoring operational life of a starter motor of an internal combustion engine of a vehicle and a method thereof as claimed and additional advantages are provided through the system and the method as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

[007] In one non-limiting embodiment of the present disclosure, a method for monitoring operational life of a starter motor of an internal combustion engine of a vehicle is disclosed. The method includes determining, by an electronic control unit (ECU), increase in speed of the internal combustion engine within a defined time period during each operation of the starter motor for cranking of the internal combustion engine. The method further includes evaluating, by the ECU, a total number of cranks performed by the starter motor for each ON cycle from OFF cycle of the internal combustion engine, based on the determination. The method further includes cumulating, by the ECU, the total number of cranks performed by the starter motor. The method further includes indicating, by the ECU, an alert signal through an indication unit when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor. In the embodiment, the alert signal is indicative of the operational life of the starter motor.

[008] In an embodiment of the present disclosure, evaluating the total number of cranks, by the ECU, includes determining both successful cranks and unsuccessful cranks performed by the starter motor for each ON cycle from OFF cycle of the internal combustion engine.

[009] In an embodiment of the present disclosure, the crank is identified as the successful crank when the internal combustion engine is cranked by the starter motor to a predetermined speed within the defined time period. In an embodiment, the ECU may be configured to determine the crank of the internal combustion engine by the starter motor to be the successful crank, when speed of the internal combustion engine is at least equal to or greater than the predetermined speed. On determining speed of the internal combustion engine relative to the predetermined speed, the ECU may disregard the defined time period at which such speed of the internal combustion engine is attained for the crank of the internal combustion engine to be successful by the starter motor. Further, successful cranking of the internal combustion engine by the starter motor also depends upon operational parameters of the internal combustion engine, such as, but not limited to, temperature of coolant employed in the internal combustion engine, speed of the internal combustion engine (in rpm) and the like.

[0010] In an embodiment of the present disclosure, the crank is identified as the unsuccessful crank when the internal combustion engine is not cranked by the starter motor to the predetermined speed within the defined time period. In an embodiment, the crank is identified as the unsuccessful crank, when the internal combustion engine is cranked by the starter motor and speed of the engine is less than predetermined speed. In an embodiment, the predetermined speed may be in the range of 400 rpm to 800 rpm.

[0011] In an embodiment of the present disclosure, the predetermined speed is an idle speed of the internal combustion engine.

[0012] In an embodiment of the present disclosure, the ECU is configured to store the cumulated number of cranks in a memory unit associated with the ECU.

[0013] In an embodiment of the present disclosure, the defined time period ranges from 1 second to 10 seconds.

[0014] In another non-limiting embodiment of the present disclosure, a system for monitoring operational life of a starter motor of an internal combustion engine of a vehicle is disclosed. The system includes an electronic control unit (ECU) associated with the internal combustion engine and the starter motor of the vehicle. The ECU is configured to determine increase in speed of the internal combustion engine within a defined time period during each operation of the starter motor for cranking of the internal combustion engine. The ECU is further configured to evaluate a total number of cranks performed by the starter motor for each ON cycle from OFF cycle of the internal combustion engine, based on the determination. The ECU is further configured to cumulate the total number of cranks performed by the starter motor. The ECU is also configured to indicate an alert signal through an indication unit when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor. In the embodiment, the alert signal is indicative of the operational life of the starter motor.

[0015] The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0016] The novel features and characteristics of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiment when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

[0017] Figure 1 illustrates schematic block diagram of a system for monitoring operational life of a starter motor of an internal combustion engine of a vehicle, in accordance with an embodiment of the present disclosure.

[0018] Figure 2 is a flow chart of a method for monitoring operational life of the starter motor of the internal combustion engine of the vehicle.

[0019] Figure 3 is another flow chart depicting an operational method of the system of Figure 1, for monitoring operational life of the starter motor of the internal combustion engine of the vehicle.

[0020] The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the system and the method illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

[0021] While the embodiments in the disclosure are subject to various modifications and alternative forms, specific embodiments thereof have been shown by the way of example in the figures and will be described below. It should be understood, however that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[0022] The terms “comprises”, “comprising”, or any other variations thereof used in the disclosure, are intended to cover non-exclusive inclusions, such that a device, assembly, mechanism, system, method that comprises a list of components does not include only those components but may include other components not expressly listed or inherent to such system, or assembly, or device. In other words, one or more elements in a system proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or method.

[0023] A cranking operation (also simply referred to as ‘cranking’) of the engine may be defined as torquing the engine’s crankshaft such that the engine begins to power itself. The cranking operation of the engine may be considered successful, only if the engine reaches a certain speed (for instance, idle speed, which may be measured in revolutions per minute (rpm)) and begins to operate on its own power. Actuation from the starter motor is not required once the engine starts running and hence, may be disengaged from the engine soon after successful cranking of the engine. On the other hand, the cranking operation of the engine is considered unsuccessful, if the engine fails to reach the idle speed, whereby engine fails to operate on its own power. The cranking operation of the engine may not be successful due to a variety of reasons such as, but not limited to, engine stalling/locking due to insufficient fuel supply, clogged fuel/air filter, mechanical failure, faulty alternator, the starter motor being unable to engage with engine flywheel’s teeth, a faulty ignition switch, sudden increase in engine load and the like.

[0024] Embodiments of the present disclosure discloses a system for monitoring operational life of a starter motor of an internal combustion engine of a vehicle. The system of the present disclosure enables monitoring of actual number of cranks performed by the starter motor, whereby enabling accurate determination of operational life of the starter motor. The system overcomes drawbacks associated with conventional arrangements of providing warranty in terms of time and distance and allows manufacturers to provide warranty in terms of actual usage of starter motor. The system provides information to user and manufacturers on starter motor performance requirements for particular vehicle usage/applications. The system according to various embodiments of the disclosure includes an electronic control unit (ECU) associated with the internal combustion engine and the starter motor of the vehicle. The ECU is configured to determine increase in speed of the internal combustion engine within a defined time period during each operation of the starter motor for cranking of the internal combustion engine. The ECU is further configured to evaluate a total number of cranks performed by the starter motor for each ON cycle from OFF cycle of the internal combustion engine, based on the determination. The ECU is further configured to cumulate the total number of cranks performed by the starter motor. The ECU is also configured to indicate an alert signal through an indication unit when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor. In the embodiment, the alert signal is indicative of the operational life of the starter motor. Further, a method for monitoring operational life of the starter motor of the internal combustion engine of the vehicle is also disclosed. The system and the method of the present disclosure is directed towards addressing drawbacks associated with conventional arrangements of providing warranty period to starter motors in terms of time and/or distance, where actual usage of the starter motor is not considered.

[0025] In an embodiment, the term ‘engine’ as used herein refers to at least one of an internal combustion engine. The term ‘starter motor’ (also referred to as ‘cranking motor’ or simply as ‘starter’ hereinafter) refers to a device used to rotate (and crank) the engine so as to initiate the engine's operation under its own power to produce torque. The starter motor employed in the vehicle may be an electric starter motor. However, the starter motor may also be at least one of a pneumatic starter motor and a hydraulic starter motor. The present disclosure is described by considering the starter motor employed in the vehicle is an electric starter motor, meanwhile such description shall also be extended to other configuration of the starter motor.

[0026] The disclosure is described in the following paragraphs with reference to Figures 1 to 3. In the figures, the same element or elements which have same functions are indicated by the same reference signs. It is to be noted that, the vehicle including the engine and the starter motor is not illustrated in the figures for the purpose of simplicity. One skilled in the art would appreciate that the system and the method as disclosed in the present disclosure may be used in any vehicles that employs/includes at least one starter motor associated with the engine of the vehicle, where such vehicle may include, but not be limited to, light duty vehicles, passenger vehicles, commercial vehicles, and the like. Also, such system and method may be employed to the starter motor associated with the engines being driven by fuel including, but not limited to, petrol, diesel, hydrogen, bio-diesel, CNG, and hybrid engines.

[0027] Figure 1 is an exemplary embodiment of the present disclosure which illustrates a system (100) for monitoring operational life of a starter motor (2) (also simply referred to as ‘starter’ hereinafter) of an engine (3) of a vehicle (not shown in figures). The system (100) includes an electronic control unit (ECU) (1) associated with the engine (3) and the starter motor (2) of the vehicle. In an embodiment, the starter motor (2) may be at least one of a three terminal starter motor and a four terminal starter motor, to be employed based on requirement. The present disclosure is described by considering the starter motor (2) as a three terminal starter motor and such description shall not be considered as a limitation of the present disclosure. The system (100) further includes a battery (6) configured to supply power to the starter motor (2). A positive terminal of the battery (6) may be connected to a first terminal of the starter motor (2). Further, the positive terminal of the battery (6) may also be connected to a switch of an ignition (5) or ignition button (simply referred to as ‘ignition’ hereinafter) associated with the starter motor (2).

[0028] The ignition (5) may be connected to a starter lockout relay (7), which is further connected to a starter crank terminal supply (8). The starter crank terminal supply (8) is further connected to a second terminal of the starter motor (2). Supply to the second terminal of the starter motor (2) from the ignition (5) (which is routed via the starter lockout relay (7) and the starter crank terminal supply (8)) may regulate (i.e., start and stop) operation of the starter motor (2). The ignition (5) along with the starter lockout relay (7) and the starter crank terminal supply (8) may be collectively referred to as a starter control circuit (9). The starter lockout relay (7) may also be connected to the (ECU) (1) to receive control signals for regulating operation of the starter motor (2). Further, a third terminal of the starter motor (2) may be configured to power windings of the starter motor (2) to drive the starter motor (2). A negative terminal of the battery (6) may be connected to a ground/earthing point such as, but not limited to, engine cylinder block, transmission, which may be positioned close to the starter motor (2). Furthermore, working and operational control of the starter motor (2) is well known in the art and is not described in detail in the present disclosure for simplicity.

[0029] The starter motor (2) may be selectively coupled to the engine (3), to impart rotational energy during cranking operation of the engine (3). The engine (3) may be further communicatively coupled the ECU (1) and a speed detection module (4). The speed detection module (4) may also be communicatively coupled to the ECU (1). The speed detection module (4) may be at least one of an engine management system (EMS) of the engine (3) and a sensor interfaced with the engine (3). The speed detection module (4) may be configured to transmit signals corresponding to speed of the engine (3) to the ECU (1).

[0030] In an embodiment, the sensor may be any sensor capable of detecting speed of the engine (3) and transmitting a signal corresponding to the speed of the engine (3). The sensor may be including but not limited to, contact type sensors, non-contact type sensors, optical sensors, inductive sensors (including both monopolar or bipolar), magnetic sensors, magneto-resistive sensors, proximity sensors, Hall effect sensors, tachogenerators, magnetic variable reluctance (VR) probes and the like.

[0031] In an embodiment, the starter motor (2) may be coupled to a ring gear (also known as ‘starter ring gear’, not shown in figures) associated with the engine (3). The ring gear may be configured to transfer rotational energy (torque) from the starter motor (2) to the engine's crankshaft, in order to crank the engine (3).

[0032] The ECU (1) may be configured to determine increase in speed of the engine (3) within a defined time period during each operation of the starter motor (2) for cranking of the engine (3). The ECU (1) determines increase in engine speed based on signals received from the speed detection module (4). In an embodiment, the defined time period may be a cumulative timespan or discrete timespan measured from commencement of cranking operation of the engine (3). For example, the defined time period may be 0.5 second (s), 1 s, 2 s, 5 s, 10 s and the like, in which the defined time period is measured cumulatively from the commencement of the cranking operation of the engine (3). However, the defined time period may also be a discrete timespan measured from commencement of the cranking operation of the engine (3) such as 0.5 s or 1 s or 2 s and the like, which may be measured at any point of time from the commencement of the cranking operation of the engine (3).

[0033] The ECU (1) may be configured to evaluate a total number of cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the engine (3), based on said determined increase in speed of the engine (3). In an embodiment, evaluating the total number of cranks by the ECU (1) includes counting of both successful cranks and unsuccessful cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the engine (3). The phrase ‘each ON cycle from OFF cycle of the engine (3)’ (also referred to as ‘OFF-ON cycle’ of the engine (3)), includes all cranking operations that are performed either until the engine (3) is successfully cranked or until the starter motor (2) is disengaged from the engine (3) upon completion of a predefined number of consecutive unsuccessful cranking operations of the engine (3). The predefined number of consecutive unsuccessful cranking operations may be in the range of 2 cranking operations, performed after the first cranking operation within same OFF-ON cycle of the engine (3). However, the predefined number of consecutive cranking operations may also be in the range of at least 3 cranking operations, however, such cranking operations may be extended to 4 cranking operations performed after the first cranking operation within same OFF-ON cycle of the engine (3).

[0034] In an embodiment, a cranking operation (also referred to as ‘crank’) may be identified as a successful cranking operation (also referred to as ‘successful crank’) when the engine (3) is cranked by the starter motor (2) to a predetermined speed within the defined time period. The cranking operation may be identified as an unsuccessful cranking operation (also referred to as ‘unsuccessful crank’) when the engine (3) is not cranked by the starter motor (2) to the predetermined speed within the defined time period. In the embodiment, the predetermined speed may be considered as a minimum engine speed that needs to be achieved within the defined time period, during the cranking operation of the engine (3). Such predetermined speed values may be stored in a memory unit associated with the ECU (1), where such memory unit is either communicatively coupled to or integral part of the ECU (1). The minimum engine speed may be defined in terms of revolutions per minute (rpm). However, the minimum engine speed may also be defined as at least one of velocity and acceleration, that may be derivable from the speed of the engine (3).

[0035] In an embodiment, the predetermined speed may be an idle speed of the engine (3). The term ‘idle speed’ as used herein refers to a rotational speed of the engine (3) when the engine (3) is idling. The term ‘idling’ as used herein refers to such condition during which the engine (3) is uncoupled from a drivetrain (i.e., operating under no load condition) and/or is on a minimum throttle setting. In the embodiment, the idle speed may be measured in revolutions per minute (rpm) of a crankshaft of the engine (3). The ECU (1) may be configured to compare the speed value incoming from the speed detection module (4) with the idle speed of the engine (3) (which may be stored in the memory unit associated with the ECU (1)). The ECU (1) may check whether the increase in engine speed (evaluated based on signals received from speed detection module (4)) matches with the idle speed value of the engine (3).

[0036] Based on the above-described comparison, the ECU (1) may be configured to evaluate the total number of cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the engine (3). The ECU (1) is also configured to evaluate the total number of cranks performed by the starter motor (2) in a next cranking operation of the engine (3). The next cranking operation of the engine (3) may be performed subsequent to failure of the first cranking operation of the engine (3). The expression ‘next cranking operation’ of the engine, as used herein, corresponds to subsequent cranking operation performed after a first cranking operation, in a subsequent OFF-ON cycle of the engine (3). Further, it should also be noted that the next cranking operation of the engine (3) will be performed only when the first cranking operation of the engine (3) is unsuccessful. As described earlier, an unsuccessful cranking operation may be defined as such condition of the engine (3), where the engine (3) fails to reach the idle speed. In the context of the present disclosure and for the purpose of simplicity, the unsuccessful cranking operation may be defined as such condition of the engine (3), where the engine (3) fails to reach the predetermined speed within the defined time period.

[0037] The ECU (1) may be further configured to cumulate the total number of cranks performed by the starter motor (2). The term ‘cumulate’ as used herein refers to addition or summation of the total number of cranks, including successful cranks and unsuccessful cranks, performed by the starter motor (2). In an embodiment, the ECU (1) may be further configured to cumulate the total number of cranks performed in the first cranking operation of the engine (3), in the next cranking operation of the engine (3) and all other subsequent cranking operations of the engine (3). The ECU (1) may be configured to store the cumulated number of cranks in a memory unit [not shown in figures] associated with the ECU (1).

[0038] The ECU (1) may also be configured to indicate an alert signal through an indication unit (10) when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor (2). In an embodiment, the alert signal may be indicative of the operational life of the starter motor (2). The predefined threshold crank limit of the starter motor (2) may be defined in terms of a minimum number of cranks that may be performed by the starter motor (2) at optimal operational life of the starter motor (2). In the embodiment, the predefined threshold crank limit of the starter motor (2) may be in a range of 15,000 cranks to 200,000 cranks, may even be in the range of 40,000 cranks to 100,000 cranks, and may further be in the range of 50,000 to 80,000 cranks, at optimal operational life of the starter motor (2). The alert signal generated and indicated by the ECU (1) may be based on a comparison between the predefined threshold crank limit of the starter motor (2) and the cumulated number of cranks performed by the starter motor (2). The alert signal may be indicative of a remaining or residual operational life of the starter motor (2). Such remaining or residual operational life of the starter motor (2) may be determined as a difference between the predefined threshold crank limit of the starter motor (2) and the cumulated number of cranks performed by the starter motor (2).

[0039] In an embodiment, the alert signal indicated by the indication unit (10) may be a signal indicating requirement of at least one of servicing and replacement of the starter motor (2). The alert signal may be generated by the ECU (1) and is indicated by the indication unit (10) based on at least one of the total unsuccessful cranks by the starter motor (2), predefined threshold crank limit of the starter motor (2), functional performance of the starter motor (2) and the engine (3), functional performance of other components included in the system (100) thereof and the like. In the embodiment, requirement of servicing of the starter motor (2) may be indicated when the cumulated number of cranks is substantially less than the predefined threshold crank limit of the starter motor (2). In the embodiment, requirement of replacing the starter motor (2) may be indicated when the cumulated number of cranks is substantially equal to or greater than the predefined threshold crank limit of the starter motor (2). In an embodiment, when the cumulated number of cranks is substantially less than the predefined threshold crank limit of the starter motor (2), then the alert signal may indicate requirement of checking starter motor (2) design parameters. Further, the alert signal may also indicate requirement of design compatibility checking of the starter motor (2), based on validated data of the vehicle. The validated data may be fetched from at least one of the ECU (1) and/or the EMS of the vehicle, where such validated data may include, such as, but not limited to, actual number of cranks performed by the starter motor, the predefined threshold crank limit of the starter motor (2) and the like.

[0040] In an embodiment, indicating the alert signal through the indication unit (10) includes notifying an operator/user operating the vehicle. The user may be notified with at least one of a requirement of servicing of the starter motor (2) and requirement of replacing the starter motor (2). However, the user may also be notified that the starter motor (2) is nearing end of its optimal operational life. The user may be notified through at least one of a beeper alarm, an audio and/or visual notification on a dashboard of the vehicle, through an application on the user cellphone and the like.

[0041] In an embodiment, the defined time period may be in a range of 1 second to 10 seconds and may even be in the range of 3 seconds to 8 seconds or more. The defined time period may be preset in the ECU (1) during End-of-line calibration performed at final stages of manufacturing of the starter motor (2) and/or the vehicle. However, the defined time period may also be a variable quantity and may be varied during lifecycle of the starter motor (2). The defined time period may be varied based on parameters including, but not limited to, type of vehicle in which the starter motor (2) is employed, percentage of charge available in the battery (6), heat buildup in windings of the starter motor (2) during the defined time period, operational requirements of the starter motor (2) and the engine (3), user requirements and the like. In an embodiment, the defined time period may be considered by the ECU (1), when the ECU (1) encounters unsuccessful cranking of the engine (3) i.e., the speed of the engine (3) being less than the predetermined speed.

[0042] In an embodiment, the ECU (1) may be configured to generate a Diagnostic Trouble Code (DTC), upon generation of the alert signal. The DTC may also be generated either prior to or subsequent to indication of the alert signal by the indication unit (10). The generated DTC may be stored in the memory unit associated with the ECU (1). However, the generated DTC may also be communicated to the user through at least one of a beeper alarm, an audio and/or visual notification on a dashboard of the vehicle, through an application on the user cellphone and the like. In addition to the above, the generated DTC may also be recorded in a memory module associated with an Engine Management System (EMS) of the engine (3) of the vehicle. The user and/or a technician servicing the vehicle may be provided with an option of erasing the record of alert signals and/or generated DTCs from the memory unit (of the ECU (1)) and/or the memory module (of the EMS), upon servicing or replacement of the starter motor (2). The generated DTC may be communicated to the EMS from the ECU (1) for recordation in the EMS and may be used by a technician/serviceman for identification of reason for failure of the starter motor (2). The generated DTC may be further analyzed using On-board diagnostics (OBD) techniques and may be used during troubleshooting and/or servicing of the starter motor (2).

[0043] Figure 2 is an exemplary embodiment of the present disclosure illustrating a flow chart of the method (200) for monitoring operational life of the starter motor (2) of the engine (3) of the vehicle.

[0044] The order in which the method (200) is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method (200). Additionally, individual blocks may be deleted from the method (200) without departing from the scope of the subject matter described herein.

[0045] As depicted at block 201, the method (200) includes determining, by an electronic control unit (ECU) (1) associated with a starter motor (2) and an engine (3) of the vehicle (as can be seen in Figure 1), increase in speed of the engine (3) within a defined time period, during each operation of the starter motor (2) for cranking of the engine (3). The increase in engine speed may be determined based on signals received from a speed detection module (4). In an embodiment, the speed detection module (4) is at least one of an engine management system (EMS) of the engine (3) and a sensor interfaced with the engine (3). In the embodiment, the defined time period may be in a range of 1 second to 10 seconds and may even be in the range of 3 seconds to 8 seconds or more. As described above in the summary section, upon determining speed of the engine (3) relative to the predetermined speed, the ECU (1) may disregard the defined time period at which such speed of the engine (3) is attained for the crank of the engine (3) to be successful by the starter motor (2). Further, successful cranking of the engine (3) by the starter motor (2) also depends upon operational parameters of the engine (3), such as, but not limited to, temperature of coolant employed in the engine (3), speed of the engine (3) (in rpm) and the like.

[0046] As depicted at block 202, the method (200) includes evaluating, by the ECU (1), a total number of cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the engine (3), based on the determination. As described above, evaluating the total number of cranks by the ECU (1), includes counting of both successful cranks and unsuccessful cranks performed by the starter motor (2) for each ON cycle from OFF cycle of the engine (3).

[0047] As depicted at block 203, the method (200) includes cumulating the total number of cranks performed by the starter motor (2). As described above, the term ‘cumulate’ as used herein refers to addition or summation of the total number of cranks, including successful cranks and unsuccessful cranks, performed by the starter motor (2). In an embodiment, the ECU (1) may be further configured to cumulate the total number of cranks performed in the first cranking operation of the engine (3), in the next cranking operation of the engine (3) and all other subsequent cranking operations of the engine (3). The ECU (1) may be configured to store the cumulated number of cranks in the memory unit associated with the ECU (1).

[0048] As depicted at block 204, the method (200) includes indicating an alert signal through an indication unit (10) when the cumulated number of cranks exceed a predefined threshold crank limit of the starter motor (2). In an embodiment, the alert signal may be indicative of the operational life of the starter motor (2). The predefined threshold crank limit of the starter motor (2) may be defined in terms of a minimum number of cranks that may be performed by the starter motor (2) at optimal operational life of the starter motor (2). The alert signal generated and indicated by the ECU (1) may be based on a comparison between the predefined threshold crank limit of the starter motor (2) and the cumulated number of cranks performed by the starter motor (2). The alert signal may be indicative of a remaining or residual operational life of the starter motor (2). Such remaining or residual operational life of the starter motor (2) may be determined as a difference between the predefined threshold crank limit of the starter motor (2) and the cumulated number of cranks performed by the starter motor (2).

[0049] In an embodiment, indicating the alert signal through the indication unit (10) includes notifying an operator/user operating the vehicle. The user may be notified with at least one of a requirement of servicing of the starter motor (2) and requirement of replacing the starter motor (2). However, the user may also be notified that the starter motor (2) is nearing end of its optimal operational life. The user may be notified through at least one of a beeper alarm, an audio and/or visual notification on a dashboard of the vehicle, through an application on the user cellphone and the like.

[0050] Figure 3 is an exemplary embodiment of the present disclosure illustrating an operational flow chart (300) of the system (100) and the method (200) for monitoring operational life of the starter motor (2) of the engine (3) of the vehicle. Initially, it is assumed that the starter motor (2) of the engine (3) is engaged with a starter motor ring gear (simply referred to as ring gear hereinafter) of the engine (3) the vehicle

[0051] As depicted at block 301, operation of the system (100) begins with initiation of cranking operation of the engine (3). As depicted at block 302, the ECU (1) verifies whether the starter motor (2) is engaged with the ring gear of the engine (3). As depicted at block 303, when it is determined that the starter motor (2) is not engaged with the ring gear of the engine (3), the ECU (1) may initiate engagement of the starter motor (2) with the ring gear of the engine (3). On the other hand, upon determining that the starter motor (2) is in engagement with the ring gear of the engine (3), cranking of the engine (3) is performed. Upon cranking, the ECU (1) proceeds towards determining increase in speed of the engine (3) within the defined time period, during each operation of the starter motor (2) for cranking of the engine (3), as depicted at block 304. The ECU (1) may determine increase in engine speed based on signals received from the speed detection module (4). Further, as depicted at block 305, the ECU (1) may determine that the cranking operation is successful (denoted by C1, also referred to as ‘successful crank’ (C1)), when the engine (3) is cranked by the starter motor (2) to the predetermined speed within the defined time period. Conversely, as depicted at block 306, the ECU (1) may determine that the cranking operation is unsuccessful (denoted by C2, also referred to as ‘unsuccessful crank’ (C2)), when the engine (3) is not cranked by the starter motor (2) to the predetermined speed within the defined time period. In the embodiment, the predetermined speed may be the ‘idle speed’ of the engine.

[0052] Further, as depicted at block 307, the ECU (1) may be configured to cumulate the total number of cranks performed by the starter motor (2). As described above, the term ‘cumulate’ as used herein refers to addition or summation of the total number of cranks (denoted by ‘C3’, where C3 = C1+C2), including successful cranks (C1) and unsuccessful cranks (C2), performed by the starter motor (2). Upon cumulating the total number of cranks, in other words, upon determining C3, the ECU (1) may compare the cumulated number of cranks (C3) performed by the starter motor (2) with the predefined threshold crank limit (denoted by ‘C4’) of the starter motor (2), as depicted at block 308. As described above, the predefined threshold crank limit (C4) of the starter motor (2) may be defined in terms of a minimum number of cranks that may be performed by the starter motor (2) at optimal operational life of the starter motor (2). Furthermore, as depicted at block 309, the ECU (1) may indicate the alert signal through the indication unit (10), when the cumulated number of cranks (C3) is equal to and/or exceeds the predefined threshold crank limit (C4) of the starter motor (2). As described earlier, indicating the alert signal includes notifying an operator/user operating the vehicle. The user may be notified with at least one of a requirement of servicing of the starter motor (2) and requirement of replacing the starter motor (2). However, the user may also be notified that the starter motor (2) is nearing end of its optimal operational life. The user may be notified through at least one of a beeper alarm, an audio and/or visual notification on a dashboard of the vehicle, through an application on the user cellphone and the like.

[0053] In an embodiment of the disclosure, the ECU (1) may be a centralized control unit, or a dedicated control unit associated with the system (100). The ECU (1) may be implemented by any computing systems that is utilized to implement the features of the present disclosure. The ECU (1) may be comprised of a processing unit. The processing unit may comprise at least one data processor for executing program components for executing user- or system-generated requests. The processing unit may be a specialized processing unit such as integrated system (bus) controllers, memory management control units, floating point units, graphics processing units, digital signal processing units, etc. The processing unit may include a microprocessor, such as AMD Athlon, Duron or Opteron, ARM’s application, embedded or secure processors, IBM PowerPC, Intel’s Core, Itanium, Xeon, Celeron, or other line of processors, etc. The processing unit may be implemented using a mainframe, distributed processor, multi-core, parallel, grid, or other architectures. Some embodiments may utilize embedded technologies like application-specific integrated circuits (ASICs), digital signal processors (DSPs), Field Programmable Gate Arrays (FPGAs), and the like.

[0054] Further, in some embodiments, the processing unit may be disposed in communication with one or more memory devices (e.g., RAM, ROM etc.) via a storage interface. The storage interface may connect to memory devices including, without limitation, memory drives, removable disc drives, etc., employing connection protocols such as serial advanced technology attachment (SATA), integrated drive electronics (IDE), IEEE-1394, universal serial bus (USB), fiber channel, small computing system interface (SCSI), etc. The memory drives may further include a drum, magnetic disc drive, magneto-optical drive, optical drive, redundant array of independent discs (RAID), solid-state memory devices, solid-state drives, and the like.

[0055] In an embodiment, the present disclosure provides a system (100) and a method (200) for monitoring actual number of cranks performed by the starter motor (2), whereby enabling accurate determination of operational life of the starter motor (2). The system (100) and the method (200) overcome drawbacks associated with conventional arrangements of providing warranty in terms of time and distance and allows manufacturers to provide warranty in terms of actual usage of starter motor (2). The system (100) and the method (200) facilitate validation of design capacity of the starter motor (2) in comparison with actual capacity (or on road performance) of the starter motor (2). The system (100) and the method (200) assist in evaluating root cause of the starter motor (2) failure. Insights that may be derived from identifying root cause of the failure may be employed in improving design and quality of the starter motor (2). The system (100) and the method (200) provide information to user’s and manufacturers on starter motor (2) performance requirements for particular vehicle usage/applications. Warranty on starter motor (2), that is provided by manufacturers and OEMs may be customized to suit specific application requirements of the starter motor (2). Aspect of generating DTC by the ECU (1)/EMS will provide an understanding on type and nature of failure experienced by the starter motor (2). The system (100) and the method (200) prevents/reduces losses that may be incurred by manufacturer’s and/or OEMs, in spite of the starter motor (2) providing sufficient number of cranks in accordance with its design capacity, during operational life of the starter motor (2).

EQUIVALENTS

[0056] With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.

[0057] It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system (100) having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system (100) having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0058] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0059] While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

REFERRAL NUMERICALS
Particulars Numerical
System for monitoring operational life of a starter motor 100
Electronic Control Unit (ECU) 1
Starter motor 2
Engine 3
Speed detection module 4
Ignition 5
Battery 6
Starter lockout relay 7
Starter crank terminal supply 8
Starter control circuit 9
Indication unit 10
Method flow chart 200
Method flow chart blocks 201-204
Operational flow chart 300
Operational flow chart blocks 301-309