The present disclosure relates, in general, to system and method for protecting a starter motor of a vehicle. The present system and method can be implemented in existing Electronic Control Unit (ECU) or can be provided as a standalone processing device for protecting the starter motor.
[0002] In particular, the present disclosure relates to system and method for detecting over-running, over-cranking, and inching conditions in the starter motor and inhibiting supply of current to the starter motor upon detection of any of the conditions to protect the starter motor by warning the user and/or restricting the functionality of starter motor.
BACKGROUND
[0003] Background description includes information that may be useful in understanding the present subject matter.
[0004] A starter motor is an electric motor that is used to crank the engine of the vehicle, whereby the engine sustains cranking thereafter due to the fuelling. The starter motor comprises a pinion rotor that projects out when the starter motor is turned on and comes in contact with the flywheel of the engine. The rotation of the rotor rotates the flywheel, whereby the flywheel pushes the crankshaft to rotate and the piston rods to move. This provides a self-sustainable rotation, whereby the engine starts to fire up and function.
[0005] However, the starter motor is a device that can be damaged due to three reasons, over-running, over-cranking and inching. Over-running is a condition that is associated when the engine is turned on due to the functioning of the starter motor and over-cranking and inching are conditions that are associated with the engine when the starter motor is not able to turn on the engine.
[0006] Over-running Condition: When the user of the vehicle inadvertently keeps starter motor on even after the engine has been turned on. In this condition, the rotor of the starter motor is still in contact with the flywheel. However, the

flywheel initiated the combustion process in the engine and the engine is now rotating the flywheel at speeds much higher than that of the speed that is achieved by the starter motor. This variation in speed (RPM) between the flywheel and the rotor (of the starter motor) results in the starter motor experiencing severe damages.
[0007] Over-cranking condition: When the engine does not turn on, it is a common thing for the user to keep the starter motor engaged in an attempt to turn on the engine. Thus, when the starter motor is continuously being engaged it results in draining of the battery and cranking issues of the starter motor. In one condition, where there is no fuel, the vehicle is unable to crank. But the user still attempts to crank multiple times, leading to damage of the starter motor.
[0008] Inching condition: When user moves the vehicle with force generated by the starter motor only. In one condition, where there is no fuel, the user attempt to jerk the engine using the starter motor in a bid to move the vehicle forward. However, this results in damage of the starter motor. Inching is a major factor for starter motor failure in market. If user engages the gear and tries to start, then vehicle will move a little due to the rotational force generated by the starter motor. Inching will cause starter failure due to high load condition for long time.
[0009] Therefore, there is need in the art to inhibit user to perform inching, over-cranking and over-running of the starter motor of the vehicle. Further it is also intended to provide cost effective system and method without addition of any new sensor or device in the vehicle to inhibit the user to perform inching, over-cranking, and over-running.
OBJECTS OF THE DISCLOSURE
[0010] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0011] A general object of the present disclosure is to provide a system and a method for failure conditions detecting, for example, over-running, over-cranking, and inching condition of starter motor in the vehicle.

[0012] It is an object of the present disclosure to avoid damage to the starter motor.
[0013] An object of the present disclosure is to provide a method and a system for warning the user and/or restricting the functionality of the starter motor upon detection of any of the failure condition.
[0014] These and other objects and advantages of the present disclosure will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.
SUMMARY
[0015] This summary is provided to introduce concepts related to a method and a system for detecting starter motor failure conditions and inhibiting the starter motor upon detection. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0016] The present subject matter relates to a system for detecting cranking issues in starter motor and warning the user and/or restricting the functionality of the starter motor upon detection of the same. The present system is implemented in the existing an electronic Control Unit (ECU) for protecting a starter motor during cranking issues in a vehicle. The ECU comprising a starter processing unit that includes an inching detection unit to detect inching condition of the starter motor based on inputs received from Camshaft and crankshaft sensor, and vehicle speed sensor; and a judgment unit warns the user and/or restricts the functionality of starter motor by disconnecting starter relay connection with ground upon detection of the inching condition of starter motor.
[0017] In an aspect, the inching detection unit determines engine speed based on inputs received from the Camshaft and crankshaft sensor; determines vehicle speed based on inputs received from the vehicle speed sensor; and detects inching

condition when the engine speed is less than predefined engine speed and vehicle speed is more than predefine vehicle speed.
[0018] In an aspect, the judgment unit warns the user and/or restricts the functionality of starter motor when inching condition is detected more than predefined threshold limit.
[0019] In an aspect, the judgment unit warns the user and/or restricts the functionality of starter motor till refuelling or certain time when inching is detected more than a threshold limit: and fuel level, based on inputs from fuel gauge sensor, in fuel tank is less than a threshold lim.
[0020] In an aspect, the processing unit includes: an over-cranking detection unit to detect over-cranking condition of the starter motor when starter is engaged for more than X sec (X is calibrate-able time) and engine is not started after a number of cranks where number of cranks are more than predefined threshold limit; and the if the fuel level is low then judgment unit inhibits the starter motor for a predefined time period or till refuelling and/or display warning to user upon detection of over-cranking condition of the starter motor.
[0021] In an aspect, the processing unit includes: an over-running detection unit to detect over-running condition of the starter motor when the starter motor is engaged with flywheel of the engine for predefined threshold time (THes) period after engine is ON; and the judgment unit restricts the functionality of starter motor till engine OFF.
[0022] In an embodiment, the present subject matter relates to a method for protecting starter motor during cranking issues in a vehicle, the method comprising: determining whether the starter engaged flag is ON; detecting inching condition of the starter motor; warning the user and/or restricting the functionality of starter motor by inhibiting supply of current to the starter motor by disconnecting starter relay connection with ground upon detection of inching condition of the starter motor.

[0023] In an aspect, the method includes the detecting inching condition of the starter motor includes: determining whether engine speed calculated based on inputs received from camshaft position (CKP) and crankshaft position (CMP) sensor is less than predefined threshold engine speed; determining whether vehicle speed calculated based on inputs received from vehicle speed sensor is more than predefined threshold vehicle speed; and detecting inching condition when the determined engine speed is less than predefined threshold engine speed and determined vehicle speed is more than predefine vehicle speed.
[0024] In an aspect, warning the user and/or restrict the functionality of the starter motor for a predefined time period when: inching condition is detected more than predefined threshold limit (THiv).
[0025] In an aspect, the method includes warning the user and/or restricting the starter motor till refuelling when inching condition or overcranking condition is detected more than a predefined threshold limit; and fuel level, based on inputs from fuel gauge sensor, in fuel tank is less than a threshold limit.
[0026] In an aspect, the method includes detecting over-cranking condition of the starter motor, the detecting over-cranking condition of the starter motor includes when starter is engaged for more than X sec (X is calibratable time) and engine is not able to self-sustain or started. This judgment applies for both single crank time limit (X) judgement as well as the number of unsuccessful cranks (Y: Calibratable number) before engine starts. Determining whether engine is started or not after cranking for predefined time period; increasing crank count by one when engine is not started after cranking for predefined time period; and detecting over-cranking condition when number of crank count are more than predefined threshold limit and inhibiting the starter motor for a predefined time period and display warning to user upon detection of over-cranking condition of the starter motor.
[0027] In an aspect, the method includes detecting an over-running condition of the starter motor, the detecting the over-running condition includes: determining whether engine is ON or not based on inputs received from the

CKP/CMP sensor; detecting over-running condition when starter flag is ON for predefined threshold time period when engine is in ON condition; and restricting the functionality of starter motor upon detection of over-running condition.
[0028] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
[0029] It is to be understood that the aspects and embodiments of the disclosure described above may be used in any combination with each other. Several of the aspects and embodiments may be combined to form a further embodiment of the disclosure.
[0030] 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 DRAWINGS
[0031] The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system and/or methods in accordance with embodiments of the present subject matter are now described, by way of example only, and with reference to the accompanying figures, in which:
[0032] Fig. 1 illustrates a system to detect crank issue conditions of starter more and to warn the user and/or restrict the functionality of starter motor upon detection of crank issue conditions, in accordance with an embodiment of the present disclosure; and

[0033] Fig. 2 illustrates a method for warning the user and/or restricting the functionality of starter motor upon detection of crank issue conditions, in accordance with an embodiment of the present disclosure;
[0034] Fig. 3 illustrates a method for detecting over-cranking condition, in accordance with an embodiment of the present disclosure;
[0035] Fig. 4 illustrates a method for detecting over-running condition of starter motor in vehicle, in accordance with an embodiment of the present disclosure;
[0036] Fig. 5 illustrates a method for detecting inching condition with starter motor in vehicle, in accordance with an embodiment of the present disclosure; and
[0037] Fig. 6 illustrates a method for warning the user and/or restricting the functionality of starter motor upon detection of over-running, over-cranking, and inching condition of the starter motor in vehicle, in accordance with an embodiment of the present disclosure.
[0038] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative systems embodying the principles of the present subject matter. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in a computer-readable medium and executed by a computer or processor, whether or not such computer or processor is explicitly shown.
DETAILED DESCRIPTION
[0039] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives

falling within the scope of the present disclosure as defined by the appended claims.
[0040] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0041] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms "comprises", "comprising", "includes" and/or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0042] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0043] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0044] Definition of engine cranking phase: To start a vehicle at least a vehicle battery, a starter motor, and an ignition switch (or start switch for keyless vehicles) is required. When the ignition key is inserted within the ignition switch and turned to a start position, or start switch pressed to start condition in case of keyless vehicles, power energizes a solenoid coil within the starter which results in a starter pinion engaging a flywheel of an engine. The pinion of the starter motor drives the flywheel for starting the engine of the vehicle. When the engine is started, the ignition key or start switch (in keyless vehicles) is released and the pinion of the starter motor retracts from the flywheel thereby terminating the engine cranking phase.
[0045] Embodiments and/or implementations described herein relate to method and system for detecting over-running, over-cranking, and inching condition of starter motor and restricting functionality of starter motor by cutting supply of current from battery by dis-connecting starter relay ground connection.
[0046] The present system for detecting over-running, over-cranking, and inching condition of starter motor can be implemented or embedded in existing Electronic Control Unit (ECU) or Electronic Control Module (ECM) of the vehicle. In another embodiment, a separate micro-controller with can be provided to over-running, over-cranking, and inching condition of starter motor and warning the user and/or restricting the functionality of the starter motor for engaging with the flywheel by stopping supply of current from the auxiliary battery to the starter motor.
[0047] FIG. 1 illustrates exemplary components of a system for detecting over-running, over-cranking, and inching condition of starter motor and warning the user and/or restricting the functionality of the starter motor upon detection, in accordance with some embodiments of the present disclosure. In the present system 100, an ECU 105 can work as a central processing unit that communicate with a plurality of electronic components, such as sensors, instrument control panel display provided in the vehicle including starter motor. The ECU 105 includes a processor(s) 106, an interface(s), and a memory 107.

[0048] The processor(s) 106 may be implemented as one or more microprocessors, microcomputers, microcontrollers, digital signal processors, logic circuitries, and/or any devices that manipulate data based on operational instructions.
[0049] Among other capabilities, the one or more processor(s) 106 are configured to fetch and execute computer-readable instructions and one or more routines stored in the memory 107. The memory 107 may store one or more computer-readable instructions or routines, which may be fetched and executed to detect over-running, over-cranking, and inching condition of the starter motor 112 and warn the user and/or restrict the functionality of starter motor 112. The memory 107 may include any non-transitory storage device including, for example, volatile memory such as RAM, or non-volatile memory, such as EPROM, flash memory, and the like.
[0050] The interface(s) may include a variety of interfaces, for example, interfaces for data input and output devices referred to as I/O devices, storage devices, and the like. The interface(s) may facilitate communication of the ECU 105 with various devices coupled, such as fuel gauge sensor to receive fuel level inputs, CKP/CMP sensor to receive engine RPM, engine coolant sensor to receive Engine temperature, and vehicle speed sensor to receive vehicle speed, starter relay to connect or disconnect with ground, instrument control panel display device to display information. The interface(s) may also provide a communication pathway for one or more components of the ECU 105. Examples of such components include, but are not limited to, processing unit(s) 108 and data 110.
[0051] The processing unit(s) 108 may be implemented as a combination of hardware and programming (for example, programmable instructions) to implement one or more functionalities. In examples described herein, such combinations of hardware and programming may be implemented in several different ways. For example, the programming for the processing unit(s) 108 may be processor-executable instructions stored on a non-transitory machine-readable storage medium and the hardware for the processing unit(s) 108 may include a

processing resource (for example, one or more processors), to execute such instructions. In such examples, the ECU 105 may include the machine-readable storage medium storing the instructions and the processing resource to execute the instructions or the machine-readable storage medium may be separate but accessible to the ECU 100 and the processing resource. In other examples, the processing unit(s) 108 may be implemented by electronic circuitry.
[0052] In an aspect, the processing unit(s) 108 may include over-running detection unit 109, over-cranking detection unit 110, Inching detection unit 111, and judgment unit 112. The processing unit(s) 108 may include other unit(s) which may implement functionalities that supplement applications or functions performed by the ECU 105 or the processing unit(s) 108.
[0053] Further, the data 113 may include data that is either stored or generated as a result of functionalities implemented by any of the components of the processing unit(s) 108. In some aspects, the data 113 may be stored in the memory 107 in the form of various data structures. Additionally, data 113 can be organized using data models, such as relational or hierarchical data models. The data 113 may store data, including temporary data and temporary files, generated by the processing unit(s) 108 for performing the various functions of the ECU 105.
[0054] The data 113 may store a predefined data, such as threshold values for detecting over-cranking, over-running, and inching condition of starter motor. The data 113 may also store predefined data, such as threshold values for warning user and/or restricting the starter motor functionality condition.
[0055] The ECU 105 is coupled with a fuel gauge sensor 101 to receive fuel level in fuel tank, camshaft position sensor and crankshaft position sensor (CKP/CMP sensor) 102 to receive engine running condition, engine coolant temperature sensor 103 to judge engine running condition, and a vehicle speed sensor 104 to determine vehicle speed. Further, the ECU 105 is coupled with the starter relay 114 of the starter motor 116 to allow and inhibit supply of current from auxiliary battery to the starter motor 116, and instrument panel display device 115 to display warning to user.

[0056] The ECU 105 disconnect supply of current from the auxiliary battery to the starter motor 116 upon detection of any of the over-running, over-cranking, and inching condition of the starter motor by disconnecting ground connection of the starter relay 114.
[0057] In operation, when an ignition is ON and engine crank request is made by inserting the ignition key in ignition switch to energize the starter motor to start the engine, the processing unit 108 of the ECU 105 detects over-cranking, over-running, and inching condition of the starter motor 116. Upon detection of any of the over-cranking, over-running, and inching condition, the judgment unit 112 inhibits supply of current to the starter motor 116 from the auxiliary battery for a predefined time period and/or until predefined condition is fulfilled.
[0058] The present over-running detection unit 109 to detects over-running condition of the starter motor 116 when the starter motor (116) is engaged with flywheel of the engine for predefined threshold time (THes) period after engine is ON. The over-running detection unit 109 determines whether engine is running or not by comparing engine revolution per minute (RPM) with RPM of engine running condition. When engine is ON, the over-running detection unit 109 whether starter flag is ON for predefined threshold time period (THsf) or not. If the starter flag is ON or rotor of the starter motor 116 is engaged with flywheel of the engine for predefined threshold time period (THsf), the over-running detection unit 109 detects over-running condition is true. Upon detecting the over-running condition, the judgment unit 112 warns the user and/or restricts the functionality of starter motor 116 by disconnecting the supply of current from the battery. The judgment unit 112 warns the user and/or restricts the functionality of starter motor by disconnecting starter relay connection with ground upon detection of the over-running condition of starter motor 116.
[0059] In another embodiment, the over-cranking detection unit 110 detects over-cranking condition of the starter motor 116 when engine first firing is not happening or engine is not started when rotor of starter motor 116 is engaged with the flywheel of the engine for a predefined threshold time period (THes). Over-

cranking is detected when starter motor 116 is engaged for more than X sec (X is calibratable time) and engine is not able to self-sustain/started. This judgment applies for both single crank time limit (X) judgement as well as the number of unsuccessful cranks (Y: Calibratable number) before engine starts. When engine is not started even after a number of cranks where the number of cranks are more than predefined threshold limit (THoc), the over-cranking detection unit 110 detects over-cranking condition of the starter motor 116. Upon detection of over-cranking condition, the judgment unit 112 warn the user and/or restricts the functionality of starter motor 116 by inhibiting supply of current from the auxiliary batter for a predefined time period and display warning to user on a connected instrument panel display device 115.
[0060] In another embodiment, the judgment unit 112 inhibits the starter motor till refuelling when overcranking condition is detected more than a threshold limit (THoc) and fuel level, based on inputs from fuel gauge sensor 101, in fuel tank is less than a threshold limit (Thf).
[0061] In an embodiment, the starter processing unit 108 includes the inching detection unit 111 to detect inching condition of the starter motor 116 based on inputs received from Camshaft and crankshaft sensor 102 and vehicle speed sensor 104. The inching detection unit 111 determines engine speed based on inputs received from the Camshaft and crankshaft sensor 102 and determines vehicle speed based on inputs received from the vehicle speed sensor 104; and detects inching condition when the engine speed is less than predefined engine speed and vehicle speed is more than predefine vehicle speed.
[0062] Upon detection of inching condition, the judgment unit 112 warns the user and/or restricts supply of current to the starter motor 116 by disconnecting starter relay 114 connection with ground upon detection of inching condition of the starter motor 116.
[0063] In an embodiment, the judgment unit 112 warns the user and/or restrict functionality of starter motor 116 for a predefined time period and display

warning to user when inching condition is detected more than predefined threshold limit (THiv).
[0064] In another embodiment, the judgment unit 112 warns the user and/or restrict functionality of starter motor 116 till refuelling when inching condition is detected more than a threshold limit (Thi) and fuel level, based on inputs from fuel gauge sensor 101, in fuel tank is less than a threshold limit (Thf).
[0065] FIG. 2 illustrates a method 200 of detection of over-running, over-cranking, and inching condition of starter motor 116 and inhibiting current supply to starter motor upon detection, according to an embodiment of the present disclosure. 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 can be combined in any appropriate order to carry out the method 200 or an alternative method. Additionally, individual blocks may be deleted from the method 200 without departing from the scope of the subject matter described herein.
[0066] At step 201, the method 200 includes detecting Ignition ON condition.
[0067] At step 202, the method 200 includes determining key start position during engine cranking phase.
[0068] At step 203, the method 200 includes determining whether starter engaged flag is ON. The starter engaged flag ON means starter motor 116 is receiving current and rotor of the starter motor 116 is engaged with the flywheel of the engine. If starter engaged flag is ON, the method 200 proceeds to step 204. When starter engaged flag is Off, no action is taken.
[0069] At step 204, the method 200 includes detecting inhibiting conditions, such as over-cranking, over-running, and inching of the starter motor 116. When there is no such condition, the method 200 proceeds as input to step 203. When inhibiting conditions are detected, the method proceeds to step 205.
[0070] At step 205, the method 205 includes warning the user and/or restricting the functionality of starter motor 116 by inhibiting supply of current by

disconnecting the starter relay 114 connection with ground. There can be other means to inhibit the supply of current to the starter motor from the auxiliary battery. One such method involves disconnecting the positive power supply of the relay.
[0071] The method 300 illustrates detection over cranking condition in the starter motor 116 at step 204 of the method 200.
[0072] At step 301, the method 300 determines whether starter engaged flag is ON or not. It same as step 203 of the method 200.
[0073] At step 302, the method 300 includes determining whether engine speed is more than predefined threshold engine rpm or engine first firing is happened or not based on inputs received from the CKP/CMP sensor 102. When engine first firing condition is false and rotor of the starter motor 116 is engaged for predefined threshold time period (THes), for example, 10-15 sec, the over-cranking detection unit 110 increase the over-crank timer by one. For example, the over-crank timer, i.e., 15 sec increased by 1 second and become 16 second.
[0074] At the step 304, the method 300 includes comparing the over-crank timer with predefined threshold over-crank time period (THoc). The over-cranking is determined when starter motor is engaged for more than X sec (X is cahbratable time) and engine is not able to self-sustain. This judgment applies for both single crank time limit (X) judgement as well as the number of unsuccessful cranks (Y: Cahbratable number) before engine starts. When the engine is not started after a number of unsuccessful cranks (Y) where number of unsuccessful cranks (Y) are more than predefined threshold limit (THoc) and the crank is detected unsuccessful when the starter motor is engaged for more than predefined time period (X sec: calibratable time), the method proceeds to step 305 else proceeds to step 306.
[0075] At step 305, the method 300 includes displaying warning to user over instrument control panel display device 115 and restricts the functionality of

starter motor for predefined time period as stored in data 113 when the over-crank timer is more than the predefined threshold over-crank time period (THoc).
[0076] At step 306, the method 300 includes set the starter flag OFF by disconnecting the current supply to the starter motor 116 when the over-crank timer is less than predefined threshold over-crank time period (THoc).
[0077] At last method 300 proceed to step 205 for warning the user and/or restricting the functionality of the starter motor 116 upon detection of over-cranking condition.
[0078] The method 400 illustrates detection over-running condition in the starter motor 116 at step 204 of the method 200.
[0079] At step 401, same as step 203.
[0080] At step 402, the method includes determining engine revolution per minute (RPM) to detect whether engine is ON or not by comparing the determined engine RPM with the running engine RPM.
[0081] At step 403, the method 400 includes determining, upon determining engine is ON, whether rotor of the starter motor 116 is engaged with the flywheel of the engine or starter flag is ON for predefined threshold time period (THsf).
[0082] At step 404, the method 400 includes detecting over-running condition when starter flag is ON for predefined threshold time period (THsf).
[0083] At last method 400 proceed to step 205 for restricting the functionality of the starter motor 116 upon detection of over-running condition.
[0084] The method 500 illustrates detection inching condition in the starter motor 116 at step 204 of the method 200.
[0085] Step 501 is same as step 203.
[0086] At step 502, the method 500 includes determining whether engine speed calculated based on inputs received from camshaft position (CKP) and crankshaft position (CMP) sensor 102 is less than predefined threshold engine speed (THes).

[0087] At step 504, the method 500 includes determining, upon determining that engine RPM is less than predefined threshold engine speed (THes), whether vehicle speed calculated based on inputs received from vehicle speed sensor (104) is more than predefined threshold vehicle speed (THvs).
[0088] At step 503, the method 500 includes no inching condition when engine RPM is more than predefined threshold engine speed (THes).
[0089] At step 505, the method 500 includes detecting inching condition when the determined engine speed is less than predefined threshold engine speed (THes) and determined vehicle speed is more than predefine vehicle speed (THvs).
[0090] At last method 500 proceed to step 205 for warning the user and/or restricting the functionality of the starter motor 116 upon detection of inching condition.
[0091] The method 600 illustrates warning the user and/or restricting the functionality of the starter motor 116 at step 205 of the method 200.
[0092] Step 601 is same as step 204.
[0093] At step 602, the method 600 includes determining whether over-cranking condition is true or over-running condition is true. If none of the condition is true, the method proceeds to step 604.
[0094] At step 603, the method 600 includes determining overcrank condition. The over-cranking is determined when starter motor is engaged for more than X sec (X is calibratable time) and engine is not able to self-sustain. This judgment applies for both single crank time limit (X) judgement as well as the number of unsuccessful cranks (Y: Calibratable number) before engine starts. When the engine is not started after a number of unsuccessful cranks (Y) where number of unsuccessful cranks (Y) are more than predefined threshold limit (THoc) and fuel level is low, the method proceeds to step 611 else proceeds to 610.
[0095] At step 610, the method includes setting starter flag to OFF by disconnecting current supply to the starter motor 116.

[0096] At step 611, the method 600 includes warning the user and/or restricting the functionality of the starter motor 116 by inhibiting supply of current from the auxiliary battery until fuel is refilled or predefined time period when the determined fuel level is equal to or less than a predefined threshold value of the low fuel level.
[0097] At step 604, the method 600 includes determining whether inching condition is true or not. When inching condition is not true, the method proceeds to step 601 to detect the cranking issue conditions.
[0098] At step 605, the method 600 includes comparing inching counter with predefined threshold limit of inching counter. When inching counter is less than predefined threshold limit of inching counter, the inching counter is increased by 1 and a warning is displayed in the instrument panel display device 115 at step 606.
[0099] At step 607, the method 600 includes determining fuel level in fuel tank based on inputs from fuel gauge sensor 101 when the inching counter is more than predefined threshold limit of inching counter. The judgment unit 112 compares the determined fuel level with the predefined threshold value of the low fuel level.
[00100] At step 609, the method 600 includes warning the user and/or restricting the functionality of the starter motor 116 by inhibiting supply of current from the auxiliary battery until fuel is refilled or predefined time period when the determined fuel level is equal to or less than a predefined threshold value of the low fuel level.
[00101] At step 608, the method 600 includes warning the user and/or restricting the functionality of the starter motor 116 by inhibiting supply of current from the auxiliary battery for predefined time period and display a warning in the instrument panel display device 115 when the determined fuel level is more than predefined threshold value of the low fuel level (THf).

[00102] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art can choose suitable manufacturing and design details.
[00103] It should be understood, however, that all of these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities. Unless specifically stated otherwise, as apparent from the discussion herein, it is appreciated that throughout the description, discussions utilizing terms such as "receiving," or "setting," or "transmitting," or the like, refer to the action and processes of an electronic control unit, or similar electronic device, that manipulates and transforms data represented as physical (electronic) quantities within the control unit's registers and memories into other data similarly represented as physical quantities within the control unit memories or registers or other such information storage, transmission or display devices.
[00104] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[00105] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

[00106] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants and others.

WE claim:

1.An electronic control unit (ECU) (105) for protecting a starter motor (116)
during cranking in a vehicle, the ECU (105) comprising:
a starter processing unit (108), including:
an inching detection unit (111) to detect inching condition of the starter motor (116) based on inputs received from camshaft and crankshaft sensor (102), and vehicle speed sensor (104); and
a judgment unit (112) to warn the user upon detection of the inching condition of the starter motor (116).
2. The ECU (105) as claimed in claim 1, wherein the inching detection unit
(111):
determines engine speed based on inputs received from the camshaft and crankshaft sensor (102);
determines vehicle speed based on inputs received from the vehicle speed sensor (104); and
detects inching condition when the engine speed is less than predefined engine speed and vehicle speed is more than predefined vehicle speed.
3. The ECU (105) as claimed in claim 1, wherein the judgment unit (112)
restricts the functionality of the starter motor (116) for a predefined time
period and displays warning to user when:
inching condition is detected more than predefined threshold limit (THiv).
4. The ECU (105) as claimed in claim 1, wherein the judgment unit (112)
warns the user till refueling when:
inching condition is detected more than a threshold limit (Thi) or over cranking is detected more than a threshold number of times (THoc) and
fuel level, based on inputs from fuel gauge sensor (101), in fuel tank is less than a threshold limit (Thf).

5. The ECU (105) as claimed in claim 1, wherein the processing unit (108)
includes:
an over-cranking detection unit (110) to detect over-cranking condition of the starter motor (116) when engine is not started after a number of unsuccessful cranks (Y) where number of unsuccessful cranks (Y) are more than predefined threshold limit (THoc) and the crank is detected unsuccessful when the starter motor is engaged for more than predefined time period and engine is not started; and
the judgment unit (112) inhibits the starter motor (116) for a predefined time period and display warning to user upon detection of over-cranking condition of the starter motor (116).
6. The ECU (105) as claimed in claim 1, wherein the processing unit (108)
includes:
an over-running detection unit (109) to detect over-running condition of the starter motor (116) when the starter motor (116) is engaged with flywheel of the engine for predefined threshold time (THes) period after engine is ON; and
the judgment unit (112) warns the user about the functionality of the starter motor (116).
7. A method (200) for protecting starter motor (116) during cranking in a
vehicle, the method (200) comprising:
determining (203) whether the starter engaged flag is ON; detecting (204) inching condition of the starter motor (116); and warning the user about the functionality of the starter motor (116) upon detection of inching condition of the starter motor (116).
8. The method (200) as claimed in claim 7, wherein the detection of inching
condition of the starter motor (116) includes:
determining (502) whether engine speed calculated based on inputs received from camshaft position (CKP) and crankshaft position (CMP) sensor (102) is less than predefined threshold engine speed (THes);

determining (504) whether vehicle speed calculated based on inputs received from vehicle speed sensor (104) is more than predefined threshold vehicle speed (THvs); and
detecting (505) inching condition when the determined engine speed
is less than predefined threshold engine speed (THes) and determined
vehicle speed is more than predefine vehicle speed (THvs).
The method (200) as claimed in claim 7, restricting the functionality of the
starter motor (116) for a predefined time period and displaying warning to
user when:
inching condition is detected more than predefined threshold limit (THiv). The method (200) as claimed in claim 7, wherein the warning the user about the functionality of the starter motor (116) till refueling when:
inching condition is detected more than a predefined threshold limit (Thiv); or
over cranking is detected more than a threshold number of times (Thoc); and
fuel level, based on inputs from fuel gauge sensor (101), in fuel tank is less than a threshold limit (Thf). The method (200) as claimed in claim 7, wherein the method (200) includes:
detecting (204, 300) over-cranking condition of the starter motor (116), the detecting (204) over-cranking condition includes:
determining (302) whether engine is started or not after cranking for
predefined time period (THcr);
increasing (303) crank count by one when engine is not started after
cranking for predefined time period (THcr); and
detecting (304) over-cranking condition when number of crank count
are more than predefined threshold limit (THoc). warning the user and/or restricting (205, 305, 603) functionality of the starter motor (116) for a predefined time period and display warning to user upon detection of over-cranking condition of the starter motor (116).

12. The method (200) as claimed in claim 7, wherein the method (200) includes: detecting (204, 300) an over-running condition of the starter motor (116), the detecting (204, 300) the over-running condition includes: determining (402) whether engine is ON or not based on inputs received from the CKP/CMP sensor (102);
detecting (404) over-running condition when starter flag is ON for predefined threshold time period (THsf) when engine is in ON condition; and
warning the user and/or restricting (603) functionality of the starter motor (116) upon detection of over-running condition.