DESC:FIELD OF INVENTION
[0001] The subject matter as described herein, relates generally to a vehicle and more particularly to a power source for integrated starter generator (ISG) controller of the vehicle.
BACKGROUND OF INVENTION
[0002] The use of integrated starter generator in a vehicle is a common general knowledge. Using an integrated starter generator gives benefits of eliminating a starter motor and at the same time, there is no requirement of a separate voltage regulator unit to charge a power source. However, since the starter generator machine has to generate torque to crank an engine, it also requires an initial high peak current, which is supposed to be supplied by the power source via the ISG (Integrated starter generator) controller.
[0003] A high current supplied by power source travels through the ISG controller and travels back to the ISG controller, the wire carrying the current is required to be of higher current carrying capacity.
[0004] Typically, a peak current of a starter motor for a 100 cc- 110 cc engine with/without decompression feature is around 160A - 200A, but for ISG fitted vehicle these values are as low as 65A-80 A. Because of this reason, it is possible to use batteries with lower cold cranking ampere (CCA) ratings. CCA rating is cold cranking ampere rating of a battery (or power source), which decides max peak current a power source can supply during worst-case cold cranking scenario.
[0005] Currently, due to large size of lead acid batteries used in automotive vehicles, the power source pack could not be integrated with the ISG controller. Since, the power source pack and ISG controller are separate, extra heavy-duty wires and connectors are required to connect the ISG controller and the power source. The use of extra heavy-duty wires and connectors results in increased cost of materials and increased time of assembly of power source and ISG controller.
SUMMARY OF THE INVENTION
[0006] The current invention is more particularly applicable to a power source for ISG controller of vehicles. Due to advent of plenty of smaller size batteries (for ex. 12 V lithium ion batteries) nowadays, there is an option available for a small compact power source to replace the bulky lead acid batteries. However, in case of integrated starter generator (ISG) there is a possibility of using smaller power source (for example lithium ion batteries) with lesser cost to meet the 12 V 80 A CCA rating. Hence, it is possible to have batteries, which can be as small as 100 mm X 20 mm X 80 mm OR 40mm X 40mm X 80mm. Since, the 12 V power source pack with compact size is available, it is possible to integrate the power source with the controller unit in order to eliminate the high current wires and coupler between the power source and the controller. The usage of a power source integrated with an ISG controller thus helps to eliminate the high current wires and couplers between the power source and the controller.
[0007] The associated advantages with the integrated power source (power source) along with the ISG controller casing/housing and ISG controller is that a larger diameter wire required between the ISG controller and the power source (power source) can be eliminated resulting in a very secure arrangement thereby eliminating any chance of short circuit. Furthermore, the proposed invention eliminates the chances of voltage drop in wires during “Start” between the power source and the ISG controller. Moreover, the elimination of high current connectors between the ISG connector and the power source (power source) results in elimination of possibility of arching between connector terminals or loose connection.
[0008] The proposed invention provides a small compact power source as only 3-4 number of small power source ( For e.g. lithium –ion cells) used as 12V batteries. Furthermore, the integrated power source (power source) along with the ISG controller casing/ housing provides huge cost benefit because of elimination of the large diameter wire between the ISG controller and the power source, high current connector and mounting location for the regular power source. The current invention also provides more customer storage space as both the ISG controller and the power source (power source) are combined.
BRIEF DESCRIPTION OF DRAWINGS
[0009] Figure 1illustrates a typical two-wheeled vehicle.
[00010] Figure 2 illustrates perspective view of the vehicle.
[00011] Figure 3 illustrates side panel open view of the vehicle to expose the ISG controller.
[00012] Figure 4 illustrates vehicle level block diagram with power source and ISG controller separate.
[00013] Figure 5 illustrates the regular vehicle level block diagram without ISG.
[00014] Figure 6 illustrates vehicle level block diagram with integrated starter generator and lithium ion power source according to the current invention.
[00015] Figure 7 illustrates PCB side exploded view of the ISG controller box.
[00016] Figure 8 illustrates power source side exploded view of the ISG controller box.
DETAILED DESCRIPTION OF THE INVENTION
[00017] A vehicle as described in the current invention has an internal combustion engine with a crankshaft coupled to a transmission system and an integrated starter generator. The integrated starter generator is mechanically coupled to the crankshaft. For cranking the engine, a power source supplies power to the ISG and the motor, which provides mechanical output from the ISG, is coupled to the crankshaft mechanically. When the ISG operates in the “starter” mode, it rotates the crankshaft and thus cranks the engine. After cranking of engine, when enough voltage could be generated from the ISG in the “generator” mode, this ISG functions as a generator and starts charging the power source and powering the vehicle load.
[00018] A conventional vehicle start-stop system involves starter, generator and flywheel of the engine, which is being replaced by a more powerful integrated starter generator (ISG) due to various advantages associated with the ISG. An ISG controller controls the operation of the ISG. The power to operate the ISG is obtained from lead acid batteries. The ISG system switches off the combustion engine at zero loads such as when standing at a traffic light and automatically restarts it when the throttle is increased. Due to advent of plenty of smaller sized 12 V lithium ion batteries nowadays, there is an option available for a small compact power source to replace the bulky lead acid batteries.
[00019] The current invention is more particularly applicable to an integrated power source for integrated starter generator (ISG) controller of vehicles. In case of integrated starter generator (ISG) there is a possibility of using smaller power source (for example lithium ion batteries) with lesser cost to meet the 12 V 80 A CCA rating. Hence, the batteries can be as small as 100 mm X 20 mm X 80 mm. OR 40mm X 40mm X 80mm. The moment the 12 V power source pack is of such a compact size there is a possibility of integrating it with the controller unit in order to eliminate the high current wires and coupler between the power source and the controller. The usage of a power source integrated with an ISG controller thus helps to eliminate the high current wires and couplers between the power source and the controller.
[00020] The associated advantages with the integrated power source (power source) along with the ISG controller casing/ housing and ISG controller is that a larger diameter wire required between the ISG controller and the power source (power source) can be eliminated resulting in a very secure arrangement thereby eliminating any chance of short circuit. Furthermore, the proposed invention eliminates the chances of voltage drop in wires during “Start” between the power source and the ISG controller. Moreover, the elimination of high current connectors between the ISG connector and the power source (power source) results in elimination of possibility of arching between connector terminals or loose connection.
[00021] Figure 1 illustrates a typical two-wheeled vehicle with a rider seat 1, an internal combustion engine 2, a side panel 3, an ignition lock 4, a rear wheel 9, and a traction motor 6. The traction motor 6 drives the rear wheel. The side panel covers the power source location 3A. The electrical power required for operating the traction motor 6 is derived from the power source.
[00022] Figure 2 shows the vehicle 10 with front panel 23, floorboard 21, rear wheel 9, front cover 22 and side panel 3. The power source for the purpose of the current invention could be located at any location on the vehicle but not limited to either inside the front panel, below the floorboard 21, behind the front cover 22 or beneath the side panel 3.
[00023] Figure 3 shows the vehicle 10 with the rider seat 1, uncovered side panel 3 thus thereby exposing the side tube 32 and the integrated ISG controller and power source casing 31. The integrated ISG controller and power source casing 31 is fastened to the side tube 32 using the fastening members 77 (Shown in Figure 7).
[00024] Figure 4 vehicle level block diagram with power source and ISG controller separate. As illustrated, the external wire connects the power source module and the ISG controller. Furthermore, an external wire is required between the ISG controller and the three-phase ISG machine. The external wire also provides the power to the ignition lock and the ISG controller provides power to the ignition coil and the suppressor cap. The objective of the current invention is to eliminate the use of external wire in between the power source module and the ISG controller.
[00025] Figure 5 illustrates the regular vehicle level block diagram without ISG. Here in a regular vehicle, a power source provides power to an ignition lock, which functions as a switch. This switch further allows or disallows the flow of power to the ignition controller. This ignition controller controls power to the ignition coil and a suppressor cap.
[00026] Figure 6 illustrates a typical two-wheeled vehicle. According to the present invention,, the power source module & ISG controller are packed in a single casing in such a way that no external wire in between ISG controller and the power source module is needed to provide power to the ISG controller from the power source. Bus bar or conducting strips molded in the integrated casing that accommodates the power source module and the ISG controller replace the external wire between the power source module and the ISG controller. The disclosed power source is preferably an acid free power source capable of being installed in any orientation and kept inside a power source casing. The power source casing is further integrated with the ISG controller casing such that the positive and negative terminals of the power source are connected to power input terminals of the ISG controller using an en-molded conducting strip or a bus bar thus thereby eliminating the external wires and couplers.
[00027] Figure 7 shows the ISG controller casing 31, plurality of batteries 71, plurality of capacitors 72, ISG controller casing LH 73, ISG controller casing RH 74, ISG micro controller 75, power source first terminals 76, mounting members 77, power source second terminals 78 and ISG controller PCB 79.
[00028] According to first embodiment of the current invention, the ISG controller PCB 79 accommodates all the circuitry including the ISG micro controller 75 and plurality of capacitors 72 on one side and the power source first set of terminals 76 and the power source second set of terminals 78 on the other side. The plurality of batteries 71 are inserted in between the power source first set of terminals 76 and the power source second set of terminals 78. The electrical power from the set of batteries 71 is transmitted to the ISG controller PCB 79 through a circuitry instead of any external wires, which add extra cost.
[00029] Figure 8 again illustrates the perspective exploded view of the ISG controller casing 31. Figure 8 shows the ISG controller casing 31, plurality of batteries 71, plurality of capacitors 72, ISG controller casing LH 73, ISG controller casing RH 74, ISG micro controller 75, power source first terminals 76, mounting members 77, power source second terminals 78 and ISG controller PCB 79.
[00030] In yet another embodiment, a second embodiment of the current invention, the ISG controller casing RH 74 is removed and the ISG controller PCB 79 itself functions as the right side casing. In this second embodiment, the set of plurality of batteries 71 are exposed to the atmosphere.
[00031] In yet another embodiment, a third embodiment of the current invention, the set of plurality of batteries first terminals 76 and power source second terminals 78 are extended to project onto the outer surface of the ISG controller casing RH 74 and the plurality of batteries 71 are inserted in between the power source first set of terminals 76 and the power source second set of terminals 78 therein on the outer surface of the ISG controller casing RH 74.
[00032] The proposed invention provides a small compact power source as only 3-4 numbers of small power source ( For e.g. lithium –ion cells) is used as 12V batteries. Furthermore, the integrated power source (power source) along with the ISG controller casing/housing provides huge cost benefit because of elimination of the large diameter wire between the ISG controller and the power source, high current connector and mounting arrangements for the regular power source. An advantage of the current invention is that, the proposed power system integrated with the ISG controller PCB or ISG Controller casing results into availability of more storage space.
,CLAIMS:We claim:
1. A power system for an ISG controller for a vehicle (10), said power system comprising:
a plurality of batteries (71), said each of the batteries comprising of two terminals namely a positive terminal and a negative terminal; the batteries being acid free & capable of being installed in any orientation;
an ISG controller casing (31) comprising of an ISG controller casing LH (73) and an ISG controller casing RH (74); an ISG micro controller (75), a plurality of capacitors (72), an ISG controller PCB (79) enclosed within said ISG controller casing (31); a plurality of batteries (71), plurality of first set of power source terminals (76), plurality of second set of power source terminals (78);
an integrated starter generator capable of receiving power from said plurality of batteries (71) through a logic defined by said ISG controller (75);
characterized in that:
said ISG controller PCB (79) at a first face (61) accommodates said ISG micro controller (75) and said plurality of capacitors (72) and on a second face (62) accommodates said plurality of batteries (71), plurality of first set of power source terminals (76) and plurality of second set of power source terminals (78) and is enclosed by said ISG controller casing LH (73) and said ISG controller casing LH (74).
2. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 wherein said plurality of batteries (71) is accommodated outside said ISG controller casing LH (73) and ISG controller casing LH (74).
3. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 wherein said plurality of first set of power source terminals (76) and plurality of second set of power source terminals (78) protrude out of said ISG controller casing RH (74).
4. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 or claim 3 wherein said plurality of batteries (71) are inserted between said plurality of first set of power source terminals (76) and plurality of second set of power source terminals (78) outside said ISG controller casing RH (74).
5. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 wherein first set of power source terminals (76) and plurality of second set of power source terminals (78) forms the positive and negative terminals for said plurality of batteries (71).
6. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 or claim 3 wherein said plurality of batteries (71) are lithium ion batteries.
7. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 or claim 3 wherein said plurality of batteries (71) are rechargeable batteries.
8. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 or claim 3 wherein said plurality of batteries (71) are metal ion batteries.
9. The power system for an ISG controller for a vehicle (10) as claimed in Claim 1 or claim 3 wherein ISG controller casing LH (73) said and said ISG controller casing LH (74) are provided with a heat sink exposed to a region outside the region enclosed by said ISG controller casing LH (73) and said ISG controller casing LH (74).