WO2025081237A1 - Module de démarrage de moteur et dispositif de décharge - Google Patents

Module de démarrage de moteur et dispositif de décharge Download PDF

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Publication number
WO2025081237A1
WO2025081237A1 PCT/AU2024/051095 AU2024051095W WO2025081237A1 WO 2025081237 A1 WO2025081237 A1 WO 2025081237A1 AU 2024051095 W AU2024051095 W AU 2024051095W WO 2025081237 A1 WO2025081237 A1 WO 2025081237A1
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WO
WIPO (PCT)
Prior art keywords
module
engine start
discharge
capacitors
start module
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/AU2024/051095
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English (en)
Inventor
Andrew James MCGEACHIE
Ricki Anthony ADAMS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Pacific Mining Parts Pty Ltd
Original Assignee
Pacific Mining Parts Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2023903352A external-priority patent/AU2023903352A0/en
Application filed by Pacific Mining Parts Pty Ltd filed Critical Pacific Mining Parts Pty Ltd
Publication of WO2025081237A1 publication Critical patent/WO2025081237A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/03—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for supply of electrical power to vehicle subsystems or for
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N11/0862—Circuits specially adapted for starting of engines characterised by the electrical power supply means, e.g. battery
    • F02N11/0866—Circuits specially adapted for starting of engines characterised by the electrical power supply means, e.g. battery comprising several power sources, e.g. battery and capacitor or two batteries
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N11/087—Details of the switching means in starting circuits, e.g. relays or electronic switches
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/12—Starting of engines by means of mobile, e.g. portable, starting sets
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/14—Starting of engines by means of electric starters with external current supply
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries
    • H02J7/34—Parallel operation in networks using both storage and other DC sources, e.g. providing buffering
    • H02J7/345—Parallel operation in networks using both storage and other DC sources, e.g. providing buffering using capacitors as storage or buffering devices
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries
    • H02J7/855—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries with circuits adapted for supplying loads from the battery
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J7/00—Circuit arrangements for charging or discharging batteries or for supplying loads from batteries
    • H02J7/90—Regulation of charging or discharging current or voltage
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N11/087—Details of the switching means in starting circuits, e.g. relays or electronic switches
    • F02N2011/0874—Details of the switching means in starting circuits, e.g. relays or electronic switches characterised by said switch being an electronic switch
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N11/00—Starting of engines by means of electric motors
    • F02N11/08—Circuits specially adapted for starting of engines
    • F02N2011/0881—Components of the circuit not provided for by previous groups
    • F02N2011/0885—Capacitors, e.g. for additional power supply
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02N—STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
    • F02N2200/00—Parameters used for control of starting apparatus
    • F02N2200/06—Parameters used for control of starting apparatus said parameters being related to the power supply or driving circuits for the starter
    • F02N2200/063—Battery voltage
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02J—ELECTRIC POWER NETWORKS; CIRCUIT ARRANGEMENTS OR SYSTEMS FOR SUPPLYING OR DISTRIBUTING ELECTRIC POWER; SYSTEMS FOR STORING ELECTRIC ENERGY
    • H02J2105/00—Networks for supplying or distributing electric power characterised by their spatial reach or by the load
    • H02J2105/30—Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles
    • H02J2105/33—Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles exchanging power with road vehicles
    • H02J2105/37—Networks for supplying or distributing electric power characterised by their spatial reach or by the load the load networks being external to vehicles, i.e. exchanging power with vehicles exchanging power with road vehicles exchanging power with electric vehicles [EV] or with hybrid electric vehicles [HEV]

Definitions

  • the present technology relates to engine start modules and devices for discharging engine start modules.
  • the present technology relates to engine start modules comprising one or more capacitors and discharge devices for discharging them, for example when vehicle maintenance is required.
  • HME heavy mobile equipment
  • HME heavy mobile equipment
  • fixed machines such as drilling rigs, generators, pumps etc.
  • lead-acid batteries can discharge over time while the engine of the vehicle or machine is powered off, especially when connected to many different electrical components in or on a vehicle that may draw parasitic current.
  • workers operating loads such as lights, air conditioning or the like when the vehicle's engine is not running, or omitting to turn them off, may inadvertently discharge the batteries excessively.
  • the voltage available from a lead-acid battery can also be reduced at cold temperatures.
  • a battery discharged to the point that the engine cannot be started is a problem in any vehicle and especially so in HMEs as, in some machines, a jump start can take an hour or more, which can present significant disruption and lost productivity.
  • an engine start module for a vehicle, the engine start module comprising: one or more capacitors, being chargeable to a charged state and configured to provide power to start a vehicle when in the charged state; one or more connectors for forming a first set of electrical connections between the one or more capacitors and at least one starter motor of the vehicle; a socket configured to receive a plug of a discharge module configured to discharge the one or more capacitors to a substantially uncharged state, the socket providing for electrical connection between the discharge module and the one or more capacitors, the socket being connectable to the plug of the discharge module without disconnection of the first set of electrical connections.
  • ESM engine start module
  • the engine start module comprises a housing, the one or more capacitors of the engine start module being housed in the housing and the socket being located on or outside of the housing.
  • the engine start module comprises multiple banks of capacitors in parallel.
  • the engine start module comprises a voltmeter configured to measure a voltage of the engine start module and a display device to display the voltage measured by the voltmeter.
  • the display device is a digital display to display a number of volts.
  • the voltmeter is activated by a switch.
  • the engine start module is connectable to one or more vehicle running batteries to enable the vehicle running batteries to charge the one or more capacitors.
  • the vehicle running batteries are charged by an alternator of the vehicle and power a running circuit separate to a cranking circuit powered by the engine start module.
  • the engine start module comprises one or more vehicle running batteries configured to charge the one or more capacitors.
  • the vehicle running batteries are connectable to an alternator of the vehicle for charging of the vehicle running batteries and power a running circuit separate to a cranking circuit powered by the engine start module.
  • the one or more capacitors of the engine start module are connected to the starter motor via an isolation station on the vehicle.
  • the socket forms part of a switch-rated connector assembly with the plug.
  • a discharge module for discharging an engine start module of a vehicle, the discharge module comprising: a plug configured to connect to a socket of the engine start module and form an electrical connection with the engine start module; an energy dissipation device providing an electrical load to dissipate electrical energy received from the engine start module via the plug to allow for discharge of the engine start module.
  • the plug forms part of a switch-rated connector assembly with the socket.
  • the discharge module comprises a housing, the energy dissipating device of the discharge module being housed in the housing, and the plug being on a lead extending from the housing.
  • the energy dissipating device of the discharge module is configured to dissipate the energy as heat.
  • the energy dissipating device comprises a resistor.
  • the energy dissipating device comprises a grid resistor.
  • the energy dissipating device is configured to discharge the capacitors in under 10 minutes, preferably under 7 minutes, preferably in or under 5 minutes.
  • the discharge module comprises a switch to complete the electrical connection between the engine start module and the energy dissipating device.
  • the discharge module comprises a voltmeter configured to measure a voltage of the engine start module indicating a level of charge of the engine start module, and further comprises a display device configured to display the voltage measured by the voltmeter to a user of the discharge module.
  • the voltmeter is powered by a power source other than the engine start module.
  • the voltmeter is self-powered by a voltmeter battery.
  • the voltmeter is activated by a switch.
  • a discharge module for discharging an engine start module, the discharge module comprising: an energy dissipation device electrically connectable to the engine start module and providing an electrical load to dissipate electrical energy to discharge the engine start module; a voltmeter configured to measure a voltage of the engine start module indicating a level of charge of the engine start module; a display device configured to display the voltage measured by the voltmeter to a user of the discharge module.
  • the discharge module further comprises a plug configured to connect to a socket of the engine start module and form an electrical connection with the engine start module.
  • the discharge module comprises a housing, the energy dissipating device of the discharge module being housed in the housing, and the plug being on a lead extending from the housing.
  • the energy dissipating device of the discharge module is configured to dissipate the energy as heat.
  • the energy dissipating device is a resistor.
  • the energy dissipating device is a grid resistor.
  • the energy dissipating device is configured to discharge the capacitors in under 10 minutes, preferably under 7 minutes, preferably in or under 5 minutes.
  • the discharge module comprises a switch to complete the electrical connection between the engine start module and the energy dissipating device.
  • the voltmeter is self-powered by a voltmeter battery. In some examples, the voltmeter is activated by a switch. In some examples, the display device is a digital display.
  • a method of discharging one or more capacitors of an engine start module comprising: connecting a discharge module to the engine start module, the discharge module providing an electrical load to discharge the one or more capacitors; actuating a discharge switch to complete an electrical connection between the one or more capacitors and the electrical load in the discharge module; reading a voltage displayed on the discharge module to confirm that the one or more capacitors are substantially discharged, the voltage indicating a level of charge of the capacitors.
  • the discharge module comprises the discharge switch.
  • the method comprises connecting a plug of the discharge module to a socket of the engine start module to form an electrical connection with the one or more capacitors of the engine start module. In some examples, the method comprises disconnecting the plug of the discharge module from the socket of the engine start module after confirming that the one or more capacitors are substantially discharged. In some examples, the method comprises discharging the one or more capacitors without making any electrical connections other than connecting the plug to the socket.
  • the method comprises a step of powering-on a voltmeter of the discharge module by actuating a voltmeter switch.
  • the step of actuating the voltmeter switch enables power to be provided from a voltmeter battery to the voltmeter.
  • the step of reading the voltage comprises reading a digital display indicating a number of volts. In some examples, the step of reading the voltage comprises reading an initial voltage indicating that the capacitors are not discharged, waiting for the capacitors to discharge and reading a final voltage indicating that the capacitors are substantially discharged. In some examples, the step of reading a final voltage comprises reading a voltage of 3V or less, preferably 2V or less, preferably IV or less, preferably 0V.
  • the method comprises leaving the plug of the discharge module connected to the socket of the engine start module while work is conducted on a vehicle in which the engine start module is installed.
  • the method comprises, after confirming that the one or more capacitors are substantially discharged, disconnecting the plug of the discharge module from the socket of the engine start module and connecting a temporary plug to the socket.
  • the temporary plug may comprise a shorting wire configured to keep the one or more capacitors of the engine start module discharged.
  • the temporary plug may comprise an indicator configured to provide an indication that the one or more capacitors of the engine start module are not discharged.
  • a system comprising: an engine start module comprising: one or more capacitors, being chargeable to a charged state and configured to provide power to start a vehicle when in the charged state; a socket providing for electrical connection to the one or more capacitors; a discharge module comprising: a plug configured to connect to the socket of the engine start module and form an electrical connection with the one or more capacitors; an energy dissipation device providing an electrical load to dissipate electrical energy received from the capacitors of the engine start module via the plug to allow for discharge of the one or more capacitors.
  • the plug and socket form a switch-rated connector assembly.
  • the engine start module comprises a housing, the one or more capacitors of the engine start module being housed in the housing and the socket being located on or outside of the housing.
  • the engine start module comprises a voltmeter configured to measure a voltage of the engine start module and a display device to display the voltage measured by the voltmeter.
  • the display device is a digital display to display a number of volts.
  • the voltmeter is activated by a switch.
  • the engine start module is connectable to one or more vehicle running batteries to enable the vehicle running batteries to charge the one or more capacitors.
  • the vehicle running batteries are charged by an alternator of the vehicle and power a running circuit separate to a cranking circuit powered by the engine start module.
  • the discharge module comprises a housing, the energy dissipating device of the discharge module being housed in the housing, and the plug being on a lead extending from the housing.
  • the energy dissipating device of the discharge module is configured to dissipate the energy as heat.
  • the discharge module comprises a switch to complete the electrical connection between the engine start module and the energy dissipating device.
  • the discharge module comprises a voltmeter configured to measure a voltage of the engine start module indicating a level of charge of the engine start module, and further comprises a display device configured to display the voltage measured by the voltmeter to a user of the discharge module.
  • the voltmeter of the discharge module may be powered by a power source other than the engine start module.
  • the system further comprises a temporary plug configured to be connected to the socket in place of the discharge module plug after the one or more capacitors are substantially discharged, the temporary plug comprising a shorting wire configured to keep the one or more capacitors of the engine start module discharged.
  • the temporary plug may comprise an indicator configured to provide an indication that the one or more capacitors of the engine start module are not discharged.
  • Fig. 1 is a schematic diagram of an engine start module according to one example of the present technology
  • Fig. 2 is a schematic diagram of a discharge module according to one example of the present technology
  • Fig. 3 is a simplified schematic diagram of the engine start module of Fig. 1 installed in a vehicle;
  • Fig. 4 is a simplified schematic diagram of the engine start module of Fig. 1 showing some internal components
  • Fig. 5 is a simplified schematic diagram of the discharge module of Fig. 2 showing some internal components
  • Fig. 6 is a view of a user interface of the discharge module of Fig. 2;
  • Fig. 7 is a front view of the discharge module of Fig. 2;
  • Fig. 8 is an energy dissipating device of the discharge module of Fig. 2.
  • Fig. 1 shows a schematic diagram of an engine start module (ESM) 100 according to one form of the present technology.
  • the ESM 100 is configured for starting an engine (such as a diesel engine) of a heavy vehicle such as a haul truck used in mining.
  • the ESM 100 may be configured for starting an engine of another vehicle or machine, such as other heavy mobile equipment (HME).
  • HME heavy mobile equipment
  • ESMs according to examples of the present technology may be configured to start engines in excavators, bulldozers, loaders and the like.
  • the ESM 100 may be configured to start an engine that is not in a vehicle, such as the engine of a generator, pump, drilling rig or a fixed machine.
  • the ESM 100 will be described in the context of use in a vehicle such as a haul truck used in mining, but it is to be understood that the ESM 100 may be applied to start engines in other vehicles or machines, mobile or fixed.
  • the ESM 100 comprises one or more capacitors.
  • the ESM 100 comprises multiple banks of capacitors in parallel.
  • the capacitors are represented by a power supply 120, which may comprise multiple capacitors arranged in capacitor banks.
  • Fig. 4 shows another schematic diagram of the ESM 100 with additional detail of the capacitors.
  • the capacitors are arranged in a plurality of capacitor banks 110.
  • the ESM 100 may comprises a different number of capacitor banks 110 depending on the amperage, e.g. cold cranking amps (CCA), required by the engine of the vehicle or machine to be started by the ESM 100.
  • CCA cold cranking amps
  • the ESM 100 may comprise one, two, three, five or more capacitor banks 110. It is also to be understood that the number of capacitors and/or capacity of each, within each capacitor bank 110, may be varied in examples of the present technology to arrive at the required overall capacity.
  • the capacitors may be identified as supercapacitors or ultracapacitors, in examples.
  • the ESM 100 is configured to replace one or more conventional (e.g. lead-acid) batteries in a vehicle.
  • the capacitors in the ESM 100 may be more reliable than traditional lead-acid batteries because they may be less likely discharge over time, less affected by temperature and/or may be able to be charged and discharged more times than a conventional lead-acid battery before becoming unreliable.
  • a large vehicle such as a mining haul truck may have traditionally had several conventional lead-acid batteries installed in parallel (e.g. either multiple 24V batteries in parallel or pairs of 12V batteries arranged in series and then in parallel with other pairs).
  • the conventional batteries have in the past been used to both start the engine and provide power during running.
  • the ESM 100 may be installed in the vehicle so that the ESM 100 provides power for starting the vehicle (cranking the engine), while other conventional batteries in the vehicle provide power for running electronics and/or electrical systems in the vehicle.
  • the conventional batteries may be charged by the vehicle's alternator and in turn may charge the capacitors of the ESM 100.
  • the arrangement also allows for electrical components in the vehicle, which may draw power while the engine is not running, to draw power only from the conventional batteries, leaving the capacitors of the ESM 100 charged so as to not affect the ability to start the engine of the vehicle.
  • the ESM 100 may comprise three electrical connectors for connecting to electrical components of the vehicle, including a battery positive (BAT+) connector 101, a battery negative (BAT-)/ground connector 102 and a starter positive (STR+) connector 103.
  • the STR+ connector 103 and the BAT- connector 102 may be used to form a circuit powered by the capacitors of the ESM 100.
  • the BAT+ connector 101 and the BAT- connector 102 may be used to connect the ESM 100 to conventional batteries to charge the capacitors of the ESM 100.
  • Each capacitor bank 110 may itself have a BAT+ terminal connected to the BAT+ connector 101 of the ESM 100, a BAT- terminal connected to the BAT- connector 102 of the ESM 100 and a STR+ terminal connected to the STR+ connector 103 of the ESM 100.
  • Each capacitor bank 110 may, as an example only, be a commercially available capacitor or capacitor bank which has a positive and negative terminal for charging and a separate positive terminal for providing power output.
  • Fig. 3 is a simplified diagram showing how the ESM 100 may be connected within the electrical system of a vehicle such as a mining haul truck.
  • the starter motor(s), prelube pump, and any other motors or pumps required during starting are represented by numeral 111 in the system shown in Fig. 3.
  • these components will be referred to as a starter motor 111 but it is to be understood that depending on the vehicle, there may also be a prelube pump and/or other components drawing power from the ESM 100 at the same time as the starter motor 111.
  • some vehicles may comprise more than one starter motor, such as two starter motors, and a reference to the starter motor 111 is to be understood to be a reference to the one or more starter motors that a vehicle may have.
  • the starter motor 111 may be connected to the STR + connector 103 and the BAT- connector 102 to draw power from the capacitors for starting. Accordingly, the STR+ connector 103 and BAT- connector 102 may form a first set of electrical connections between the one or more capacitors and at least one starter motor 111 of the vehicle.
  • the ESM100 may comprise two STR+ connectors 103, to provide two starter motor connections for vehicles with two starter motors. In such examples the STR+ terminal on each capacitor bank 110 may be connected to both STR+ connectors 103. In other examples two starter motors may be connected to a single STR+ connector 103 of the ESM 100.
  • a vehicle in which the ESM 100 is installed may comprise conventional (e.g. lead-acid) batteries for providing power during running and to loads other than the starter motor 111.
  • the conventional batteries may be identified as vehicle running batteries 108 as shown in Fig. 3.
  • the ESM 100 is connectable to one or more of the vehicle running batteries 108 to enable the vehicle running batteries 108 to charge the one or more capacitors.
  • one or more vehicle running batteries 108 may be connected between the BAT+ connector 101 and BAT- connector 102.
  • the negative terminal of each vehicle running battery 108 may be connected to the BAT- connector 102 either directly or via ground (e.g. a busbar and/or vehicle chassis, frame etc.) and/or via an isolation station 112.
  • Each vehicle running battery 108 may be a 24V battery or may be a pair of 12V batteries connected in series. In vehicles with a 12V system, the vehicle running battery 108 or batteries 108, as the case may be, may be 12V batteries.
  • the vehicle running batteries 108 may be charged by an alternator 109 of the vehicle, which may be connected in parallel to the batteries 108.
  • the vehicle running batteries 108 are then able to charge the capacitors of the ESM 100 as they are connected across the BAT+ connector 101 and BAT- connector 102 (in this example via both an isolation station 112 and ground).
  • the vehicle running batteries 108 may power a running circuit separate to a cranking circuit powered by the ESM 100.
  • the starter motor 111 is not connected across the vehicle running batteries 108. Instead, the starter motor 111 is connected between the STR+ connector 103 of the ESM 100 and ground to form a cranking circuit separate from the running circuit energised by the vehicle running batteries 108. In this way, when the starter motor 111 draws power it does so from the capacitors of the ESM 100, to receive the benefits provided by capacitors (e.g. consistent voltage and/or reliable availability of power).
  • the ESM 100 itself comprises one or more vehicle running batteries 108 configured to charge the one or more capacitors. That is, the one or more vehicle running batteries 108 may be integrated into the ESM 100 such that the ESM 100 does not need to be connected to other batteries in the vehicle and the ESM 100 can replace all of the conventional vehicle running batteries 108 of the vehicle.
  • the vehicle running batteries 108 would be connectable to an alternator 109 of the vehicle for charging of the vehicle running batteries 108.
  • the vehicle running batteries 108 would also still power a running circuit separate to a cranking circuit powered by the ESM 100.
  • the one or more capacitors of the ESM 100 are connected to the starter motor 111 via an isolation station 112 on the vehicle. As shown in Fig. 3, the connection between the STR+ connector 103 and the starter motor 111 passes through an isolation station 112. Similarly, the connections to ground of the batteries 108 and starter motor 111 pass through the isolation station 112.
  • the isolation station 112 may comprise switches allowing these connections to be interrupted and/or locked out during maintenance and repair and may also comprise other components such as indicator lights, as is known the art.
  • FIG. 3 The diagram of Fig. 3 is simplified to show how the ESM 100 may be integrated into a system together with conventional batteries 108, an alternator 109 and starter motor(s)/prelube pump 111 and it is to be understood that there will in practice be many other electrical components forming the electrical system of a vehicle as is known the art, such as fuses, busbars, switches, relays, sensors, control units, loads etc. In some examples, substantially all of the electrical components, e.g.
  • the ESM 100 may comprise a housing, which may be identified as an ESM housing 105.
  • the one or more capacitors of the ESM 100 may be housed in the ESM housing 105.
  • the ESM housing 105 may be shaped and sized to fit onto a battery shelf of the vehicle in which it is to be installed.
  • the ESM housing 105 may have a shape and size corresponding to one or more conventional batteries 108 that the ESM 100 is replacing.
  • the housing 105 may be formed from any suitable material, including plastic or steel.
  • the ESM 100 comprises a voltmeter.
  • the voltmeter may be identified as an ESM voltmeter 106 as shown in Fig. 1.
  • the ESM voltmeter 106 may be configured to measure a voltage of the ESM 100 indicating a level of charge of the ESM 100 (e.g. of the capacitors).
  • the ESM 100 may further comprise a display device to display the voltage measured by the ESM voltmeter 106.
  • the display device is a digital display to display a number of volts.
  • the display device may be an analogue gauge or other display indicating a level of charge.
  • the ESM voltmeter 106 may be activated by a switch, which may be a flip switch or push button.
  • the ESM voltmeter 106 may be used to confirm the voltage available from the capacitors of the ESM 100 and so may itself be powered by the capacitors in the ESM 100.
  • the ESM voltmeter 106 is self-powered, for example by a battery (e.g. a 9V battery), so that it is able to function whether the capacitors in the ESM 100 are charged or not.
  • the ESM voltmeter 106 indicating whether the capacitors are charged or not may advantageously provide a safety feature enabling a user or technician to confirm that the capacitors are discharged prior to maintenance.
  • the ESM 100 may also comprise a control panel 111, shown in Fig. 4 which includes a button for each capacitor bank 110.
  • Each button may be configured to switch a respective one of the capacitor banks 110 on and off.
  • Each button may include an indicator light, for example an LED light, to display a status of the respective capacitor bank 110. For example, each button may indicate whether the respective capacitor bank 110 is on, off or charging.
  • the capacitors of the ESM 100 may have large amounts of stored energy and are also able to provide high current for starting large engines.
  • a discharge module (DM) 200 shown in Fig. 2, 5, 6 and 7, configured to discharge the one or more capacitors of the ESM 100 to a substantially uncharged state. This may be necessary during maintenance, repair, testing or replacement of the ESM 100 or electrical components of the vehicle.
  • the ESM 100 may comprise a socket 104 configured to receive a plug 204 of the DM 200.
  • the socket 104 is shown in Figs. 1 and 4 for example, and provides for an electrical connection between the DM 200 and the one or more capacitors of the ESM 100.
  • the plug 204 is configured to connect to the socket 104 to form an electrical connection with the ESM 100.
  • the ESM 100 comprises connectors (e.g. the STR+ connector 103 and BAT- connector 102) forming a first set of electrical connections between the one or more capacitors of the ESM 100 and the starter motor 111 of the vehicle.
  • the socket 104 is connectable to the plug 204 of the DM 200 (e.g.
  • the socket 104 may comprise two pin sockets, each connected to one of the STR+ and BAT- terminals of the capacitor banks 110.
  • the socket 104 may be located on or outside of the housing 105 of the ESM 100. In some examples the socket 104 is fixed in place on the housing 105, while in other examples the socket 104 may be attached to a lead which can be extended away from the housing 105 when required.
  • the control panel 111 comprises the socket 104. In the example shown in Fig. 4 the socket 104 is provided on a different side of the ESM housing 105 than the control panel 104.
  • Each of the socket 104 of the ESM 100 and the plug 204 of the DM 200 may be configured to form part of a switch-rated connector assembly.
  • the connector assembly may function to both mechanically connect the plug 204 to socket 104 and also provide an electrical switch which interrupts any electrical connection between plug 204 and socket 104 until the mechanical connection is completed. This may provide for a safe way for a user or technician to make the connection between the ESM 100 and DM 200.
  • the plug 204 and socket 104 may be provided by a DecontactorTM connector from Marechai Electric Group.
  • the DM 200 may comprise an energy dissipation device 201 providing an electrical load to dissipate electrical energy received from the ESM 100 to the allow for discharge of the ESM 100.
  • the electrical energy may be received via the plug 204.
  • the DM 200 may comprise a housing, which may be identified as a DM housing 205.
  • the energy dissipating device 201 of the DM 200 is in this example housed in the DM housing 205.
  • the plug 204 is on a lead 202 extending from the DM housing 205.
  • the plug 204 and lead 202 are not shown in Figs. 2 or 7.
  • the DM 200 may comprise a handle 211 connected to the housing 205 to allow a user to carry the DM 200 to the vehicle or machine they will be working on.
  • the electrical energy received by the energy dissipating device 201 may be dissipated as a different form of energy.
  • the energy dissipating device 201 is configured to dissipate the energy as heat.
  • the energy dissipating device 201 may comprise a resistor (or one or more resistors.
  • the energy dissipating device 201 comprises a grid resistor.
  • a different type of resistor, or different type of electrical load may be used to form the energy dissipating device 201.
  • the DM 200 may comprise a blower to cool the energy dissipating device 201 to help dissipate the heat.
  • Fig. 8 shows an example of an energy dissipating device 201 in the form of a grid resistor.
  • the grid resistor comprises terminals 212 and a body 213.
  • the body 213 is depicted as a block and in practice is the grid of the grid resistor.
  • the energy dissipating device 201 is configured to discharge the capacitors in under 10 minutes.
  • the energy dissipating device 201 is configured to discharge the capacitors in under 7 minutes and, more preferably, in or under 5 minutes. This can be accomplished by ensuring the energy dissipating device draws and can handle sufficient current/power to extract enough energy from the capacitors in the desired length of time. For example, if the capacitor banks 110 of the ESM 100 have a combined capacity of 128 Wh (as an example only), the energy dissipating device 201 would need to dissipate energy at a rate of 1.54 kW to deplete the capacitors in 5 minutes.
  • each capacitor bank 110 If the output voltage of each capacitor bank 110 is 26.2V then the energy dissipating device would need to take about 58.9A of current and would therefore need an overall/equivalent resistance of 0.440 to draw 1.54 kW of power.
  • the ability to discharge the ESM 100 safely in under 5 minutes may provide of increased productivity during maintenance or repair procedures and reduced machine downtime.
  • the energy dissipation device 201, the DM 200 and any cooling system may be configured to discharge the ESM 100 quickly and safely without unacceptable heat or safety risk.
  • the discharge module comprises a discharge switch 203 to complete the electrical connection between the ESM 100 and the energy dissipating device 201 of the DM 200.
  • the provision of a switch allows the user of the DM 200 to begin the discharge procedure only when ready, after the plug 204 has been safely received in socket 104 and the DM 200 is positioned safely and securely.
  • Fig. 6 shows a control panel 214, which provides a user interface of the DM 200.
  • the discharge switch 203 is provided on the control panel 214 although in other examples the switch may be provided elsewhere on the DM 200, for example elsewhere on the housing 205.
  • the DM 200 may also comprise a voltmeter, which may be identified as a DM voltmeter 206, configured to measure a voltage of the ESM 100 indicating a level of charge of the ESM 100 (e.g. the level of charge of the capacitors).
  • the DM 200 in this example also comprises a display device 207 configured to display the voltage measured by the DM voltmeter 206 to a user of the DM 200.
  • the display device 207 is a digital display to display a number of volts, as shown in Fig. 6.
  • the display device may be an analogue gauge or other display indicating a level of charge.
  • the DM voltmeter 206 may be activated by a switch, which may be a flip switch or push button. In the examples shown in Figs. 6 and 7 the switch is in the form of a push button 209 to power on and power off the DM voltmeter 206 and display device 207.
  • the DM voltmeter 206 is powered by a power source other than the ESM 100, e.g. a power source that is not the capacitors of the ESM 100, such as a separate battery.
  • a power source e.g. a power source that is not the capacitors of the ESM 100, such as a separate battery.
  • the DM voltmeter 206 is self-powered, for example by a battery (e.g. a 9V battery).
  • this allows the DM voltmeter 206 to function whether the capacitors in the ESM 100 are charged or not. That is, the DM voltmeter 206 will work even when there is no power in the capacitors of the ESM 100 (e.g. when they are completely discharged). This allows the user to see the voltage reading go all the way to zero, since the DM voltmeter 206 is not relying on power from the ESM 100. This may advantageously provide a safety feature enabling a user or technician to confirm that the capacitors are discharged prior to maintenance.
  • the control panel 214 may also comprise a cable hole 210.
  • the lead 202 may extend from this cable hole, optionally through a waterproof fitting such as an IP67 cable gland or other suitable fitting.
  • the cable hole 210 may be replaced by a plug to which a socket on the lead 202 (at the opposite end of the lead 202 to the plug 204) may be connected.
  • the control panel 214 or at least the voltmeter 206 may itself be provided in an IP67 enclosure.
  • Fig. 5 shows a simplified system diagram of the DM 200.
  • the socket 104 comprises two pin sockets, one connected to the STR+ terminals of the capacitor banks 110 and one connected to the BAT- terminals of the capacitor banks 110.
  • the plug 204 of the DM 200 may comprise two pins, and positive pin configured to be electrically connected to the STR+ terminals of the capacitor banks 110 in the ESM 100 via the socket 104 and a negative pin configured to be electrically connected to the BAT- terminals of the capacitor banks 110 of the ESM 100 via the socket 104.
  • the energy dissipating device 201 is provided across the positive pin and negative pin to draw power from the capacitor banks 110 when the circuit is completed.
  • Discharge switch 203 is depicted in series with the energy dissipating device 201 to interrupt power supply to the energy dissipating device 201 until the user is ready to begin discharge.
  • the DM voltmeter is also shown in Fig. 5 and, as illustrated, is powered by a voltmeter battery 208 when push button, depicted as a switch, is actuated to complete the circuit.
  • the ESM 100 and DM 200 may together form a system.
  • the system may therefore comprise an engine start module 100 comprising one or more capacitors, being chargeable to a charged state and configured to provide power to start a vehicle when in the charged state, and a socket 104 providing for electrical connection to the one or more capacitors.
  • the system may further comprise a discharge module (DM) comprising a plug 204 configured to connect to the socket 104 of the engine start module 100 and form an electrical connection with the one or more capacitors, and an energy dissipation device 201 providing an electrical load to dissipate electrical energy received from the capacitors of the engine start module 100 via the plug 204 to allow for discharge of the capacitors.
  • DM discharge module
  • the engine start module may be the ESM 100 as described above including any of the variations.
  • the method may comprise using the DM 200 as described above including any of the variations.
  • the method may be performed by a user or technician of the vehicle or machine in which the ESM 100 is installed and the user or technician may use the DM 200 to discharge the ESM 100 prior to commencing work on the vehicle or machine, as a safety precaution.
  • the method may therefore comprise connecting the DM 200 to the ESM 100 so that the DM 200 provides an electrical load to discharge the one or more capacitors.
  • the method may then comprise actuating the discharge switch 203 to complete an electrical connection between the one or more capacitors and the electrical load in the DM 200.
  • the method may then comprise a step of reading a voltage displayed on the DM 200 to confirm that the one or more capacitors are substantially discharged, where the voltage indicates a level of charge of the capacitors.
  • the DM 200 may comprise the discharge switch 203, for example on a control panel 214 thereof.
  • the method may also comprise connecting the plug 204 of the DM 200 to the socket 104 of the ESM 100 to form an electrical connection with the one or more capacitors of the ESM 100. After discharge is complete, the method may further comprise disconnecting the plug 204 of the DM 200 from the socket 104 of the ESM 100 after confirming that the one or more capacitors are substantially discharged.
  • the method may comprise discharging the one or more capacitors without making any electrical connections other than connecting the plug 204 to the socket 104. This may advantageously provide for safe discharge able to be performed by a user or technician with fewer qualifications that may otherwise be required.
  • the method may comprise a step of powering-on a voltmeter 206 of the DM 200 by actuating a voltmeter switch 209.
  • the step of actuating the voltmeter switch 209 may enable power to be provided from a voltmeter battery 208 to the voltmeter 206.
  • the step of reading the voltage comprises reading a digital display indicating a number of volts.
  • the step of reading the voltage may comprise reading an initial voltage indicating that the capacitors are not discharged, waiting for the capacitors to discharge and reading a final voltage indicating that the capacitors are substantially discharged.
  • the step of reading a final voltage may comprise reading a voltage of 3V or less, preferably 2V or less, preferably IV or less, preferably 0V. In some scenarios, less than 2V or 3V may be considered safe. In other scenarios it may be considered necessary to wait for the capacitors to have a voltage of no more than IV or 0V.
  • the method may comprise leaving the plug 204 of the DM 200 connected to the socket 104 of the ESM 100 while work is conducted on a vehicle in which the ESM 100 is installed. If, for whatever reason, the capacitors inadvertently began to be energised, the DM 200 may advantageously dissipate that energy.
  • the method comprises, after confirming that the one or more capacitors are substantially discharged, disconnecting the plug 204 of the DM 200 from the socket 104 of the ESM 100 and connecting a temporary plug to the socket 104.
  • the temporary plug may comprise a shorting wire configured to keep the one or more capacitors of the ESM 100 discharged.
  • the temporary plug 104 may comprise an indicator (e.g. an indicating device) configured to provide an indication (e.g. an alarm/alert) that the one or more capacitors of the ESM 100 are not substantially discharged.
  • the indication provided by the temporary plug may prompt a worker to check the ESM 100 and discharge the capacitors as required, for example using the DM 200.
  • the indication may be provided if the shorting wire of the temporary plug becomes open-circuited and the capacitors become at least partially energised (e.g. due to a fault or inadvertent recharging), which may generate the alert. If the capacitors are discharged, there may be no voltage available that can energise the indicator to generate the alert. Alternatively, the temporary plug may provide an indication that the capacitors are (or remain) discharged.
  • the technology may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Power Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Charge And Discharge Circuits For Batteries Or The Like (AREA)

Abstract

L'invention concerne un système comprenant : un module de démarrage de moteur qui comporte : un ou plusieurs condensateurs conçus pour fournir l'énergie nécessaire au démarrage d'un véhicule, et une douille pour assurer la connexion électrique avec les condensateurs ; un module de décharge qui comporte : une fiche conçue pour se connecter à la douille du module de démarrage de moteur et pour assurer la connexion électrique avec les condensateurs, et un dispositif de dissipation d'énergie qui fournit une charge électrique pour dissiper l'énergie électrique reçue des condensateurs par l'intermédiaire de la fiche. Le module de démarrage de moteur, le module de décharge et un procédé sont également divulgués.
PCT/AU2024/051095 2023-10-20 2024-10-18 Module de démarrage de moteur et dispositif de décharge Pending WO2025081237A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2023903352A AU2023903352A0 (en) 2023-10-20 Engine start module and discharge device
AU2023903352 2023-10-20

Publications (1)

Publication Number Publication Date
WO2025081237A1 true WO2025081237A1 (fr) 2025-04-24

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Application Number Title Priority Date Filing Date
PCT/AU2024/051095 Pending WO2025081237A1 (fr) 2023-10-20 2024-10-18 Module de démarrage de moteur et dispositif de décharge

Country Status (1)

Country Link
WO (1) WO2025081237A1 (fr)

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140049205A1 (en) * 2012-08-15 2014-02-20 Rbc Manufacturing Corporation Start capacitor assemblies and methods for operating electric motors
KR101436787B1 (ko) * 2013-12-31 2014-09-11 주식회사 뉴인텍 하우징 내장형 자동차 인버터용 저 인덕턴스 커패시터
KR101729632B1 (ko) * 2015-11-03 2017-05-02 주식회사 뉴인텍 하우징 내장형 커패시터의 방전 저항기 장착 구조
CN209544163U (zh) * 2019-01-15 2019-10-25 安徽瀚宇电气有限公司 一种高寿命三相低压电容器
CN114883111A (zh) * 2022-05-26 2022-08-09 中国第一汽车股份有限公司 一种集成滤波器及放电电阻的模块化母线电容

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20140049205A1 (en) * 2012-08-15 2014-02-20 Rbc Manufacturing Corporation Start capacitor assemblies and methods for operating electric motors
KR101436787B1 (ko) * 2013-12-31 2014-09-11 주식회사 뉴인텍 하우징 내장형 자동차 인버터용 저 인덕턴스 커패시터
KR101729632B1 (ko) * 2015-11-03 2017-05-02 주식회사 뉴인텍 하우징 내장형 커패시터의 방전 저항기 장착 구조
CN209544163U (zh) * 2019-01-15 2019-10-25 安徽瀚宇电气有限公司 一种高寿命三相低压电容器
CN114883111A (zh) * 2022-05-26 2022-08-09 中国第一汽车股份有限公司 一种集成滤波器及放电电阻的模块化母线电容

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