Bendix Commercial Vehicle Systems LLC

Marv Hamdan

David J Pfefferl

Joseph M Macnamara

Kenneth A Grolle

Mark A Matko

Kirit A Thakkar

Claude Abraham

Gusztav Holler

When starting a screw-type air compressor in sub-zero conditions, current spikes are mitigated by detecting an over-current condition and/or a below-threshold temperature, and a warm-up routine is initiated in which compressor motor speed is ramped in a sawtooth fashion between two speeds that are substantially lower than a nominal operating speed of the compressor motor. In this manner, the internal components of the compressor are warmed prior to fully starting the compressor, which mitigates current spikes, reduces blown fuses, and extends the life of the compressor motor and other compressor components.

Current control via speed control for driving screw compressor under cold conditions

Systems and methods for detecting a blocked air discharge line of an air compressor are described, which include monitoring motor current (IMTR) drawn by a compressor motor, and calculating a three-point moving average for a steady state current drawn by the compressor motor upon the motor reaching steady state (nominal) operating speed. After expiration of a predetermined time period Tthat commences upon the compressor motor reaching steady state speed, a determination is made regarding whether a difference between a current drawn by the compressor motor and the three-point moving average has exceeded a predetermined current value Iand is consistent with a current profile indicative of a blocked air line. If a blocked air line is detected, a compressor shut-off command is generated and transmitted to the compressor motor to shut the compressor motor off prior to opening of a safety valve on the compressor.

Robust electric screw compressor blocked air line detection via motor current monitoring

Systems and methods for detecting a blocked air discharge line of an air compressor are described, which include monitoring motor current (IMTR) drawn by a compressor motor (), and calculating a three-point moving average for a steady state current drawn by the compressor motor () upon the motor reaching steady state (nominal) operating speed. A current threshold (IMTR_LIMIT) () is calculated as a function of the three-point moving average, and a determination is made regarding whether a current drawn by the compressor motor () has exceeded the current threshold () and is consistent with a current profile () indicative of a blocked air line (). If a blocked air line is detected, a compressor shut-off command is generated and transmitted to the compressor motor () to shut the compressor motor off prior to opening of a safety valve () on the compressor ().

Detection of blocked air line for electric compressor at start up

The described systems and methods relate to employing an Electric Air Charging System (EACS) to maintain a hybrid commercial vehicle (or the like) battery within a desired range of charge. The innovation facilitates reducing battery charge when the state of charge is too high, such as by adjusting air compressor cut-in and cut-out pressure thresholds to cause the air compressor to compress air for the brake system when there is excess charge in the battery, as well as triggering a brake regeneration protocol and/or other charge regeneration protocol(s) to restore charge to the battery when the state of charge of the battery is too low.

State of charge adjusted compressor control

When controlling an air compressor () for a pneumatic braking system on a large hybrid commercial vehicle (e.g., a bus, a package delivery truck, etc.), PID control of an air compressor motor () is employed during normal system operation such as when the motor shaft is spinning, and state machine control is employed during startup or upon a system disturbance such as a shaft seizure or stall. In this manner, stalling events that occurs due to PID control inability to correct for unexpected disturbances are mitigated by employing state machine control.

Robust PID control for BLDC motor controller

A method of transmitting data over a power line of a switch mode power supply system includes encoding a switch frequency of the switch mode power supply with the data. A ripple voltage is generated at the encoded switch frequency relative to a voltage generated by the switch mode power supply. The ripple voltage is conducted over the power line of the system. The ripple voltage is de-coupled from the power line and the data is decoded from the encoded switch frequency of the coupled ripple voltage.

System and method for data transmission over a power line of a switch mode power supply by frequency modulating the switch frequency thereof

A system and method for detecting alternator condition is provided. Information is taken from the vehicle powerline and the communication links, and processed by the vehicle ECU, such as the vehicle antilocking brake system ECU, to obtain data. The battery voltage ripple amplitude is then calculated and compared at different engine speeds. If the difference in the ripple amplitude at the different engine speeds is greater than a predetermined threshold value, a signal is sent indicating that the alternator has failed.

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North Olmsted, OH, United States of America

Marv Hamdan