Three phase regulator rectifier for automotive battery charging and control application suitable for of a two wheeled vehicle

Abstract

A three phase regulator rectifier for automotive battery charging applications of a two wheeled vehicle having a few discrete components and providing programmable feedback control for improved efficiency in battery charging applications.

Claims

1. A three phase regulator rectifier, for two wheeler battery charging application, adapted to rectify an alternating current output of a rotary power generating member first to energize connected electrical components of the two wheeler and second to apply a defined potential difference between terminals of a lead acid battery to maintain a charged state of said battery, said device comprising: (i) a plurality of stationary coils annularly positioned around magnetic flux of a rotary member; said coils interconnected in sets of three so as to induce electromagnetic force alternating from positive to negative in each of the three sets in a phased manner; (ii) Semiconductor circuits adapted to modify said induced electromagnetic force from an alternating form to a steady state in each of said three set of coils; (iii) an integrated programmable semiconductor chip provided with circuits adapted to sense continuously variable physical quantity and magnitudes in discrete units of a physical quantity; said semiconductor chip adapted to vary said alternating and steady state electromagnetic force to energize connected electrical components of the two wheeler and to apply a defined potential difference between terminals of a lead acid battery respectively; and (iv) a feedback and control circuit integral to said programmable semiconductor chip adapted to sense varying energy load of said electrical components so as to intermittently maintain a preset steady state potential difference between said battery terminals.

2. A three phase regulator rectifier for two wheeler battery charging application as claimed in claim 1, wherein the integrated programmable semiconductor chip provided with configurable circuits including low pass or band pass filters, digital buffers, programmable gain amplifiers, programmable PWM signal generators, programmable Temperature sensors, ramp or signal generators, zero crossing detectors and charge pump circuits.

3. A three regulator rectifier for two wheeler battery charging application as claimed in claim 1, wherein the semiconductor circuits comprises of SCR, MOSFET, IGBT and such other circuits in combination of at least two connected either in series or in parallel between stationary coils of the rotary power generating member and lead acid battery.

4. A three regulator rectifier for two wheeler battery charging application as claimed in claim 1, wherein the semiconductor circuits are connected between the stationary coils of rotary power generating member and the battery of the vehicle system with or without fuse links in between.

5. A regulator rectifier for two wheeler battery charging application as claimed in claim 1, wherein said integrated programmable semiconductor chip in cooperation with said feedback and control circuit and semiconductor circuits are adapted to control three phase rectification bridge connected to the rotary power generating member.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) All aspects and advantages of the present invention will become apparent with the description of the preferred non limiting embodiment, when read together with the accompanying drawings, in which:

(2) FIG. 1 is the basic working diagram of conventional battery charging function of a automotive vehicle using an alternator;

(3) FIG. 2 is the block diagram of a three phase automotive alternator and power rectification SCR (Silicon-controlled) rectifier circuit connected in series showing aspects and the inter connection in accordance with this invention;

(4) FIG. 3 is the block diagram of a three phase automotive alternator and power rectification SCR (Silicon-controlled) rectifier circuit connected in parallel (shunt) showing aspects and the inter connection in accordance with this invention;

(5) FIG. 4 is the block diagram of a three phase automotive alternator and power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in series showing aspects and the inter connection in accordance with this invention;

(6) FIG. 5 is the is the block diagram of a three phase automotive alternator and power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in parallel (shunt) showing aspects and the inter connection in accordance with this invention;

(7) FIG. 6 is the working logic flow chart of the three phase automotive alternator based battery charging system, having a MOSFT bridge rectification, in accordance with this invention;

(8) FIG. 7 is the basic configuration diagram of the, three phase automotive alternator based battery charging, power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in series in accordance with this invention;

(9) FIG. 8 is the basic configuration diagram of the, three phase automotive alternator based battery charging, power rectification SCR (Silicon-controlled) rectifier circuit connected in series rectifier circuit connected in series in accordance with this invention;

(10) FIG. 9 is the basic configuration diagram of the, three phase automotive alternator based battery charging, power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in parallel (shunt) in accordance with this invention;

(11) FIG. 10 is the basic configuration diagram of the, three phase automotive alternator based battery charging, power rectification SCR (Silicon-controlled) rectifier circuit connected in series rectifier circuit connected in parallel (shunt) in accordance with this invention;

(12) FIG. 11 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 1,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage;

(13) FIG. 12 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 2,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage;

(14) FIG. 13 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 3,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage;

(15) FIG. 14 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 4,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage; and

(16) FIG. 15 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 5,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

(17) FIG. 16 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 6,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

(18) FIG. 17 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 7,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

(19) FIG. 18 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 8,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

(20) FIG. 19 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 9,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

(21) FIG. 20 is the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 10,000 rpm depicting wave forms of (a) alternator output, (b) battery charging voltage.

DETAILED DESCRIPTION OF THE INVENTION

(22) The Indian patent application having reference number 3563/MUM/2014, having priority date 20 Nov. 2014, filed by the same assignee, is hereby incorporated by reference.

(23) Conventional battery charging systems consist of voltage regulator with either a discrete transistor or a custom integrated circuit known as an Application Specific Integrated Circuit (ASIC). These types of voltage regulator circuits often are hard-wired circuits provided with custom designed specific functions suitable only for a specific type of vehicle.

(24) Some of the other versions of automotive battery charging systems have deleted the voltage regulator altogether and use microprocessor controllers as part of the ignition module or vehicle control module that controls all functions of the motorcycle. Other vehicle designs have used voltage regulators with advanced microprocessor functions that maintain a regulated voltage produced by an alternator, but include advanced clock and memory circuits that store battery and power supply reference data, battery voltage and generator rotation speed, and determine how much the battery is being charged and at what rate at any point in time. The present invention relates to a three phase regulator rectifier for automotive battery charging applications of a two wheeled vehicle having lesser discrete components and feedback control for improved efficiency

(25) Referring to FIG. 1, the basic functional details of the system components are depicted. The alternator (100) produces alternating current and the rectifier regulator (200) converts the alternating current to direct current and a constant voltage is applied to the lead acid battery (300) to keep it in charged condition.

(26) Referring to FIG. 2, is the block diagram of a three phase automotive alternator and power rectification SCR (Silicon-controlled) rectifier circuit connected in series showing aspects and the inter connection. The series voltage regulator operates by using a variable element in series with the load. In this way a series voltage regulator provides an effective form of voltage regulation. The series voltage regulator uses a variable element placed in series with the load. The advantage of the series voltage regulator is that the amount of current drawn is effectively that used by the load, although some will be consumed by the circuitry associated with the regulator. Unlike the shunt regulator, the series regulator does not draw the full current even when the load does not require any current. As a result the series regulator is considerably more efficient.

(27) Referring to FIG. 3, is the block diagram of a three phase automotive alternator and power rectification SCR (Silicon-controlled) rectifier circuit connected in parallel (shunt) showing aspects and the inter connection. A shunt regulator detects output voltage variation via external resistors by using an error amplifier and controls a transistor connected in parallel to the load to keep the output voltage constant.

(28) Referring to FIG. 4, the block diagram of a three phase automotive alternator and power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in series and the inter connection between control circuit and load is shown. A variable element in series with the load is used to provide an effective form of voltage regulation.

(29) Referring to FIG. 5, the block diagram of a three phase automotive alternator and power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in parallel (shunt) and the inter connecting circuit is shown. A shunt regulator detects output voltage variation via external resistors by using an error amplifier and controls a transistor connected in parallel to the load to keep the output voltage constant.

(30) Referring to FIG. 6 is the working logic flow chart of an embodiment of the invention using a MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit for three phase rectification.

(31) Referring to FIG. 7 depicts the basic configuration of the, three phase automotive alternator based battery charging, power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in series.

(32) FIG. 8 depicts the basic configuration of the, three phase automotive alternator based battery charging, power rectification SCR (Silicon-controlled) rectifier circuit connected in series rectifier circuit connected in series.

(33) FIG. 9 depicts the basic configuration of the, three phase automotive alternator based battery charging power rectification MOSFET (Metal-oxide-semiconductor field-effect transistor) rectifier circuit connected in parallel (shunt).

(34) FIG. 10 shows the basic configuration of the, three phase automotive alternator based battery charging SCR (Silicon-controlled) rectifier circuit connected in parallel (shunt) in accordance with this invention;

(35) A system based on the use of a mixed signal programmable chip and a battery of 12 volt output, to be mounted on a two wheeler having pre defined potential loads (engine, lights and such other related loads) was designed. A Harvard-architecture processor having operating voltage: 3.0 V to 5.25 V and capable of withstanding a temperature range −40° C. to +85 was selected. A rectifier regulator in accordance with this invention was designed and built.

(36) The completed assembly of the rectifier regulator in accordance with this invention was mounted on a test rig and rotated at speeds of 1000, 2000, 3000, 4000 and 10000 rpm of the rotor at varying load levels designated as night mode and twilight mode. The wave forms of the alternator output, load side and battery charging voltage were recorded. A FIGS. 12 to 20 depicts the wave forms recorded at the different load conditions.

(37) FIGS. 11 to 20 are the test result of a three phase battery charging rectifier regulator system manufactured in accordance with this invention having a SCR (Silicon-controlled) rectifier connected in series mode, under test conditions at speed of 1,000 to 10,000 rpm in steps of 1000 rpm, depicting wave forms of (a) alternator output, (b) battery charging voltage.

(38) The test results show that the rectifier regulator in accordance with this invention has the following advantages: 1. Flicker less circuit 2. Re-programmability for adding new feature 3. Less number of the components compare to prior art regulator rectifier (75˜80% Less) 4. Soldering Points Reduced by 60% 5. Reduction in PCB Size 6. Reduced casting Size 7. Reduced process rejections.

(39) While considerable emphasis has been placed herein on the particular features of a “three phase regulator rectifier for automotive battery charging and control application suitable for of a two wheeled vehicle” and the improvisation with regards to it, it will be appreciated that various modifications can be made, and that many changes can be made in the preferred embodiment without departing from the principles of the invention. These and other modifications in the nature of the invention or the preferred embodiments will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.