# US 10,501,070 B2 · High-power, low-voltage generator with starter-support function and torque compensation

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- Number: US 10,501,070 B2
- Document ID: US10501070B2
- Status: Granted
- Kind: B2
- Application number: 15/726,844
- Filed: 2017-10-06
- Published: 2018-04-12
- Granted: 2019-12-10
- Earliest claimed: 2016-10-06
- Assignees: LSP Innovative Automative Systems GmbH
- Applicants: LSP Innovative Automotive Systems GmbH
- Inventors: Thomas Leiber; Christian Köglsperger; Franz Schöglmann
- Web page: https://patentgrep.com/patent/US10501070B2

## CPC

- H02P 9/30: using semiconductor devices
- B60K 6/24: characterised by the combustion engines
- B60W 10/08: including control of electric propulsion units, e.g. motors or generators
- B60W 20/17: for noise reduction
- F02N 11/006: {using a plurality of electric motors}
- F02N 11/04: the motors being associated with current generators
- F02N 11/087: {Details of the switching means in starting circuits, e.g. relays or electronic switches}
- F02N 11/12: Starting of engines by means of mobile, e.g. portable, starting sets
- H02K 1/00: Details of the magnetic circuit (magnetic circuits for relays H01H50/16)
- H02K 1/187: {to inner stators}
- H02K 3/522: {for generally annular cores with salient poles}
- H02K 7/006: {Structural association of a motor or generator with the drive train of a motor vehicle}
- H02K 9/19: for machines with closed casing and closed-circuit cooling using a liquid cooling medium, e.g. oil
- H02K 9/227: {Heat sinks}
- H02M 7/797: using semiconductor devices only
- H02P 9/48: Arrangements for obtaining a constant output value at varying speed of the generator, e.g. on vehicle (H02P9/04 - H02P9/46 take precedence)
- B60L 2210/30: AC to DC converters
- F02N 11/00: Starting of engines by means of electric motors
- F02N 15/023: {of the overrunning type}
- F02N 2011/0896: {Inverters for electric machines, e.g. starter-generators}
- H02P 2101/25: for combustion engines
- H02P: CONTROL OR REGULATION OF ELECTRIC MOTORS, ELECTRIC GENERATORS OR DYNAMO-ELECTRIC CONVERTERS; CONTROLLING TRANSFORMERS, REACTORS OR CHOKE COILS
- B60K: ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60W: CONJOINT CONTROL OF VEHICLE SUB-UNITS OF DIFFERENT TYPE OR DIFFERENT FUNCTION; CONTROL SYSTEMS SPECIALLY ADAPTED FOR HYBRID VEHICLES; ROAD VEHICLE DRIVE CONTROL SYSTEMS FOR PURPOSES NOT RELATED TO THE CONTROL OF A PARTICULAR SUB-UNIT
- F02N: STARTING OF COMBUSTION ENGINES; STARTING AIDS FOR SUCH ENGINES, NOT OTHERWISE PROVIDED FOR
- H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53})
- H02M: APPARATUS FOR CONVERSION BETWEEN AC AND AC, BETWEEN AC AND DC, OR BETWEEN DC AND DC, AND FOR USE WITH MAINS OR SIMILAR POWER SUPPLY SYSTEMS; CONVERSION OF DC OR AC INPUT POWER INTO SURGE OUTPUT POWER; CONTROL OR REGULATION THEREOF (transformers H01F; dynamo-electric converters H02K47/00; controlling transformers, reactors or choke coils, control or regulation of electric motors, generators or dynamo-electric converters H02P)
- B60L: PROPULSION OF ELECTRICALLY-PROPELLED VEHICLES (arrangements or mounting of electrical propulsion units or of plural diverse prime-movers for mutual or common propulsion in vehicles B60K1/00, B60K6/20; arrangements or mounting of electrical gearing in vehicles B60K17/12, B60K17/14; preventing wheel slip by reducing power in rail vehicles B61C15/08; dynamo-electric machines H02K; control or regulation of electric motors H02P); SUPPLYING ELECTRIC POWER FOR AUXILIARY EQUIPMENT OF ELECTRICALLY-PROPELLED VEHICLES (electric coupling devices combined with mechanical couplings of vehicles B60D1/64; electric heating for vehicles B60H1/00); ELECTRODYNAMIC BRAKE SYSTEMS FOR VEHICLES IN GENERAL (control or regulation of electric motors H02P); MAGNETIC SUSPENSION OR LEVITATION FOR VEHICLES; MONITORING OPERATING VARIABLES OF ELECTRICALLY-PROPELLED VEHICLES; ELECTRIC SAFETY DEVICES FOR ELECTRICALLY-PROPELLED VEHICLES

## Abstract

A vehicle, e.g., an off-road vehicle, may include an internal combustion engine, a starter motor coupled to the engine via a multi-stage transmission during a starting process, a further electric machine coupled to a crankshaft of the engine, and a converter arranged to supply at least one energy storage unit, e.g., a battery. The converter may be configured as a 4-quadrant regulator having a B6 circuit of MOSFETs.

## Claims

### Claim 1

A vehicle, including:
a combustion engine with less than six cylinders,
a starter motor configured to drive the combustion engine,
a multi-stage transmission, wherein the starter motor is configured to drive the combustion engine during a starting process, and
wherein, following the starting process, the starter motor is decoupled from the combustion engine via an uncoupling mechanism,
an electric machine, distinct from the starter motor, configured to be operated as a motor and generator, having a fixed connection to a crankshaft of the combustion engine and by which the combustion engine is able to be driven, and
a converter, having an electrical connection with windings of the electric machine, and which is configured to convert an alternating current generated by the electric machine to a direct current,
wherein the converter is configured to supply at least one energy store in the form of a battery, and
wherein the converter comprises a 4-quadrant regulator comprising a B6 bridge circuit of metal-oxide-semiconductor field-effect transistors (MOSFETs).

### Claim 2 (depends on 1)

The vehicle according to claim 1, further including a control unit configured to drive the 4-quadrant regulator of the converter in such a way that the electric machine, during motor operation, works to support the starter motor.

### Claim 3 (depends on 2)

The vehicle according to claim 2, wherein the control unit is configured to drive the 4-quadrant regulator of the converter in such a way that electrical compensation currents flow into the electric machine driven by the combustion engine, which compensation currents bring about compensation torques to suppress torque fluctuations of the combustion engine and thus improve the quietness and noise performance of the combustion engine.

### Claim 4 (depends on 1)

The vehicle according to claim 1, wherein the electric machine is an external rotor motor, wherein the rotor is fitted with permanent magnets.

### Claim 5 (depends on 4)

The vehicle according to claim 4, wherein an oil mist is provided in the electric machine, which serves to improve heat dissipation from exciter coils of a stator of the electric machine and the permanent magnets of the rotor.

### Claim 6 (depends on 4)

The vehicle according to claim 4, wherein the electric machine further comprises an inner stator with exciter coils, wherein the inner stator with the exciter coils, on a side facing towards the rotor, is not, or is only partially, covered with a casting compound, wherein an uncovered part of the inner stator and/or an uncovered part of the exciter coils is/are in contact with an oil mist.

### Claim 7 (depends on 4)

The vehicle according to claim 4, wherein, in order to reduce iron losses in the rotor, the rotor comprises a laminated construction or comprises a stamped laminated core inserted in the rotor.

### Claim 8 (depends on 1)

The vehicle according to claim 1, wherein the electric machine comprises a laminated inner stator with exciter coils, a rotor and a metallic intermediate section, wherein the exciter coils of the inner stator are arranged across their radial longitudinal extension with an axial clearance, which is less than 2 mm from the intermediate section, and wherein the inner stator with the exciter coils and the intermediate section are filled with a filler with a heat conductance greater than that of air, wherein the intermediate section is connected to a housing of the electric machine by means of a screwed connection.

### Claim 9 (depends on 8)

The vehicle according to claim 8, wherein the intermediate section is designed so that the exciter coils have the axial clearance from the intermediate section, such that a thermal resistance for generators with stator diameters of <200 mm (performance level for 500 W to 3000 W) is less than 2 k/W.

### Claim 10 (depends on 8)

The vehicle according to claim 8, wherein the intermediate section or an area of the intermediate section is inset in the axial direction between the housing and the stator and rests against both, with axially aligned surfaces, such that a thermal resistance between the stator and the housing is as small as possible, and wherein the intermediate section is made from aluminium.

### Claim 11 (depends on 8)

The vehicle according to claim 8, wherein the filler has a high specific conductance, and contains boron nitride and/or is formed from a thermoplastic or thermosetting plastic.

### Claim 12 (depends on 1)

An assembly comprising: an inner stator with exciter coils and intermediate section in the vehicle according to claim 1, further including a filler comprising a thermoplastic, a cast material or a thermosetting plastic, wherein a space between the exciter coils and an intermediate section is filled using an injection moulding, vacuum casting or thermosetting manufacturing method, and the inner stator thereby has a positive connection with the intermediate section.

### Claim 13 (depends on 1)

The vehicle according to claim 1, wherein the uncoupling mechanism comprises an overrunning clutch.