Note: Descriptions are shown in the official language in which they were submitted.
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GENERATION AND MANAGEMENT OF MASS AIR FLOW
TECHNOLOGY FIELD
[0001] The present invention generally relates to the field of air flow
generation. More
particularly, the present invention relates to systems and methods for
generating and managing
mass air flows, and subsets thereof including high velocity, high pressure,
high density, and the
like. This technology is particularly suited, but by no means limited, for
application to hybrid
vehicles, vehicles propelled by internal combustion engines, stationary
applications of internal
combustion engines, and ancillary uses of such air flows.
BACKGROUND
[0002] Applications in research, industrial, commercial and consumer
applications for
pressurized air flows are long standing and well known. Pneumatic systems,
using generated or
stored pressurized air, are well known and were common even in the early parts
of the twentieth
century. The availability of air pumps based on fan or blower technologies
(such as, for
example, centrifugal, spiral, and axial flow air effector devices) is
widespread and common.
[0003] Air charging refers to the provision of air, or fluid handling like a
gas, for
purposes both to pressurize an outflow air stream, and to depressurize an
intake air source
volume. In applications, this may support using a velocity mass air flow
device to either fill,
with a pressure above the ambient, an outflow need, or to evacuate an intake
air source volume
that may be a fixed or variable volume container.
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[0004] In many extant approaches in the known art there are shortcomings and
problems with the performance of air charging devices where the resistance
from existing
structures, gas pressure, or resistive load degrades the ability of the air
charging device to be
serviceable.
[0005] Existing pressurized air flow applications have additional shortcomings
that
include (varying by the device being compared), for example:
1) Existing devices fail to provide a mass air flow sufficient to complete a
task within the
desired time window although the mass air flow over a much longer time period
may be
sufficient.
2) Existing devices fail to provide the necessary control feedback and use
measurements
to limit possible damage from an uncontrolled velocity or mass air flow.
3) Existing devices fail to provide for operation without a substantial fixed
installation
that generates, or stores, high pressures that can be transformed into a high
velocity mass air
flow.
4) Existing devices place a high load on the equipment supplying power (e.g.,
combustion engine, electrical feed, gas pressure, etc.) on a highly dynamic
basis that causes
unwanted side-effects in the system the application is supporting.
5) Existing devices place demands for space or physical configurations that
cause
additional costs and resource requirements beyond that desirable.
6) Existing devices fail to provide the flexibility to use high-velocity mass
air flows, or
slower less massive flows, to allow optimization of power expenditure, or for
other purposes.
7) Existing devices fail to provide power management alternatives that allow
multiple
operating uses to optimally use power available in an application environment.
8) Existing devices fail to provide full coverage to handle all of the aspects
of the
apparatus from the low level control of the electrical motor to the
connections to the entire
application's apparatus structure.
9) Existing devices do not have extensive safety provisions and features to
protect the
device, the platform on which it is operating, or the human users.
10) Existing devices are not easily integrated into an overall platform power
management
and operating plan that allows flexible usage of their capabilities while
managing their impact on
power expenditure, instantaneous demand, and overall power capacity.
[0006] Conventional devices and applications have sought with limited success
to meet
one or more of these applications requirements with a wide variety of power
mechanisms, air
effector configurations, and control loops.
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[0007] For example, conventional fan devices may generate a significant volume
of air,
but generate an output pressure of less than 15% increase from normal
conditions. Thus, a
typical fan device is inadequate for applications that require a combination
of high air flow with
higher pressure. The physical diameter and consequent physical guards required
also are
disadvantages of conventional fan devices in even volume applications.
[0008] Also, a centrifugal air actuator may generate modest pressure, but
typically
requires a very large diameter blower to generate a higher pressure output.
Blowers for high
volume operation may achieve considerable flow rates, at modest pressures, but
range up to
almost 60 centimeters in diameter. The electrical power and motors necessary
(or other power
source) for large centrifugal blowers is also a large consideration when using
centrifugal air
actuators in high air flow applications.
[0009] The efficiency of other air actuator devices (such as compressors in
the form of
scrolls or overlapped spirals) are not as high as that of the high volume mass
air flow devices
described in this application. Further, extant compressor applications tend to
be specialized and
constrained.
[0010] To generate pressure, a fixed compressor and tankage system (such as
found in
many industrial environments) may be used to provide high pressure, but the
pneumatic
infrastructure is substantial and the possible faults and complexity of the
control systems are
substantial.
[0011] Thus, in view of the foregoing, there is a need for systems and methods
that
overcome the limitations and drawbacks of the prior art. In particular, there
is a need for systems
and methods capable of moving a pressurized stream of air (air charging) at a
high flow rate and
that addresses one or more of these limitations and drawbacks, and preferably
addresses most of
these limitations and drawbacks, and more preferably the entire range of these
shortcomings and
provides superior applications performance in many situations. Embodiments of
the present
invention provide such solutions.
[0012] In a hydrogen fuel-cell vehicle, a recognized concern is the ability of
the vehicle
to operate in cold-weather/ambient conditions. The Department of Energy has
selected a series
of goals for fuel-cell developments reaching through 2010. U.S. Patent No.
6,727,013 B2,
entitled "Fuel cell energy management system for cold environments," issued to
William S.
Wheat et al., discloses the use of a resistive heater to warm the fuel cells.
But this approach
reduces usable capacity of the fuel cells. U.S. patent No. 6,797,421 B2,
entitled "Fuel cell
thermal management system," issued to Eric T. White, also discloses the use of
a resistive
heater to warm the fuel cells with a coolant process (with an unspecified
cooling mechanism) to
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cool them. In U.S. Patent No. 6,815,103, entitled "Start control device for
fuel cell system,"
issued to Hiroyuki Abe et al., at Figure 3, Label S01, a reference is made to
the use of a hot air
supply, but no mechanism or control structure for such a mechanism is
described. U.S. Patent
No. 6,616,424 B2, entitled "Drive System and Method for the Operation of a
Fuel Cell System"
issued to Raiser discloses the use of compressed air to assist in fuel cell
operations, however a
hot gas supply is not used.
[0013] In the body of U.S. Patent No. 7,200,483 B1, entitled "Controller
Module for
Modular Supercharger System," issued to Kavadeles, the supercharger described
and controlled
is powered by a mechanical belt and pulley arrangement (see, Figure 1 elements
102, 136,138,
142). Thus, the operation of supercharger is dependent on the mechanical RPM
of the engine
and reduces the power available from engine at low RPM when torque is needed
for acceleration
or other functions.
[0014] U.S. Patent Nos. 6,141,965; 6,079,211, 5,867,987; 5,771,868 and
5,904,471
disclose conventional approaches to pre-conditioning and directing inflows of
air into a device
using various pre-whirl strategies, diverters, and vanes; and outlet
conditioning of outflows of air
for disposal or application. However, these references do not disclose or
teach according the
inlet and outlet condition of flows full consideration in the deployment and
operation of the
devices. None of these references teaches the capacity to actively incorporate
active pre- and
post- conditioning of the flows while managing the power and operating
characteristics of the
electric motor subassembly. In U.S. Patent Nos. 5,771,868 and 6,102,672, the
control concepts
extend to the incorporation of EGR (engine gas recirculation) and bypass air
sources. But these
references do not disclose or teach incorporation of active inlet and outlet
conditioning of flows
while managing the power and operating characteristics of the electric motor
assembly. U.S.
Patent Nos. 6,062,026 and 5,867,987 disclose using various sensors to assist
the air charging
units during operations. However, the teachings of these references do not
support greater
diversity of sensors, sensor interconnection methods, methods of utilizing
sensor and sensor-
based information (e.g., with direct data, or other apparatus and methods
subassemblies). U.S.
Patent Nos. 5,560,208 and Reissued 36,609 disclose air charging mechanisms
with
interconnections to the engine (such as Element 40 in Figure 6). These
references, however, do
not disclose incorporation of engine controls, other vehicular subsystems,
diagnostic,
comfort/entertainment, communication, or human external controls into the
operation of a
method and apparatus that closely operates with considerations of power
modules, electric motor
subassembly management, and air flows' management. U.S. Patent No. 5,787,711
discloses the
incorporation of multiple air moving devices in a co-axial relationship. The
device of this
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reference does not incorporate connections to sensors and control logic to
manage the thermal
and operating needs of the device, nor does it teach availing the apparatus of
multiple sensor
feeds, actively able to manage both thermal and power considerations, and the
operating
characteristics of an electric motor subassembly. U.S. Patent Nos. 6,029,452;
6,182,449; and
6,205,787 disclose how various configurations of electric motor subassemblies
can be applied to
the air charging needs of two and four cylinder combustion engines (either
diesel or gasoline
powered). But these references do not teach providing a means to handle active
power
management with the operating characteristics of the electric motor
subassembly.
SUMMARY
[0015] The following summary is a simplified summary of the invention in order
to
provide a basic understanding of some of the aspects of the invention. This
summary is not
intended to identify key or critical elements of the invention or to define
the scope of the
invention.
[0016] Embodiments of the present invention are directed to unique and
innovative
solutions to the limitations and problems described above in the prior art
while preserving many
advantages for the consumer. Embodiments of the present invention are capable
of moving a
pressurized stream of air (air charging) at a high flow rate. The application
of a high velocity
mass air flow effector and computing apparatus and methods combine to accrue
new benefits to
applications/consumers by providing services and performance not available
with conventional
air actuator systems and methods. Operating the device with different inlet
and outlet
management, electric motor subassembly rotating and control settings also
provides for air flows
and beneficial effects.
[0017] Embodiments of the present invention may use and combine conventional
elements with unique and novel additions and improvements in order to solve
technological
limitations, as discussed above, in conventional systems and methods. The air
charging methods
and systems are preferably compatible with existing frameworks in
technological, legal,
regulatory, and cultural settings. The air charging methods and apparatus for
generating a high
velocity mass air flows may address one or more, if not all, of the
limitations cited in prior art
and others known to practitioners. The application of the device at other than
high velocity
flows may address other needs not met by extant devices.
[0018] The systems and methods for generation and management of high velocity
mass
air flows may be used by individuals and businesses in research, industry,
commercial, and
consumer applications for both applications requiring high velocity mass air
flow and for
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applications where space, power supply, and/or application system
considerations provide
benefits to users. The alternative operating modes at other than high velocity
flows expands the
applications for a single, or product family, of devices.
[0019] The installation of a specific embodiment of the invention into usage
is referred
to herein as an instantiation of the embodiment. The instantiation of an
embodiment may use
subsets of the complete embodiment's description in order to economize on a
specific function
(for an illustrative example, omitting active outlet management in some cases
where an engine
intake manifold already has said feature and this would be redundant and
duplicative). The
environment and situation of the usage of the embodiment is referred to as the
"platform."
Specific components of an embodiment are referred to "elements" or
"components."
[0020] One exemplary embodiment of the invention may include a power supply
module, an electric motor with an air effector in combination with a computer-
based apparatus
controller implementation employing computing equipment, software, and
(optionally) a
communications network.
[0021] Economies can be gained when applying more than one embodiment
(possibly a
plurality of embodiments on a single applications' platform) installed on the
same platform.
Shared control elements, shared power stores, shared maintenance spares, and
shared control of
dynamic behavior can yield results not otherwise found when multiple apparatus
of other
descriptions are applied. The capability of shedding demand on combustion
engine torque in
high demand situations is well known (illustrated by shutting down an air
condition compressor
during periods of high acceleration on a small engine, or variable power
assist mechanisms). In
analogous fashion, the use of shared control elements (connected logically or
physically) can
shed demand for power in embodiments of the invention in: high demand
situations according to
operational optimizations defined in the profiles for the devices' operation,
to meet the overall
operational needs (power, air charging, comfort, and others) across an entire
trip, or to operate
the device to meet specific high demands (such as meeting the needs for
generated power in a
high load condition for a hybrid). Physical locations for multiple devices on
a single platform
(illustrated by needs for multiple air charging or emissions control
embodiments in an engine
compartment, heating/ventilating embodiments for passenger compartment
comfort, battery/fuel
cell heating/ventilating, and heating/ventilating embodiments for
cargo/equipment
compartments) may be in multiple discrete areas, but the control elements of
the embodiments
may, or may not, communicate or interact with a plurality of the other
embodiments instantiated
on the same platform through communications media or other interactions
(illustrated below in
the exemplary embodiments). Multiple embodiments present for a single
application (such as
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multiple air charging devices on a single combustion engine) may interact in a
plurality of
instantiations with the greatest benefits found when control element, power
management, power
storage modules, or sensor connections are combined with operating profiles as
described more
fully in the detailed description of illustrative embodiments.
[0022] An exemplary embodiment for the support of applications of high
velocity mass
air flows include a system and apparatus that receives electrical power,
control signals (data
flows), and an intake media (normally, but not limited to, gases such as
ambient air, inert gases,
or other fluids where behavior is like an "air" or gaseous fluid flow).
Electrical power stored
within the unit's power module may be sufficient for some applications and
limited operations,
but certain applications may utilize an electrical power supply at some point
during a normal
operating cycle. Having a separate stored power capacity within the apparatus
also enables
capabilities for operational optimization and flexibility not available
without this integrated
feature. Control signals may be as limited as an on/off (e.g., switch
originated) signal, or may be
as complex as a communications network message that is interpreted by the
control apparatus as
a stimulus to initiate one or more operations. The control signals may flow
over media as simple
as an open or closed circuit, or the control signals may flow over a complex
communications
network mediated by one or more specialized electronic circuit apparatus and
that may utilize
linear, or non-linear, communications protocols to pass messages, sensor data,
meta-data, and the
like that is interpreted by the control apparatus as stimulus to perform one
or more operations
(that may be pre-defined or dynamically determined) to control the electric
motor, control valves
(optional), sensors (optional), and air effector.
[0023] According to another aspect of the invention, the power module,
containing in
the exemplary embodiments both a power management element and a power storage
element,
may have the capability of controlling, or cooperating in, the optimal and
flexible consumption
of power, power capacity, and power distribution for the entire platform where
the embodiment
is applied. Operating under the control of the Control Apparatus the Power
Module
Subassembly can conduct operations using a plurality of one or more power
sources; the Power
Module Subassembly can determine, or be controlled, optimal uses (or
conservation) of power
supply, power expenditure, or capacity (including recharge); and the Power
Module
Subassembly can act to provide safety features to the apparatus. Thus, in
instantiations of the
embodiment where multiple power sources (grid power, alternator/generator,
Power Storage
Module, auxiliary platform batteries, hybrid primary electrical storage, or
others) are present the
Power Module Subassembly can control, or cooperate in, the choice of power
supply (source
optimization), power expenditure (drain optimization), power capacity (overall
platform capacity
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and resource allocations such as recharging, recharge times, and priorities),
and power
distribution (source or drain optimization based on overall platform
distribution and utilization).
[0024] The "air effector" referred to throughout this application may be
considered as
one embodiment of a fluid/media flow device that is related to a transport or
movement that can
be described by fluid-dynamics. Thus, the "air effector" may include devices
otherwise
described with terms such as "wheels," "impellers," "propellers," "discs,"
"bladed assembly,"
"fan," "flow director," "mover," and the like. Preferred embodiments of the
invention may use a
close physical proximity between the electrical motor and the effector
subassembly. This may
also be the case with alternate embodiments described, but practitioners will
note that a larger
physical distance (coupled mechanically, pneumatically, magnetically, or in
other fashion)
accomplishes identical functions within exemplary method and control apparatus
configurations
of the invention. Embodiments of the invention may use other air effectors to
optimize for other
application design criteria (such as acoustic signature, component materials,
ease of field
maintenance, flow characteristics, etc.).
[0025] In like manner, the presence of sensors (such as, for example, in the
intake,
outflow, air effector housing, motor housing, or other positions on the
equipment; sensors may
also be placed environmentally or fed remotely to the control apparatus for
safety, feedback,
control, performance measurement, comparison, testing, device self-assessment,
or process
control purposes) may be optional in some applications, but most applications
are envisioned to
incorporate some sensor capabilities into the control apparatus handling to
assure proper
operations, safety of operation (e.g., to people and other facilities and
equipment), for optimal
operation, etc. Sensors in the preferred embodiments may include temperature
sensing, pressure
sensing, and electrical measurements. In alternative embodiments, a plurality
of sensors
measuring, for example, temperature, pressure, electrical, emissions, gas
composition, vibration,
acoustic signature, battery condition, fuel, historical sensor information,
engine conditions, etc.
may be components of the invention. Sensors providing control, monitoring,
historical, and
profile information to the apparatus can be direct data feeds from an engine
control module or
fuel control module; a direct sensor feed from a sensing apparatus (such as a
thermocouple,
accelerometer, coupling value, or diaphragm pressure sensor); an indirect
sensor access (such as
a bus or network connected sensor); a surrogate sensor feed (derived from
relayed or
preprocessed sensor data in another module); or inferred sensor data (produced
by observations
of other operating, environmental, or engine characteristics.
[0026] One exemplary embodiment of the present invention may include the
following
major component elements.
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[0027] An intake subassembly (element 1) that brings in the medium (normally
air as
has been described) and passes it into an air effector (element 2). The air
effector increases the
velocity (flow) and pressure, and therefore the mass air volume (over time),
from ambient
conditions to those desired in the application. This output is passed through
an outflow
subassembly (element 3).
[0028] Additional elements, obvious to practitioners, include filtering for
inflows and
outflows of the device in order to effect protection of the embodiments of the
invention and to
protect the application applying these airflows. As a safety feature there may
be sensors present
to indicate the absence of these filters and thus limit the automatic
operation of an embodiment
to safe conditions. Manual operation of the embodiments could include an
override mode when
the operation of the embodiment of the invention is less than optimal safety
conditions are
warranted due to larger application safety concerns or optimization.
[0029] Intake (inlet) and outflow (outlet) subassemblies occur in most
embodiments of
the invention to support optimization of airflow through the air effector
subassembly. The
plurality of components in the inlet and outlet subassemblies is illustrated
by instantiations
including diverter valves, active swirl assemblies in the inlet, outlet
directing vanes, active swirl
assemblies in the outlet, and the appropriate valves such as iris, servo, or
diaphragm types. Both
active and passive valves can be applied to inlet or outlet functions. Both
powered and
unpowered valves can be applied with solenoids or other powered mechanisms
used for valve
controls.
[0030] In another exemplary embodiment, the capability of an inlet control to
manage
the pre-swirl on a dynamic basis can alter the functional delivery of a mass
air flow to a very
different set of efficiency bands. In an exemplary embodiment the capability
of an outlet control
to manage the pre-swirl on a dynamic basis for the outflow going into another
component of a
multi-stage embodiment (thus it becomes the pre-swirl of the next stage) can
alter the functional
delivery of the mass air flow of the next stage of an application.
[0031] As an illustration of just one function, active outlet controls can be
used to
manage waste-gate functionality when the devices are operating at a higher
level than needed
instantaneously by the platform application. The control element may be
responsible for the
control of the outlet so that the embodied output of the air effector is used
for the optimal priority
selection of the platform application while maintaining the availability of a
high mass airflow
level for output on a demand basis. In an alternate embodiment this control
capability might be
shared with application control mechanism such that the embodiment's control
element
communicated with the application control mechanism to effect the waste gate
functionality.
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[0032] A power supply module (element 4) may pass power to an electric motor
(element 5) that drives the air effector (element 2). A control apparatus
(element 6) that may use
control loops, logic and decision-making capability, and communications with
the external
application environment to determine the sequence of events, controls the
power supply module
(element 4), the electric motor (element 5), and possibly controls element 1
and/or element 3 if
those elements are implemented as including controllable valves, cutoffs,
diverters, or other flow
management devices.
[0033] The inflow subassembly (element 1) may include a mechanical coupling
and
supply of air to transport. The outflow subassembly (element 3) may include a
mechanical
coupling and outlet for the air transported. The power module (element 4) may
include a
plurality of electrical storage devices, a continuing electrical supply input,
or other power source
(such as, for example, pneumatic, chemical, thermal, etc.) that can be
converted to its output
electrical power to be supplied.
[0034] The electric motor (element 5) may include a mechanical coupling be
made
linking the rotary action of the electric motor into the mechanical action
driving the air effector
(element 2). The control apparatus (element 6) may include control data flows
(such as, for
example, on/off, open/close, etc.) to be established and effective between it
and at minimum the
electric motor (element 5). Additional data flows between the control
apparatus (element 6) and
the intake and outflow subassemblies (elements 1 and 3) may take the form of
controls,
feedback, sensor measurements, or sequencing. The control apparatus (element
6) may also
receive, manage, control, integrate, and process data flows to and from the
sensors (element 7
through n, number not fixed), any external information (such as, for example,
control, feedback,
indirect sensor, safety, management, or meta-data such as rule parameters or
interpretive
information), and may use some or all of the available data to control and
manage the other
elements of the apparatus and process as embodied (such as, for example,
automated diagnostics,
safety management, power management, flow management, reporting, metrics,
controls for
licensing, etc.).
[0035] The motors used in the exemplary embodiments of the invention may be
sensorless brushless direct current motors. The selection of these motors
includes their
advantages of high speed, efficient power consumption, and compatibility with
operating
environments. However, in alternate embodiments of the invention, a wide
variety of motor
types can be used including sensored and sensorless motors, switched
reluctance, alternating
current motors, brushed/brushless motors, and others that meet the needs of a
specific
embodiment. The selection of a motor technology and its application in
embodiments of the
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invention may be supported by features in the control elements' use of
profiles and functional
isolation of the power and motor control sub-assemblies within the power
elements and control
elements. The selection, in an alternate embodiment, of a sensor based direct
current motor may
accommodate an applications' requirement of very fine shaft controls using
hall-effect or optical-
encoded sensors.
[0036] The motor controls used in the exemplary embodiments may be capable of
starting, stopping, running, and controlling the running of motors in small
increments. In an
embodiment of the invention using direct current motors, the rotation of the
motor may be
controlled by the motor controls to the extent that discrete electrical timing
pulses are handled by
the motor controls to cause the sequence of electrical events rotating the
shaft of the motor. This
level of motor control allows the control element to support multiple speeds
of rotation, different
motor startup and shutdown, different energy management settings in motor
operations, and
different motor diagnostics. In exemplary embodiments, the power module
supplying current to
the motor subassembly may also contain a plurality of active (e.g., current
limiters, electrical
supply conditioning and filters, and others) and passive (e.g., safety
interlocks against incorrect
wiring, keyed connectors, and others) safety features to protect the
embodiments operation.
[0037] The sensor(s) (element 7), may be emplaced in, around, or alongside the
physical elements of the apparatus. The sensor element(s) may measure various
parameters,
such as for example: temperature, pressure, operations of the electric motor,
the conditions of the
power storage component of the power module, element 4, the conditions of the
control
apparatus (such as internal temperatures to provide for a thermal shutoff if
needed), the
conditions of the environment (intake external ambient temperatures and
pressures), the possible
conditions at the outflow (temperatures, pressures, etc.), and the state of
control valves (intake
element 1, inside the air effector element 2 (if any), outflow element 3),
etc.
[0038] The physical packaging of different embodiments of the invention may
take
different forms that may be dictated by the application. The preferred
embodiment described,
and the alternate embodiments, provide for a variety of exemplary physical
packaging
configurations.
[0039] In heating, ventilating, and/or air cooling applications, packaging
advantages not
present in other air moving techniques may be found. An exemplary embodiment
may use a
highly compact 70 mm ducted-fan assembly controlled and powered by the
elements otherwise
described to replace a series of 200 mm blower assemblies. A separate
alternate embodiment for
an air exhaust application may apply the single 20 centimeter high velocity
air movement
configuration to replace multiple 20 centimeter blower assemblies.
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[0040] The computing apparatus that implements the control apparatus (element
6) can
be any of the configurations that support the set of environmental software
supporting the
application. The communications connections may include one or more linkages
to the local
application network (such as marine, automotive, building management,
appliance management,
local device network, point to point signaling, and the like), Internet (wide
area network), private
virtual networks, direct telecommunications connections, using wired,
wireless, or fiber-optic
media. It will be appreciated to those practicing in the art that the various
embodiments allow
for considerable flexibility in the configuration and deployment of the
control apparatus element.
The connections to sensors or sensing data can occur through a similar wide
variety of
communications mediums and exchange protocols.
[0041] The embodiment support transformational or transmitting functions may
include
a system and apparatus comprising a plurality of the control apparatus
operating environment as
described for support of various embodiments with additional capacity for
storage (such as
optical, magnetic, or solid state memory), systems capabilities (storage
management, system
management, operational and usage management, etc.), and specific interface
tasks (or
processes) residing in one or more physical (or virtual) operating
environments residing in one or
more systems and communications networks. The rule-based application software
codes specific
to embodiments of the invention may be invoked on the demand, or schedule, of
the operations
required and may incorporate functionality to log, audit, and validate all
conducted operations.
[0042] The embodiment support for functions supporting the system and
apparatus may
maintain a complete data trail for purposes of reporting regulatory
compliance, auditing,
marketing analytics, demographic analysis, performance/capacity management,
warranty
management, license management, customer service and the like. The system and
apparatus may
be additions to the capacities to operate the invention's embodiments in a
minimal application, or
with additional capacity and capability in the device controller to support
the processing,
transformations, transmissions that additional software modules (including
Report Writers,
performance and capacity analysis, log and audit trail analytics, compliance
checking, market
analyzers, and added demographic and verification subsystems, among others).
The support
functions can also be used to optimize customer experiences; provide
customization of operating
parameters, set points, and algorithms; and enforce compliance with operating,
regulatory, or
user preferences.
[0043] As is evident to practitioners of the art, the embodiments of invention
can also
be combined with other air-charging mechanisms. The combinations or
integration with other
air charging mechanisms can occur in a wide variety of applications
(illustrated, for example, by
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those in propulsion, stationary, mobile generators, rotary power generation,
industrial testing,
controlled combustion, and others). The physical interconnections of inlets,
outlets, and shared
or unique plenums, lead to a wide variety of possible combinations. The
logical operating
behavior of sequential (one or more operate in a sequence with others),
exclusive (solitary
operation excluding others), combined (simultaneous operations possibly at
different operating
behavior), shared (interdependent operations), staged (input of one possibly
dependent on one or
more others), or independent (operating without regard to others) also lead to
a wide variety of
possible combinations. The dynamic control of multiple embodiments of an
invention
concurrently in the same applications platform (illustrated, for example, by
the use of multiple
high velocity mass air flow devices outputting to a single output plenum to
increase the total
flow available for an application), with the instantiation of the invention
using a plurality of
elements (illustrated, for example, by multiple power storage modules,
multiple sensors, multiple
motors, or multiple inlet/outlet controls) is also within the embodiments of
the invention. The
presence of additional elements (illustrated, for example, by redundant
control elements,
redundant sensors, redundant interconnections, redundant power modules, or
redundant
motor/effector assemblies) for fault tolerance, high availability, high
capacity, or high capability
instantiations is also contemplated in those instantiations of embodiments of
the invention where
the application requires those qualities.
[0044] Additional features and advantages of the invention will be made
apparent from
the following detailed description of illustrative embodiments that proceeds
with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The foregoing summary, as well as the following detailed description of
preferred embodiments, is better understood when read in conjunction with the
appended
drawings. For the purpose of illustrating the invention, there is shown in the
drawings exemplary
constructions of the invention; however, the invention is not limited to the
specific methods and
instrumentalities disclosed. Included in the drawing are the following
Figures:
[0046] Figure 1 is a block diagram illustrating an overview of an exemplary
system and
major elements to provide generation of high velocity mass air flows in
accordance with the
present invention;
[0047] Figure 2 is a cutaway view showing an exemplary electric motor and air
effector;
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[0048] Figure 3 is a flowchart illustrating an exemplary process and logical
organization to provide generation of high velocity mass air flows;
[0049] Figure 4 is a partial cutaway view showing an exemplary apparatus for
generating high velocity mass air flows;
[0050] Figure 5 is a cutaway view showing another exemplary apparatus for
generating
high velocity mass air flows;
[0051] Figure 6 is a block diagram illustrating an exemplary hybrid electrical
and
combustion engine having a mass air flow device;
[0052] Figure 7 is an example of an embodiment of the invention on an internal
combustion engine platform including a hybrid engine and electrical power
drive;
[0053] Figure 8 is an example of an embodiment of the invention on an internal
combustion engine platform including a combustion engine turbocharger;
[0054] Figure 9 is an example of an embodiment of the invention acting as an
air-
charging device for an internal combustion engine platform;
[0055] Figure 10 is an example of an embodiment of the invention including a
bypass
valve subassembly;
[0056] Figure 11 is a simplified drawing focusing on the functional placement
of
elements of an embodiment in an air moving application;
[0057] Figure 12 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform including dual superchargers;
[0058] Figure 13 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform with a parallel installation of an
embodiment of an air-
charging effector and a turbocharger;
[0059] Figure 14 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform with multistage supercharging;
[0060] Figure 15 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform with parallel turbocharging;
[0061] Figure 16 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform with secondary air injection into engine
gas recirculation;
[0062] Figure 17 is an example of an embodiment of the invention as applied to
an
internal combustion engine platform with secondary air injection into the
exhaust catalytic
assembly;
[0063] Figure 18 is an example of an exemplary embodiment of a power source
module
and power storage devices;
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[0064] Figure 19 is an example of an embodiment of the invention as applied to
the
application of warming a hybrid vehicle battery compartment;
[0065] Figure 20 is an example of an embodiment of the invention as applied to
the
application of warming a vehicle's interior passenger, cargo, or electronics
compartments;
[0066] Figure 21 is an example of an embodiment of the invention as applied to
the
application of cooling a hybrid vehicle battery compartment;
[0067] Figure 22 is an example of the embodiment of the invention as applied
to the
application of cooling a vehicle's interior passenger, cargo, or electronics
compartments;
[0068] Figure 23 is an example of an embodiment of the invention as applied to
the
application of inflating or deflating a plenum of air;
[0069] Figure 24 is an example of an embodiment of the invention applied to an
airflow
such as those found in a heating, ventilating, or air conditioning
application;
[0070] Figure 25 is an example where multiple embodiments are applied for
multiple
uses in a single platform exploitation of the invention's different
capabilities;
[0071] Figure 26 is an example of an embodiment where the instantiation of the
apparatus and method is used to cool a space containing an internal combustion
engine;
[0072] Figure 27 is an example of an embodiment where the instantiation of the
apparatus and method is used to warm a space during adverse conditions;
[0073] Figures 28, 29, and 30 illustrate different hybrid, plug-in type
hybrid, and pure
type hybrid vehicle platforms;
[0074] Figure 31 is an example view of exemplary apparatus for inlet controls;
[0075] Figure 32 is an example view of exemplary apparatus for outlet
controls;
[0076] Figure 33 is a very simple exemplary connection of a sensor directly
into the
Control element of the invention;
[0077] Figure 34 is an illustrative example of the acquisition of a sensor
value into the
Control element of the invention;
[0078] Figure 35 shows an illustrative example sensor, for pressure,
communicating
with the Control element via a sensor, or sensor data, multiplexor interface;
[0079] Figure 36 shows an illustrative example sensor, for pressure,
communicating
with the Control element via a local application platform network;
[0080] Figure 37 shows an exemplary interconnection of the local platform
application
control units to the Control element;
[0081] Figure 38 shows an exemplary interconnection of indirect controls to
the Control
element of the invention;
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[0082] Figure 39 shows an exemplary interconnection of indirect controls to
the
Control element of the invention;
[0083] Figure 40 shows the addition of the electrical and communications
methods to
access desired data via local network, or bus, monitoring;
[0084] Figure 41 shows an exemplary interconnection from the identification or
metadata sources in the local application platform to the Control element;
[0085] Figure 42 shows an exemplary interconnection from the diagnostic,
archive,
data logging, or other stored data values within the local application
platform;
[0086] Figure 43 shows an exemplary interconnection of the User Profile data
with the
Control element of the embodiment of the invention via a communication media
such as a
network;
[0087] Figure 44 shows an exemplary interconnection of User Profile data with
the
Control element of the embodiment of the invention directly into the unit;
[0088] Figure 45 shows an exemplary interconnection of emissions sensor data
with the
Control element of the embodiment of the invention via a network interface;
[0089] Figure 46 is the interconnection of a predictive unit with the Control
element of
the embodiment of the invention via a network interface; and
[0090] Figure 47 shows an exemplary interconnection of human input through a
user
interface, and then via a plurality of communications media, protocols, and
connections present;
to the Control element of the embodiment of the invention.
DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS
[0091] The present invention includes embodiments of systems and methods for
the
generation of high velocity mass air flows, or designed air flows, for use in
the combustion
elements of a hybrid combustion-electric vehicle.
[0092] The present invention includes embodiments of systems and methods for
the
generation of high velocity mass air flows, or designed air flows, for use in
the combustion
support elements of a hybrid combustion-electric vehicle.
[0093] The present invention also includes embodiments of systems and methods
for
the generation of high velocity mass air flows, or designed air flows, for use
in the electrical
elements of a hybrid combustion-electric vehicle for cooling applications.
[0094] The present invention also includes several exemplary embodiments of
systems
and methods for the generation of high velocity mass air flows, or designed
air flows, for use in
the electrical elements of a hybrid combustion-electric vehicle for heating
applications.
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[0095] Also, the present invention includes embodiments of systems and methods
for
the generation of high velocity mass air flows, or designed air flows, for use
in the passenger
elements of a hybrid combustion-electric vehicle for cooling applications.
[0096] In addition, the present invention includes embodiments of systems and
methods
for the generation of high velocity mass air flows, or designed air flows, for
use in the passenger
elements of a hybrid combustion-electric vehicle for heating applications.
[0097] The present invention also includes embodiments of systems and methods
for
generation of high velocity mass air flows, or designed air flows, for use in
the operation of an
internal combustion-engine vehicle propulsion operations.
[0098] The present invention may also includes embodiments of systems and
methods
for generation of high velocity mass air flows, or designed air flows, for use
in the operation of
an internal combustion-engine used in stationary operations.
[0099] Exemplary embodiments can be applied to vehicular propulsion, vehicular
power generation, stationary, and marine platforms where internal combustion
engines are used.
Although there are variances in the platform environments, platform controls,
and operating
patterns the usage of embodiments of the invention possess high levels of
commonality. In
propulsion, vehicular power generation, marine propulsion, marine power
generation, and
stationary generator operations the internal combustion engines often require
air charging. The
presence of air charging subsystems in these platforms, such as turbochargers,
superchargers,
compressed air subsystems, and the like, have direct instances where the
embodiments of the
application can be instantiated. The combinations and integration of the air
charging features of
embodiments of the invention and the extant air charging equipment is similar
(by illustration
multi-stage turbocharging, multi-stage supercharging, parallel turbocharging,
or secondary air
injection). The platform controls may vary in specific implementation (for
example, CAN bus
vehicular applications share many characteristics with NMEA marine
applications) but the
operating requirements of the platform controls remains highly similar (such
as stationary
Modbus or control-loop). Operating patterns are also highly similar in subtle,
but important,
ways when viewing power management and local power storage module elements of
the
embodiments of the invention. For vehicular power generation and stationary
generator uses
multiple managed power sources are common operating pattern requirements. In a
vehicle the
managed capacity and power expenditure controls for the primary electrical
storage component
has very high commonality of operating patterns with a stationary generator
coupled with an
uninterruptible power supply electrical storage component. The commonality of
applications
platform requirements lead to instantiations of the embodiments of the
invention that are
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functionally the same even though the platform environments vary as to
location. Although
embodiments of the invention are discussed with particular application to
vehicular, stationary,
marine, or other platforms it is obvious to practitioners that the embodiments
can be applied to
other platforms without change of the novel and unique features of the
invention from which the
benefits derive.
[0100] Moreover, the present invention may include embodiments of systems and
methods for generation of high velocity mass air flows, or designed air flows,
for use in the
operation of emissions control functions used for internal combustion engines.
In these
embodiments the invention is applied to the supply of air, on a designed or
demand basis, to the
emissions control functions used for internal combustion engines. The uses of
air include the
secondary air injection into an exhaust gas stream for cooling or
pressurization prior to
recirculation into the intake manifold or air intake of an internal combustion
engine. Secondary
air injection for purposes of continued reaction (or burning) of residual fuel
in the exhaust stream
(particularly of engines without sophisticated fuel management) can greatly
assist in the
reduction of emissions of unburned fuel and the capture of additional thermal
energy for
application (illustrated by embodiments used in multi-stage combustion
systems). An exemplary
embodiment shown in Figure 17 is the use of an embodiment of the invention,
either on a
dedicated or shared basis, to supply secondary air injection into the
catalytic converter assembly
for a plurality of requirements such as pre-heating, accelerating heating to
an operating
temperature, and supply of additional air into the assembly for optimal
operating conditions.
[0101] The present invention also includes systems and methods for the
generation of
high velocity mass air flows. The systems and methods are capable of moving a
pressurized
stream of air (i.e., air charging) at a high flow rate. For purposes of the
described embodiments,
the general design point for the exemplary devices described are at about 1000
torr, and about
1,000,000 cc/min air flow. Exemplary devices may show a mass air flow of about
28 gm/sec or
more when running at full operational potential. Alternate embodiments with
other air effectors
(such as those used in an axial flow configuration) may operate a design point
up to 50,000,000
cc/min air flow and 100 torr.
[0102] In contrast to existing devices, such as centrifugal blowers, large
diameter fans,
or other air movement actuators, certain preferred embodiments may share a
common set of form
factors that generally fall within a roughly cylindrical package approximately
22 centimeters in
diameter and 15 centimeters in length. Associated electrical power
subassemblies (including the
secondary apparatus power storage devices and power control), apparatus
control electronics,
and connections for such a unit may be packaged to fit an enclosure (that may
be physically
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proximate and/or separated) approximately 15 centimeters in length, 10
centimeters in width, and
7.5 centimeters in depth. Existing devices of similar capabilities may require
a cylindrical
mechanical package of approximately 25 centimeters in diameter and 25
centimeters in length,
accompanied by electrical components 32 centimeters in length, 26 centimeters
in width, and 15
centimeters in depth. If mechanical and electrical components are packaged
separately, they
may be connected by one or more cables for power, sensor, and control
transmission. For
alternate embodiments, an environmentally appropriate implementation of
electrical, sensor, and
control modules may be integrated into the mechanical assembly design with
minimal effect on
the overall size of the mechanical assembly. Additional alternate embodiments
for applications
requiring smaller mass air flows or pressures of air movement, where
applications, may be
fulfilled by sub-optimal operation, may also vary in size and packaging (for
example, such
variance may be due to the smaller needs of an air effector, smaller or larger
inlet/outlet modules,
or the presence of multiple copies of an element). Also, where alternate power
or control
provisioning applies, alternate embodiment may allow instantiations where both
mechanical and
electrical assemblies may be reduced in size by up to about 50%. Scaling for
larger assemblies is
also possible in alternate embodiments for different demands. In addition to
the clear
functionality and energy management benefits obtained by developing a new
embodiment of the
invention the packaging of the invention saw a reduction of more than 80% of
the size of the
prior product family's controller and a reduction of more than 80% of the new
motor
technologies are incorporated herein. For smaller axial flow units not
requiring collectors or
volutes the reduction in size and packaging involved are more than 50%. For
such units,
actuators may fall into a cylindrical form factor 12 centimeters in diameter
and 15 centimeters in
length or smaller.
[0103] In some applications the ability to control and regulate the product of
a high air
flow at a pressure may be more important than the need to run at peak
efficiency. Exemplary
embodiments of the invention may have the ability to be applied even at sub-
optimal
efficiencies, or at much lower mechanical stress, to meet a specific
application need (such as a
requirement at specific parts of the operating range). Thus, the operation of
the units at sub-
optimal levels may be one characteristic of the innovation that adds to its
unique character. A
specific use of this capability is to operate in a sub-optimal mode to develop
a temperature
variant air flow for applications.
[0104] Referring now to Figure 1, there is illustrated an overview of an
exemplary
system 100 in accordance with the present invention. Figure 1 shows the major
component
elements that may comprise system 100, including intake subassembly 1, air
effector
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subassembly 2, outflow subassembly 3, power module subassembly 4, electric
motor
subassembly 5, control apparatus subassembly 6, and sensor(s) elements 7.
[0105] Intake subassembly 1 brings in a medium (normally air as has been
described)
and passes the medium into the air effector 2. The air effector 2 increases
the velocity (flow) and
pressure, and therefore the mass air volume (over time), from ambient
conditions to those desired
in the application. This output is passed through the outflow subassembly 3.
[0106] The power supply module 4 passes power to the electric motor 5 that
drives the
air effector 2. Control apparatus 6 may, for example, include control loops,
logic and decision
making capability, and communications with the external application
environment to determine
the sequence of events, control the power supply module 4, the electric motor
5, and may
possibly control the intake element 1 and/or outlet element 3 if, for example,
those elements are
implemented as including controllable valves, cutoffs, diverters, or other
flow management
devices.
[0107] The inflow subassembly 1 may include a mechanical coupling and supply
of air
to transport. The outflow subassembly 3 may include a mechanical coupling and
outlet for the
air transported. The power module 4 may include a plurality of electrical
storage devices, a
continuing electrical supply input, or other power source (such as, for
example, pneumatic,
chemical, thermal, etc.) that can be converted to an output electrical power
to be supplied.
[0108] The electric motor 5 may include a mechanical coupling linking the
rotary
action of the electric motor into the mechanical action driving the air
effector 2. The control
apparatus 6 may include control data flows (such as, for example, on/off,
open/close, etc.) to be
established and effective between the control apparatus 6 and the electric
motor 5. Additional
data flows between the control apparatus 6 and the intake and outflow
subassemblies (elements 1
and 3) may take the form of controls, feedback, sensor measurements, or
sequencing. The
control apparatus 6 may also receive, manage, control, integrate, and process
data flows to and
from the sensors (element 7 through n, number not fixed), any external
information (such as, for
example, control, feedback, indirect sensor, safety, management, or meta-data
such as rule
parameters or interpretive information), and may use some or all of the
available data to control
and manage the other elements of the apparatus and process as embodied (such
as, for example,
automated diagnostics, safety management, power management, flow management,
reporting,
metrics, controls for licensing, etc.).
[0109] The sensor(s) 7 may be emplaced in, around, or alongside the physical
elements
of the apparatus. The sensor element(s) may measure various parameters, such
as for example:
temperature, pressure, operations of the electric motor, the conditions of the
power storage
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component of the power module, element 4, the conditions of the control
apparatus (such as
internal temperatures to provide for a thermal shutoff if needed), the
conditions of the
environment (intake external ambient temperatures and pressures), the possible
conditions at the
outflow (temperatures, pressures, etc.), and the state of control valves
(intake element 1, inside
the air effector element 2 (if any), outflow element 3), etc.
[0110] The physical packaging of different embodiments of the invention may
take
different forms that may be dictated by the application. The preferred
embodiment described,
and the alternate embodiments, provide for a variety of exemplary physical
packaging
configurations.
[0111] The computing apparatus that implements the control apparatus 6 can be
any of
the configurations that support the set of environmental software supporting
the application. The
communications connections may include one or more linkages to the local
application network
(such as marine, automotive, building management, appliance management, local
device
network, point to point signaling, and the like), Internet (wide area
network), private virtual
networks, direct telecommunications connections, using wired, wireless, or
fiber-optic media. It
will be appreciated to those practicing in the art that the various
embodiments allow for
considerable flexibility in the configuration and deployment of the control
apparatus element.
The connections to sensors or sensing data can occur through a similar wide
variety of
communications mediums and exchange protocols.
[0112] An embodiment supporting transformational or transmitting functions may
include a system and apparatus comprising a plurality of the control apparatus
operating
environment as described for support of the invention embodiments with
additional capacity for
storage (such as optical, magnetic, or solid state memory), systems
capabilities (storage
management, system management, operational and usage management, etc.), and
specific
interface tasks (or processes) residing in one or more physical (or virtual)
operating
environments residing in one or more systems and communications networks. The
rule-based
application software codes specific to the invention may be invoked on the
demand, or schedule,
of the operations required and may incorporate functionality to log, audit,
and validate all
conducted operations.
[0113] The embodiment support for required functions supporting the system and
apparatus may maintain a complete data trail for purposes of reporting
regulatory compliance,
auditing, marketing analytics, demographic analysis, performance/capacity
management,
warranty management, license management, and customer service. The system and
apparatus
may be additions to the capacities to operate the invention's embodiments in a
minimal
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application, or with additional capacity and capability in the device
controller to support the
processing, transformations, transmissions that additional software modules
(including Report
Writers, performance and capacity analysis, log and audit trail analytics,
compliance checking,
market analyzers, and added demographic and verification subsystems, among
others) provide
these functions in support of the invention. The support functions can also be
used to optimize
customer experiences; provide customization of operating parameters, set-
points, and algorithms;
and enforce compliance with operating, regulatory, or user preferences.
[0114] Figure 2 illustrates further details of an exemplary system and depicts
a cross-
sectional view of system 100 showing elements and related sub-elements. As
shown in Figure 2,
an electric motor 5 and air effector 2 may be housed in a housing 245. Intake
subassembly 1
may include an air intake 200. Air effector subassembly 2 may include an air
effector 250.
Outflow subassembly 3 may include an air outlet 280. Electric motor
subassembly 5 may
include an electric motor 240. As shown, the electric motor and air effector
subassembly
housing 245 holds both the electric motor 240 and the air effector 250. The
power and control
cable 300 connects to an external control apparatus (not shown) and power
module subassembly
(not shown). The additional mechanical attachments for the rotational shaft
linking the electric
motor 240 and air effector 250 may include support and bearing subassembly
310. The
illustrated embodiment has the advantages of a very compact form factor
packaging, cooling air
drawn across the electrical motor and control apparatus assembly, and ability
to integrate sensors
into a compact design as required. Figure 2 shows one possible configuration
of the power
module subassembly 4 and electric motor subassembly 5.
[0115] Figure 3 provides a flowchart of an exemplary logical organization and
flow of
data during operation of the system 100. The major component elements shown in
the overview
of Figure 1 are shown in Figure 3 with associated data flows to illustrate
both the relationships
and data flows on a more dynamic representational basis.
[0116] In operation, a flow of air, or other fluid flow, through the unit, as
described in a
simplified fashion through the intake subassembly, air effector subassembly,
and outlet
subassembly, component elements 1, 2, and 3 (see Figure 1). The flow of air
follows the path
depicted in Figure 3 from an air intake 100, and then successively through a
control valve
subassembly (intake) 200, past a sensor subassembly (intake) 300, past an air
charging motor
subassembly 400 (optionally, this may not be present in all embodiments), the
air charging
effector subassembly 500, past a sensor subassembly (outflow) 600, and then
through a control
valve subassembly (outflow) 700 before exiting the apparatus 100 through the
air outflow 800.
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[0117] In several embodiments, the complexity and presence of the sensor
subassembly
(intake) 300 and sensor subassembly (outflow) 600 will depend on the needs of
the application
and the types of data that need to be collected for the apparatus controller
subassembly's 900
handling. In similar fashion the need for actuators, controlled from the
apparatus controller
subassembly 900, may vary in the control valve subassembly (intake) 200 and
control valve
subassembly (outflow) 700. In some embodiments, actuators in these units 200,
700 may need to
divert airflows, change which of the application choices for inflows or
outflows is selected, or
assure the safe operation of the unit. As one simple example, the closure of
these valves may be
effected simply to reduce, or eliminate, continued exposure to marine (salt)
conditions when the
unit is not used on a frequent basis. In similar fashion the control valve
subassembly 200 could
allow for selection of tanked, pressurized, or pre-cleaned gas flows (such as
for material handling
hoods) instead of ambient air. In similar fashion the control valve
subassembly 700 could select
an outflow direction that varies depending on whether the airflow was used to
purge a chamber
of gas or simply exit a waste gate. In a very simple embodiment application
the air intake 100
and control valve subassembly in combination can be combined to select for an
application
choice to inflate or deflate a variable chamber of a gas or air (with
coordination of the control
valve subassembly 700 and air outflow 800). Along with connections to the
source and
destinations of flow that may be appreciated to practitioners the invention is
capable of providing
for high velocity air charge for a variety of applications.
[0118] The various data flows communicating control, sensor data, feedback,
management information, component configuration, component operating state
information,
error conditions, warning conditions, and other information may be shown with
the logical
directions of exemplary data flows for embodiments of the invention (shown in
Figure 3, for
example, with primary respect to the apparatus controller subassembly 900).
The embodiments
of the invention provide for many different sensor connections and the ability
of the apparatus
controller subassembly 900 to access, communicate, manage, or interact in a
variety of fashions
(see e.g., Figures 33 through 47). As may be appreciated to practitioners, the
low-level
communications mechanisms are in many, if not most, cases bidirectional in a
communications
sequence of events dictated by a communications protocol. Examples of these
communications'
content include:
1) sensors may include presets for data scaling or sensitivity 300, 400, 600,
1000, 1200,
1300, 1400, 1600;
2) control valves may report current operating states and conditions 200, 700,
1100,
1700;
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3) the power source module 1000 may report the conditions of stored power,
operating
capacities, and diagnostic information; and
4) the apparatus and controller subassembly 900 may need a connection to
external
applications configuration 1800.
[0119] The physical embodiments that connect these logical components of the
invention may pass data over many possible physical connection media including
wired,
wireless, fiber-optic, common signaling media, through integrated sensor
loops, or the like.
Embodiments of the invention may be constrained to any particular physical
embodiment that
creates and maintains the physical connection media. This may be an important
consideration in
certain embodiments because the application of the invention may require that
it operate in an
integrated functional configuration where a vehicle, marine, avionic,
appliance, alarm, power
management, building management, factory integration, data collection, or
other multiple device
connection (network or standalone) in a wide range of connection topologies
(such as bus, star,
point-to-point, relay, message passing, or routed mesh) are applied for the
entire application.
The advantages of integrating the available apparatus controller subassembly
900 into a larger
set of physical and logical connections (shown as the control data flows and
external interfaces
1800) to control, manage, diagnose, acquire the data, or provide a regulated
function for the
invention are beneficial.
[0120] Another application shown in Figure 3 may be the role and composition
of the
power source module 1000. The power source module 1000 supplies electrical
current (in
certain applications one or more feeds of DC power) to the air charging motor
subassembly 400
and to the apparatus controller subassembly 900. Other embodiments may also
supply the sensor
subassembly (intake) 300, the sensor subassembly (outflow) 600, the control
valve subassembly
(intake) 200 (if powered), the control valve subassembly (outflow) 700 (if
powered), and the
control data flows and external interfaces 1800 (if required) from the power
source module 1000
as well.
[0121] As previously discussed with respect to some embodiments, the apparatus
may
retain the capability to locally supply the DC power from one or more power
storage modules
(not shown). In addition, the capability to bypass the power storage modules
(optionally in a
specific embodiment), have multiple supply paths for energy to be converted or
supplied through
the power source module 1000 to the air charging motor subassembly 400, and be
able to
control, manage, report, and diagnose these features from the apparatus
controller subassembly
900, provides other advantages unique to this invention. Power storage
components managed by
the power source module 1000 may be with, or without, internal capabilities
providing data (such
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as, for example, manufacturer, model, serial number, cumulative usage, current
capacity levels,
etc.).
[0122] The capability to convert multiple supply energy sources to DC power
(for
example, but not limited to, AC power, DC power at a different voltage,
pneumatic power,
chemical energy, thermal energy, an induction power supply, etc.) provides for
high levels of
flexibility and options for continued operations by the user. An example of
this multi-source
capability is the availability of either AC power (in various voltages,
phases, and amperages), or
DC power (in a mobile power plant supply feed) that may then be conditioned
(e.g., rectified)
appropriately to provide operating charge to the power storage capacity. The
technology
enabling the power storage module can be a simple rechargeable battery
technology (including
choices such as Ni-Cad, Lead-Acid, Li-Ion, NMH, and others), or a different
form such as a
super-capacitor, fuel cell, wet cell, thin metal film cell, etc.
[0123] A design priority for the power source module 1000 may be that it can
provide a
consistent sensor and control data flows 1400 for the apparatus controller
subassembly 900. This
can be accomplished while providing a power flow 1500 to the air charging
motor subassembly
400 that is better conditioned (e.g., clean and consistent) than externally-
supplied power. In
some applications this may be modified to meet lower requirements for some
embodiments, but
other embodiments will use this capability to provide power source module 1000
alternatives for
user application configuration. Thus, a single embodiment may have multiple
models or product
family members depending on the application configurations for power supply.
[0124] An example of a preferred embodiment of the power source module 1000 is
the
use of Boulder Technologies GP100TMFSC batteries in the 12-V (or 24-V)
configuration to
provide a power source that is mediated using a current limiter and power
sensing circuit. This
preferred embodiment provides local storage capacity for the power source
module 1000 and
resources to be managed by apparatus controller 900.
[0125] Another characteristic of the exemplary systems and methods described
is the
ability to use power sources, such as those described in the preferred
embodiment, or others, to
provide a power source that is independent of external power sources and that
is under the direct
control of the apparatus controller subassembly that can optimize its power
expenditure while
having closely monitored operations. This feature may allow an embodiment to
apply the use of
a local power supply, not required to support other functions outside the air-
moving application,
that can be used to overcome in-rush current requirements, manage outage
conditions (such as
after-cooling), and handle control actuation needs to self-protect the entire
air handling
apparatus.
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[0126] The apparatus controller subassembly 900 may use the information from
the
sensor and control data flows for motor 1300 and the sensor and control data
flows 1400 from
the power source module 1000 to determine appropriate operations, sequencing,
and control
processes for the invention. In turn, the power source module 1000 may
incorporate current
limiters, programmable power management, or other active electrical energy
management that
provide for the system to be efficient with its utilization of electrical
power and supplies. Use of
up-line supply sensing (not shown) can also be integrated into embodiments of
the invention to
supply some applications considerations such as hot switching, hot unplugging,
or cold
attachments. The application of the highly intelligent apparatus controller
subassembly may
provide the above described advantages, and others, over extant applications
within the state of
art and practice.
[0127] Figure 4 illustrates an exemplary apparatus for generation of high
velocity mass
air flow. Figure 4 shows the air charging motor subassembly 400, from the
drawing for Figure 3,
along with a set of connected components. In this embodiment the air inflow
110 is equivalent
to the air intake 100 in Figure 3. The air charging effector and motor housing
145 holds the air
charging effector subassembly 150 and the air charging motor subassembly 140.
The air
charging effector subassembly 150 corresponds to the air charging effector
subassembly 500 in
Figure 3. The air charging motor subassembly 140 corresponds to the air
charging motor
subassembly 400 in Figure 3. The air outflow 180 corresponds to the air
outflow 800 in Figure
3. The cable for apparatus controller and power 190 corresponds to the
physical connection
alluded to by the block diagram elements sensor and control data flows for
motor 1300 in Figure
3, the power flow 1500 in Figure 3, and sensors integrated into the housing or
the air charging
motor subassembly (not shown).
[0128] In this preferred embodiment, the air charging effector subassembly 150
contains an air charging wheel that pressurizes and accelerates air to meet
the applications needs
for a high velocity mass air flow. In other embodiments the air charging
effector subassembly
150 may contain other air flow effector devices. In Figure 4, the air charging
wheel may be
driven by an electric motor where the electric motor shaft may be directly
coupled in-line with
the air charging wheel. The apparatus controller subassembly is normally held
in a separate
enclosure that may incorporate additional sealing (for environmental
protection), cooling,
connectors, interfaces, or external interfaces. The apparatus controller
subassembly may also
contain the power source module or this may be enclosed separately depending
on the physical
mounting for the invention.
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[0129] The apparatus controller subassembly 900 may include the ability to
interact
with the power source module 1000 to control the deployment of the power
source in a manner
consistent with a series of profiles, or user demand characteristics, that are
supported by the
operation of the apparatus controller subassembly. The apparatus controller
subassembly may be
capable of operating certain functions of the invention on an autonomous basis
(for example, for
manufacturing testing, field diagnostics, failure/fallback operations,
application system
diagnostics, maintenance functions, and the like) or under the direction of
the external flows
through the control and data flows from external interfaces 1800. In a
preferred embodiment,
this may be transported across an application-network such as NMEA 2000. Other
transport
could be via CAN, IEEE 802, IEEE 1394, or the like.
[0130] The thermal management 195 provisions for some embodiments may be
relatively simple. In more complex embodiments there may be active, or
passive,
heating/cooling thermal management provisions that may be managed by the
apparatus
controller subassembly based on sensor, operating, design, or application
requirements.
[0131] In the normal operation of preferred embodiments, the duty cycle of the
unit
may be either continuous or intermittent (regular or irregular cycles,
depending on the
application needs). This characteristic may be true of some embodiments, and
driven by a unit
interfacing with the apparatus controller subassembly.
[0132] Figure 5 illustrates another exemplary embodiment of an apparatus for
generating a high velocity mass air flow. As shown in Figure 5, the air
charging motor and air
effector subassemblies housing 45 may be directly connected to the apparatus
controller housing
95. The power source model is not shown. The air intake 10 corresponds to the
logical
functions shown as the air intake 100 in Figure 3. The air intake 10 allows
the flow of air across
the baseplate for the apparatus controller subassembly and across the air
charging motor and air
effector subassembly providing a mechanism for integrated cooling and heat
dissipation. The air
outflow 80 corresponds to the logical functions shown as the air outflow 800
in Figure 3. The air
charging motor subassembly 40 and the integrated sensors that correspond to
the sensor and
control data flow for motor 1300 in Figure 3 are in the same housing as the
air effector
subassembly 50. A connector for control sensors, data flow, and external
interfaces 180 is also
shown. The power source module (not shown) may also feed information back to
the apparatus
controller subassembly 90 and power is locally transformed through the
apparatus controller
subassembly's 90 control.
[0133] In this alternate embodiment, the integration of the apparatus
controller
subassembly 90 suppresses additional costs in the cabling, attachment, and
support of the
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invention in more than one packaging article. The power supply module 100
cables can allow
for simplifying the power supply module 100 to eliminate the stored power
configuration if the
lowest possible price-point is a highly desired design requirement.
[0134] This embodiment has the advantages of a very compact form factor
packaging,
cooling air drawn across the electrical motor and control apparatus assembly,
and ability to
integrate sensors into a compact design if needed. This alternate embodiment
shows that the
physical packaging for the invention can vary across embodiments.
[0135] Other features, advantages, and benefits are described below. In
accordance
with another aspect of the present invention(s), the methods and systems allow
for a user to
obtain a high velocity mass air flow while the user retains control of the
operation of the
apparatus.
[0136] In accordance with another aspect of the invention, the methods and
systems
allow for the user to obtain a high velocity mass air flow that utilizes a
power module
subassembly that is integrated into the control of the control apparatus
element.
[0137] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow that can be controlled externally in an application
through the application
of a highly capable control apparatus.
[0138] In accordance with yet another aspect of the invention, the methods and
systems
allow the user to obtain a high velocity mass air flow where the apparatus
controller is capable of
controlling a plurality of an electric motor, power supply module, thermal
management, control
valves, and sensors.
[0139] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow that can use sensor, or sensor based, information for
control of the
apparatus.
[0140] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow that is controlled by a control apparatus capable of
determining
appropriate functional and environmental, operating and non-operating
conditions and modes
that protect the safety of the apparatus.
[0141] In accordance with another aspect of the invention, the methods and
systems
allow for the user to obtain a high velocity mass air flow that is controlled
by a control apparatus
capable of determining appropriate functional and environmental operating
conditions and
modes that enable automatic operational and performance adjustment of the
apparatus.
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[0142] In accordance with another aspect of the invention, the methods and
systems
allow for the user to obtain a high velocity mass air flow that utilizes an
electric motor, coupled
to an air effector, powered by a power module detached from a continuous
supply of power.
[0143] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow that utilizes an electric motor, coupled to an air
effector, where the unit
may be directly connected to an electrical, or other, power source external to
the unit, and where
the unit can operate, in a different operating mode, without the direct
provision of such a power
source.
[0144] In accordance with another aspect of the invention, the methods and
systems
allow for the user to obtain a high velocity air mass flow that utilizes an
electric motor, coupled
to an air effector, where the unit may be directly connected to an electrical,
or other, power
source external to the unit, and where the unit can operate in a mode that
provides supplemental
power to the unit when power demand exceeds the external power source supply.
[0145] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow where the information on these activities is relayed
for purposes of audit,
control, management, assessment, compliance or examination.
[0146] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow where the data from the operation of the unit can
provide diagnostic,
operating history, sensor measurements, or other metrics from the unit as part
of controlled
operation.
[0147] According to another aspect of the invention, the user may obtain a
high
velocity mass air flow where the information on these activities is processed
by an apparatus
(that may include human participation) to determine if compliance with "terms
and conditions of
use" (internal compliance), contractual compliance, regulatory compliance
(compliance with
administrative or cooperative regulations), and legal compliance (by statute,
treaty, or common
law) has been appropriate and as specified.
[0148] In accordance with another aspect of the invention, the methods and
systems
provide for the safe operation of the unit that is governed by a control
apparatus that utilizes
available sensor and control inputs to decide whether safe operation is
possible.
[0149] According to yet another aspect of the invention, the user may obtain a
high
velocity mass air flow that can directly control intake and outflow control
valves that change the
characterization of the apparatus' performance.
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[0150] According to another embodiment of the invention, the device may be
used as
an "inflator/deflator" for partial, or fully, marine vehicles, entertainment
and advertising,
modular constructions for shelters, and industrial framing components.
[0151] According to another embodiment of the invention, the device may be
used as a
mass air flow device in an HVAC system.
[0152] According to another embodiment of the invention, the device may be
used as a
mass air flow device to manage the air charging requirements in a vehicular or
other
transportation device where an internal combustion engine is combined with a
plurality of one or
more other motive power subsystems. Such applications include those sometimes
identified as
"hybrid" or "plug in" propulsive mechanisms. There are also applications for
such a device in
purely electrical vehicles, as well as, non-vehicular fixed/mobile
applications where the motive
power is used for production, operations, and/or generation. In an exemplary
application, the
device may be linked with the existing propulsive mechanism control modules as
either a
controlled sub-system peripheral (e.g., extending the ability of the
propulsive mechanism control
to air charging as well as other functions), or as an independent or
autonomous device that
provides a self-managed capability to provide air charging in a tailored
fashion to the propulsive
application requirement.
[0153] For propulsive mechanisms where both a combustion engine and an
electrical
component are incorporated, an mass air flow device embodiment enables
efficient operation of
the combustion mechanism by providing air charging, supports the application
of smaller (and
lighter) propulsive mechanisms, and allows optimization of propulsive
mechanism operation by
choosing where, how, and for what performance to expend electrical power and
combusted fuels.
The selection of an optimization strategy may be accomplished by the mass air
flow device
embodiment, by interactions with the vehicular control modules, or under the
direct instruction
of the vehicular control modules. The incorporation of the mass air flow
device allows the
propulsive mechanism control modules flexibility in managing combusted fuel -
air mixtures'
stoichiometric ratio (where the ratio by weight may dynamically range from
about 9:1 for
ethanol (e.g., 9.7:1 for E85) to about 14.67:1 for gasoline, to about 17:1 for
compressed natural
gas (e.g., primarily methane) and the ratio may vary depending on other
environmental,
operating history, operating optimizations, and the like) on a dynamic basis.
[0154] A benefit of incorporating a mass air flow device into the air charging
management regime for a propulsion application is to provide operational
performance,
practicality or diverse fueling, and reliability by dynamically adjusted
operation of the entire
propulsion mechanism. Because the mass air flow device embodiments described
are driven by
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electrical power sources, the presence of large electrical capacities provides
for a range of air
charging not otherwise possible in air charging devices coupled directly to
combustion cycles
and combustion. A direct consequence of the availability of the mass air flow
device
embodiment is the availability of air heated by compression that can also
significantly improve
the operation of many electrical battery mechanisms by subsystem warming. The
same mass air
flows can also be diverted for the comfort, or preservation, of passengers and
cargo.
[0155] Figure 6 illustrates an embodiment of the invention in a vehicle
implementation
with a hybrid electrical (e.g., battery) and a combustion engine. The
embodiment functions in a
manner similar to the embodiment described with reference to Figure 3, supra.
Additional
vehicle components are shown that are not part of the earlier embodiment to
illustrate other
aspects of the invention. As shown in Figure 6, the flow of air follows the
path from the vehicle
air intake 100 through a control valve subassembly (intake) 200, sensor
subassembly (intake)
300, air charging effector subassembly 500, sensor subassembly (outflow) 600,
and control valve
subassembly (outflow) 700, into a vehicle air intake manifold 1900 and into a
vehicle
combustion engine 2000. In some embodiments, control valve subassemblies 200
and/or 700, as
well as airflow sensor subassemblies 300 and/or 600 may be excluded or an
integral part of an
existing intake air management system, in which case sensor and control data
flows 1100, 1200,
1600, and 1700 may be replaced or supplanted by control and data flows through
control data
flows and external interface 1800.
[0156] As shown in Figure 6, torque produced by the vehicle combustion engine
2000
may be passed by mechanical coupling into a hybrid vehicle motor/generator
2100, creating
electrical power stored in a vehicle power storage component 2200. In some
embodiments, this
electrical power will require conditioning or regulation by a power regulator
2300, before
flowing into the apparatus power storage component 2400. Stored electrical
power may then be
delivered to the air charging motor subassembly 400 by a power source module
1000. Power
flow 1500 may be regulated by the apparatus controller subassembly 900 by
means of sensor and
control data flows 1400. The controller subassembly 900 may monitor the
operation of
combustion engine 2000 through control and data interface 1800 and modulates
power delivery
to the air charging system to optimize the engine combustion cycle. The
apparatus controller
subassembly 900 may then control the operations of the embodiment according to
dynamic or
preset operations.
[0157] For hybrid and plug-in automotive (and other transportation)
applications,(there
are other fixed installation applications such as standby generators, on-site
power, and fixed
plant motors where this applies as well), the mass air flow device described
may be used with
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particular benefits. The application of an "intelligent" air charging
subsystem can be combined
with other vehicular subsystems such as, for example, active drive trains,
active suspension,
fuel/ignition management, emissions controls, electrical management,
environmental sensing,
active braking, dynamic engine management, or active environmental
(compartment)
management and the like to optimize the fuel efficiency, comfort, operational
flexibility, or
performance of the vehicle.
[0158] In Figure 7 an exemplary embodiment of the invention is shown with a
large
illustrative suite of sensors. The exemplary embodiment illustrates the
application of an
embodiment of the invention to use with an internal combustion engine (on a
platform such as
those shown in Figures 28, 29, and 30; or a distinct internal combustion
engine propulsion,
stationary application, marine or portable power generation, marine
propulsion, or testing
application) 7-1900, 7-2000, 7-2100 where air charging is provided to the air
intakes. The
embodiment apparatus controller 7-900 uses internally stored codes, internally
stored data,
profile information from vehicle systems 7-3000 (illustrated by historical
data 7-700, user profile
data 7-7 10, user demand 7-720), internally stored 7-900 or from the vehicle
engine control unit
(ECU) 7-2500)), to control the apparatus. The control is manifest through the
actions of the
power source module 7-1000, the air-charging motor 7-400, and through inlet
and outlet valve
management (as shown in Figures 31 and 32 and the bypass valve 7-510). The
apparatus
controller 7-900 may also be responsible for some safety functions. The air
charging motor 7-
400 drives the air charging effector 7-500. The airflow through the embodiment
in this
application has an air intake 7-100 going through an inlet air filter 7-101.
After going through
the air charging effector 7-500 the air may be re-circulated or vented by the
bypass valve 7-510.
Additional air charging occurs via the Turbocharger subassembly 7-103 where
the air is vented.
The additional airflow from the Turbocharger assembly also ends up in the air
intake 7-1900.
After going through the internal combustion engine 7-2100 the air exhausts 7-
2000 and then may
be used for the turbocharger 7-103 to air charge more inlet air from the inlet
air filter 7-101 and
deliver it back into the air intake 7-1900. The air charging motor 7-400 may
be controlled by the
apparatus controller 7-900 that can control the rotating assembly, the
electric operations, and
access to the data and sensors present in the air charging motor 7-400. The
sensors for
temperature 7-620, pressure 7-610, airflow 7-600, voltage 7-650, battery
condition 7-695,
vibration 7-660, gas composition 7-630, current 7-640, emissions 7-635, engine
condition 7-690,
acoustic 7-685, fuel data 7-670 (from fuel tank 7-2510), position 7-680, and
information from
the engine control unit 7-2500 may be used by the apparatus controller 7-900.
The transfer of
data from sensors to the apparatus controller can occur across a plurality of
communications and
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methods, such as described in Figures 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,
43, 44, 45, 46, and
47. The power source module may manage a local secondary power device, such as
described in
Figure 18, and may handle related safety features.
[0159] Figure 8 shows an embodiment of the invention that is applied to the
generation
of boosted air for an internal combustion engine with a turbocharger also
present. The airflow
starts at an air intake 8-100 and air filter 8-101 to be routed to the
turbocharger 8-103 or to the air
charging effector of the embodiment 8-500. The outlet flow from the air
charging effector 8-500
may be rerouted by a bypass valve 8-510 or is supplied to an internal
combustion engine 8-2100
(illustrated as a vehicle, but which could be a stationary generator, mobile
generator, test unit, or
other such article) through the air intake 8-1900. After use by the internal
combustion engine 8-
2100 the air exhaust through the outlet 8-2000 can be used to power the
turbocharger assembly
8-103. As shown, the air charging effector 8-500 is driven by the air charging
motor 8-400
under the control of the apparatus controller 8-900. Power for the apparatus
controller 8-900, air
charging motor 8-400, and the bypass valve 8-510 (optional) may be supplied by
a power source
module (not shown) and secondary power storage device (not shown). Sensors and
other data
inputs (not shown) may also be used by the unit (including the control,
sensor, and power flows
between the air charging motor 8-400 and apparatus controller 8-900). In like
fashion to the
embodiment shown in Figure 7, sensors, inlet and outlet valves, and
connections and
communications with other platform functions can embellish the embodiment.
[0160] In Figure 9, an embodiment of the invention is applied to the
generation of air
charging for an internal combustion engine. As shown, the airflow starts at an
air intake 9-100
and air filter 9-101 to be routed to the air charging effector of the
embodiment 9-500. The outlet
flow from the air charging effector 9-500 may be supplied to an internal
combustion engine 9-
2100 (illustrated as a vehicle, but which could be a stationary generator,
mobile generator, test
unit, or other such article) through the air intake 9-1900. After use by the
internal combustion
engine 9-2100 the air exhaust through the outlet 9-2000 can be used to power
the turbocharger
assembly 9-103. As shown, the air charging effector 9-500 is driven by the air
charging motor 9-
400 under the control of the apparatus controller 9-900. Power for the
apparatus controller 9-
900, air charging motor 9-400, and the bypass valve (optional, not shown) may
be supplied by a
power source module (9-1000) and secondary power storage device (not shown).
Sensors and
other data inputs (such as those from the electronics control unit 9-2500 or
not shown) may also
be used by the unit (including the control, sensor, and power flows between
the air charging
motor 9-400 and apparatus controller 9-900). In like fashion to the embodiment
shown in Figure
7, sensors (pressure 9-610, temperature 9-620, or mass airflow 9-600), inlet
and outlet valves,
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and connections and communications with other platform functions can embellish
the
embodiment.
[0161] Figure 10 shows an embodiment of the invention that is applied to the
generation of air charging for an internal combustion engine. The airflow may
start at an air
intake 10-100 and air filter 10-101 to be routed to the air charging effector
of the embodiment
10-500. The outlet flow from the air charging effector 10-500 can be rerouted
by the bypass
valve 10-510 or supplied to an internal combustion engine 10-2100 (illustrated
as a vehicle, but
which could be a stationary generator, mobile generator, test unit, or other
such article) through
the air intake 10-1900. After use by the internal combustion engine 10-2100,
the air may exhaust
through the outlet 10-2000. The air charging effector 10-500 may be driven by
the air charging
motor 10-400 under the control of the apparatus controller 10-900. Power for
the apparatus
controller 10-900, air charging motor 10-400, and the bypass valve (optional)
may be supplied
by a power source module (not shown) and secondary power storage device (not
shown).
Sensors and other data inputs (not shown) are also used by the unit (including
the control, sensor,
and power flows between the air charging motor 10-400 and apparatus controller
10-900). In
like fashion to the embodiment shown in Figure 7, sensors, inlet and outlet
valves, and
connections and communications with other platform functions can embellish the
embodiment.
[0162] Figure 11 is a simplified drawing illustrating the functional placement
of
elements of an embodiment in an air moving application. The use of an
embodiment of the
invention in an air-moving application calls for an inflow process through an
air intake. The
inflow may be subject to a plurality of operations including modification,
limitation,
augmentation, or conditioning by a subassembly referred to as the inlet
control valve 11-530.
The modification of the airflow is illustrated by the use of devices to reduce
turbulence in the air.
The limitation of the airflow is illustrated by the use of limiting valves
(such as pop-off pressure
valves), barriers (such as butterfly valves), or orifice constraint (such as
iris valves). The
augmentation of the airflow is illustrated by the addition to the air intake
from re-circulated gas,
additional flows (such as added mixture components or additives to the airflow
for combustion
augmentation), or combining the flows of multiple subassemblies. The
conditioning of the
airflow is illustrated by the use of a device to pre-swirl the air in the
intake. The outflow may be
subject to a plurality of operations like those of the inflow with additional
paths possibly present
to re-circulate, bypass, or divert outputs 11-520. The recirculation path
returns some, or all, of
the output from the air charging effector 11-500 to the intake and inflow
operations. The bypass
path 11-510 is illustrated by the venting of the device to atmosphere. The
diversion of outflow
air is illustrated by dividing the stream for different applications or for
further air charging
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operations in an additional stage. Numerous filtering, sensor measurement, and
airflow path
combinations are possible without impacting the essential innovative content
of the invention. A
specific embodiment of the invention may have none, some, or all of the inlet
and outlet airflow
functions other than a direct path.
[0163] The air charging effector 11-500, present in all embodiments of the
invention,
operates on the airflow to change its measured characteristics. In other
alternate embodiments
where instantiations of the invention are used to generate vacuum other
effectors may be used.
The air charging effector may change the rate of flow, the pressure of flow,
the volume of flow,
or it may not change things at all depending on the operating target set for
it by the apparatus
controller. A change in the rate of flow may be illustrated by the increase in
the velocity of the
airflow measured in meters/second. A change in the pressure of the flow may be
illustrated by
the increase in measurable pressure due to the compression of the flow by a
compressor wheel
and collector measured in torr. A change in the volume of flow may be
illustrated by the
increase in measureable volume due to the air effector measured in cc per
minute.
[0164] The air charging motor 11-400 may be directly connected to the
apparatus
controller 11-900 and may also be connected to electrical power. The apparatus
controller 11-
900 may be capable of starting, stopping, running, and controlling the running
of motors (like
11-400) in small increments. In exemplary embodiments using direct current
motors, the
rotation of the motor may be controlled by the motor controls to the extent
that discrete electrical
timing pulses are handled by the motor controls to cause the sequence of
electrical events
rotating the shaft of the motor 11-400. The connections between the air
charging effector 11-500
and the air charging motor 11-400 are coupled and are illustrated by
connections that are directly
mounted onto the shaft of the electric motor, hooked to the electric motor 11-
400 through a
gearbox subassembly, coupled by various mechanical means such as small belts
or coupled via
other shaft rotation conversions. The apparatus controller sub-assembly 11-900
makes use of
control signals and feedback indicators from the air charging motor sub-
assembly. Illustrative
examples of the control signals and feedback indicators are the position
information on the
rotating assembly, electrical feedback indicators, and electrical current
measurements. In various
alternative embodiments, none, one, some, or all, of the connections between
the air charging
motor and apparatus controller may be absent depending on the application for
the embodiment
or the nature of the specific air charging motor.
[0165] Present throughout the embodiment of the apparatus may be safety
features and
considerations. Self protection for the air charging effector subassembly in
the embodiment of
the invention is provided by the apparatus controller. Simpler mechanical
protections (such as
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bypass or relief valves) may also be present in alternative embodiments. The
packaging of the
embodiment may incorporate safety features as well to present incorrect
electrical terminations,
mis-wired sensors, or missing airflow path ducts' connections. The apparatus
controller 11-900
may then handles a plurality of connections to other elements such as sensors,
data devices, or
other control mechanisms. (See Figures 33, 34, 35, 36, 37, 38, 39, 40, 41, 42,
43, 44, 45, 46, and
47).
[0166] In alternative embodiments the apparatus controller 11-900 can be a
self-
sufficient and standalone device and thus requiring minimal connections to
external controls or
functions. In other alternative embodiments, the apparatus controller may have
substantial
quantities of connections for sensors, communicating with the application'
apparatus, and
communicating with other control devices outside the scope of this
application. Not illustrated
on this Figure 11 are the power control subassembly (see Figure 18) with
alternatives for power
management, storage, and connections. The apparatus controller 11-900 may have
the capability
to control the power control subassembly 11-400 and power storage modules (not
shown) in the
exemplary embodiments. It is possible for an alternative embodiment to not
have this control
because of control being vested in an external control apparatus. (not shown).
[0167] In Figure 12 illustrates an embodiment of the invention for an internal
combustion engine application with two stages of supercharging and two
superchargers. As
shown, the airflow starts at an air intake 12-100 and air filter 12-101 to be
routed to the
supercharger 12-104 or to the air charging effector of the embodiment 12-500.
The outlet flow
from the air charging effector 12-500 may be rerouted by a bypass valve 12-510
or may be sent
to the supercharger assemblies 12-104. Air is supplied to an internal
combustion engine 12-2100
(illustrated as a vehicle, but which could be a stationary generator, mobile
generator, test unit, or
other such article) through the air intake 12-1900. After use by the internal
combustion engine
12-2100 the air may exhaust through the outlet 12-2000. As shown, the air
charging effector 12-
500 is driven by the air charging motor 12-400 under the control of the
apparatus controller 12-
900. Power for the apparatus controller 12-900, air charging motor 12-400, and
the bypass valve
12-5 10 (optional) may be supplied by a power source module (not shown) and
secondary power
storage device (not shown). Sensors and other data inputs (not shown) may also
be used by the
unit (including the control, sensor, and power flows between the air charging
motor 12-400 and
apparatus controller 12-900). In like fashion to the embodiment shown in
Figure 7, sensors, inlet
and outlet valves, and connections and communications with other platform
functions can
embellish the embodiment.
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[0168] The embodiment illustrated uses a shared apparatus controller 12-900
for both
air charging motors 12-400. In an alternate embodiment, each motor could have
its own
apparatus controller (for example if demanded by physical spacing). In this
embodiment, the air
charging motors 12-400 could have a single power control module (not shown)
and share a
single secondary power storage device (not shown) or have their own dedicated
secondary power
storage devices (not shown).
[0169] In Figure 13, an embodiment of the invention is applied to the
generation of
boosted air for an internal combustion engine with a turbocharger also
present. As shown, the
airflow starts at an air intake 13-100 and air filter 13-101 to be routed to
the turbocharger 13-103
or to the air charging effector of the embodiment 13-500. The outlet flow from
the air charging
effector 13-500 may be rerouted by a bypass valve 13-510 or may be supplied to
an internal
combustion engine 13-2100 (illustrated as a vehicle, but which could be a
stationary generator,
mobile generator, test unit, or other such article) through the air intake 13-
1900. After use by the
internal combustion engine 13-2100, the air may exhaust through the outlet 13-
2000 can be used
to power the turbocharger assembly 13-103. The air charging effector 13-500
may be driven by
the air charging motor 13-400 under the control of the apparatus controller 13-
900. Power for
the apparatus controller 13-900, air charging motor 13-400, and the bypass
valve 13-510
(optional) may be supplied by a power source module (not shown) and secondary
power storage
device (not shown). Sensors and other data inputs (not shown) may also be used
by the unit
(including the control, sensor, and power flows between the air charging motor
13-400 and
apparatus controller 13-900). In like fashion to the embodiment shown in
Figure 7, sensors, inlet
and outlet valves, and connections and communications with other platform
functions can
embellish the embodiment.
[0170] The embodiment in Figure 13 may be applied as a series turbocharging
configuration to overcome turbo lag. The air charging effector 13-500 may be
engaged on a
demand basis by the apparatus controller 13-900 to increase the incoming
pressure air to the
turbocharger assembly 13-103. This configuration allows the turbocharger to
spool up more
quickly and thus deliver more air charging to the internal combustion engine.
[0171] Figure 14 shows an embodiment of the invention comprising an internal
combustion engine application with multistage supercharging. Three stages of
supercharging are
shown. Also as shown, the airflow starts at an air intake 14-100 and air
filter 14-101 to be routed
to the supercharger 14-104 or to the air charging effector of the embodiment
14-500. The outlet
flow from the air charging effector 14-500 may be rerouted by a bypass valve
14-510 or may be
routed through the two stages of supercharger compressor assemblies 14-104.
Air may be
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supplied to an internal combustion engine 14-2100 (illustrated as a vehicle,
but which could be a
stationary generator, mobile generator, test unit, or other such article)
through the air intake 14-
1900. After use by the internal combustion engine 14-2100, the air may exhaust
through the
outlet 14-2000. The air charging effector 14-500 may be driven by the air
charging motor 14-
400 under the control of the apparatus controller 14-900. Power for the
apparatus controller 14-
900, air charging motor 14-400, and the bypass valve 14-510 (optional) may be
supplied by a
power source module (not shown) and secondary power storage device (not
shown). Sensors
and other data inputs (not shown) may also be used by the unit (including the
control, sensor, and
power flows between the air charging motor 14-400 and apparatus controller 14-
900). In like
fashion to the embodiment shown in Figure 7, sensors, inlet and outlet valves,
and connections
and communications with other platform functions can embellish the embodiment.
[0172] The exemplary embodiment illustrated uses a shared apparatus controller
14-
900 for both air charging motors 14-400. In an alternate embodiment each motor
could have its
own apparatus controller (for example if demanded by physical spacing). In
this embodiment
the air charging motors 14-400 could have a single power control module (not
shown) and share
a single secondary power storage device (not shown) or have their own
dedicated secondary
power storage devices (not shown). In this application, the multiple stages of
superchargers may
be used to provide very high volumes of air and high flow rates, but at the
penalty of high power
demanded by the supercharger compressor assemblies 14-104. One use of this
embodiment of
the invention may be to increase the effectiveness of the supercharger stages
by providing them
with air charging (especially at low power rates transferred to the
supercharger assemblies 14-
104).
[0173] Also, the plurality of the superchargers illustrated in Figure 14-104
could be
powered by either belt drive or exhaust gas flows. In alternate embodiments,
additional electric
motor 14-400 and air effector assemblies 14-500 could be substituted for any
or all of the
superchargers illustrated. In this alternate embodiment, different electric
motor 14-400 and air
effector assemblies 14-500 could be substituted to replace belt or exhaust
drive superchargers for
one or more stages of the air charging process. In an alternate embodiment,
the air charging
function next to the engine intake 14-1900 could be an air effector assembly
14-500. This
alternate embodiment has the advantage of no ducting, plenum, or manifold to
add latency (turbo
lag) to the air charging process. In an alternate embodiment where the air
effector assembly 14-
500 is placed between a supercharger and another supercharger, the purpose of
the embodiment
may be to compensate for a notch, or lack of overlap, between the flow ranges
of two devices. In
this embodiment, the apparatus controller 14-900 may be able to smooth the
transition between
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air charging states for the internal combustion engine 14-2100. The power
source module (not
shown) and the secondary power storage device (not shown) may be managed by
the apparatus
controller 14-900 in accordance with optimal operations under a profile. In an
alternate
embodiment, the use of a series of air effectors 14-500 (multiple stages, or
multiple stages with
and without other belt or exhaust driven units 14-404) driven by electric
motors 14-400 and
controlled by the apparatus controller 14-900 has the advantage of having the
air charging
process under the management and control of a single, or cooperating,
apparatus controller 14-
900. For any of these with one or more electric motor 14-400 and air effector
assemblies 14-500
a plurality of power source modules (not shown) and secondary power storage
devices (not
shown) could be managed by the apparatus controller 14-900 or more than one
apparatus
controller. In like fashion a plurality of additional inlet and outlet valves
(as discussed in Figures
31 and 32) can be applied to manage the isolation, combination, or routing of
airflows
throughout the combinations of devices in multiple embodiments.
[0174] Figure 15 shows in an internal combustion engine application with
multistage,
parallel supercharging. As shown, the airflow starts at an air intake 15-100
and air filter 15-101
to be routed to the turbocharger 15-103 or to the air charging effector of the
embodiment 15-500.
The outlet flow from the air charging effector 15-500 may be rerouted by a
bypass valve 15-510
or may be routed through the two stages of supercharger compressor assemblies
15-103.
Additional bypass and gas control valves route air as needed 15-540 15-550.
Air may be
supplied to an internal combustion engine 15-2100 (illustrated as a vehicle,
but which could be a
stationary generator, mobile generator, test unit, or other such article)
through the air intake 15-
1900. After use by the internal combustion engine 15-2100, the air may exhaust
through the
outlet 15-2000 to power the turbochargers and finally exhausted 15-105. The
air charging
effector 15-500 may be driven by the air charging motor 15-400 under the
control of the
apparatus controller 15-900. Power for the apparatus controller 15-900, air
charging motor 15-
400, and the bypass valve 15-510 (optional) may be supplied by a power source
module (not
shown) and secondary power storage device (not shown). Sensors and other data
inputs (not
shown) may also be used by the unit (including the control, sensor, and power
flows between the
air charging motor 15-400 and apparatus controller 15-900). In like fashion to
the embodiment
shown in Figure 7, sensors, inlet and outlet valves, and connections and
communications with
other platform functions can embellish the embodiment.
[0175] The embodiment illustrated may use a shared apparatus controller 15-900
for
both air charging motors 15-400. In an alternate embodiment, each motor could
have its own
apparatus controller (for example if demanded by physical spacing). In this
embodiment the air
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charging motors 15-400 could have a single power control module (not shown)
and share a
single secondary power storage device (not shown) or have their own dedicated
secondary power
storage devices (not shown). In this application the multiple stages of super
turbochargers are
used to provide very high volumes of air and high flow rates, but at the
penalty of high power
demanded by the super turbocharger compressor assemblies 15-1043. The use of
the
embodiment of the invention may be to increase the effectiveness of the
supercharger stages by
providing them with air charging (especially at low power rates transferred to
the super
turbocharger assemblies 15-1043). The embodiment thus reduces turbo lag at a
design point
where the primary and secondary turbocharger assemblies 15-103 are ineffective
or less
effective.
[0176] Figure 16 is another embodiment illustrating the application of the
invention to
an air charging requirement including the use of exhaust gas return for an
internal combustion
engine (i.e., secondary air injection into exhaust gas recirculation). As
shown, the airflow starts
at an air intake 16-100 and air filter 16-101 to be routed to the air charging
effector of the
embodiment 16-500. The outlet flow from the air charging effector 16-500 can
be rerouted by
the bypass valve 16-510 or may be supplied to an internal combustion engine 16-
2100
(illustrated as a vehicle, but which could be a stationary generator, mobile
generator, test unit, or
other such article) through the air intake 16-1900. After use by the internal
combustion engine
16-2100, the air may exhaust through the outlet 16-2000. The exhaust gas
return control valve
16-550 controls the recirculation of exhaust gas back through the air charging
effector 16-500 or
its venting 16-105. The air charging effector 16-500 may be driven by the air
charging motor
16-400 under the control of the apparatus controller 16-900. Power for the
apparatus controller
16-900, air charging motor 16-400, and the bypass valve (optional) may be
supplied by a power
source module (not shown) and secondary power storage device (not shown).
Sensors and other
data inputs (not shown) may also be used by the unit (including the control,
sensor, and power
flows between the air charging motor 16-400 and apparatus controller 16-900).
In like fashion to
the embodiment shown in Figure 7, sensors, inlet and outlet valves, and
connections and
communications with other platform functions can embellish the embodiment.
[0177] In Figure 17, an embodiment of the invention is applied to the
generation of air
charging for an internal combustion engine and secondary air injection into
the exhaust catalytic
conversion assembly 17-2400. As shown, the airflow starts at an air intake 17-
100 and air filter
17-101 to be routed to the air charging effector of the embodiment 17-500. The
outlet flow from
the air charging effector 17-500 can be rerouted by the bypass valve 17-5 10
or may be supplied
to an internal combustion engine 17-2100 (illustrated as a vehicle, but which
could be a
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stationary generator, mobile generator, test unit, or other such article)
through the air intake 17-
1900. An alternate pass controlled by the exhaust air injection control valve
17-530 may provide
an airflow to exhaust catalyst subassembly. After use by the internal
combustion engine 17-2100
the air exhaust through the outlet 17-2000. The air charging effector 17-500
may be driven by
the air charging motor 17-400 under the control of the apparatus controller 17-
900. Power for
the apparatus controller 17-900, air charging motor 17-400, and the bypass
valve (optional) may
be supplied by a power source module (not shown) and secondary power storage
device (not
shown). Sensors and other data inputs (not shown) may also be used by the unit
(including the
control, sensor, and power flows between the air charging motor 17-400 and
apparatus controller
17-900). In like fashion to the embodiment shown in Figure 7, sensors, inlet
and outlet valves,
and connections and communications with other platform functions can embellish
the
embodiment.
[0178] This embodiment may provide an improvement over older techniques that
used
belt-driven air pumps or other power take offs to power the air pumping
assembly. For example,
the embodiment could, at different times, be applied to pumping cooling or
heating air to the
exhaust catalyst 157-2400 or to supply oxygen to the exhaust catalyst assembly
175-2400.
[0179] Figure 18 shows an exemplary embodiment of the power source module and
power storage devices. The embodiment provides for flexibility and control of
multiple power
sources 18-1100 18-1200 29-1010 18, and the use, in exemplary embodiments, of
a local
secondary power storage device 18-1200. The availability of power in these
embodiments from
the local secondary power storage device 18-1200, the common electrical grid
18-1100, the
engine battery 29-1010, the engine in generator mode 18-2200, and any
secondary battery
storage 29-1010 (other than a hybrid primary storage battery or fuel-cell)
allows the apparatus
power storage module 18-1000 to select from a plurality of sources for a
plurality of uses
(including recharging the local secondary power storage device 18-1200). The
operations of the
apparatus power source module may be directed by the apparatus control
subassembly using the
profiles of operation and optimization strategies derived from the current
operating profiles
requirements. The management of power expenditure by the embodiment may
include the air
charging motor 18-400 and may also include sub-optimal air flow generation,
apparatus safe
operation, and power management for inlet and outlet management as present in
certain
embodiments. Different embodiments present in a single platform (illustrated
simply by a hybrid
car plugged into the power grid) can be simultaneously applied to separate
operating needs
(illustrated by keeping the cargo compartment of a vehicle warm, maintaining a
warmth level in
a battery compartment, and maintaining a warmth level in the engine emissions
control) under
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the operation of the apparatus controller and profiles. Across an operating
period could place the
priority for a sequence of operations of the apparatus power source module 18-
100 to recharge
its own secondary power storage device 18-1200, maintaining warmth levels in
various
compartments of the vehicle (such as prioritizing warmth in the battery
compartment while
recharging is conducted), and then shifting to warming the passenger
compartment only shortly
before more vehicle use takes place. The apparatus controller may also respond
to external
conditions known from sensor data (such as heat or cold) and dynamically
change apparatus
power source module operations under a profile for these conditions. Under
dynamic load
conditions (such as route planned power consumption, steep hills, or high
performance
requirements) the apparatus power source module in an embodiment can, under
control and
cooperation of the apparatus control subassembly, plan, distribute, supply,
restore, and conserve
power capacity, power expenditure, power distribution, and power intake.
[0180] The capabilities of the apparatus power source module may be common to
exemplary embodiments of the invention with specific instantiations subject to
variances for
requirements and optimizations in a specific platform environment. In the
embodiments of the
invention described herein, the assumption is that the functions of the
apparatus power source
module and secondary power storage device are functionally common and
consistent with the
description provided for the embodiment of Figure 18.
[0181] Figure 19 illustrates an embodiment of the invention for heating of air
to be
supplied to warm a battery compartment. As shown, the airflow starts at an air
intake 19-100 and
air filter 19-101 to be routed to the air charging effector of the embodiment
19-500. The outlet
flow from the air charging effector 19-500 can be rerouted by the
recirculation valve 19-510 or
may be supplied to the battery compartment 19-190 (illustrated as a vehicle,
but which could be
a stationary room, mobile plenum, test unit, or other such article) through
the air intake. After
cycling through the compartment the air may be re-circulated or vented 19-510.
The air charging
effector 19-500 may be driven by the air charging motor 19-400 under the
control of the
apparatus controller 19-900. Power for the apparatus controller 19-900, air
charging motor 19-
400, and the recirculation valve (optional) may supplied by a power source
module (not shown)
and secondary power storage device (not shown). Sensors 19-610 19-620 19-600
and other data
inputs (such as those from the engine control unit 19-2500) may also be used
by the unit
(including the control, sensor, and power flows between the air charging motor
19-400 and
apparatus controller 19-900). In like fashion to the embodiment shown in
Figure 7 sensors (19-
610, 19-620, 19-600), inlet and outlet valves, and connections and
communications with other
platform functions can embellish the embodiment. The nature of running a
compressive air
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charging effector 19-500 is that the energy transferred may also increase the
heat of the air
output by up to about 20 degrees or more (depending on ambient conditions and
air intake
setups). The availability of warming for the battery compartment may serve to
keep the
available energy capacity of the battery up in very cold conditions. The use
of a local secondary
power storage device (not shown) or plug-in grid power to externally power the
air charging
motor 19-400 may also provide a mechanism to maximize the battery capacity
available at low
or very high ambient temperatures.
[0182] Figure 20 shows an embodiment of the invention that may be applied to
the
heating of air to be supplied to warm a passenger, cargo, or electronics
assembly compartment.
As shown, the airflow starts at an air intake 20-100 and air filter 20-101 to
be routed to the air
charging effector of the embodiment 20-500. The outlet flow from the air
charging effector 20-
500 can be rerouted by the recirculation valve 20-510 or may be supplied to
the passenger, cargo,
or electronics assembly compartment 20-19200 (illustrated as a vehicle, but
which could be a
stationary room, mobile plenum, test unit, or other such article) through the
air intake. After
cycling through the compartment, the air my be re-circulated or vented 20-510.
The air charging
effector 20-500 may be driven by the air charging motor 20-400 under the
control of the
apparatus controller 20-900. Power for the apparatus controller 20-900, air
charging motor 20-
400, and the recirculation valve (optional) may be supplied by a power source
module (not
shown) and secondary power storage device (not shown). Sensors 20-610 20-620
20-600 and
other data inputs (such as those from the engine control unit 20-2500) may
also be used by the
unit (including the control, sensor, and power flows between the air charging
motor 20-400 and
apparatus controller 20-900). In like fashion to the embodiment shown in
Figure 7, sensors (20-
610, 20-620, 20-600), inlet and outlet valves, and connections and
communications with other
platform functions can embellish the embodiment.
[0183] The nature of running a compressive air charging effector 20-500 as
shown is
that the energy transferred may also increase the heat of the air output by up
to about 20 degrees
or more (depending on ambient conditions and air intake setups). The
availability of warming
for the passenger, cargo, or electronics assembly compartment will serve to
keep the available
energy capacity of the passenger, cargo, or electronics assembly up in very
cold conditions. The
use of a local secondary power storage device (not shown) or plug-in grid
power to externally
power the air charging motor 20-400 may also provide a mechanism to maximize
the passenger,
cargo, or electronics assembly capacity available at low or very high ambient
temperatures. Of
particular benefit in a vehicular application at low temperatures is the
availability of heated air in
a very short (e.g., less than one minute) period of time. Existing hybrid
vehicles and electric
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vehicles use either primary electrical storage power for a resistance heater
and fans, or heated air
or coolant from an internal combustion engine, or generated electricity for
resistance heating
from the internal combustion engine to generate this heat. The illustrated
embodiment can
provide both an airflow and heated air in a very short period of time possibly
using only its
onboard secondary power storage device (if properly sized) for power until
other power is
available, for example, from the hybrid electrical systems. In a power
configuration and profile
using grid power the embodiment acts as a warmer assembly similar to those
extant using
resistive elements and fans.
[0184] Figures 21 shows an embodiment of the invention as applied to the
cooling of
air to be supplied to cool a passenger, cargo, or electronics assembly
compartment. As shown,
the airflow starts at an air intake 21-100 and air filter 21-101 to be routed
to the air charging
effector of the embodiment 21-500. The outlet flow from the air charging
effector 21-500 can be
rerouted by the recirculation valve 21-510 or may be supplied to the heat
exchanger/chiller
assembly 21-2600. As shown the heat exchanger/chiller assembly then supplies
the cool air to
the passenger, cargo, or electronics assembly compartment 21-2050 (illustrated
as a vehicle, but
which could be a stationary room, mobile plenum, test unit, or other such
article) through the air
intake. After cycling through the compartment, the air may be re-circulated or
vented 21-510.
The air charging effector 21-500 may be driven by the air charging motor 21-
400 under the
control of the apparatus controller 21-900. Power for the apparatus controller
21-900, air
charging motor 21-400, and the recirculation valve (optional) may be supplied
by a power source
module (not shown) and secondary power storage device (not shown). Sensors 21-
610 21-620
21-600 and other data inputs (such as those from the engine control unit 21-
2500) may also be
used by the unit (including the control, sensor, and power flows between the
air charging motor
21-400 and apparatus controller 21-900). In like fashion to the embodiment
shown in Figure 7,
sensors (21-610, 21-620, 21-600), inlet and outlet valves, and connections and
communications
with other platform functions can embellish the embodiment.
[0185] The nature of running an air charging effector 21-500 is that the
airflow may be
supplied to the heat exchanger/chiller assembly 21-2500. The heat
exchanger/chiller assembly
21-2500 can take the form of a simple intercooler or be used to drive the
exchange in a fluid
cooling cycle. The availability of airflow for the passenger, cargo, or
electronics assembly
compartment may serve to keep the available energy capacity of the passenger,
cargo, or
electronics assembly up in very hot conditions. The use of a local secondary
power storage
device (not shown) or plug-in grid power to externally power the air charging
motor 21-400 may
also provide a mechanism to maximize the passenger, cargo, or electronics
assembly capacity
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available at very high ambient temperatures. Existing hybrid vehicles and
electric vehicles
typically use either primary electrical storage power for a cooler/chiller and
fans, or cooled air or
coolant from an external source. The illustrated embodiment may provide both
an airflow and
cooling air in a very short period of time possibly using only its onboard
secondary power
storage device (if properly sized) for power until other power is available,
for example, from the
hybrid electrical systems. In a power configuration and profile using grid
power, the exemplary
embodiment may act as an airflow assembly. When used in alternate embodiments
of the
invention, spiral or scroll effectors may be used for cooling applications
where they are more
appropriate than compression based air-effectors.
[0186] Figures 22 shows another embodiment of the invention that may be
applied to
the cooling of air to be supplied to cool a passenger, cargo, or electronics
assembly compartment.
As shown, the airflow starts at an air intake 22-100 and air filter 22-101 to
be routed to the air
charging effector of the embodiment 22-500. The outlet flow from the air
charging effector 22-
500 can be rerouted by the recirculation valve 22-510 or may be supplied to
the heat
exchanger/chiller assembly 22-2600. The heat exchanger/chiller assembly then
supplies the cool
air to the passenger, cargo, or electronics assembly compartment 22-2050
(illustrated as a
vehicle, but which could be a stationary room, mobile plenum, test unit, or
other such article)
through the air intake. After cycling through the compartment, the air may be
re-circulated or
vented 22-510. The air charging effector 22-500 may be driven by the air
charging motor 22-
400 under the control of the apparatus controller 22-900. Power for the
apparatus controller 22-
900, air charging motor 22-400, and the recirculation valve (optional) may be
supplied by a
power source module (not shown) and secondary power storage device (not
shown). Sensors 22-
610 22-620 22-600 and other data inputs (such as those from the engine control
unit 22-2500)
may also be used by the unit (including the control, sensor, and power flows
between the air
charging motor 22-400 and apparatus controller 22-900). In like fashion to the
embodiment
shown in Figure 7, sensors (22-610, 22-620, 22-600), inlet and outlet valves,
and connections
and communications with other platform functions can embellish the embodiment.
[0187] The nature of running an air charging effector 22-500 as shown is that
the
airflow may be supplied to the heat exchanger/chiller assembly 22-2500. The
heat
exchanger/chiller assembly 22-2500 can take the form of a simple intercooler
or be used to drive
the exchange in a fluid cooling cycle. The availability of airflow for the
passenger, cargo, or
electronics assembly compartment may serve to keep the comfort level of the
passenger, cargo,
or electronics assembly in very hot conditions. The use of a local secondary
power storage
device (not shown) or plug-in grid power to externally power the air charging
motor 22-400 may
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also provide a mechanism to maximize the passenger, cargo, or electronics
assembly comfort
available at very high ambient temperatures. The illustrated embodiment may
provide both an
airflow and cooling air in a very short period of time possibly using only its
onboard secondary
power storage device (if properly sized) for power until other power is
available, for example,
from the hybrid electrical systems. In a power configuration and profile using
grid power, the
embodiment may act as an airflow assembly. When used in alternate embodiments
of the
invention, spiral or scroll effectors can be used for cooling applications
where they are more
appropriate than compression based air-effectors.
[0188] Figure 23 shows an exemplary embodiment that may be used as an
inflator/deflator for a plenum or flexible membrane. As shown, a relatively
simple embodiment
of the invention may be coupled via airflow connections to a plenum. Depending
on the settings,
or controlled by the apparatus controller 23-900, the air charging effector 23-
500 inflates or
deflates the plenum 23-4000 by the operation of the air charging motor 23-400.
Simple sensor
outputs (not shown) to detect pressure may be used by the apparatus controller
23-900 to control
operation of the rotating element of the air charging motor subassembly 23-500
to halt continued
operations when no longer necessary. In alternative embodiments, the apparatus
controller 23-
900 may have sensor inputs from human users that cause it to automatically
control the settings
of the inflator and deflator valves 23-520 23-530 of the embodiment. Relief 23-
570 and check
valves 23-560 may serve to protect the assemblies and plenum 23-4000. The
power
management control subassembly 23-1000 and power storage module subassemblies
(not shown
on the Figure for clarity) can be present with local power storage and power
management, or
may simply be fed in an alternative embodiment directly to the apparatus
contro123-900 and air
charging motor 23-500. The device/system may comprise a portable packaging
including a
power management contro123-1000 subassembly and power storage module. The
entire
package may be about 23 centimeters in length, about 20 centimeters in width,
and about 15
centimeters in depth, for example. The application of this embodiment may
include a large
number of fixed plenum sized applications (such as rigid inflatable boats,
inflatable industrial
bladders, inflatable buildings, moon bouncers, and others) and some
applications where a
continued pressurized airflow is needed (such as advertising semi-rigids).
[0189] Figure 24 is an embodiment of the invention with a minimal illustration
for
application of the invention to heating, ventilating, and other airflow
applications (i.e., non-
automotive). As shown, the airflow starts at an air intake 24-100 and air
filter 24-101 to be
routed to the air charging effector of the embodiment 24-500. The outlet flow
from the air
charging effector 24-500 can be rerouted by the outlet control valve 24-520 or
may be supplied
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to an air plenum. The air charging effector 24-500 may be driven by the air
charging motor 24-
400 under the control of the apparatus controller 24-900. Power for the
apparatus controller 24-
900, air charging motor 24-400, and the valves 24-520 24-530 (optional) may be
supplied by a
power source module (not shown) and secondary power storage device (not
shown). Sensors
and other data inputs (not shown) may also be used by the unit (including the
control, sensor, and
power flows between the air charging motor 24-400 and apparatus controller 24-
900). In like
fashion to the embodiment shown in Figure 7, sensors, inlet and outlet valves,
and connections
and communications with other platform functions can embellish the embodiment.
[0190] For example, the high velocity and mass air flow of one such embodiment
can
be used as a substitute for the large fans used to furnish air into combustion
heating furnaces.
Another embodiment could be used to supply ambient airflow to a heat
exchanger/chiller
assembly with an air charging effector optimized for flow. Units as small as
400g for a
50,000,000 cc/min air mover are possible with this configuration optimized for
smaller spaces
and features. Multiple embodiments sharing the apparatus controller 24-900 and
power
management modules (not shown) can reduce average controller and packaging to
less than
about 3kg.
[0191] Figure 25 is illustrative of multiple embodiments of the invention
applied to a
single platform having multiple applications. As shown in Figure 25, the
airflow begins at an air
inlet and filter 25-101 that provides air to air charging effectors 25-500
likely to be in three
different physical compartments of the platform. The air charging needs may be
for
heating/cooling the battery compartment 25-2010, supplying charge air to the
vehicle internal
combustion engine 25-1900, and for heating/cooling the
interior/cargo/electronics compartment
25-2020. Common to the each of the instantiations of the three embodiments is
the air charging
motor 25-400 and air charging effector assembly 25-500 (although the air
effectors present in
each instantiation may be distinct). Recirculation and other valves (forms of
the inlet and outlet
controls discussed with Figures 31 and 32) 25-530, 25-510 may be used to
control air flow to the
end areas and devices. As shown, heat exchangers/chiller assemblies are
present as needed for
cooling 25-2500 or compressive heating is used for warming. The internal
combustion engine
takes air in through the intake 25-1900 and then exhausts it. In this
combination of
embodiments, the power control module (not shown) and secondary power storage
device (not
shown) (discussed with reference to Figure 18) may exist for each
instantiation or be shared
depending on specific platform requirements. The apparatus controller 25-900
may also be
shared, or replicated in the same or slightly different forms, depending on
platform requirements.
A plurality of sensors and other communications connections (such as those
shown in Figure 7
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and detailed in Figures 33, 34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45,
46, 47) may be used for
each instantiation of an embodiment combined to meet the needs of a platform
and multiple
applications.
[0192] Figure 26 is an embodiment of the invention applied to exhausting the
air from
an engine compartment. As shown, the airflow starts at an air intake and air
filter to be routed to
the air cooling heat exchanger 26-2500 (supplied by a cooling fluid cycle 20-
106) and then
through the plenum 26-2050 to the air charging effector of the embodiment 26-
500. The outlet
flow from the air charging effector 26-500 can be rerouted by the outlet
control valve (not
shown) or may be removed from an air plenum 26-2050. The air charging effector
26-500 may
be driven by the air charging motor 26-400 under the control of the apparatus
controller 26-900.
Power for the apparatus controller 26-900, air charging motor 26-400, and the
valves (not shown
optional) may be supplied by a power source module (not shown) and secondary
power storage
device (not shown). Sensors and other data inputs (not shown) may also be used
by the unit
(including the control, sensor, and power flows between the air charging motor
26-400 and
apparatus controller 26-900). In like fashion to the embodiment shown in
Figure 7 sensors, inlet
and outlet valves, and connections and communications with other platform
functions can
embellish the embodiment.
[0193] The high velocity and mass air flow of one such embodiment can be used
a
substitute for the large fans used to furnish air into combustion heating
furnaces. Another
embodiment could be used to supply ambient airflow to a heat exchanger/chiller
assembly with
an air charging effector optimized for flow. Units as small as about 400g for
a 50,000,000
cc/min air mover are possible with this configuration optimized for smaller
spaces and features.
Multiple embodiments sharing the apparatus controller 26-900 and power
management modules
(not shown) can reduce average controller and packaging to less than about
3kg. Engine
manufacturers continually look for ways to keep the total heat environment of
their
compartments in control. This embodiment of the invention can be connected to
the engine
control unit or platform control unit to actively cool (by exhausting) the
engine environment
(connections using the communications or capabilities shown to sensors in
Figures 33, 34, 35,
36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47). In many applications
platforms the structural
disadvantages of holes in the engine compartment are at least partially
overcome by using the
smaller aperture (nominally less than about 12 centimeters in an embodiment)
than extant fans
(often in excess of about 20 centimeters).
[0194] In Figure 27, an embodiment of the invention is applied to the heating
of air to
be supplied to warm a passenger, cargo, or engine compartment. As shown, the
airflow starts at
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an air intake 27-100 and air filter 27-101 to be routed to the air charging
effector of the
embodiment 27-500. The outlet flow from the air charging effector 27-500 can
be rerouted by
the recirculation valve 27-510 or may be supplied to the passenger, cargo, or
engine
compartment 27-200 (illustrated as a vehicle, but which could be a stationary
room, mobile
plenum, test unit, bubbling air, or other such article) through the air
intake. After cycling
through the compartment the air may be re-circulated or vented 27-510. In an
alternate
embodiment, the plenum 27-2050 may include an open bubbling-air device that
feeds the heated
air as small bubbles into a fluid. The air charging effector 27-500 may be
driven by the air
charging motor 27-400 under the control of the apparatus controller 27-900.
Power for the
apparatus controller 27-900, air charging motor 27-400, and the recirculation
valve (optional)
may be supplied by a power source module (not shown) and secondary power
storage device
(not shown). Sensors and other data inputs (such as those from the engine
control unit 27-2500)
may also be used by the unit (including the control, sensor, and power flows
between the air
charging motor 27-400 and apparatus controller 27-900). In like fashion to the
embodiment
shown in Figure 7, sensors, inlet and outlet valves, and connections and
communications with
other platform functions can embellish the embodiment.
[0195] The nature of running a compressive air charging effector 27-500 as
shown is
that the energy transferred may also increase the heat of the air output by up
to about 20 degrees
or more (depending on ambient conditions and air intake setups). The
availability of warming
for the passenger, cargo, or engine compartment may serve to keep the comfort
of the passenger,
cargo, or engine up in very cold conditions. The use of a local secondary
power storage device
(not shown) or plug-in grid power to externally power the air charging motor
27-400 may also
provide a mechanism to maximize the passenger, cargo, or engine capacity
available at low
ambient temperatures. The embodiment can provide both an airflow and heated
air in a very
short period of time possibly using only its onboard secondary power storage
device (if properly
sized) for power until other power is available from the grid electrical
systems. In a power
configuration and profile using grid power, the embodiment may act as a warmer
assembly
similar to those extant using resistive elements and fans. In an example
embodiment, the
apparatus may be applied to the warming of compartments and facilities in
bodies of water. This
is needed both to maintain comfort conditions and to maintain the operating
character of the
engine compartments by keeping them sufficiently heated (and air circulated)
to avoid formation
of ice and frost. Depending on the outlet device the heated airflow can also
be augmented by
resistive heating elements to increase its airflow temperature to be applied
to frost or ice
reduction.
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[0196] Intake (inlet) and outflow (outlet) subassemblies occur in most
embodiments of
the invention to support optimization of airflow through the air effector
subassembly. The
plurality of components in the inlet and outlet subassemblies is illustrated
by instantiations
including diverter valves, active swirl assemblies in the inlet, outlet
directing vanes, active swirl
assemblies in the outlet, and the appropriate valves such as iris, servo, or
diaphragm types. Both
active and passive valves can be applied to inlet or outlet functions. Both
powered and
unpowered valves can be applied with solenoids or other powered mechanisms
used for valve
controls. An exemplary example of embodiments of active inlet (Figure 31) and
active outlet
(Figure 32) show that the valve subassemblies may use power sourced from the
local Power
Source Module 31-1000/32-1000, control from the Apparatus Controller 31-900/32-
900, and
related sensor data 31-880/32-880 to conduct operations of a valve actuator 31-
410/32-410 and
consequently a valve 31-530/32-530.
[0197] In another exemplary embodiment, the capability of an inlet control to
manage
the pre-swirl on a dynamic basis can alter the functional delivery of a mass
air flow to a very
different set of efficiency bands. In an exemplary embodiment the capability
of an outlet control
to manage the pre-swirl on a dynamic basis for the outflow going into another
component of a
multi-stage embodiment (thus it becomes the pre-swirl of the next stage) can
alter the functional
delivery of the mass air flow of the next stage of an application.
[0198] Valves in the embodiments of the invention include inlet, outlet,
bypass valves,
re-circulating valves, vents, exhausts, and connections points between
airflows. Unpowered inlet
and outlet valves are illustrated by the use of `diverters' or `gates' that
may be operated by a
plurality of methods such as manual intervention, pressure in the airway, or
mechanical linkages.
Powered inlet and outlet valves may also have unpowered `safe' or `fallback'
settings (that use
mechanisms such as pressure loading or mechanical springs) to handle
conditions of power loss
or to protect against damage. In like manner, powered valves may have manual
or mechanical
settings (that use methods such as vacuum pressure, mechanical linkages, or
manual stops) to
ensure access to 'safe' or 'fallback' settings. For valves (inlet and outlet
valves in general
including bypass valves, re-circulating valves, vents, and exhausts) in
general the provision of
feedback, pressure, temperature, or other sensors in the assembly also implies
a need for the
information for the control element to properly manage the valve or know its
setting. Local
safety provisions in the valve may override control setting in the event of
sensor failure detected
in the valve assembly.
[0199] Figures 33-47 are examples of various methods and configurations for
sensors,
sensor data, identification and metadata, messages, inquiries, stored
information, human
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interactions, and interactions with other control elements in exemplary
applications where the
embodiments of the invention may be in use. These examples are illustrative
and instantiations
of the invention may have a plurality of these, and similar, elements.
[0200] Figure 33 is a simple connection of a sensor directly into the Control
element of
the systems and methods for generation and management of mass air flow. The
illustrative
example of a thermocouple outputs an electrical signal that may be translated,
for example, into a
useful digital representation and then into a control domain value for action
and processing.
Thus, signal conditioning, calibration, ranging, and other sensor management
and sensor control
functions can be supported directly by the control element as the
instantiation of the embodiment
requires. Data acquisition, data translation, data validation, data context,
and data integration are
also functions that may be directly supported by the control element as the
instantiation of the
embodiment requires. Other functions may also similarly be supported.
[0201] Figure 34 illustrates the acquisition of a sensor value into the
Control element of
the systems and methods for generation and management of mass air flow. The
illustrative
example is of a pressure sensor that converts the raw sensor response into a
useful digital or
analog representation that may subsequently be transferred into the control
domain for action and
processing. Thus, the handling of sensor functions can be divided between
elements of the
invention and external components at the useful convenience of the
instantiation of the
embodiment.
[0202] Figure 35 has the illustrative example sensor, for pressure,
communicating with
the Control element via a sensor, or sensor data, multiplexor interface.
[0203] Figure 36 has the illustrative example sensor, for pressure,
communicating with
the Control element via a local application platform network. Thus, the
illustrations are showing
that multiple communications media, methods, and connections can be used with
interfacing and
connection functionality divided between elements of the invention and
external components at
the useful convenience of the instantiation of the embodiment.
[0204] Figure 37 is the interconnection of the local platform application
control units to
the Control element. The illustrative example shows an engine control unit, or
a fuel
management system control unit, connected via an engine network to the Control
element. Other
embodiments may also interface to a plurality of other controls such as
emissions controls,
entertainment controls, suspension controls, drive train controls, power
management controls,
lighting controls, passenger comfort controls, security controls, or monitors
as needed for the
efficient and effective control of the particular embodiment.
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[0205] Figure 38 shows an exemplary interconnection of indirect controls to
the
Control element of the systems and methods for generation and management of
mass air flow.
The illustrative example shows other controls including, for example,
Passenger Comfort,
Suspension, or Fuel Level, connection via another control or diagnostics unit
that then sends the
data onwards to the controller. Although the fuel level (or electrical
capacity as an example) that
may be useful in managing the system's power usage is not normally available
directly to the
Control element of the invention; it may be available to another control or
diagnostics unit that
can provide an access point by which said data can be conveyed to the Control
element. The
Control element may then perform a plurality of functions on the data that
includes process, act,
store, retrieve, and communicate said data. Illustrations of these indirect
controls (that can also
be connected more directly to the Control Element of the embodiments of the
invention in
alternate embodiments) include accelerometers, global position tracking,
vehicle weight on
wheels, ambient lighting conditions, vehicle total power consumption, or
battery cycling, age,
charge state information, etc.
[0206] Figure 39 shows an example of the interconnection of indirect controls
to the
Control element. Like Figure 38, this figure is an illustrative example of the
connection of the
Control element with the control, diagnostics, or other data unit in the
application platform
(shown as connected via a controls interface and a transmission media). This
may be
accomplished by a plurality of the wide range of transmission media,
transmission protocols, and
transmission physical senders and receivers.
[0207] Figure 40 is like Figure 36, but includes the addition of the
electrical and
communications methods to access desired data via local network, or bus,
monitoring. This
monitoring (sometimes called `snooping') allows a less costly interconnection
of an embodiment
of the invention. The passive observation of the data traffic in the device
can be used by the
Control element to dynamically alter the behavior of embodiments of the
invention.
[0208] Figure 41 shows an example of an interconnection from identification or
metadata sources in the local application platform to the Control element.
Identification or
metadata sources in the local application platform are the values such as
those representing the
model, serial number, version, configuration management, manufacturing source,
engineering
control, performance values, data configuration, connection, security, power
management,
capabilities, or capacities of the other functional elements in the local
application platform. A
plurality of these data elements can be used by a specific instantiation of an
embodiment for the
control, monitoring, and behavioral management of the invention. These data
elements may also
be accessed, for the local invention, directly by the Control element.
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[0209] Figure 42 shows an example of the interconnection from a diagnostic,
archive,
data logging, or other stored data values within the local application
platform. Stored data such
as the times of the last platform operations, operating status, last known
configuration or
behavioral settings, set points, sensor configuration, diagnostic state,
length of operation,
duration of run, prior error conditions seen by the device, and conditions of
other platform
elements can be used by the Control element in managing and controlling
embodiments of the
invention.
[0210] Figure 43 shows an example of the interconnection of User Profile data
with the
Control element via a communication media such as a network. User Profile data
is a set of data
that provides parameters, set points, operating protocols, limits, behavioral
directives, and startup
data values for the optimal operation of the embodiment. The Control element
may access this
information, to dynamically control the behavior of embodiments of the
invention.
[0211] Figure 44 shows an example of the interconnection of User Profile data
with the
Control element directly into the unit. This provides a simplified case for
alternate embodiments
of the invention from the more complex case in Figure 43.
[0212] Figure 45 shows an example of the interconnection of emissions sensor
data
with the Control element via a network interface. As an illustrative example
the provision of
additional air charging for use by a catalytic converter, emissions gas
recirculation, or other
emissions function the Control element can thus has data to determine the
optimal dynamic
behavior of embodiments of the invention.
[0213] Figure 46 is an exemplary interconnection of a predictive unit with the
Control
element via a network interface. The illustrative example shows the
availability of prediction
data to the Control element. Prediction data may be produced from a variety of
methods, such as
historical patterns (as an example, normal length of drive or number of air
charging events in a
time period), hyper-real time predictions based on sensor and behavioral data,
or defined
parameters allowing predictions (such as the appropriate optimal settings for
operations during
startup, shutdown, maintenance, diagnostic, or specific operating profiles).
The access to this
data may thus allows the Control element to manage elements such as rotating
assemblies, power
consumption, data access, or flow management (inlets, outlets, operating set
points, operating
rotational controls) on a dynamic basis.
[0214] Figure 47 shows an example interconnection of human input through a
user
interface, and then via a plurality of communications media, protocols, and
connections present;
to the Control element. The human input can be used to dynamically control the
instantiation of
the invention.
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[0215] Exemplary applications include, but are not limited to:
1. Active Drive Trains: that may use an air charging subsystem to manage
the availability of torque to the engine for dead stop take offs or
transitions between drive
train ("shift") states; and heavy engine load conditions, such as going up a
steep hill;
2. Active Suspension: that may use an air charging subsystem to preset
suspension characteristics for `lags' in acceleration;
3. Fuel/ignition management: that may use an air charging subsystem to
handle flexible fuel (Ethanol, gasoline, diesel, natural gas, hydrogen, or
combination
fuels) in the same engine by dynamic air charging configuration;
4. Emissions controls: that may use the air charging subsystem to handle the
needs for additional air flows (such as Engine Gas Recirculation, Emissions
cooling, pre
heating of catalytic converters, active filtration or emissions heating);
5. Electrical management: that may use an air charging subsystem to handle
the needs to reduce battery demand during combustion engine operations or to
add
additional performance to power generation capacity while in a demand mode for
combustion engine operation or to act in managing overall power supply,
capacity, and
expenditure;
6. Environmental sensing: that may use an air charging subsystem to handle
the effects of very cold conditions on battery performance, engine fuel
burning
temperature performance, or for supplying non combustion heat to vehicular
components;
7. Active braking: that may use the air charging subsystem to efficiently add
power for electrical generation in the engine for powered (magnetic or
friction) braking
of the vehicle.
8. Dynamic Engine Management can use the air charging subsystem to add
pressurized air intake or exhaust as needed to optimize engine configuration
of
mechanical functions (such as engine cycle configuration, operation of engine
cycle
components, and pneumatic controls); and
9. Environmental Management: that may use an air charging subsystem to
add warm air to a passenger or cargo compartment prior to electrical or
combustion based
heating. This can also be used to warm batteries for better performance in
cold
conditions. This can also be used to cool batteries with airflow for better
performance in
hot conditions.
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10. Active brake cooling can use the air charging subsystem to blow air across
the brakes thereby providing a cooling effect and providing a means for
cleaning the
brakes under limited soiling circumstances.
11. An embodiment could be employed to generate large number of bubbles
for an instantiation where the heat and bubbles were used to oppose the
formation of ice
onto surfaces.
12. An embodiment could be employed to generate a lowered plenum pressure
in an area where a negative pressure should be maintained for cleanliness
purposes.
[0216] These applications use two features of an embodiment of the invention:
1) the
use of a compressive capacity that heats the air while generating the mass air
flow, and 2) the
capability of the control module of the embodiment to act autonomously, in
integration, or under
the control of an external management capability.
[0217] Common to all of the preferred embodiments of the invention are the
specific
capabilities providing a comprehensive range of apparatus management of power
(power
consumption and capacity), air charging mechanism management (electric motor
subassembly
management of the rotating subassembly, inlet/outlet active management
features, and dynamic
management of fluid flow), and capabilities and capacity to consider sensor,
control, and stored
information to function in a complex operating environment.
[0218] Another capability or capacity of the apparatus is the functioning of
the device
in a safe manner with an incorporated set of features to protect the device,
operating
environment, and human users. Examples of a plurality of features incorporated
through the
elements composing the invention are safety limits (illustrated by current
limiting in the Power
Module or operating thermal limits hot and cold for the rotating assembly),
sequences of
behavior to limit possibly hazardous conditions (illustrated by self-shutdown
of the rotating
assembly, distinct startup sequences in response to environment conditions,
fail-safe settings for
inlets and outlets in the event of missing or invalid sensor data) (sometimes
called safety
protocols), element controls for components of the inventions (illustrated by
turning off power to
network interface connections if repeatedly creating network errors on
operations), indicators
and annunciators (illustrative means such as visual, audible, tactile, or via
connections) of the
status of the device, safety optimization rules (illustrated by reduction of
functionality to
restricted levels to conserve power to maintain limited operations instead of
a total functional
shutdown), data logging and archiving (illustrated by storage and archiving of
operating states,
events, durations, commands, or other diagnostic information during
manufacturing test, field
test, diagnostic test, or on command from an external control unit),
regulatory compliance
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restrictions (illustrated by rejection of operating conditions that would
create a regulatory
compliance exception, tracking of regulatory compliance exceptions, or storing
compliance
measurements), and self-management of the device (illustrated by rejection of
an invalid set
point, conflicting operating parameters, or rejection of commands that could
create a hazard
condition).
[0219] Embodiments of the invention may differ in their specifics, but
exemplary
embodiments of the invention may incorporate a plurality of features that are
an innovative
exploitation of, for example, the available sensor, fine motor control, and
power management
capabilities. These features can include the management of the device
(including inlet, outlet,
and air effector management) to reduce or restrict operations in surge or
stall conditions. In an
analogous fashion to the operation of anti-skid brakes or anti-slip
transmission features the
control elements of the invention's embodiments can manage a plurality of the
features of the
embodiment (including inlet, outlet, airflow, air effector, and power
management) to maintain
the effective levels of operation possible to the device within its targeted
operating profile. The
active management of the features present in an embodiment of the invention
also support device
capabilities of self-protecting the apparatus from operating conditions
possibly harmful to the
device (such as extended operations at levels with certain harmonics, or
operations at levels with
high vibration or shock conditions, or operations at levels damaging to the
recipient of the
outflow, or operations where power consumption would cause negative effects).
The power
management module present in an exemplary embodiment may also provide for the
functional
enablement of safety and protection features of the device such as management
of power
consumption for safe operation of the power storage module, management of
power
consumption for safe operation of the larger battery/power storage module in
the application
(such as a hybrid battery or fuel cell), protection for the device against
electrical quality concerns
(such as sags, surges, fade, spikes, or drops in supply), and management of
the device for the
application (illustrated by preferences for the operation of the platform over
passenger comfort
without an override).
[0220] Operation of the embodiments of the invention may occur under a profile
of
usage. The use of stored profiles of usage for embodiments of the invention
provides specific
benefits not available to other conventional systems or elements. The basic
concept of a stored
profile can be found in a wide variety of implementations in both vehicular
and non-vehicular
implementations. Some of the novel and innovative aspects of the application
of profiles to the
embodiments of the present invention may include the availability of the
extent and capabilities
of profiles from high level operating strategies through low level motor
controls. A profile for
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an embodiment of the invention may include a plurality of parameters, set
points, configuration
information, operating capabilities, communications sequences and
interactions, data handling
rules, data storage requirements, security information, stored processing
codes, stored objects,
encoded personal data, location information, optimization priorities,
operating user preferences,
maintenance state, operating constraints, and regulatory requirements.
[0221] The storage, communication, and processing of these profiles can be
accomplished with a wide variety of extant representations, media,
communications methods and
apparatus, processing modules, interpretation methods, storage media, storage
handling,
integrity, validity, and security methods, encodings, encryption, partial or
complete retrievals,
partial or complete storage, constructions, version and configuration
controls, external
representations, translations, and dynamic algorithmic transformations.
[0222] The operational application of profiles in the embodiments of the
invention can
include both the retrieval, storage, and processing of the numeric,
measurement values, textual,
or selection indicators for use by the control element of embodiments of the
invention, and the
dynamic changes and modifications of the profiles that may occur during
normal, and abnormal,
functions applied to the storage, representation, and translations of the
profile components.
Profiles in the context of the invention applies to all of the
representations, storage, and
processing of the individual, and collective, numerical, measurement, textual,
or selection
indicators at any point in their existence and handling.
[0223] "Parameters" can be a plurality of numerical, measurement values, or
selection
indicators for use by the control element of embodiments of the invention. The
parameters cover
the requirements of the control element of the embodiments of the invention to
properly control
the apparatus. The parameters may vary based on the instantiation of the
embodiment, but can
include a plurality of motor parameters (e.g., startup, shutdown, motor
electrical interfacing,
motor rotational characteristics, motor electrical consumption, diagnostic and
error conditions,
availability of diagnostic or configuration information via separate motor
interfacing, motor type,
motor electrical configuration of windings/poles, motor thermal
characteristics, motor response
curves, motor efficiency, motor safety responses, motor safe operation, and
others), measurement
and sensor translation values (such as conversions from thermocouples or
pressure sensors to
data ranges normally used by the control element, sensor conversion values for
external sensors,
or other information), and other such values.
[0224] "Set points" can be a plurality of numerical, measurement values, or
selected
operating labels for use by the control element of the embodiments of the
invention. The set
points cover the dynamic operating values that the control element of the
embodiments of the
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invention applies to the consistent operation of the device. The set points
may vary based on the
instantiation of the embodiment, but can include a plurality of the values
such as idle rotational
speeds, minimum operating speeds, tables of operating speeds against ambient
temperature or
pressure, minimal or maximal temperatures, minimal or maximal pressures,
minimal or maximal
speeds for conditions of other components in the apparatus, a table of normal
operating
conditions known as `low', `medium', `high' (or other labeled operating
conditions uniform
between profiles, but having different set point values), tables of operating
values for different
power store levels, tables of operating values for different power store
types, tables of operating
values for different power store discharge rates, tables of operating values
for different power
consumption rates, or other such values.
[0225] "Configuration Information" can be a plurality of numerical,
measurement
values, textual, or selected operating labels for use by the control element
of the embodiments of
the invention. The configuration information covers the static and dynamic
operating values that
the control element of the embodiments of the invention applies to the
consistent operation of the
device. The configuration information may vary based on the instantiation of
the embodiment,
but can include a plurality of the values that identify the components,
versions, or engineering
controls; that identify the number of components present and their capacities
or capabilities as
needed by the control element; the configuration possibilities for the correct
interoperation of the
device with its application (such as requirements for other information,
device configuration,
number and type of other elements present, or requirements for proper
operations); the
information labeling other collections of data useful for handling external
(human or apparatus
driven functions) functions (such as warranty, factory records, minimum
training or certification
requirements for safe maintenance, compatibility with replacement parts, or
other labels); and
other such values.
[0226] "Operating Capabilities" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The operating capabilities may vary based on the instantiation of
the embodiment, but
can include a plurality of the values that the control element of the
embodiments of the invention
applies to the consistent operation of the device. The operating capabilities
can include the non-
sensor information that identifies controls for the inlet and outlet controls
(active or passive), the
static operating demands for the behavior of the apparatus (such as the
presence or absence of a
connection to a secondary air injection requirement), the fault tolerance
element presence or
absence (redundant modules, redundant air effectors and motors, absent backup
power storage
modules, redundant human interfaces, redundant support for multiple external
diagnostic
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interfaces, and others), the static or dynamic condition of air inlets and
outlets, the static or
dynamic condition of filters; the static or dynamic condition of sensors,
communications
methods and apparatus connections.
[0227] "Communications sequences and interactions" can be a plurality of
numerical,
measurement values, textual, or selected operating labels for use by the
control element of the
embodiments of the invention. The communications sequences and interactions
cover the
dynamic operating values that the control element of the embodiments of the
invention applies to
the consistent operation of the device. The communications sequences and
interactions may vary
based on the instantiation of the embodiment, but can include a plurality of
the values illustrated
by communications timeouts, sequencing of protocols to be used during
operations, sequences of
data transmission, error handling codes for communications integrity checking,
encryption keys,
encryption algorithm identification, communications media checking and
preferences,
communications protocols, identification values for broadcast or
communications
interconnections, availability of communications functions such as diagnostic
data retrieval, data
communications archiving, or control and diagnostic interactions.
[0228] "Data handling rules" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The data handling rules covers the dynamic operating values that
the control element
of the embodiments of the invention applies to the consistent operation of the
device. The data
handling rules may vary based on the instantiation of the embodiment, but can
include a plurality
of the values covering data logging intervals, data logging contents,
responses to diagnostic data
retrieval requests, data archiving, event logging, sensor value handling,
power component
characteristics, and handling values for other application platform needs.
[0229] "Data storage requirements" can be a plurality of numerical,
measurement
values, textual, or selected operating labels for use by the control element
of the embodiments of
the invention. The data storage requirements cover the dynamic operating
values that the control
element of the embodiments of the invention applies to the consistent
operation of the device.
The data storage requirements may vary based on the instantiation of the
embodiment, but can
include a plurality of the values and operations related to size and speed of
the available data
store; the capacity for logging, archiving, and redundant storage functions;
the data organization
and data structure of stored numerical, measurement values, textual, or label
data, representation,
and structural information; data storage sequences, events, connections, and
interactions.
[0230] "Security information" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
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invention. The security information covers the dynamic operating values that
the control
element of the embodiments of the invention applies to the consistent
operation of the device.
The security information may vary based on the instantiation of the
embodiment, but can include
a plurality of the values such as encryption keys, identities, authentication
sequences, access
controls, functional controls, integrity checking, validity checking, and
conformance. The
purposes of the security information handling are to control knowledge,
access, integrity,
validity, and conformance for functions such as factory testing, diagnostics,
warranties,
protections against stolen or misappropriated devices, protections against
access of information
when not controlled, operational integrity, valid operating combinations,
maintenance access,
modification and reconfiguration controls, and conformance to specifications.
[0231] "Stored processing codes" can be a plurality of numerical, procedural
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The stored processing codes cover the dynamic operations that the
control element of
the embodiments of the invention applies to the conduct of the device. The
stored processing
codes may vary based on the instantiation of the embodiment, but can include a
plurality of the
functional representations used to store the events, flow of events,
evaluations, calculations, and
data management during the conduct of operations. The availability in the
profiles of stored
processing codes supports the extension of functions of the control element,
and other apparatus
components, by the ability to statically or dynamically add, change, delete,
access, or copy the
pre-existing processing codes. The profile provides a specific mechanism and
functionality to
update, reduce, extend, copy, validate, verify, or replace processing codes in
the control element,
or other component elements, or the apparatus that embodies the invention.
[0232] "Stored objects" can be a plurality of stored data, stored processing
codes,
configuration information, security information, encoded personal data, or
other profile
representations stored as objects for use by the control element of the
embodiments of the
invention. The stored objects covers the static and dynamic operating objects
that the control
element of the embodiments of the invention applies to the consistent
operation of the device.
The maintenance state may vary based on the instantiation of the embodiment,
but can include a
plurality of the objects stored as one or more parts of the profile. Thus, a
profile consists of a
variety of collections of stored objects that can be statically or dynamically
handled and
processed during the normal functions of the control element of the
embodiments or the
invention or by components of the embodiments of the invention depending on
the instantiation
of the invention.
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[0233] "Encoded personal data" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The encoded personal data covers the data that the end user or
device operator of the
embodiments of the invention applies to the presence in the apparatus. The
encoded personal
data may vary based on the instantiation of the embodiment, but can include a
plurality of the
data such as identification of asset the apparatus is attached to, the routing
for retrieved stored
data, identification of the data handling of archived or logged measurement
values and operating
information, batch or group identification for multiple apparatus, lot
tracking information,
materials or disposal handling, and other such data.
[0234] "Location information" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The location information covers the dynamic operating values that
the control
element of the embodiments of the invention applies to the consistent
operation of the device.
The location information may vary based on the instantiation of the
embodiment, but can include
a plurality of the values useful to the embodiments of the invention such as
current location,
route planning, energy plan for routing, operational plans for device
functions on route, route and
time dependencies, or such other data. The purposes of the location
information for the control
element may be to allow the optimization priorities for the apparatus to be
acted upon. Thus, the
knowledge of a long uphill grade at a certain part of a forthcoming route can
allow the control
element of the apparatus to plan for the energy consumed during that part of
the route (longer
and higher level operations of an air charging device in this example). In
analogous fashion, a
long downhill grade with regenerative recapture of the energy in a hybrid
vehicle thus allow
higher levels of battery warming or passenger comfort operations during that
part of the route.
Routing and time dependencies can provide for additional air charging for dual-
transmission
vehicles allowing higher performance from the combustion engine component in
order to adjust
speeds on a longer trip to reach a destination in a time period. For very
short runs the need for
passenger comfort may outweigh the need for conserving power capacity. For
long runs the
need for battery warming may exceed that of air charging. The availability of
location
information to the Control unit of the embodiment of invention enables this
capabilities and
functions when needed.
[0235] "Optimization priorities" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The optimization priorities cover the dynamic operating values that
the control
element of the embodiments of the invention applies to the operation of the
device. The
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optimization priorities may vary based on the instantiation of the embodiment,
but can include a
plurality of the values that allow operation of the device supporting a
variety of optimizations.
An embodiment of the apparatus can always be composed where the safety
features of the
apparatus and method are always the highest automatic priority for the device.
In alternative
embodiments the conservation of power capacity, the ability to reach a
destination at certain
time, the maintenance of comfort for passengers, cargo, or vehicle components,
or the need for
internal combustion engine fuel can be priorities for control of the apparatus
at the lowest level.
An additional illustration of an optimization priority is providing a choice
to the platform human
user between cabin comfort and environmental emissions levels; or between
depletion of
electrical capacity and fuel capacity. In these cases the optimization
priorities can be
dynamically modified by human (as part of an informed decision) or application
systems
intervention in pre-selected types of conduct.
[0236] "Operating user preferences" can be a plurality of numerical,
measurement
values, textual, or selected operating labels for use by the control element
of the embodiments of
the invention. The operating user preferences cover the dynamic operating
values that the
control element of the embodiments of the invention applies to the consistent
operation of the
device. The operating user preferences may vary based on the instantiation of
the embodiment,
but can include a plurality of the sensor, pre-selection, and automated
selection of the
optimization priorities, operating constraints, and operating profiles to be
applied at specific
instances by the Control element. The functions addressed are the
identification, selection, and
initiation of the profile in the operations controlled by the Control element.
Further, the
switching, adding, deleting, modification, updating, replacement, or
translation/transformation of
profiles in response sensor, pre-selection, or automated selection is also a
function of the Control
element of the invention.
[0237] "Maintenance state" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The maintenance state covers the dynamic operating values that the
control element
of the embodiments of the invention applies to the consistent operation of the
device. The
maintenance state may vary based on the instantiation of the embodiment, but
can include a
plurality of the values for functions of the apparatus and methods for hot
swapping components
of the apparatus, the ability to bypass certain operating constraints,
regulatory requirements,
optimization priorities, sensor measurements, or conformance requirements such
that a qualified
user can access the functionality of the device in a secure access controlled
manner.
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[0238] "Operating constraints" can be a plurality of numerical, measurement
values, or
selected operating labels for use by the control element of the embodiments of
the invention.
The operating constraints cover the dynamic operating values that the control
element of the
embodiments of the invention applies to the consistent operation of the
device. The operating
constraints may vary based on the instantiation of the embodiment, but can
include a plurality of
the values time or calendar values (such as those limiting the hours of the
day, days of the week,
duration in hours, duration in days, other bounding values), values for
minimal and maximal
limits of continuous operations, values for minimal or maximal apparatus
behaviors in normal or
abnormal conditions (such as pre-run, after-run, maintenance cycles,
diagnostic cycles, or in
override conditions), values for consistent operations (illustrated by
compatibility with other
configuration information, regulatory requirements, or air charging
requirements), and other
information.
[0239] "Regulatory requirements" can be a plurality of numerical, measurement
values,
textual, or selected operating labels for use by the control element of the
embodiments of the
invention. The regulatory requirements cover the dynamic operating values that
the control
element of the embodiments of the invention applies to the consistent
operation of the device.
The regulatory requirements may vary based on the instantiation of the
embodiment, but can
include a plurality of the values that delimit the operating states or
operating requirements of the
apparatus. The regulatory requirements may include a plurality of requirements
such as
minimum/maximum operating elapsed times, minimum/maximum operating
temperatures,
minimum/maximum operating pressures, average performance over a defined
interval of time or
elapsed time, minimum/maximum operating components functional, minimum/maximum
data
logging, minimum/maximum operator interactions, and other such data.
[0240] The usefulness of these profiles can be illustrated by the following
examples,
but the scope and coverage of the embodiments of the invention are not limited
to these
examples.
[0241] In a simple embodiment for a propulsion vehicle a human operator of the
apparatus and methods might select between `high performance', `best energy
conservation',
`most comfortable', or `regulatory testing' profiles, for example.
[0242] In a complex embodiment for a hybrid propulsion vehicle having multiple
power stores, the profiles might be applied, and changed, for dependencies of
vehicle routing,
ambient conditions, power store status, levels of available internal
combustion fuel, fuel mixture,
user preferences, and the like.
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[0243] The air charging mechanism (subsystem where the embodiment is
implemented)
effects on engine performance are such that a smaller engine may be used where
a larger,
heavier, or higher fuel-consumption engine may otherwise have been required.
The vehicle
designers, operators, or managers can also select the usage pattern, control
points, performance
trade-offs, and other characteristics of the vehicle operations depending on
what features, energy
usage, and/or controls are appropriate at design, deployment, or in dynamic
operation of the
vehicle.
[0244] The extant trend to flexible fuel vehicles (which may be particularly
important
in emerging world markets) allows a wider range of fuel capabilities because
the mass air flow
device air charging characteristics allow for fuels such as ethanol (with, for
example, a 9.1:1 by
weight stoichiometric ratio), E85 (9.7:1), gasoline (14.7:1), or natural gas
(17:1) to be
combusted. This range (of over 80% variance) is even more complex when
environmental (such
as outside temperature), operating history (engine status), fuel blend (that
may be a combination
of fuels), or operating needs (high altitude, high demand, low demand) are
factored into vehicle
management on a dynamic basis. The ability (reliability) to operate the
vehicle may depend on
the ability of the air charging subsystem to supply appropriate amounts of air
when attempting to
operate on specific fuels and conditions.
[0245] The application of the invention's mass air flow devices into a hybrid,
plug-in,
or electrical vehicle (see e.g., Figures 28-30) may be especially beneficial
because it enables
operating possibilities and performance characteristics not easily achieved by
even combinations
of other devices.
[0246] Another feature of exemplary embodiments of the present invention
includes the
flexibility and capability of the mass flow device to interact with the
external controls and
environment in ways not previously available. For example, earlier attempts at
high velocity
mass air moving devices were limited in many situations to simply being turned
on or off by a
switch control. Other devices were limited to a set palette of operating flows
or very limited
operating cycles. The limitations from these earlier devices were often due to
immediately
available power, lack of sensory or control inputs, or highly constrained
motor control functions.
[0247] The various embodiments of the invention may include a plurality of the
features documented here, but many different combinations are possible due to
the ability to
"soft configure" the device at design, manufacturing, and/or in the field. The
ability to
customize the configuration of the device while using the same base physical
components (such
as, for example, the motor, connectors, physical fittings, etc.) also are
advantageous to the
control of design costs (e.g., using high levels of reuse, design for
configuration, design for
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customization, and component design for design cost control), control
manufacturing costs (e.g.,
common components, design for manufacturing, integrated features for test
management,
integrated features for manufacturability, integrated features for mass
customization in
manufacturing, integrated features for quality assurance), and in the field
(e.g., common
replaceable components, design for field service, integrated self-test
features, integrated self-
protection features, integrated features for field service quality assurance,
and integrated features
for field flexibility).
[0248] The interactions of the different embodiments of the invention may
include
several categories of interactions. These exemplary categories are not
mutually exclusive, nor
are the embodiments limited to a subset of the interactions. Depending on the
embodiment, the
invention may be capable, with appropriate control flows, of operating in any,
or all, of the
described interactions with full capability (or a subset as required).
[0249] The interactions of the mass flow device can occur in both direct
(e.g., control
flows, signals, or switching) and indirect (e.g., power states, sensor inputs,
common actuator
states, broadcast data bus/transport messages) methods. The interactions can
occur as conditional
requests, preemptory commands, and/or as informational status only. Note that
example
messages may be dependent on implementation and any specific device embodiment
may handle
interactions in a manner consistent with the specific implementation and
product environment.
[0250] The table below illustrates exemplary interactions:
Interaction Direct- Interaction Examples
Description Indirect
Control Flow Direct Conditional Report Power Module State,
Request Bring Up Check
Control Flow Direct Preemptory Set mass air flow desired,
Command Turn Device Off
Control Flow Direct Informational Power availability High
Status Accelerating
Stopping
Parked-Idle
Control Flow Direct Preemptory Enter diagnostic mode
Command
Control Flow Direct Conditional Report history of operation
Request
Control Flow Direct Preemptory Change operating customization or
Command configuration
Control Flow Direct Informational Sensors available
Status
Signals Direct Change in Change to Performance profile
Profile Change to Energy Saver profile
Change to City Profile
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Change to High Altitude Profile
Signals Direct Preemptory Entering external power module
Command recharge
Signals Direct Conditional Generate heated airflow if possible
Request
Switching Direct On/Off Power feed from external power goes
to zero
Switching Direct Informational Going from external power generator
Status to stored power
Power State Indirect Informational Power Current available is reduced
(measured by device sensor)
Power Current available is reduced
(external bus message from external
power unit)
Power State Indirect Preemptory External bus interface issues power
Command reset
Power State Indirect Conditional Broadcast external bus message
Request requesting power consumption to be
reduced if possible
Sensor Inputs Indirect Informational High Temperature Conditions
Status Low Temperature Conditions
Overpressure Condition
Underpressure Condition
Sensor Inputs Indirect Conditional Local energy cell reports 50%
Request available capacity
Sensor Input Indirect Conditional Local energy cell reports fully
Request charged
Sensor Input Indirect Preemptory Local energy cell reports zero
Command available capacity
Common actuator Indirect Preemptory Outflow actuator set to waste gate
state Command output until needed
Common Actuator Indirect Conditional Inflow closed due to obstruction -
state Request reduce operation if needed
Broadcast messages Indirect Preemptory Retransmit - last message had an
Command error
Broadcast message Indirect Conditional Selective Rollcall for devices
Request Report any warning or diagnostic
messages
Report any fault conditions
[0251] Exemplary categories of interactions between the various mass flow
device
embodiments and the external include:
Interaction Description Example
None Isolated Unit Predefined On/Off Air Flow
Cycle
External Switched Power Up/Down Controlled for specific
operating cycle by On/Off
external control flow
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Independent Operates without outside Uses own sensors to
direction of controls determine if mass air flow
flushing is required
Uses own controllers to
operate simple or complex
cycling of mass air flows
Independent - Indirect Operates with indirect Sensors shared with other
sensor or control flow devices that trigger mass air
information flows when needed (such as
emergency failover)
Triggered by low
temperature sensors that
other devices need
supportive heated air flows
Independent - Operates independently but Operates independently
Informational provides information to supplying intake and
other devices for history, outflow information to
diagnostics, and operations other devices
Operates independently
while supplying operating
conditions, sensor readings,
and diagnostic information
to other devices
Fully Integrated Slave Controlled completely by Under control of engine
external management unit management, or
HVAC environmental
controller
Fully Integrated Peer Operates under highly Cooperating with fuel and
autonomous management environmental management
with information and controllers, or I
control requests from other HVAC environmental units
devices distributed in a facility
[0252] None Category of Interaction:
[0253] An exemplary embodiment of the "None" category of interactions may
include
uses of the high velocity mass flow device for ventilation purposes. For many
types of this use,
the high velocity mass flow device may be coupled to an inflow and outflow
that directs the
mass air flow to or from the compartment. Operations run either until stopped
by an operator or
sensors indicate that the function is complete or needs to be halted for other
(such as, for
example, diagnostic failure) reasons.
[0254] External Switched Category of Interaction:
[0255] An exemplary embodiment of the "External Switched" category may include
a
power up/down interaction where the external power supplied to the unit may be
controlled by
the external application. A simple application occurs when an "automated
warming" or an
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"automated inflator" function is initiated by an external control application
to refresh air in an
otherwise overheated passenger compartment. The external controller (such as a
climate control
module for the passenger compartment) switches the mass flow device by Power
Up/Down
supplied to the device. Operations may run either until stopped by this
external switching or
because of other reasons (such as, for example, reaching a pre-set run time or
diagnostic failure).
[0256] Independent Category of Interaction:
[0257] An exemplary embodiment of the "Independent" operation includes an
application wherein the mass flow device may be deployed to act as a mass air
flow for flushing
a specified compartment on a self controlled basis. The device' sensors may
act to trigger a
control flow that initiates a mass air flow flush (for example, to expel
unwanted concentrations
of gas or particles). Operations may run until a preprogrammed operating cycle
is completed or
until other conditions are reached (such as, for example, sensors reporting a
clearance state,
diagnostic failure, or low power conditions). An example of this embodiment is
flushing all of
the too warm or too cold air from a vehicular compartment (battery or
passenger) on a fixed
basis, or to purge accumulated gaseous by-products as part of preset operating
profile.
[0258] Independent - Indirect Category of Interaction:
[0259] An exemplary embodiment of the "Independent - Indirect" operation may
include a mass flow device deployed in concert with other devices in an
environmental control
situation or in an environmental protection role for sensitive equipment (such
as, for example,
batteries, instrumentation, etc.). Sensors hooked into the communications
interface (external)
from the device that detect a state that requires the application of a mass
air flow are then acted
in response by the mass flow device. An example of this sensing state includes
the failure of
another mass air flow device or a falling temperature. This state sensing then
triggers operations
of the device to provide a mass air flow (that will act as a heat transfer due
to the compressive
heating of the creation of the pressurized flow) to support the required
environment. Operations
may run a condition such as those that show the sensor data is now within
control limits without
the operation of the embodiment, that the state of power support is
inadequate, or until a
preprogrammed operating cycle is complete.
[0260] Independent - Informational Category of Interaction:
[0261] An exemplary embodiment of the "Independent - Informational"
application of
the mass flow device occurs when the embodiment is in direct control (and
possibly in sole
interface) to sensors in the air flow path (e.g., intake, and outflow, or,
onto other elements of
environment hooked to the external data interface) or other data flows in the
environment (such
as, for example, control states, power information, or operating profiles
based on time, events, or
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sequences). The device is responsible for interpreting and acting upon the
received sensor or
data flows and conducting operations in response that may be a simple
operating cycle, or a
complex algorithmic response, or a heuristic control system process.
Autonomous operations in
response to the sensor or data flows can be monitored, recorded, or relayed to
other devices,
management reporting systems, maintenance stations, archival recording
devices, or other
readouts and storage as may be required. Additional control flows, data flows,
and sensor relay
may occur in addition as in those operating modes where the embodiment acts as
a primary
management controller in a larger environment. Operations may continue until
sensor inputs,
operating profiles, local power switching, or other indications cause the
embodiment to
discontinue operations.
[0262] Fully Integrated Slave Category of Interaction:
[0263] An exemplary embodiment of the "Fully Integrated Slave" application of
the
mass flow device occurs when the embodiment is under the direct control of an
external
management unit that controls the starting and stopping of the unit (with
local exceptions in the
embodiment to self-management directives), conduct of operations (including
application of, for
example, preset profiles, operating control strategies, and feedback driven
controls), and provide
data (such as, for example, diagnostic, sensor, operating, or status
information). The external
management may be responsible for directly commanding the unit to perform
operations (even
though it may be acting on sensor information provided by the embodiment or by
status
information related to the state of power module activity). The operations of
the embodiment
may continue until the unit completes the commanded operations (that may
return it to a specific
operating mode, such as continuing to relay sensor data), the embodiment acts
under self-
management directives (such as, for example, to fault and cease operations in
self-protection or
due to conditions where damage would result to the embodiment, persons, or
surrounding
devices), the embodiment is commanded by the external management via a control
flow to
interrupt operations, or until insufficient power is available to operate.
[0264] Fully Integrated Peer Category of Interaction:
[0265] An exemplary embodiment of the "Fully Integrated Peer" application of
the
mass flow device may occur when the embodiment is operating both under the
control of an
external management controller (in similar fashion to all of the functions
described for the "Fully
Integrated Slave" category of interaction) while in addition the unit pursues
independent
operations as previously established for the unit (for example, conducting
self-diagnostic checks
and "warm up" actions when the embodiment first receives power or has idle
functional time).
The unit may be responsible for arbitrating both the Requested Functions,
Preemptory
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Commands, and responding to direct and indirect signals and flows (e.g., data,
control, or sensor)
that may occur. The unit is responsible for maintaining operations under a set
of strategies (such
as, for example, profiles, operating modes, and information actions such as
those found in the
"Independent - Informational" interaction category). The complexity of actions
of the device in
the "Fully Integrated Peer" category of interaction may be determined based on
the particular
application in which the device may be operating such as, for example, with
heuristic, pre-
planned, or control-loop response strategies. The functions that provide
information to outside
devices (directly via the external data and control flows interface or
indirectly via sensor
information that is shared/relayed/available) may continue as controlled by
the embodiment.
[0266] The following are exemplary engine and vehicle applications in which
the mass
flow device may be used and/or incorporated. Exemplary applications include:
1. IC Engine / Fuel Types:
1. Gasoline:
[0267] Gasoline engines benefit from reduced pumping losses with positive
intake
pressure. Active control of intake air pressure optimizes combustion
efficiency at varying engine
speeds and under wide ranging ambient pressure and temperature conditions.
2. Diesel / Biodiesel:
[0268] In addition to benefits for gasoline engines, compression of intake air
charge
provides heat for starting and running at low ambient temperatures. Active
control of intake air
pressure and temperature optimizes combustion under various mixes of
traditional and bio-
derived fuels. On-demand pressurized intake charge reduces particulate (smoke)
emissions by
optimizing combustion under acceleration.
3. Ethanol:
[0269] Active control of intake mass air flow allows for most efficient
combustion of
pure ethanol or intermediate gasoline/ethanol blends. Heated intake charge
aids fuel
vaporization for engine operation at low ambient temperatures. Additional mass
air flow allows
for full combustion of larger volume of ethanol as required to produce
equivalent power to
gasoline fuels.
4. Natural Gas:
[0270] Active control of intake mass air flow allows for precise optimization
of lean-
burn or stoichiometric combustion of natural gas blends of varying gas
compositions. Increased
mass air delivery increases maximum power available from natural gas fuels.
5. Hydrogen:
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[0271] Increased mass air flow to engine allows for complete combustion under
stoichiometric conditions requiring significantly more airflow than
traditional fuels. Compressed
intake flow compensates for volume of combustion chamber displaced by gaseous
hydrogen
fuel. It has been shown that the stoichiometric or chemically correct A/F
ratio for the complete
combustion of hydrogen in air is about 34:1 by mass. This means that for
complete combustion
under normal operating conditions, 34 pounds of air are required for every
pound of hydrogen.
This is much higher than the 14.7:1 A/F ratio required for gasoline.
[0272] Due to hydrogen's low ignition energy limit, igniting hydrogen may be
easy and
gasoline ignition systems can be used. At very lean A/F ratios (e.g., about
130:1 to about 180:1)
the flame velocity may be reduced considerably and the use of a dual spark
plug system may be
preferred. Also, hydrogen engines are typically designed to use about twice as
much air as
theoretically required for complete combustion. At this A/F ratio, the
formation of NOx may be
reduced to near zero. Unfortunately, this also reduces the power out-put to
about half that of a
similarly sized gasoline engine. To make up for the power loss, hydrogen
engines may be larger
than gasoline engines, and/or may be equipped with a mass flow device.
6. Hydrogen Fuel-Cell:
[0273] In a hydrogen fuel-cell vehicle a recognized concern is the ability of
the vehicle
to operate in cold-weather/ambient conditions. The embodiment of the invention
can be applied
to the direct realization of these goals. The unique and innovative features
of the invention, in
these two embodiments, are the provision of a fuel cell warmer that does not
depend on electrical
resistive heating while providing warm air for other purposes, a fuel cell
cooler that also has
unique and innovative features, and that the control and management of air
moving devices are
under the control of an apparatus that can either manage, be managed, or
jointly manage the
provision of heating and cooling to the fuel cell apparatus. Specifically, the
fuel cell warmer uses
a compressive heating mechanism, instead of a resistive electrical element,
that also can cycle
warm air for passenger or cargo comfort. The fuel cell cooler can be more
effective with a full
integration of the cooling power consumption process with the fuel cell power
management
control.
II. Power Storage / Hybrid Types:
1. Battery Cell:
[0274] Power stored by hybrid vehicle motor/generator is available to maintain
sufficient charge in apparatus power storage. Air charge produced by mass
airflow device may
be used to maintain vehicle batteries at optimal operating temperature. Power
supplied by hybrid
power storage cells at variable high voltage levels may require voltage
regulation, isolation, and
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conditioning to supply power to airflow apparatus power storage device.
Positive pressure mass
air flow provides combustion engine with additional torque for acceleration
when vehicle battery
reserves are depleted or to optimize combustion for recharging process. See
Figure 28.
2. "Plug-in" Hybrid:
[0275] Hybrid vehicles operated on electric power to the limits of battery
capacity are
left without electric motor assist when batteries are depleted. On-demand mass
air flow provides
for additional engine torque as needed during such periods. See Figure 29.
3. "Pure" Hybrid:
[0276] Hybrid applications in which an internal combustion engine is used only
to
provide electrical power to motor systems benefit from the ability to closely
control operating
cycle of engine for maximum efficiency under varying environmental conditions
and fuel
supplies. See Figure 30.
[0277] While the present invention has been described in connection with the
exemplary embodiments of the various Figures, it is not limited thereto and it
is to be understood
that other similar embodiments may be used or modifications and additions may
be made to the
described embodiments for performing the same function of the present
invention without
deviating therefrom. Therefore, the present invention should not be limited to
any single
embodiment, but rather should be construed in breadth and scope in accordance
with the
appended claims. Also, the appended claims should be construed to include
other variants and
embodiments of the invention, which may be made by those skilled in the art
without departing
from the true spirit and scope of the present invention.
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