USRE40820E1 - Multi-battery fuel saving and emissions reduction system for automotive vehicles - Google Patents

Abstract

A multi-battery charging system for reduced fuel consumption and emissions for an automotive vehicle. The system starts the vehicle with a start battery in a fuel savings manner, removing electrical torque from the alternator shaft, and allows a second (run) battery to provide all or some of the current required by the vehicle loads as a fuel savings measure. The system also utilizes an electrically heated catalytic converter (EHC) and a third (EHC or storage) battery to provide a 3 to 15 second preheat and/or a 20 second current, during vehicle start, to the EHC heater coil, e.g., of a small EHC located in series with a standard catalytic converter for emissions reduction to reduce emissions during start. The start battery is recharged after start and switched out of the system fully charged for future vehicle starts. The run battery is recharged when its charge level drops below a predetermined level with an on board battery charging device powered from a 115 volt or 220 volt ac power line source external to the vehicle.

Description

More than one reissue applications have been field for the reissue of U.S. Pat. No.6,466,024. The reissue applications are application Ser. Nos.11/810,155 (the present application)and10/967,704(abandoned).

RELATED APPLICATIONS

This is a divisional of application(s) Ser. No. 07/977,921 filed on Nov. 18, 1992, now issued as U.S. Pat. No. 5,397,991, and a continuation-in-part of U.S. patent application Ser. No. 07/919,011, filed Jul. 23, 1992 in the name of Wesley A. Rogers and entitled An Improved Battery State of Charge Monitor, now issued as U.S. Pat. No. 5,444,378, which is a continuation-in-part of U.S. patent application Ser. No. 07/607,237, filed Oct. 31, 1990 in the name of Wesley A. Rogers and entitled Apparatus for Monitoring the State of Charge of a Battery, now issued as U.S. Pat. No. 5,179,340, which is a continuation-in-part of U.S. patent application Ser. No. 07/218,539, filed Jul. 13, 1988 in the name of Wesley A. Rogers and entitled Apparatus for Monitoring the State of Charge of a Battery, now issued as U.S. Pat. No. 4,968,941.

FIELD OF THE INVENTION

This invention relates to a multi-battery operating system for automotive vehicles that provides improved fuel economy and reduced emissions during operation and during starting, more particularly a three battery system having a start battery for starting the vehicle, a run battery for providing the vehicle load and accessory current, and a storage battery for preheating a catalytic converter during starting.

BACKGROUND OF THE INVENTION

In the normal operation of an automotive vehicle, a fully charged six cell battery having between 2.05 and 2.1 volts per cell (hereinafter referred to as a “start” battery) is used to start the engine and to operate accessory loads when the engine is not running. The conventional start battery is well suited to provide large start currents to the start motor on the order of 150 to 250 amperes.

The start battery is provided with thin plates between its individual cells that provides for a rapid, large current, shallow discharge during vehicle start. Unfortunately, the start battery cannot be deeply discharged in a repetitive manner without damaging the thin cell separator plates.

It has long been the practice to provide an alternator driven by the engine that can be used to recharge the start battery after vehicle start and provide current to both the vehicle run and accessory loads. It has also been the practice to maintain the alternator charging voltage at a nominal value of 14.0 volts at an ambient temperature of 85 degrees F. The nominal value is raised to 14.6 volts at minus 20 deg. F. and lowered to 13.6 volts at 140 deg. F. This provides adequate charge current as a function of ambient temperature and thereby extends battery life.

A voltage regulator is used to inject a controlled current into the alternator rotor. This in turn provides a controlled current in the stationary (stator) field coils. This in turn yields the rectified dc output voltage required for battery recharge after start and to supply the required vehicle load currents.

OBJECTS AND SUMMARY OF THE INVENTION

It has been realized by the inventor that the conventional operation of a start battery and alternator based electrical system of an automotive vehicle wastes energy. First, the alternator requires the engine to provide fuel consuming torque to operate the alternator at a nominal value, e.g., a 14.6 volt dc output level, in order to recharge the start battery and provide the required current to the vehicle loads. Second, the vehicle electronic circuits contain power consuming voltage regulator circuits that reduce the alternator output voltage to a 12 or 5 volt level. Third, the alternator places a mechanical torque on the engine as a function of the alternator output voltage and the current drawn to supply the load requirements and to charge the start battery. The fuel consumed by the engine to overcome the alternator counter torque is an unnecessary expense. Fourth, the vehicle engine and alternator are substantially less than 100% efficient and consume a correspondingly greater amount of fuel.

In addition, the inventor has realized that if the state of charge of the vehicle batteries are reliably and accurately determinable over their useful life it is possible to control the alternator output voltage, as required, either to charge the vehicle batteries or to allow one or more batteries to provide all the current required by the vehicle loads.

It is a further object of the invention to increase alternator output voltage during deceleration of an automotive vehicle, thereby using vehicle momentum to provide an increased torque load that is used to charge a battery.

It is another object of the invention to turn off selected vehicle accessory loads when the vehicle is parked and to turn off selected vehicle accessory loads when the state of charge of the battery providing current drops below a selected level.

It is another object of the invention to provide a storage battery for providing the current required to heat an electrically heated catalytic converter (EHC) during or prior to vehicle start when the engine temperature is below a selected level.

In accordance with the present invention, apparatus, systems, and methods are provided for providing sufficient electrical power to start and run an engine, to reduce the energy expended and fuel consumed and associated emission by-products in starting and running the engine, and optionally in operating a battery charging device to maintain a sufficient charge on each battery for the range of operating load conditions.

One aspect of the invention concerns a battery charging and run system for starting the engine of an automotive vehicle and operating the electrical loads of the automotive vehicle with improved fuel economy.

One embodiment of this aspect of the invention concerns a battery charging system for an automotive vehicle having;

• • a start battery for use in starting the vehicle engine;
  • a run battery for operating the vehicle accessory and non accessory loads;
  • a battery charging device, such as an alternator, having a controllable output voltage when the vehicle is running;
  • a first BSOC channel for monitoring the state of charge of the start of battery;
  • a second BSOC channel for monitoring the state of charge of the run battery; and
  • a first circuit, such as a voltage regulator, for controlling the output of the battery charging device to provide one of a first output voltage that varies in a first range as a function of ambient temperature when the sensed start battery state of charge level is below a first charge level and a second output voltage when the battery state of charge level is above the first charge level, a third output voltage to recharge the run battery when the run battery state of charge is below a second charge level, and a fourth output when the run battery state of charge is above the second charge level.

Preferably a switch is provided to switch the start battery out of the system after it is recharged. The switch is responsive to the sensed state of charge of the start battery and open circuits the start battery upon reaching the first charge level.

In operation, the start battery is employed to start the vehicle engine. Its state of charge thus fall below the first charge level (corresponding to the present charge level). This causes the control circuit/voltage regulator to control the battery charging device to provide a first output voltage to recharge the start battery, e.g., between 16.4 and 13.6 volts dc, according to the ambient temperature in the conventional manner.

When the sensed state of charge of the start battery is at the first charge level, the control circuit/voltage regulator may then control the battery charging device to provide the second output voltage level to maintain a full charge on the start battery. In a preferred embodiment, the switch is configured to respond automatically to the start battery state of charge returning to the first charge level and switch the start battery out of the charging system in a fully charged state. Alternatively, the switch may be manually operated by the operator who acts in response to a prompt, such as a light, audible tone, or battery state of charge display.

When the start battery is switched out, the two battery system then may operate in one of two modes. In the first preferred mode of operation, the automotive vehicle electrical load is run off the run battery entirely. In this mode, once the start battery is switched out (and, as described below, an ECH battery is switched out), the control circuit controls the battery charging device to provide the fourth output by reducing the field current until the bridge rectifier diodes become back-biased. When the control circuit is a controllable voltage regulator, the battery charging device is an alternator, and the voltage regulator output into the alternator rotor coil is about zero, there is little, if any alternator counter torque on the engine and the rectified alternator output bridge diodes are backed biased and provide no current. Accordingly, the run battery will discharge to operate the vehicle load. During this discharge, the absence of the alternator counter torque results in improved fuel economy.

However, when the state of charge of the run battery falls to the second charge level, which corresponds to a low charge (deep discharge) level that will not damage the run battery, the control circuit/voltage regulator controls the battery charging device to provide the third output voltage. The third output voltage is then used to provide power for the vehicle load.

The third output voltage level may be selected as follows. It may be a level that will power the vehicle load and maintain the run battery at the second charge level. This selected level may be adjusted to prevent any further reduction in the state of charge of the run battery. In this case, the third output voltage may be on the order of 12 volts, as adjusted for ambient temperature conditions. Alternatively, the third output voltage may be a level that will power the vehicle level and recharge the run battery to a fully charged state, e.g., a voltage between 13 and 14.6 volts dc, as a function of ambient temperature. Once the run battery is recharged, it is allowed to discharge down to the second charge level, during which time the vehicle loads are again run exclusively off the run battery. Thus, whenever the alternator output voltage is reduced from the conventional full charging state, the alternator counter torque on the engine is less and there is improved fuel economy.

In all cases, the run battery is preferably recharged using a conventional battery charger which is powered from an external line source, e.g., a 220 or 115 volt ac line power supply. This permits replacing the amp-hour charge that was removed from the run battery by the vehicle loads with a source of electricity external to the vehicle. The external electricity source typically costs less per unit of energy than petroleum and alcohol based fuels and avoids consuming the incremental fuel that was saved during discharge of the run battery to generate the power needed to recharge the run battery. Such a battery charger may be mounted on or off the vehicle.

In another mode of operation, after the start battery and run batteries are recharged, the start battery is switched out and the battery charging device is operated to provide a fifth output voltage level and current for operating the vehicle accessory load. The fifth output voltage level is preferably selected to provide just enough current to operate the vehicle accessory loads, e.g., 12 volts for a 12-volt system and also applied a trickle charge current on the run battery. This mode also reduces the energy consumed as compared to prior voltage regulator start battery alternator systems that always produced more voltage than was required by the vehicle loads.

Switches and control circuits may be used to control automatically and/or manually the battery charging device and to connect selectively the battery charging device to one or both of the run and start batteries, and to provide the desired output voltage(s) and current(s) to recharge the batteries, singly or jointly, to operate the accessory and non accessory loads. A microprocessor may be used to control the various battery state of charge monitors, control circuits, and switches. Alternatively, a logic circuit network or a state machine comprising discrete and solid state components may be used as a control circuit. In addition, an operator display and manual switching system may be used.

Another aspect of this invention concerns providing a switch to connect one battery in place of the other battery if one of the batteries should fail to hold an adequate charge, and to use both batteries in parallel or in series when conditions so require. This is particularly useful in very cold weather when an additional source of start current is desired, and where one battery either fails or is not fully recharged before the engine is turned off.

Optionally, a measure of the amplitude and direction of the current flow into or out of the run battery or the start battery may be included for decision making purposes in selecting a voltage level. A large start battery discharge current may confirm a starting operation and raise the alternator output voltage level. An increased flow of current out of the run battery, i.e., a load current that might deplete charge from the run battery if the trickle charging voltage was maintained, could result in raising the trickle charging voltage, the load current and the battery state of charge.

Preferably, the start battery is a conventional automotive battery having thin cell plates and the run battery is a deep discharge, marine or cycle-proof battery. Such run batteries have thick cell plates and can be deep discharged to levels repeatedly, without seriously shortening their useful life. The thick plate construction also allows longer operation as an energy source than comparable thin cell plate starter batteries. However, run batteries typically cannot develop the high discharge currents suitable for starting the engine of an automotive vehicle. Other types of run batteries which are capable of repeated deep discharge are becoming available and may be used. For example, Ford Motor Company has announced such a high charge storage run battery for use in its forthcoming electric vehicle. Other batteries, such as sodium sulphur batteries having increased amp-hour ratings, as compared to lead acid batteries, also may be used. Further, when deemed appropriate, the size ofrun battery20 may be reduced to a five cell battery to have a 12 volt rating or increased to 24-25 volt with a DC/DC convector to increase the time for running offrun battery20, and to reduce the size of the alternator.

Advantageously also, it has been discovered that a fuel and cost savings can be achieved by the reduced alternator mechanical load on the engine and lower fuel consumption whenever, and to the extent that, the alternator field current is decreased to back bias the output rectifier diodes. Another advantage results from recharging a discharged battery using lower cost electricity from a source external to the vehicle.

Preferably, the state of charge (BSOC) monitoring monitored by a battery state of charge (BSOC) monitoring circuit channel. Any device capable of reliably integrating the net charge over time may be used. Preferably, the BSOC circuit includes a section of the battery return cable as a shunt or a shunt resistor in series with the battery negative terminal and a circuit having a very large capacitance for integrating the current though the shunt continuously. See e.e., the circuits disclosed in the aforementioned U.S. Pat. No. 4,968,941 and copending and commonly assigned U.S. patent applications Ser. Nos. 07/607,237 and 07/919,011, which patent and applications are expressly incorporated herein by reference in their entirety.

Another aspect of the invention concerns apparatus and methods for controlling the charging voltage level applied to a battery in an automotive vehicle in response to the deceleration of the vehicle. Broadly, this aspect of the invention concerns sensing the deceleration of a vehicle and causing the battery charging device to produce a high level charging voltage for rapidly recharging a battery during deceleration. When the vehicle is decelerating, the alternator is driven by the momentum of the vehicle turning the wheels, drive shaft, and, hence, the engine, and not by the engine burning fuel. Thus, during deceleration some of the energy stored in the momentum of the vehicle can be converted by the alternator to energy which is stored in the run battery.

Accordingly, during deceleration events, the control current to the alternator rotor is increased. This raises the alternator output voltage and results in an increased resistance to rotation of the alternator rotor coil. As a result, the charge on the battery is rapidly increased without consuming incremental fuel to do so. Another advantage is that the increased alternator counter torque load on the engine aids in slowing the vehicle without increased brake wear or effort.

The deceleration feature is particularly useful in stop and go traffic such that the battery charging device is turned off during steady state and accelerating driving conditions and is turned on to provide a high charging voltage during deceleration. The recharging during each deceleration will effectively prolong the time the vehicle can operate solely off the run battery. It also is useful when operating the battery charging device at a charging voltage just to maintain a charge on the run battery, for recharging start batteries, whether in the two battery charging system or a single battery charging system.

During the onset of deceleration, it may be desirable to ramp the control signal to raise the battery charging device output of a high voltage to minimize slippage and wear on the alternator. A switch may be provided to disable temporarily the deceleration feature when desired so that, for example, a driver can coast.

The various aspects of the invention are not limited to battery charging systems for automotive vehicles. They are applicable to any apparatus having a start battery that consumes energy to charge an electrical energy storage device that is connected to operate an electrical load or device, including without limitation, electrically starting combustion engines such as a generator for household (or industrial) current, a gas operated lawn mower, a powered vehicle or device, aircraft, spacecraft, watercraft, emergency lighting or power plants.

A further aspect of the invention provides a battery which provides a very high current to a heating coil of an electrically heated catalytic converter (EHC) unit which performs the emission control functions of a standard catalytic converter that is heated by the engine. This battery is referred to as an “EHC” battery or a “storage” battery. The EHC unit may be a small catalytic converter that is placed in series with a standard catalytic converter, or it may be incorporated into an otherwise standard catalytic converter by, for example, the introduction of suitable heating coils as a part of the catalytic converter unit.

In operation, the EHC battery is switched, for about 20 seconds, to the EHC unit heater coil during the vehicle start operation. This provides a very high discharge current at a selected level, on the order of 500 to 650 amps, preferably 600 amps. The current discharge is high enough for the heater coil to heat rapidly at the EHC unit to its effective operating temperature and maintain it there during the heating period. The EHC battery may be disconnected after a preset time period, after the engine temperature exceeds a selected threshold, or when the state of charge of the EHC battery falls to a selected charge level. Further, the EHC battery may be switched to the EHC heater until the engine temperature is suitably high. This provides for preheating the catalytic converter so that it reaches an effective operating temperature sooner than conventional catalytic converter systems, which rely solely on engine temperature to heat the catalytic converter. Advantageously, by preheating the catalytic converter electrically, vehicle emissions are substantially reduced during vehicle starting, particularly in cold operating conditions. A third BSOC circuit channel could be used to monitor the EHC battery state of charge. If a BSOC channel is used, the control circuit is preferably responsive to the sensed EHC battery state of change (with appropriate switches) to recharge the EHC battery if its charge level is below the predetermined level. Provision also is made to recharge the ERC battery with an on or off-board battery charger from a source of 220 or 115 volt ac line power.

Furthermore, the EHC battery may be periodically switched to the EHC heater coil during operating conditions whenever the engine operating temperature is insufficient to heat the catalytic converter to its effective operating condition. This mode of operation may be selectively enabled or disabled, and the EHC battery may be recharged whenever its state of charge falls below a selected charge threshold.

Although each of the EHC battery system, the two-battery charge system, and the deceleration recharging system may be used separately, they are preferably combined to provide a more fuel efficient and reduced emission automotive vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the invention, in which like reference numerals refer to like elements, and in which:

FIG. 1 is a block diagram of a non-microprocessor controlled three battery fuel saving and reduced emission operating and battery charging system in accordance with a first embodiment of the invention;

FIG. 2 is a circuit diagram of a battery state of charge circuit ofFIGS. 1 and 7;

FIG. 3A is a circuit and schematic of a first solid state switch ofFIGS. 1 and 7;

FIG. 3B is a circuit and schematic of a second solid state switch ofFIGS. 1 and 7;

FIG. 3C is a circuit and schematic of a third solid state switch ofFIGS. 1 and 7;

FIG. 4 is a circuit diagram of the thermistor circuits ofFIGS. 1 and 2;

FIG. 5 is a circuit diagram of the deceleration circuit shown inFIG. 1;

FIG. 6 is a circuit diagram of the non-microprocessor controlled voltage regulator and alternator ofFIG. 1;

FIG. 7 is a block diagram of a microprocessor controlled three battery fuel saving and reduced emission operating and battery charging system in accordance with a second embodiment of the invention; and

FIGS. 8 and 9 are measured fuel consumption runs for two different vehicles under different operating conditions showing load current in amperes versus miles per gallon and indicating the fuel savings obtained with the non-microprocessor controlled system of FIG.1.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIG. 1, an apparatus for a three battery charging system in accordance with a first embodiment of the present invention is shown. The apparatus includes astart battery10, arun battery20, anEHC battery300, battery state of charge (BSOC)channels60a,60b, and60c, analternator40, avoltage regulator42, apendulum circuit70 andvehicle deceleration circuit90, and anignition switch30 including ganged wipers W1, W2, W3 and W4. When wiper W1 ofignition switch30 is placed in the start position atcontact32, current is provided fromstart battery10 on line L1 to startsolenoid31.Start solenoid31 is thus energized and closescontact52. This switches startbattery10 to startmotor50 on line L2 and provides the required current to turn overstart motor50.

When the engine (not shown) starts, wiper W1 is conventionally returned to the run position, contact35. A signal is then applied fromstart battery10 on line L3 through wiper W1 and line L35 that turns on a solid state switch32SB. When startbattery10 is less than fully charged, theBSOC channel60a output on line L25 is low and switch32SB is conducting. Solid state switch32SB connects startbattery10 to the output ofalternator40 on line L5. This allowsalternator40 to rechargestart battery10. When startbattery10 is recharged the output voltage on line L25 fromBSOC channel60a switches to high. A high signal on line L25 turns switch32SB off, thus disconnecting fully chargedstart battery10 from the system. A fully chargedstart battery10 is one that has an arbitrary high percentage of its actual full charge, e.g., 90% of full charge.

In the run position, wiper W2 ofignition switch30 is atcontact34. This connects runbattery20 to output line L5 ofalternator40, to vehicle run load R_L, and to vehicle accessory load R_Athrough solid state accessory switch34ac. In this condition, runbattery20 is being recharged byalternator40, in the event that it happened to be partially discharged, and vehicle loads R_Lare placed across the output L5 ofalternator40. For maximum safety, the vehicle lamps, illustrated as HL, are connected directly off both the run and startbatteries10 and20 through manual switch S1.

Switch34AC is controlled by a NAND Gate G2 which receives one input from a “park”position indicator15 corresponding to the vehicle being parked (a logical high state), e.g., the shift lever being in the park position in a vehicle having an automatic transmission. The second input is from theBSOC channel60b output line L7, which indicates when the state of charge ofrun battery20 is above (logical high state) or below (logical low state) the second predetermined charge level. Thus, when the vehicle is not in park and therun battery20 state of charge is above the preselected charge level, switch34AC is closed and accessory circuits R_Aare switched tobattery20. Otherwise, switch34AC is open and circuits R_Aare switched out. In this embodiment, accessory circuits R_Aare noncritical accessory devices the loss of which will not impair driving safety. A warning alarm device ACW is connected to the output of NAND gate G2 to produce a visual or audible alarm when switch34AC switches out accessory circuits R_A. Critical accessory load are always connectable to a battery and manually operable, e.g., headlights.

When runbattery20 has been recharged in accordance with ambient temperature requirements, the output voltage on line L6 fromBSOC channel60b switches from a low state to a high state.BSOC channel60b also has output line L7 which indicates, by changing from high to low states, when runbattery20 discharges below a preselected charge level.

WhenEHC battery300 is fully recharged, the signal on output line L306 fromBSOC channel60c switches from a low state to a high state. At this event, the three signals on lines L6, L7 and L306, which are inputs to logic NAND gate G1, are in the high state. NAND gate G1 is a part of voltage regulator42 (seeFIG. 6) of which only a portion is illustrated in FIG.1. (If noBSOC channel60c is used, NAND gate G1 may have only two inputs, i.e., lines L6 and L7.)

Referring toFIGS. 1 and 6, the above set of high state input conditions causes the output of NAND gate G1 involtage regulator42 to switch to the low state. This reduces the field current I_Finalternator40 to zero and back biases the bridge rectifier output diodes. This preventsalternator40 from delivering current to output line I5, which connects to runbattery20 and the vehicle loads R_Land accessory circuits R_A. Withalternator40 unable to provide current to line L5, runbattery20 is required to provide all the current to the vehicle loads R_Land R_Auntilrun battery20 discharges to a predetermined level. When this occurs, the voltage on output line L7 fromBSOC channel60b drops from a high to a low state. A low state on line L7 causes the output of NAND gate G1 to switch to the high state, thus increasing the field current I_Fofalternator40 from zero to its normal operating level. This forward biases the rectifier diodes.Alternator40 is now able to rechargerun battery20 and provide the load current required to operate the vehicle. During this time, switch34AC will remain closed when the vehicle is not in park and the run battery is above a predetermined charge level.

In summary, the following task sequence is accomplished by the system:

• • 1) started the vehicle withstart battery10 whenignition switch30 was placed in the start position;
  • 2) rechargedstart battery10 to its original state, rechargedrun battery20, if necessary, and rechargedEHC battery300 after it has provided a 20 second duration 600 amp heater current to an electrically heated catalytic converter (EHC)320;
  • 3) switched thealternator40 out of the system after rechargingbatteries10,20, and30 by reducing field current I_Fto zero, thus preventing it from generating current to output line L5;
  • 4) allowed therun battery20 to provide all the current required on line L5 to operate vehicle loads R_Land R_Aunder all operating conditions (except as noted);
  • 5) switchedalternator40 back into the system afterrun battery20 was discharged to a predetermined level by the vehicle loads R_Land R_A; and
  • 6) recharged therun battery20 and provided required load currents withalternator40 in its normal operating state until an external power source can be obtained.

Preferably, runbattery20 is recharged as soon as possible with aconventional battery charger91, also referred to as a “line power charger”, which is optimally mounted on board the vehicle, after the charge level ofrun battery20 drops to the predetermined charge level where a recharge is required. The normal battery recharge procedure from a conventional external 115 or 220volt power outlet90 would be to connect apower cord93 betweenoutlet90 and avehicle connector92 and provide battery charge current with onboard battery charger91.

Run battery20 may be recharged usingalternator40 when an external source is not available. However, this essentially eliminates the fuel and cost savings obtained by usingrun battery20 to power the vehicle loads R_Land R_A. The output line L7 ofBSOC channel60b may be used to provide a recharge warning signal for a display located on the instrument panel, e.g., illuminating a lamp, tone generator, or other indicator (not shown). This warning signal advises the vehicle operator that runbattery20 requires a recharge and that an external wayside orgarage power outlet90 should be located to rechargerun battery20 as soon as possible. Alternately, the recharge warning would be activated based on a charge level that is above the predetermined charge level or which causes output line L7 to switch to a low state, thus giving the operator time to locate a power supply beforealternator40 is automatically switched in to rechargerun battery20. Further, a charge level gauge, similar to a fuel gauge, could be used to display the state of charge of one or more batteries.

Non-Microprocessor Three Battery Version

Advantageously, a considerable emissions reduction can be realized by heating a small insulated electrically heated converter (EHC) that operates in series with the conventional catalytic converter (not shown) or a standard catalytic converter, collectively illustrated asEHC heater coil320 in FIG.1. The problem with heating theEHC coil320 during start with conventional battery charging systems that have only a start battery is that approximately 600 amperes of current is drawn from the battery during and after start for approximately 20 seconds. This current load would prevent startmotor50 from turning over.

It has been realized by the inventor that by using a dedicated heater storage battery, e.g.,EHC battery300, a 600 ampere current draw for twenty seconds reduces the amp-hour charge level in such a battery by only four amp-hours. It also has been realized by the inventor that a 24 volt 120 amp-hour very highdischarge EHC battery300 can produce such a four amp-hour charge, which charge can be replaced by anormal alternator40 or by an externallypowered battery charger91, in a relatively short period of time, e.g., between ten to forty minutes, more typically about fifteen minutes.

Both the non microprocessor and microprocessor based systems described herein can be configured to either rechargeEHC heater battery300 after each 20 second heating period during vehicle start, or allowEHC battery300 to be deeply discharged (i.e., down to a preselected charge level) before recharging it, preferably from an externalpower line source90, or fromalternator40.

The EHC heater system of the present invention also could be used to inhibit vehicle start for 15 seconds, as is done with diesel engine vehicles to preheat the glow plugs, to apply a preheat to theEHC coil320 for this period and for a 3 to 5 second period after start. The Table I below indicates the relatively reduces emission levels obtained during vehicle start with normal operation and with the preheat operation of theEHC320.

	TABLE I
	Preheat Time	Post Heat	Hydrocarbons	Carbon Monoxide
	seconds	Time	grams/mile	grams/mile

	0	18	0.025	0.5
	15	3	0.017	0.42

In comparison, the emission levels during start when the same vehicle engine is at ambient temperature are: 1 gram of hydrocarbons per mile, and 29 grams of carbon monoxide per mile. Thus, during the period until the vehicle engine temperature reaches the steady state temperature level where the conventional catalytic converter properly functions, theEHC battery300 andcoil320 provide for substantially reduced emissions.

EHC Battery Control System

When wiper W1 ofignition switch30 is turned to the start position atcontact32, a high state voltage turn-on signal is sent to atimer circuit352. The turn-on signal initiates a twenty second output pulse on output L52 oftimer352. The twenty second pulse has a high state which turns on a solid state switch332EHC for the duration of the twenty second period.

At this time, the engine temperature is monitored by athermistor circuit350.Circuit350 provides a low state output voltage when the engine temperature is below a predetermined level which is not high enough to heat sufficiently the catalytic converter and a high state output voltage when the engine temperature is above the predetermined level, e.g., 500° F. In the instance where the engine temperature is low,engine thermistor circuit350 sends a low state signal on output line L18 to solid state switch331EHC, which turns switch331EHC on. Assuming that the twenty second period has not ended, this completes the path for current flow fromECH battery300 which energizesEHC solenoid coil323. Thesolenoid coil323 pulls incontacts322 and324 which are ganged together.EHC battery300 is preferably a 24 volt battery and closingcontact322 delivers 600 amperes of current (I_EHC) toEHC heater coil320.Closing contact324 shorts theshunt303 in series withbattery300 to avoid overheating shunt303 during the period thatbattery300 is delivering 600 amperes. Whenshunt303 is a length of wire between two contact pins, or when noBSOC channel60c is used, contact324 may be omitted.

At the end of the twenty (20) second timing period, the output voltage on output line L52 oftimer352 drops from a high to a low state. Consequently, solid state switch332EHC is turned off andcontacts322 and324 both open. This removes the EHC heater current I_EHCtocoil323 and switches outbattery300.

In the event that the engine temperature is above the predetermined level, it is not necessary to apply heater current toEHC heater coil320. In this case, although the output voltage fromtimer circuit352 on line L52 is in the high state (during the pulse period) and switch332EHC is on, solid state switch331EHC is turned off. This inhibits current flow to solenoid323 and leaves contact322 open.

The release ofcontact324 also placesshunt303 toEHC battery300 in the line. The voltage acrossshunt303 can therefor be monitored during recharge ofbattery300 byBSOC channel60c to determine whenbattery300 is fully charged (e.g., when a 4 amp-hour charge perEHC320 heating event has been restored), and apply a high state input to NAND gate G1 involtage regulator42. Because the load current drawn fromECH battery300 bycoil320 and the time period are known, the amp-hour charge lost can be simulated by a suitable “start” circuit inBSOC channel60c, which removes an amount of charge from the BSOC integrator capacitive storage element corresponding to the heater current delivered. Alternately,BSOC channel60c may simply measure when either a 4 amp-hour recharge has been delivered or the charging current tobattery300 has dropped to a trickle charge, after each start operation.

The high state voltage output line L306 fromBSOC channel60c also is transmitted to solid state switch334EHC which turns it on and allows the recharge fromalternator40 to be stepped up bycircuit340 from 12 volts dc to 24 or 25 volts dc, in order to rechargeEHC battery300.

Module Circuit Descriptions

FIG. 2 illustrates a schematic of the battery state ofcharge circuit channels60a,60b and60c, which are preferably identical. The circuits shown on the schematic ofFIG. 2, except current monitoring amplifiers A1 through A4, may be constructed as described in the aforementioned U.S. Pat. No. 4,968,940, and application Ser. Nos. 607,237 and 919,011.

Theintegrator amplifier361 in each BSOC channel is an analog type that integrates the battery charge current I_CHand discharge current I_DCthrough its shunt (i.e., shunts11,21 and303 and shown in FIG.1), over time. The voltage drop V_Sacross the shunt is proportional to the current flowing through it. An arbitrary shunt may be selected, e.g., to produce 2.3 millivolts per amp of current, more preferably, a length of battery return cable between two contact pins. A battery charging current I_CHthrough the shunt produces a positive output voltage V_Sand a discharge current I_DCproduces a negative V_Sas illustrated in FIG.2.

A positive voltage V_Scauses the integrator output V_Ato rise as the battery charges. A negative V_Scauses V_Ato drop in the negative direction over time as the battery discharges. The battery state of charge can therefore be displayed on a meter in the same manner as a fuel gauge displays the amount of fuel in the tank. Any type of integrator, including digital types, will operate equally well in the circuit.

The integration slope of eachintegrator circuit361 has been arbitrarily established to provide a 2 volt dc output signal to the vehicle display on the output line (lines L361, L362 and L363) when its battery (batteries10,20 or300, respectively, inFIG. 1) is fully charged and an arbitrary low voltage output when the associated battery charge drops to a level where a recharge is required.

The integrator output voltage V_Aramps up and down very slowly over time and therefore cannot be easily used to operate circuit devices that perform command functions etc.

Consequently, it is necessary to employ switching circuits that either rise from a low to a high voltage or drop from a high to low voltage when the output voltage V_Ais at predetermined points on the rising or falling voltage ramp as the battery is being charged or discharged.

Amplifier A4 switches from zero volts to 10 volts dc when the battery is fully charged and the integrator output voltage V_Ais 2 volts dc. This signals voltage regulator42 (FIGS. 1,6) that the battery being monitored is fully charged.

Amplifier A3 switches from 10 volts dc to 0 volts when the state of the battery being monitored drops to an arbitrary, e.g., 50% for arun battery20, discharge level. This occurs when the integrator output voltage V_Adrops to 1 volt dc. This signalsvoltage regulator42 that a battery is discharged to the point wherealternator40 must be used to recharge it.

Amplifiers A1 and A2 provide a dc output voltage proportional to the charge and discharge currents through the shunt. These currents vary quite rapidly and consequently produce a rapidly changing positive and negative going output voltages at the output of A2. The integrator smooths these rapid changes over time and thus provides a slowly moving output voltage V_A.

The current amplifiers are used to provide display information that indicates the direction and magnitude of current flow into and out of the batteries. The output of amplifier A4 could be used to provide an indication of battery charge level if desired. The charge current I_CHinto a battery fromalternator40 is very high, approximately 30 amps at the start of recharge, and drops to a level of approximately 2 to 3 amperes when the battery is fully charged. The shunt voltages V_Scorresponding to these currents could therefore be monitored by amplifier A1 and the output voltage to amplifier A4 used to indicate ful battery charge tovoltage regulator42 inFIG. 1 if desired.

Badbattery cell circuit364 switches from a zero output voltage to 10 volts dc in the event that the battery being monitored has a bad cell. The operation of this circuit is explained in the referenced patent applications.

The automatic turn on-turn offcircuit362 senses when a small charge or discharge current produces a small positive or negative voltage V_Sacross the battery current shunt and applies battery voltage (e.g., 12 volts) to all the battery state of charge channel circuits. In the turn off state (standby state) each BSOC channel60 draws approximately 1 milliampere from the battery, e.g., runbattery20. This allows the BSOC channel60 to be permanently wired to the battery terminals. When the BSOC channel senses current through the battery, the turn oncircuit362 energizes an internal BSOC power supply that provides approximately 50 milliamperes of current from the battery to the remainder of the BSOC channel circuits.

Battery capacity versustemperature circuit365 provides a signal corresponding to the change in battery capacity with sensed ambient temperature. This is a conventional circuit that is commonly used in existing voltage regulator systems.

Start circuit363 ensures, during vehicle start, that theintegrator amplifier361 ofBSOC channel60a measures the proper amount of charge removed fromstart battery10 bystarter motor50. In the case that shunt303 is a resistor in series withEHC battery300, asimilar start circuit363 may be used to simulate the discharge of current across shortedshunt303 forEHC battery300 so thatintegrator amplifier circuit361 ofBSOC channel60c measures the proper amount of charge removed frombattery300 byEHC coil320.

Referring toFIG. 3A, solid state start battery switch32SB, includes two pop transistors3AQ1 and3AQ3 which are in the on state when both npn transistors3AQ2 and A3Q4 are conducting. This occurs when the input on line L3 (i.e., the input from wiper W1 of ignition switch30) is high and the input on line L25 (i.e., the output fromBSOC channel60a) is low. Switch32SB is off for all other input conditions.

Referring toFIG. 3B, solid switches332EHC and34AC each include a pnp transistor3BQ1, which is in the conducting state when npn transistor3BQ2 is conducting. This occurs when the respective input, line L52 fromtimer circuit352 or line L34 from NAND gate G2, is high.

Referring toFIG. 3C, solid state switch331EHC includes transistor3CQ1 which is in the on state when transistor3CQ2 is conducting. This occurs when the input on line L18 fromengine thermistor circuit350 is low.

Enginethermistor switching circuit350 is shown in FIG.4.Circuit350 senses the temperature of the engine housing near the electrically heated catalytic converter. The thermistor TR2 is a negative coefficient type device having a series resistance that reduces as engine temperature rises. When the engine temperatures has reached a predetermined level, the resistance of thermistor TR2 drops to the point where the voltage on line L51 drops below the reference voltage on line L49. This causes the output line L18 of operational amplifier4A1 to switch from a low to a high voltage state. The reference voltage may be provided in any manner, e.g., a voltage divider between a +12 volt source across a 10 kΩ resistor and a 4v zener diode as illustrated in FIG.4.

Pendulum circuit70, shown inFIGS. 1 and 5, includes apotentiometer71 having its wiper W-71 operated by apendulum72. When the vehicle decelerates,pendulum72 swings in the “vehicle forward” direction and moves wiper W-71 ofpotentiometer71 in a direction that produces a sudden change, e.g., an increase in both the rate of change and magnitude of the voltage output on line L45. The sudden change in magnitude and rise time of the voltage on line L45 is sensed bydeceleration circuit90 and the output voltage on output line L46 switches from a low state to a high state output voltage.

Proper selection of the resistive and capacitor components indeceleration circuit90 will cause the output of switching amplifier5A3 to switch when vehicle deceleration exceeds any predetermined rate. In this regard, capacitor C1, resistors R1 and R2 and amplifier5A1 comprise a conventional differentiator circuit that will not produce an output voltage unless the vehicle decelerates at a rate greater than a predetermined level. The magnitude of the voltage at the output of amplifier5A1 is given by:
Eout=R1×C1×(E2−E1)/(t2−t1)

Proper selection of component values in the differentiating equation will produce an output voltage having the proper magnitude for a predetermined vehicle deceleration rate.

The voltage at the output of amplifier5A1 is amplified by amplifier5A2 and applied to the non-inverting input of amplifier5A3. When the applied voltage exceeds the reference voltage provided on the inverting input of amplifier5A3, amplifier5A3 switches from a low state to a high state.

Alternately,pendulum circuit70 can be replaced with any type of vehicle deceleration detection circuit device, including wheel speed pickoff types, that can be modified to provide an output voltage having a magnitude and rise time sufficiently proportional to vehicle deceleration to operate withdeceleration circuit90.

Referring now toFIG. 6,voltage regulator42, in accordance with the non-microprocessor controlled version of the present invention, is similar to many off-the-shelf type of voltage regulators that control the magnitude of the output voltage V_Aofalternator40. The regulation principle is well known and has been in use almost as long as the automobile has been in existence. Early voltage regulator circuits sensed the level of the output voltage V_Afrom thealternator40 and commanded a relay contact to remain closed for a longer period of time than open when the output voltage V_Awas below a preset level, such as 14.0 volts dc. When the sensed output voltage V_Awas above the reference level, the contact was commanded to remain open for a longer period of time than closed. This switching action maintained the output voltage V_Ain the vicinity of 13.6 volts dc in a reasonable manner.

The voltage regulator circuit also sensed the ambient temperature and modified the on-off switching time as a function of temperature. It also modified the switching on-off time to cause the contact to remain on for a slightly longer period when ambient temperature was low and to remain off for a slightly longer period of time when the ambient temperature was high. This raised alternator nominal 14.0 volt dc output level to 14.8 volts at low temperatures and reduced the nominal 14.0 volt output to 13.6 volts dc at high ambient temperatures. The nominal output voltage, when raised to 14.8 volts dc, provided more current to thealternator rotor coil44R at low ambient temperatures and less current when it was reduced to 13.6 volts at high ambient temperatures, thus maintaining a proper charging current to the start battery under all driving and ambient temperature conditions.

Relay contact controlled voltage regulators have been replaced with more reliable transistor switching types that control the alternator rotor, and thus field current, in much the same manner as described above, i.e., by changing the duty cycle of the current.

In accordance with the present invention, referring toFIG. 6,voltage regulator42 includes an on-off switching circuit comprised of a logic NAND gate G1, a pnp transistor Q606, temperature sensitive diodes6D1,6D2, zener diode6Z1, operational amplifier6A1, voltage driver resistors6R1,6R2 and darlington power switching transistors6Q1 and6Q2.

When wiper W3 ofignition switch30 is placed in the run position (contact37) prior to start, an exciter current fromstart battery10 is delivered throughrotor coil44R ofalternator40 and series transistor6Q2 to ground. This provides sufficient current to overcome the residual magnetism inrotor coil44R which allowscoil44R to develop the required current to operate properly alternator40.

There are a variety of solid state switching voltage regulators in operation at the present time. Most of them can be activated and deactivated to switch the current intorotor44R on and off by grounding a key signal line in the circuit. This can be manually done with a switch and automatically done with inputs of the type illustrated inFIGS. 1 and 6 or with a microprocessor.

When the output voltage V_Aofalternator40 is below a nominal 14.0 volt dc level, zener diode6Z1 does not contact current. Consequently, the voltage at its base on top of resistor6R3 is zero. The second alternator output voltage V_Ais, however, present at the non-inverting input to amplifier6A1, thus causing it to switch to a high state output voltage level. This causes transistors6Q1 and6Q2 to turn on. This in turn causes current to flow throughrotor coil44R which raises the current infield windings703. The increased current in field windings703 (stator coils44S) raises the alternator output voltage V_Aabove 14.0 volts. The output voltage V_Ais produced by the phase rectifier bridge comprising diodes7D4,7D5,7D6,7D7,7D8, and7D9 (and the feedback output voltage V_A2is provided by an exciter bridge comprising diodes7D1,7D2,7D3) in a conventional manner.

When output voltage V_Arises above 14.0 volts, zener diode6Z1 conducts current and a voltage appears at the inverting input of amplifier6A1 that is higher than the voltage on the non-inverting input. This causes amplifier6A1 to switch from a high voltage state to a low voltage state, thus turning transistor6Q1 and6Q2 off. This reduces the output voltage V_Abelow 14.0 volts.

This on-off switching action maintains the alternator output voltage V_Aat 14.0 volts dc, regardless of changes in the alternator shaft rotational speed.

The forward voltage drop of diodes6D1 and6D2 decreases at high temperature which increases the voltage level at the top of zener diode6Z1. This causes zener diode6Z1 to turn off thevoltage regulator42 earlier in the switching cycle. This causes the nominal alternator output charging voltage to drop to a selected level below 14.0 volts.

The forward voltage drop of diodes6D1 and6D2 increases in a low ambient temperature which decreases the voltage level at the top of zener diode6Z1. This causes zener diode6Z1 to conduct later in each switching cycle. This causes the nominal alternator output charging voltage to increase above the 14.0 level.

Diode6D1 could be placed nearstart battery10 to obtain a better measure of battery temperature. Alternately, a more suitable temperature sensitive circuit could be used in its place.

Thevoltage regulator circuit42 described above is disabled by reducing the base voltage of transistor Q606 to zero. This occurs when all the inputs to NAND gate G1 are in a high state and the input on line L46 is a low state. This set of conditions causes the output of NAND gate G1 to switch to the low state and turn transistor Q606 on. When transistor Q606 switches on it reduces the voltage level on line L606 to the non-inverting input of amplifier6A1 to zero. This prevents amplifier6A1 from turningvoltage regulator42 on.

When the overriding deceleration input fromcircuit90 on line L46 goes to the high state during vehicle deceleration, the base of transistor Q606 is raised, regardless of the input signal levels to NAND gate G1. This causes transistor Q606 to turn off, thus allowing amplifier6A1 to operatevoltage regulator42 as required. When any of the lines L6, L7 and L306 are in the low state, the output of NAND gate G1 switches high to the state, thus raising the base of transistor Q606, and enablingvoltage regulator42. When all three lines L6, L7 and L306 are in the high state,regulator42 is disabled (unless overridden by a high state input on line L46 from the deceleration circuit90).

Logic NAND gate G1 can be replaced, if desired, by a manual switch operated by the driver. A manual switch can be used to turnvoltage regulator circuit42 on and off in order to switchalternator40 in and out of the system. A second manual switch could be used to turn solid state switch32SB on and off to switchstart battery10 in and out of the system.

A meter indicating the state of charge of each battery could be located along with manual solid state switch controls on the instrument panel of the vehicle or in another suitable location. It is to be understood that all of the functions described above and illustrated inFIGS. 1-6 could be performed by manually operated switches if desired.

MICROPROCESSOR SYSTEM CONTROLLED EMBODIMENT OF THE INVENTIONVehicle Run and Battery Charge Control with a Microprocessor

The non-microprocessor embodiment of the invention described above does not require the sophistication of a microprocessor to control the level of alternator current required to provide rectified output current to the batteries and vehicle loads or alternately to allow the run battery to provide all the vehicle load current.

Nevertheless, there are advantages afforded by using a microprocessor controlled voltage regulator including the ability to operate a complex voltage regulator, to operate a complex display, complex decision making capability, reprogramming flexibility, and a less complex vehicle installation (both as original vehicle equipment and as an aftermarket retrofit apparatus) than the non-microprocessor version.

Most four to sixteen bit microprocessors having suitable memory capacity can be used to replace the discrete circuit non-microprocessor based voltage regulator described in the non-microprocessor system version of the invention, as will be clear from the following.

Referring toFIG. 7, onesuitable microprocessor200 is a 16-bit microprocessor, Model No. 8397-90, which is available from Intel. This model microprocessor includes a 10-bit analog-to-digital converter, interrupt source inputs, a pulse width modulated output port, a 232 byte register, memory to memory architecture, a 16×16 bit multiplier, a 32 by 16 bit divider, a full duplex serial port, five 8 bit input/output ports, watchdog timers, four 16 bit timers, two external 64K (8K by 8 bits) memory devices, a one milliamp standby current drain, and a display driver interface including an eight segmentliquid crystal display80 and a 6×6button keyboard82.

Onesuitable memory device845 for use withmicroprocessor200 is EPROM Model P27C64/87C64, which is available from Intel. This device includes two 64K (8K×8 bit) memory units which are conventionally connected to the Intel model 8397-90 microprocessor. The pin designations are those provided by the manufacturer. Instructions for programming the Intel Model 8397-90 microprocessor can be found on pages 19-10 through 19-27 of the Intel Automotive Handbook, part order number 231792-002, available from Intel.

In the preferred embodiment,microprocessor200 is provided with suitable software program instructions in memory so that the vehicle operator can obtain and display information regarding time, date, an alarm function, estimated time of arrival, time on remaining fuel to recharge station, time on remaining fuel to an empty fuel tank, the remaining distance to go on a trip, the distance to travel since the fuel tank was last filled, and the distance to travel on the remaining fuel. Many of these functions may be programmed in a conventional manner by a person of ordinary skill in the art. Devices commonly referred to as trip computers, which incorporate many of these functions, have been commercially available in automotive vehicles at least since 1986.

In accordance with the present invention,microprocessor200 also may be programmed to provide information regarding fuel efficiency and fuel being consumed in the fuel tank (based on the octane reading of the fuel). This would indicate average fuel efficiency and miles per gallon, the instantaneous fuel efficiency, the total fuel used on the trip since the trip began, the fuel used since the tank was last refilled, and the fuel left in the tank. Also, themicroprocessor200 may provide information regarding how long the vehicle may continue operating until an external battery recharge is required, the time required to rechargerun battery20 afteralternator40 is switched back in to rechargerun battery20, and how long the vehicle may safely operate in the run state before requiring a recharge. It is noted that in the run state refers toalternator40 being either switched out or operating at a reduced voltage output that merely maintains a trickle charge onrun battery20 without attempting to fully rechargebattery20.

Also,microprocessor200 may provide information regarding average vehicle speed and may includes an anti-theft capability, based on requiring the driver to enter a code on thekeyboard82 prior to starting the vehicle.Microprocessor200 also may be utilized to monitor vehicle inputs not indicated above for vehicle diagnostic purposes. By sampling the alternator output load conditions, battery current levels, battery state of charge levels (in amp-hours), and alternator voltage levels, in addition to other vehicle sensory inputs,microprocessor200 can perform many useful diagnostic functions. For example, a gradual inability to recharge properly any of the batteries, or for any battery to provide appropriate load currents upon demand in certain situations, can result in a diagnostic message indicating a problem with either the given battery,alternator40, the wiring harness of the vehicle, vehicle loads (R_Land R_A), or even battery terminal connections.Microprocessor200 also can be programmed to identify the following diagnostic conditions: a bad battery, a malfunctioning alternator, a short in a vehicle accessory or wiring harness causing excessive current drain, a bad diode bridge, the onset of a load dump condition, and other related diagnostic matters based on sensed states-of-charge, voltages and currents over time. The bases for these determinations are more fully described in the copending and commonly assigned application Ser. No. 07/919,011.

The input/output circuits744,745,746, and747 whichinterface microprocessor200 and the vehicle sensor signals, are standard scaling, gain, and reset circuits. The design and construction of these circuits as well as the programming ofmicroprocessor200 are within the abilities of the person of ordinary skill in the art, are well known, and do not require elaboration.

In this embodiment, a pulse width modulated signal is output on line L39 at pin39 ofmicroprocessor200, when it passes through inputoutput interface circuit747. The corresponding pulse width modulated output fromcircuit747 on line L747, which is input to the darlington drive transistors7Q1 and7Q2, is a pulse train having a fixed period of 256 state times and a programmable width of from 0 to 255 state times. Pulse width is programmed by loading the desired value for optimum fuel economy, as determined bymicroprocessor200, into a microprocessor pulse width modulation (PWM) control register (not shown). The varied number of state pulses over the 256 pulse period determines the average current provided by drive transistor7Q1 and7Q2 inFIG. 7 to the coil ofrotor44R ofalternator40.Rotor44R generates a conventional three phase electromagnetic field voltage in the stator coils44S (see also coils703 inFIG. 6) having a magnitude proportional to the level of the dc input field current I_F. The alternating field current of the stator coils44S is then rectified by diode bridges740 (diodes7D1,7D2,7D3) and742 (diodes7D4,7D5,7D6,7D7,7D8,7D9) to provide the dc output voltage V_Aon line L5.

Preferably,microprocessor200 is programmed for receiving and processing the various sensor input parameters and controlling thealternator40 output voltage V_Aon line L5 betweenalternator40 and runbattery20 over the range of 0 to 17 volts, according to a set of defined operating conditions stored in a look-up table or an algorithm. Preferably, look-up tables are used which comprise data curves of, for example, alternator output voltages (start and run conditions, including EHC preheat operations) versus various vehicle load and ambient temperature conditions, states of charge, and other data useful for the aforementioned diagnostic purposes. The data curves preferably correlate the range of sensor parameters and predetermined operating conditions and, in response to the determined inputs, provide a suitable output voltage to maximize fuel economy. The look-up tables utilized by the microprocessor may be empirically derived according to the specific vehicle operating conditions, operating mode, and battery characteristics.

In this embodiment,microprocessor200 may monitor ambient temperature conditions and engine speed and regulate the bias of the alternator output voltage in a conventional manner. In accordance with the present invention,microprocessor200 also may monitor the charging current I_CHby sensing the voltage signal representing the deceleration of the vehicle, and the state of charge and current signals charge/discharge fromBSOC channels60a,60b and60c.

These sensed parameters are then compared to data in the look-up tables and an appropriate output voltage is selected. The look-up table and data stored inmemory device845 provide fuel economy calculation information. Software formicroprocessor200 and the look up tables and algorithms may be created in a conventional manner using an emulator board and stored inmemory845.

A watchdog circuit (not shown in FIG.7), is located between pins55 and45 of Intel model 8377-90microprocessor200 and provides a graceful recovery from software errors. In this regard, a 16 bit counter inmicroprocessor200 will count state times until it overflows. If an overflow occurs prior to correction of an error,microprocessor200 is reset. Aclock204 is used for state timing and other signal processing functions. Preferably a 12MHz clock204 is employed.

Referring toFIG. 7, the interconnection betweenmicroprocessor200,keyboard82 anddisplay80 is shown. In this embodiment,keyboard82 is a conventional 6×6 keyboard having vertical and horizontal contact lines laid out in a 6×6 grid, and an associated eightcharacter LCD display80. Such keyboard devices can be readily implemented using the Intel 8397-90 microprocessor. Six of the keyboard lines are connected along line L32B-A, which is a parallel data bus, to pins P2.6, P2.7, P4.7, P4.0, P0.1, and P0.0 onmicroprocessor200. The pin numbers are not shown inFIG. 7 for clarity of illustration. The other six keyboard lines are connected by line L32B-B, also a parallel data bus, to pins P4.1-P4.6 onmicroprocessor200. The key designation ofkeyboard82 is selected by appropriate programming of intersecting contact lines.

Outputs P1.0-P1.4 ofmicroprocessor200 are connected by line L24B-A, a parallel data bus, to a binary coded decimaldigit driver circuit81, which in turn is connected to display80. Also,microprocessor200 outputs P3.0-P3.7 are connected along line L24B-B, a parallel data bus, tosegment driver83, which, in turn, provides information to display80.

In this driver interactive system, the driver may select which condition of the vehicle or which diagnostic parameter or trip computer function to display at any given time. Accordingly, specific keys inkeyboard82 may be dedicated for displaying state of charge ofrun battery20, startbattery10 orEHC battery300 upon actuation. Alternatively, the key functions may be selected according to a displayed menu of selections, such that different keys have different functions depending on the menu selected.

In addition,microprocessor200 may be programmed to display the state of charge measures automatically when the state of charge of the respective battery falls below a preselected level or to display an appropriate message when a diagnostic routine indicates that a problem has been detected. Such an automatic display may be accompanied by a warning indication, e.g., a indicator light on the instrument panel or an audible tone. A distinctive warning could be used to indicate to the driver that the vehicle has switched from run battery operation only to running on the alternator, e.g., during a recharge ofrun battery20. A suitable message also may be displayed to indicate how long it will take to recharge the battery with the alternator before automatically switching back to run battery operation. Other variations may be selected as a matter of design choice, provided that the selectedmicroprocessor200 andmemory845 have sufficient processing capability.

The previously discussed microprocessor pulse width modulation (PWM) circuit output on pin39 and line L39 ofmicroprocessor200 smoothly varies the current to driver transistors7Q1 and7Q2, which in turn smoothly varies the current intorotor44R in response to system sensor inputs and the dc output level (V_A2) ofalternator40 on line L602.

Microprocessor200 compares the level of alternator voltage V_A2on line L602 (through interface circuit747) with a reference voltage level stored in memory. When V_A2is higher than the reference voltage, e.g., a nominal 14.6 volts dc, the duty cycle of the PWM output is lowered until V_A2returns to 14.6 volts dc. When V_A2is below 14.6 volts dc,microprocessor200 increases the duty cycle until V_A2is at 14.6 volts dc. The nominal 14.6 volt level may be altered if required with a software change.

Microprocessor200 also senses a signal on line L748 from ambienttemperature sensor circuit748, which is passed through inputoutput interface circuit745 for scaling and shaping, and accordingly adjusts the duty cycle of its PWM output on line L39 to vary the alternator charging voltage (V_A2) between 16.4 and 13.6 volts in accordance with conventional battery charging current versus temperature requirements.

When wiper W1 ofignition switch30 is turned to the start position, as shown inFIG. 1,ignition switch contact32 provides current to actuatestart solenoid31 which pulls incontact52 thus allowing startbattery10 to provide the current required to operatestart motor50.Microprocessor200 also actuatesEHC solenoid coil323 during vehicle start by turning on solid state switches331EHC and332EHC for a selected timing period of twenty seconds. When switches331EHC and332EHC are turned on, as noted,solenoid323 pulls in gangedpower contacts322 and324. Power contact322 routes heater current fromEHC battery300 to theEHC heater coil320 and contact324 shorts outshunt303. At the end of the selected timing period,microprocessor200 opens solid state switches331EHC and332EHC. In the event thatmicroprocessor200 detects a signal fromengine thermistor circuit350 that corresponds to the engine temperature being above a preselected “hot” temperature,microprocessor200 opens solid state switch331EHC, which prevents current from reaching theEHC solenoid coil323, thus preventing heater current from flowing into theEHC heater coil320. Separate control lines L331 and L332 respectively connectmicroprocessor200 to switches331EHC and332EHC. It should be understood that, rather than a timing period, a first signal could be used to close switches331EHC and thethermistor circuit350 could be used to open circuit the switch once the engine has reached the desired temperature.

When wiper W1 is returned to the run position, as indicated inFIG. 7, a high input signal is applied on line L35 through I/O circuit745. This high signal is sensed bymicroprocessor200 which, in response, monitors the outputs ofBSOC channels60a,60b and60c on lines L25, L6 and L306 respectively, and maintains the output voltage ofalternator40 at a level required to recharge the start, run andEHC batteries10,20 and300 in accordance with ambient temperature requirements. This charging continues until their respective charge levels are above a predetermined point. Again, as in the non-microprocessor version, contact324 may be omitted where theshunt303 is a length of battery cable, andBSOC channel60c may be omitted.

Whenmicroprocessor200 receives signals on lines L25, L6 and L306 fromBSOC channels60a,60b and60c respectively indicating that all three batteries are recharged, it reduces the PWM duty cycle on line L39 to cause the alternator output voltage V_Ato drop to a level low enough to allow the terminal voltage ofrun battery20 to back bias therectifier diodes742 on line L5. This removes the engine torque from the shaft ofalternator40 and allows therun battery20 to provide all the vehicle load current. This is the preferred mode of operation for maximum fuel savings.

Thereafter, whenmicroprocessor200 receives a signal on line L7 fromBSOC channel60b that indicates runbattery20 state of charge is below a predetermined charge level,microprocessor200 increases the alternator output voltage to a point where it can operate the vehicle in such a manner that it provides the required load current and a recharge current to runbattery20. (Alternately, the alternator output voltage is raised to a point whererun battery20 does not discharge further, but is not necessarily recharged.) The driver is also warned bydisplay80 that a source of charge external to the vehicle should be located as soon as possible to rechargerun battery20. An on board battery charger is preferably provided (not shown inFIG. 7, see FIG.1).

Microprocessor200 also monitors battery recharge current on lines L390, L391 and L392 which are respectively passed throughinput output circuit744, to determine when recharge occurs. (See the output of amplifier A2 on FIG.2).

In this embodiment, a wheelspeed indicator circuit95 is provided.Circuit95 includes apermanent magnet96 on a wheel speed ortransmission shaft97. It produces pulses proportional to wheel speed which are sensed eachtime magnet96 passes astationary pickup coil98. Consequently, a train of pulses having a period inversely proportional to wheel speed is transmitted on line L95 to apulse squaring circuit99. The output ofpulse squaring circuit99 is transmitted on line L99, passed through inputoutput interference circuit745, tomicroprocessor200.Microprocessor200 thus can sense and record vehicle instantaneous speed, average speed, deceleration, and acceleration. It can use this information in the software program for controlling the system in response to these inputs. Vehicle deceleration, for instance, is computed by calculating the reduction in vehicle speed over a given time period. In particular, the use ofwheel speed circuit95 makes thependulum circuit70 of the non-microprocessor embodiment (seeFIG. 1) unnecessary in the microprocessor controlled embodiment.

Whenmicroprocessor200 senses vehicle deceleration it increases the output voltage V_A2ofalternator40. As a result, the vehicle momentum, rather than the engine, is used to apply torque to the alternator shaft and provide a recharge current for chargingrun battery20. This procedure applies recharge current without any fuel expenditure, and effectively extends the time the vehicle loads R_L+R_Acan be operated off ofrun battery20 without requiring an external recharge or rechargingbattery20 by burning fuel.

Microprocessor200 provides the operational advantage of not having to reduce the excitation current completely fromrotor44R ofalternator40 when the system is operating withrun battery20 providing current to the vehicle electrical loads.Microprocessor200 can, in response to sensor inputs, provides a pulse width modulated current having a duty cycle just sufficient to provide the lowest possible current toalternator rotor44R required to avoid sharing current withrun battery20 when it is being used. This removes the alternator torque from the engine as effectively as when all the current is turned off torotor44R.

The current torotor44R can be smoothly varied bymicroprocessor200 to vary the output voltage level ofalternator40 to allow it to (a) share any portion of its output current to the vehicle loads along withrun battery20, (b) share none of its output current with therun battery20, or (c) provide all of its output current to the vehicle loads andcharge run battery20. The desired alternator operating mode, a, b or c, above could be programmed fromkeyboard82 by the system operator.

Microprocessor200 also provides the capability of being reprogrammed to accommodate changing vehicle operating requirements that may occur between vehicles and with the addition of options.

Current outputs fromBSOC channels60a,60b, and60c on lines L390, L391, and L392, respectively, also are sensed bymicroprocessor200 at the corresponding outputs of I/O circuit744. The direction and amplitude of the currents into and out ofbatteries10,20 and300 on the above lines are monitored for control and display purposes.

Microprocessor200 also monitors the battery current in each ofshunts11,21, and303 for diagnostic and reset purposes. Failure of the charge current to drop below a preselected level on lines L390, L391 and L392 when the state of charge voltage of the monitored battery is above a preset level on lines L25, L6 and L306 respectively, is an indication of a bad cell in the associated battery.

Microprocessor200 may be used to turn off automatically selected vehicle electrical accessories when the vehicle is parked, the ignition key is in the accessory position, and the start battery state of charge is below a preselected level. In this regard, a high voltage state signal from the “PRNDL”gear shift circuit15 is transmitted on line L15 (through I/O circuit745) when the shift lever (not shown) is in the park “P” position. A high voltage state signal also is transmitted on line L38 (passed through I/O circuit745) when ignition switch wiper W4 is in the accessory position (contact38) and a low voltage level signal is transmitted on line L25 when the state of charge ofstart battery10 is below a preselected level. When these three conditions are satisfied,microprocessor200 transmits a turn off signal on line L34 to solid state switch34AC which removes battery discharge current from selected vehicle accessories R_Land R_A.

EXAMPLES

The advantages of the present invention are illustrated with reference to the fuel consumption test drives made with a 1988 General Motors Oldsmobile Cutlass, shown inFIG. 8, and a 1984 Ford Mercury Lynx, shown in FIG.9.

All fuel measurements were made based on two-hour runs, under the weather conditions described below and the load currents on the alternator specified.Plot8A represents highway driving in warm and dry road conditions.Plot8B represents a combination of city and highway driving in light to heavy traffic and cool and raining road conditions.Plot8C represents suburban driving in cool and dry road conditions.Plot8D represents city driving in cool and dry road conditions.Plot8E represents city driving in heavy traffic in cool and dry road conditions.Plot9A represents highway driving.Plot9B represents suburban driving in light traffic.Plot9C represents suburban driving in heavy traffic.Plot9D represents city driving in heavy traffic. For highway traffic, each car was driven one hour in one direction and one hour in the opposite direction, to balance out windage and other factors. Similarly, for suburban and city traffic, the path followed during one hour was essentially reversed during the second hour.

The current load on the alternator was varied by turning on various electrical devices in the car (such as the radio, windshield wiper, headlights, etc.), and was measured by one shunt in series with the alternator and one shunt in series with the battery. The fuel measurements were made by connecting a first fuel-flow meter in series with the gasoline tank supply line and a second fuel-flow meter in series with the fuel pump return line and subtracting the difference.

The percentage fuel savings achieved by operating at zero-load conditions, as compared with various current load conditions, can be calculated by the expression:$\%\text{Fuel savings}=\frac{{\mathrm{MPG}}_0-{\mathrm{MPG}}_{\mathrm{LOAD}}}{{\mathrm{MPG}}_{\mathrm{LOAD}}}\times 100$
wherein MPG₀is miles per gallon at zero current load on the alternator and MPG_LOADis miles per gallon at the selected load conditions and current load in amps.

The percentage fuel savings for the 1988 Oldsmobile Cutlass are shown below under Table I and inFIG. 8, while those for the 1984 Mercury Lynx are shown under Table II and in FIG.9. The average of both is shown under Table III. The current load at 18 amps is a hypothetical driving condition based on the curves inFIGS. 8 and 9. With respect to Table III, the overall average includes highway, suburban and city driving, assuming that there is an equal amount of driving in each of these categories.

InFIGS. 8 and 9, the parenthetical numbers correspond to (amps, miles per gallon) (% fuel savings).

TABLE I
1988 OLDSMOBILE CUTLASS

			Current	%
			Load	Fuel
Driving Conditions	MPG0	MPGLOAD	(amps)	Savings

Highway Traffic	17.7	17.3	8	2.3
	17.7	16.8	18	5.4
Warm, Dry Conditions	17.7	16.25	26	8.9
	17.7	14.64	46	20.9
Highway and City	17.0	16.5	8	3.0
Traffic	17.0	16.3	18	4.3
Rainy, Cool Conditions	17.0	15.9	26	6.9
	17.0	13.8	46	23.2
Suburban Traffic	12.32	11.9	8	3.5
	12.32	11.05	18	7.6
Cool, Dry Conditions	12.32	10.97	26	12.3
	12.32	10.3	46	19.6
City Traffic	12.0	11.5	8	4.3
	12.0	11.1	18	8.1
Cool, Dry Conditions	12.0	10.6	26	13.2
	12.0	9.9	46	21.2
Heavy City Traffic	9.7	9.25	8	4.8
	9.7	8.8	18	10.2
	9.7	8.3	26	16.9
	9.7	6.8	46	42.6

TABLE II
1984 MERCURY LYNX

			Current	%
			Load	Fuel
Driving Conditions	MPG0	MPGLOAD	(amps)	Savings

Highway Traffic	32.5	31.8	8	2.2
	32.5	30.8	18	5.5
	32.5	30.2	26	7.6
	32.5	26.5	48	22.6
Suburban Light Traffic	25.5	24.2	8	5.4
	25.5	23.0	18	10.9
	25.5	21.5	26	18.6
	25.5	18.0	48	41.7
Suburban Heavy Traffic	23.2	23.1	8	0.4
	23.2	21.3	18	8.9
	23.3	20.5	26	13.2
	23.22	16.8	48	38.1
City Heavy Traffic	17.4	16.45	8	5.8
	17.4	15.0	18	16.0
	17.4	14.0	26	24.3
	17.4	11.8	48	47.5

TABLE III
Fuel Savings Average for Both Cars

Current Load	Driving Conditions	Percentage Fuel Savings

8	amps	Highway average	2.5
		Suburban average	3.1
		City average	5.0
		Overall average	3.53
18	amps	Highway average	5.3
		Suburban average	9.3
		City average	11.4
		Overall average	8.53
26	amps	Highway average	7.8
		Suburban average	14.6
		City average	18.1
		Overall average	13.5
46	amps	Highway average	22.2
		Suburban average	33.1
		City average	37.1
		Overall average	30.8

The cost savings from rechargingrun battery20 from a conventional 115-volt line source is illustrated from the information set forth in Table IV. This information compares the cost of fuel to supply each of a very heavy current load, a moderately heavy current load, and a light current load from the alternator, to the cost of recharging the battery using an external line power charger. All of the examples are based on a 60 amp-hour and 720 volt-amp-hours discharge/charge (a 12-volt battery) while the vehicle was travelling in highway traffic at 60 mph.

The cost of electricity is based on 11.6¢ per Kw hr, which is a calculated average rate for electricity (summer and winter) for residential use in New York City ca. 1991-92, independent of taxes and other charges. Commercial rates for electricity tend to be higher depending upon volume and time of consumption. If the power source is the battery, corresponding to no load current from the alternator, the cost of electricity to recharge the battery from an external battery charger and restore 720 volt-amp-hours (0.72 Kw-hr), at 11.6¢ per Kw-hr, would be 8.4¢. This amount is the same for all examples.

The cost of fuel is based on $1.30/gallon. If the power source is the alternator, such that no current is provided by the battery, the fuel cost for running the electrical load off the alternator would be:$\mathrm{Cost}\left(\$\right)=\frac{{\mathrm{MPG}}_0-{\mathrm{MPG}}_{\mathrm{LOAD}}}{{\mathrm{MPG}}_{\mathrm{LOAD}}}\times \frac{\left[\mathrm{time}\mathrm{period}\times 60\mathrm{MPH}\right]}{{\mathrm{MPG}}_{\mathrm{LOAD}}}$
The time period is selected to obtain the 60 amp-hour discharge for the given current load at 60 MPH. The result of the calculations using the above formula and the data points on Tables I and II are set froth under Table IV below.

TABLE IV
			Cost of
	Time	Cost of	Operating
Current	60 Amp-Hour	Recharging	Off The	Cost Ratio
Load	Discharge	From External	Alternator	Fuel/
(Amps)	(hours)	Charger (¢)	(¢)	Electricity

1984 Mercury Lynx-Highway driving at 60mph

8	7.5	39	8.4	4.6/1
26	2.3	42	8.4	5/1
48	1.25	67.6	8.4	8/1

1988 Oldsmobile Cutlass-Highway driving at 60mph

8	7.5	76.4	8.4	9.1/1
26	2.3	91	8.4	10.8/1
48	1.3	$1.20	8.4	14.3/1

Generally, the greater the current load of the vehicle, the greater the savings when the current load is driven byrun battery20 only, provided thatrun battery20 is recharged by an external line power charger.

The improvement in fuel economy realized by the present invention is proportional to the time the alternator is operated at a relatively reduced output voltage, e.g., at 12 or zero volts versus 13.6 to 14.7 volts.

A 10% fuel saving on every gas powered vehicle in the United States would amount to a reduction of 13.5 billion gallons of gasoline per year in the USA. This corresponds to saving approximately 20 billion dollars a year at the retail pump. It also translates into substantial reduction in undesirable gaseous and particulate emissions which result from fuel consumption.

One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments which are presented for purposes of illustration and not of limitation.

Claims (69)

1. A battery charging system for an automotive vehicle including a starter motor, a catalytic converter for reducing emissions, a fuel burning engine, and vehicle load and accessory load circuits, comprising:

a start battery for providing a discharge current for operating the starter motor to start the engine;

a run battery for operating vehicle load and accessory load circuits;

a storage battery having a first very high discharge current;

a heater for heating the catalytic converter to an elevated temperature in response to the first high discharge current;

means for initiating a starting operation by connecting the start battery to the start motor for a first period of time and for connecting the storage battery to the heater for a second period of time;

an alternator having a variable output condition including a regulated and selectable output voltage with an output current, the alternator being driven by the vehicle engine;

a first circuit for connecting the alternator output to the start battery for recharging the start battery;

a second circuit for connecting the alternator output to the run battery for recharging the run battery; and

a third circuit for recharging the alternator output to the storage battery for recharging the storage battery.

2. The system ofclaim 1 wherein the initiating means further comprises an ignition switch and control circuit for connecting the storage battery to the heater for at least a portion of the second time period prior to connecting the start battery to the start motor so that the catalytic converter is heated to an elevated temperature before actuating the start motor.

3. The system ofclaim 1 further comprising:

a fourth circuit for monitoring the state of charge of the start battery;

a fifth circuit for monitoring the state of charge of the run battery;

a control circuit for controlling the output of the alternator in response to the second states of charge of the start and run batteries, wherein the alternator output has one of a first output condition when the sensed state of charge of the start battery is above a first charge threshold and the sensed state of charge of the run battery is above a second charge threshold;

a second output condition when the sensed state of charge of the start battery is below the first charge threshold; and

a third output condition when the sensed state of charge of the start battery is above the first charge threshold and the sensed state of charge of the run battery is below the second charge threshold.

4. The system ofclaim 1 further comprising:

a fourth circuit for monitoring the state of charge of the start battery;

a fifth circuit for monitoring the state of charge of the run battery;

a sixth circuit for monitoring the state of charge of the storage battery;

a control circuit for controlling the output of the alternator in response to the sensed states of charge of the start, run and storage batteries, wherein the alternator output has one of

a first output condition when the sensed state of charge of the start battery is above a first charge threshold, the sensed state of charge of the run battery is above a second charge threshold, and the sensed state of charge of the storage battery is above a third charge threshold;

a second output condition when one of the sensed state of charge of the start battery is below the first charge threshold and the sensed state of charge of the storage battery is below the third charge threshold; and

a third output condition when the sensed state of charge of the start battery is above the first charge threshold and the sensed state of charge of the run battery is below the second charge threshold.

5. The system ofclaim 4 further comprising a first switch for switching the start battery out of the system when the start battery state of charge is above the first charge threshold and for connecting the start battery to the alternator output when the start battery state of charge is below the first charge threshold.

6. The system ofclaim 4 further comprising a first switch for switching the storage battery out of the system when the storage battery state of charge is above the third charge threshold and for connecting the storage battery of the alternator output when the storage battery state of charge is below the third charge threshold.

7. The system ofclaim 4 wherein the first output condition corresponds to no current being provided by the alternator to any of the run, start, and storage batteries and the second output condition corresponds to a recharge voltage and current being provided by the alternator to the start battery.

8. The system ofclaim 7 wherein the second and third output conditions are the same.

9. The system ofclaim 4 further comprising a line power charger for recharging the start, run, and storage batteries.

10. The system ofclaim 9 further comprising a switching network for selectively connecting the line power charger to those batteries that have less than a full state of charge.

11. The system ofclaim 4 further comprising a switch for disconnecting selected accessory loads from the run battery when the run battery state of charge falls below a fourth selected charge threshold.

12. A method of operating a battery charging system for an automotive vehicle including a starter motor, a catalytic converter for reducing emissions, a fuel burning engine, and vehicle load and accessory load circuit, comprising:

providing a start battery for providing a discharge current for operating the starter motor to start the engine;

providing a run battery for operating vehicle load and accessory circuits;

providing a storage battery having a first very high discharge current;

providing a heater for receiving the first high discharge current and heating the catalytic converter to an elevated temperature;

providing an alternator having a variable output condition including a selectable output voltage with an output current, the alternator being driven by the vehicle engine;

monitoring the state of charge of the start battery;

initiating a starting operation by connecting the start battery to the start motor for a first period of time and connecting the storage battery to the heater for a second period of time; placing the alternator output at a first output condition when the state of charge of the start battery is below a first charge threshold;

connecting the start battery to the alternator output for recharging the start battery following the starting operation; and

disconnecting the start battery from the alternator output when the start battery state of charge is above the first charge threshold.

13. The method ofclaim 12 further comprising:

monitoring the state of charge of the run battery;

setting the alternator output at a second output condition when the state of charge of the run battery is above a second charge threshold, the second charge threshold being less than a full charge; and

setting the alternator output at a third output condition when the state of charge of the run battery falls below a second charge level and applying the alternator third output condition to the run battery until the run battery is fully charged, the third output condition being at a higher voltage level than the second output condition.

14. The method ofclaim 13 wherein the third output condition provides for a fast recharge of the run battery, the method further comprising resetting the alternator output to the second output condition output when the run battery is fully charged.

15. The method ofclaim 12 further comprising:

monitoring the state of charge of the storage battery;

setting the alternator output voltage at a second output condition when the state of charge of the storage battery is above a second charge threshold, the second charge threshold being less than a full charge; and setting the alternator output voltage at a third output condition when the state of charge of the storage battery falls below the second charge threshold and applying the alternator third output condition to the storage battery until the storage battery is fully charged, the third output condition being at a higher output voltage level than the second output condition.

16. The method ofclaim 12 wherein initiating a starting operation further comprises connecting the storage battery to the heater for at least a portion of the second time period prior to connecting the start battery to the start motor so that the catalytic converter is heated before connecting the start battery to the start motor.

17. The method ofclaim 12 further comprising:

monitoring the state of charge of the run battery;

monitoring the state of charge of the storage battery;

controlling the output of the alternator in response to the sensed states of charge of the start, run and storage batteries, wherein the alternator output is selected to be one of

a first output condition when the sensed state of charge of the start battery is above a first charge threshold, the sensed state of charge of the run battery is above a second charge threshold, and the sensed state of charge of the storage battery is above a third charge threshold;

a second output condition when the sensed state of charge of the start battery is below the first charge threshold;

the second output condition when the sensed state of charge of the storage battery is below the third charge threshold; and

a third output condition when the sensed state of charge of the start battery is above the first charge threshold and the sensed state of charge of the run battery is below a fourth charge threshold.

18. The method ofclaim 17 further comprising switching the start battery out of the system when the start battery state of charge is above the first charge threshold and connecting the start battery to the alternator output when the start battery state of charge is below the first charge threshold.

19. The method ofclaim 17 further comprising switching the storage battery out of the system when the storage battery state of charge is above the third charge threshold and for connecting the storage battery to the alternator output when the storage battery state of charge is below the third charge threshold.

20. The method ofclaim 17 wherein in response to the run battery state of charge falling below the third level, the alternator output is maintained at the third output condition until the run battery is fully charged.

21. The method ofclaim 17 wherein the first output condition corresponds to no current being provided by the alternator to any of the run, start, and storage batteries.

22. The method ofclaim 21 wherein the second and third output conditions are the same and apply a charging current.

23. The method ofclaim 17 further comprising recharging the start, run, and storage batteries using a line power charger.

24. The method ofclaim 23 wherein the recharging step using a line power charger further comprises selectively connecting the line power charger to each of the start, run and storage batteries that have less than a full state of charge.

25. A battery charging system for an automotive vehicle having electrical accessory circuits and a fuel consuming engine comprising:

a start battery for starting the engine;

a rechargeable storage battery for operating the accessory circuits;

a circuit for monitoring the state of charge of the storage battery;

means for indicating when the storage battery state of charge is below a selected threshold charge level; and

a line power charger for recharging the storage battery having an input for receiving a supply of electricity.

26. The system ofclaim 25 further comprising:

an alternator having a selectable output voltage;

a circuit for electrically connecting the alternator output voltage to the battery for charging the battery;

a fuel consuming engine for driving the alternator; and

a control circuit for selecting the output voltage of the alternator in response to the sensed state of charge of the battery wherein the alternator output voltage has a first level when the sensed state of charge is above a first charge threshold and a second level when the sensed state of charge is below the first charge threshold.

27. The system ofclaim 26 wherein the second voltage level is selected to charge the battery to a full state of charge.

28. The system ofclaim 26 further comprising:

a start battery for starting the engine;

a second circuit for monitoring the state of charge of the start battery;

a first switch circuit for switching the start battery out of the system when the engine is operating and the start battery is fully charged;

an EHC battery for heating an EHC coil during vehicle starting;

a circuit for monitoring the engine temperature;

a second switch circuit for switching the EHC battery out of the system in response to one of the engine temperature being above a selected temperature and the end of a preselected time period; and

a switching network for connecting the line power charger to each of the storage battery, the start battery and the EHC battery.

29. The system ofclaim 25 wherein the line power charger is mounted on board the vehicle.

30. In an automotive vehicle having a start battery, a start motor, an ignition switch having a vehicle start operation for connecting the start battery to the start motor for starting the vehicle engine and a catalytic converter for reducing undesired vehicle engine emissions, a system for reducing vehicle emissions during starting comprising:

a rechargeable storage battery having a very high discharge current capacity;

a line power charger for recharging the storage battery having an input for receiving a supply of electricity;

a heater for heating the catalytic converter to an elevated temperature in response to receiving the high discharge current;

a switch having a closed condition for connecting the storage battery to the heater so that the high discharge current will pass into the heater which then heats the catalytic converter and an open condition for switching the storage battery out of the system; and

a control circuit for placing the switch in the closed condition during the vehicle start operation so that the high discharge current will pass into the heater which heats the catalytic converter.

31. The system ofclaim 30 further comprising:

a circuit for monitoring the state of charge of the storage battery; and

a switch for connecting the storage battery to the line power charger when the sensed state of charge of the storage battery is below a selected charge threshold for charging the storage battery.

32. The system ofclaim 30 wherein the control circuit further comprises a timing circuit for closing the switch for a selected first period of time in response to the onset of the vehicle start operation.

33. The system ofclaim 32 wherein the control circuit further comprises:

a sensor for providing a signal representing the temperature of the vehicle engine; and

a second switch for disconnecting the storage battery from the heater in response to the sensed engine temperature being above a selected temperature corresponding to the temperature at which the catalytic converter is effective to reduce engine emissions.

34. The system ofclaim 32 wherein the control circuit further comprises a delay circuit, responsive to the beginning of the vehicle start operation, for delaying connecting the start battery to the start motor for a selected second time period following closing of the switch for connecting the storage battery to the heater so that the catalytic converter is heated prior to starting the vehicle engine.

35. The system ofclaim 34 wherein the second time period is shorter than the first time period.

36. The system ofclaim 32 wherein the first time period is on the order of twenty seconds.

37. The system ofclaim 32 further comprising a second catalytic converter in series with the other catalytic converter, wherein the second catalytic converter is normally heated to an effective operating temperature by the engine.

38. The system ofclaim 31 in which the vehicle includes an alternator for charging the start battery, wherein the storage battery has greater voltage rating than the start battery and the system further comprises a voltage converter for charging the storage battery from the alternator.

39. The system ofclaim 30 in which the vehicle includes an alternator for charging the start battery, further comprising:

a switch for selectively connecting either the alternator or the line power charger to the storage battery to recharge the storage battery.

40. In an automotive vehicle having a start battery, a start motor, an ignition switch having a vehicle start operation for connecting the start battery to the start motor for starting the vehicle engine, and a catalytic converter for reducing undesired vehicle engine emissions, a method for reducing vehicle emissions during starting comprising:

(a) providing a rechargeable storage battery having a very high discharge current;

(b) providing a line power charger for recharging the storage battery having an input for receiving a supply of electricity;

(c) providing a heater for heating the catalytic converter to an elevated temperature in response to receiving the high discharge current;

(d) connecting the storage battery to the heater during the starting operation so that the high discharge current will pass into the heater which heats the catalytic converter; and

(e) switching the storage battery out of the system after the vehicle engine has started.

41. The method ofclaim 40 in which the vehicle includes an alternator for charging the start battery, further comprising:

monitoring the state of charge of the storage battery; and

connecting the storage battery to the line power charger when the sensed state of charge of the storage battery is below a selected charge threshold for charging the storage battery.

42. The method ofclaim 40 wherein step (d) further comprises connecting the storage battery to the heater for a selected first period of time in response to the beginning of the vehicle start operation.

43. The method ofclaim 42 wherein steps (d) and (e) further comprise:

sensing the temperature of the vehicle engine; and

disconnecting the storage battery from the heater in response to the sensed engine temperature being above a selected temperature corresponding to the temperature at which the catalytic converter is effective to reduce engine emissions.

44. The method ofclaim 42 further comprising delaying connecting the start battery to the start motor for a selected second time period in response to beginning the vehicle start operation and following connecting the storage battery to the heater so that the catalytic converter is heated prior to starting the vehicle engine.

45. The method ofclaim 44 wherein the second time period is shorter than the first time period.

46. The method ofclaim 42 wherein the first time period is on the order of twenty seconds.

47. The method ofclaim 40 in which the vehicle includes an alternator for charging the start battery, wherein the storage battery has a greater voltage rating than the start battery and the method further comprises providing a voltage converter for charging the storage battery from the alternator.

48. The method ofclaim 40 in which the vehicle includes an alternator for charging the start battery, further comprising:

selectively connecting either the alternator or the line power charger to the storage battery to recharge the storage battery.

49. The method ofclaim 40 further comprising providing a second catalytic converter in series with the other catalytic converter and heating the second catalytic converter to an effective operating temperature from the engine.

50. A method of operating an automotive vehicle that contains a fuel consuming engine, an electric generator driven by the engine, a battery charger, and at least one rechargeable run battery of the deep discharge type, capable of being discharged to and recharged from a deep discharge level repeatedly, said method comprising the steps of:

(a)supplying energy to the vehicle from the at least one run battery;

(b)discharging the at least one run battery to a substantially deep discharge level while the at least one run battery is supplying energy to the vehicle;

(c)determining when the at least one run battery has discharged to the substantially deep discharge level;

(d)automatically charging the at least one run battery from the substantially deep discharge level to a recharged level by supplying energy from the electric generator to the at least one run battery;

(e)repeating steps(b), (c)and(d)a multiplicity of times;

(f)recharging the at least one run battery from an external power source using the battery charger, the battery charger converting voltage from the external power source to a d-c voltage of a suitable level for recharging the at least one run battery; and

(g)repeating step(f)a multiplicity of times.

51. The method ofclaim 50, wherein the recharged level is about at a full charge of the at least one run battery, and wherein said step (d)includes automatically charging the at least one run battery from the substantially deep discharge level to about the full charge.

52. A method of operating an automotive vehicle that contains a fuel consuming engine, an electric generator driven by the engine, a battery charger, and at least one rechargeable run battery of the deep discharge type, capable of being discharged to and recharged from a deep discharge level repeatedly, said method comprising the steps of:

(a)supplying energy to the vehicle from the at least one run battery;

(b)discharging the at least one run battery to a substantially deep discharge level while supplying energy to the vehicle;

(c)determining when the at least one run battery has discharged to the substantially deep discharge level;

(d)automatically supplying energy from the electric generator to the at least one run battery to maintain the charge of the at least one run battery at about the substantially deep discharge level, while the at least one run battery is supplying energy to the vehicle;

(e)recharging the at least one run battery from an external power source using the battery charger, the battery charger converting voltage from the external power source to a d-c voltage of a suitable level for recharging the at least one run battery; and

(f)repeating steps(b), (c), (d)and(e)a multiplicity of times.

53. A method of operating an automotive vehicle that contains a fuel consuming engine, an electric generator driven by the engine, a battery charger, and at least one rechargeable run battery of the deep discharge type, capable of being discharged to and recharged from a deep discharge level repeatedly, said method comprising the steps of:

(a)supplying energy to the vehicle from the at least one run battery;

(b)discharging the at least one run battery from approximately its full charge level to a predetermined level that is no more than50%below its full charge level, while the at least one run battery is supplying energy to the vehicle;

(c)determining when the at least one run battery has discharged to the predetermined level;

(d)automatically charging the at least one run battery from the predetermined level toward a recharged level by supplying energy from the electric generator to the at least one run battery;

(e)repeating steps(b), (c)and(d)numerous times;

(f)recharging the at least one run battery from a home power source using the battery charger, the battery charger converting voltage from the power source to a d-c voltage of a suitable level for recharging the at least one run battery; and

(g)repeating step(f)numerous times.

54. The method ofclaim 53, wherein the recharging of the at least one run battery is done from the home power source numerous times when the state of charge of the at least one run battery is above the predetermined level.

55. The method ofclaim 53, wherein the recharging of the at least one run battery from the electric generator is done repeatedly, whenever the state of charge of the at least one run battery decreases to the predetermined level.

56. The method ofclaim 53, wherein the at least one run battery generates a first dc voltage potential, said method further comprising the step of converting the first dc voltage potential to a second dc voltage potential, said step (a)including applying the second dc voltage potential to the vehicle.

57. The method ofclaim 53, further comprising the steps of:

sensing the deceleration of the vehicle; and

automatically supplying a charging current to the at least one run battery in response to the deceleration of the vehicle.

58. The method ofclaim 53, further comprising the steps of:

sensing when the vehicle is accelerating and decelerating in stop and go traffic; and

automatically supplying a charging current to the at least one run battery when the vehicle is decelerating in stop and go traffic.

59. The method ofclaim 53, further comprising the steps of:

indicating how long it will take to recharge the at least one run battery.

60. The method ofclaim 53, further comprising the step of:

providing an indication, after the at least one run battery has begun to discharge, when a preselected charge level of the at least one run battery has been reached, the preselected charge level being above the predetermined level to give an advance warning that the charge of the at least one run battery is approaching the predetermined level.

61. A method of operating an automotive vehicle that contains a fuel consuming engine, an electric generator driven by the engine, and at least one rechargeable run battery of the deep discharge type, capable of being recharged from a deep discharge repeatedly, said method comprising the steps of:

(a)supplying energy to the vehicle from the at least one run battery;

(b)discharging the at least one run battery to a predetermined level while the at least one run battery is supplying energy to the vehicle;

(c)determining when the at least one run battery has discharged to the predetermined level;

(d)automatically supplying energy from the electric generator to the at least one run battery, once the charge on the at least one run battery has discharged to said predetermined level, to increase the charge on the at least one run battery;

(e)recharging the at least one run battery from an external power source using a battery charger, the battery charger converting voltage from the external power source to a d-c voltage of a suitable level for recharging the at least one run battery; and

(f)repeating steps(b), (c), (d)and(e)numerous times.

62. A passenger car comprising:

at least one rechargeable run battery of the deep discharge type, capable of being discharged to and recharged from a deep discharge level repeatedly;

a fuel consuming engine;

an electric generator coupled to said engine and to said at least one run battery, and responsive to said engine for charging said at least one run battery;

a first circuit connected to said at least one run battery and configured to determine when said at least one run battery has discharged to a predetermined discharge level;

a second circuit, responsive to said first circuit and coupled to said generator, for automatically supplying energy repeatedly from said generator to said at least one run battery each time said predetermined discharge level is determined, the energy supplied from said generator to said at least one run battery being a charging current that charges said at least one run battery toward as recharged level; and

a battery charger mounted onboard the car for repeatedly recharging said at least one run battery from an external power source, said battery charger converting a-c voltage from the external power source to a d-c voltage of a suitable level for recharging said at least one run battery.

63. A passenger car as inclaim 62, further comprising:

an indicator in the car for indicating how long it will take to recharge the at least one run battery.

64. A passenger car as inclaim 62, further comprising:

an indicator in the car for indicating the charge remaining on said at least one run battery during the time said at least one run battery is discharging to said predetermined discharge level.

65. A passenger car as inclaim 64, further comprising:

a warning indicator that provides a visible or audible warning a preselected time before the predetermined discharge level is reached.

66. A passenger car comprising:

at least one rechargeable run battery of the deep discharge type, capable of being discharged to a deep discharge level and recharged repeatedly;

a fuel consuming engine;

an electric generator coupled to said engine and to said at least one run battery, and responsive to said engine for charging said at least one run battery;

a first circuit connected to said at least one run battery and configured to determine when said at least one run battery has discharged to a predetermined discharge level;

a second circuit, responsive to said first circuit and coupled to said generator, for automatically supplying energy from said generator to said at least one run battery when said at least one run battery has discharged to the predetermined level, the energy supplied from said generator to said at least one run battery being a charging current that charges said at least one run battery toward a recharged level; and

a battery charger mounted onboard the car and connected to said at least one run battery for repeatedly recharging said at least one run battery from an external power source, said battery charger converting voltage from the external power source to a d-c voltage of a suitable level for recharging said at least one run battery.

67. A passenger car as inclaim 66, wherein:

said first circuit determines each time said at least one run battery has discharged to the predetermined level;

and wherein said second circuit responds to a signal from said first circuit each time said first circuit determines that said at least one run battery has discharged to the predetermined level, to supply energy repeatedly from the generator to said at least one run battery.

68. A passenger car as inclaim 66, further comprising:

a sensing circuit for sensing deceleration of the car; and

a battery charging circuit responsive to said sensing circuit for supplying a charging current to said at least one run battery when deceleration of the car is sensed.

69. A passenger car as inclaim 66, further comprising:

a sensing circuit for sensing when the car is accelerating and decelerating in stop and go traffic; and

a battery charging circuit responsive to said sensing circuit for supplying a charging current to said at least one run battery when the car is decelerating in stop and go traffic.

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