Control Methods and Systems for Dual Mode Cooling Pump

Abstract

Methods and systems for controlling the operation of a dual mode engine accessory, such as a dual mode cooling pump. The dual mode device has two modes of operation, an electric motor operation and a mechanical pulley-driven operation. A friction clutch mechanism controlled by the control system is utilized to switch between the two modes of operation. The speed of the electrical motor can be changed to be substantially the same as, or changed in the direction of, the speed of the mechanical pulley-driven system.

What is claimed is: 
     
         1 . A dual mode cooling pump device comprising:
 a pump housing member;   a pulley assembly attached to said pump housing member;   an impeller member positioned in said pump housing for pumping coolant;   an impeller shaft connected to said impeller member;   an electric motor positioned inside said pulley assembly and adapted to selectively rotate said impeller member;   a friction clutch assembly positioned inside said pump housing member and adapted to selectively rotate said impeller shaft member;   wherein said dual mode cooling pump is operated by said electric motor for a first period of time and by said pulley assembly for a second period of time, and wherein the speed of the electric motor is increased immediately prior to said second period of time, wherein a smooth transition results in changing from electric motor operation to pulley assembly operation.   
     
     
         2 . The dual mode cooling pump as described in  claim 1  wherein said friction clutch assembly comprises a friction lining carrier members and a compression spring member fixedly attached to said friction lining carrier member. 
     
     
         3 . The dual mode cooling pump as described in  claim 2  wherein the amount of force necessary to compress the spring member lessens over displacement once it has reached a peak amount of force. 
     
     
         4 . The dual mode cooling pump as described in  claim 1  further comprising a solenoid mechanism, and wherein said solenoid mechanism causes said compression spring member to compress. 
     
     
         5 . The dual mode cooling pump as described in  claim 1  wherein said electric member is a brushless electric motor. 
     
     
         6 . The dual mode cooling pump as described in  claim 1  wherein friction clutch assembly is prevented from engagement during said first period of operation and disengaged from said electric motor during said second period of operation. 
     
     
         7 . A dual mode cooling pump device comprising:
 a pump housing member;   a pulley assembly attached to said pump housing member;   an impeller member positioned in said pump housing for pumping coolant;   an impeller shaft connected to said impeller member;   an electric motor positioned inside said pulley assembly and adapted to selectively rotate said impeller member;   a friction clutch assembly positioned inside said pump housing member and adapted to selectively rotate said impeller shaft member;   wherein said pulley assembly rotates said cooling pump impeller at a first rate of speed, and said electric motor rotates said cooling pump impeller at a second rate of speed, and wherein when a change is made between the two modes of operation, the first and second rates of speed are brought closer to the same rate of speed.   
     
     
         8 . A method of operating a dual mode component for a vehicle system comprising supplying electrical power to the dual mode component to drive the same during clutch engagement to drive the dual mode component using mechanical power, wherein the amount of electrical power supplied to the dual mode component during clutch engagement is such that the speed of a shaft rotating in the dual mode component is substantially the same as the speed that the shaft would be if the dual mode component were operated by mechanical power at the engine speed and at the time the clutch is engaged, and thereafter reducing the electrical power supplied to the dual mode component in one of a step or ramp fashion until no electrical power is being supplied to the dual mode component and the dual mode component is being driven by only mechanical power. 
     
     
         9 . The method as set forth in  claim 8  wherein the mode of operation is switched from one mode to the other with little or no overlap of the two power sources. 
     
     
         10 . The method as set forth in  claim 8  wherein the system includes a battery and wherein supplying electrical power comprises delivering electrical power from the battery. 
     
     
         11 . The method as set forth in  claim 8  further comprising recovering energy from a first vehicle component, converting the energy to electrical power, storing the electrical power in a battery, and supplying electrical power from the battery to the dual mode component constructed and arranged to drive a second vehicle component using mechanical power and electrical power. 
     
     
         12 . The method as set forth in  claim 8  wherein the first vehicle component comprises a braking system. 
     
     
         13 . The method as set forth in  claim 11  wherein the recovering energy from a first vehicle component comprising recovering thermal energy. 
     
     
         14 . The method as set forth in  claim 11  wherein the recovering energy from a first vehicle component comprising recovering mechanical energy. 
     
     
         15 . A method of operating a vehicle system including at least one dual mode component comprising supplying electrical power and mechanical power at the same time to the at least one dual mode component to drive the same, wherein the vehicle system includes a combustion engine, a cooling system including a radiator and a fan positioned to force air onto the radiator, plumbing connected to the radiator and the engine to deliver coolant from the radiator to the engine and back to the engine, the at least one dual mode component constructed and arranged to operate using electrical and mechanical power, the at least one dual mode component connected to at least one of the fan or pump to drive the same, the mechanical power being provided directly or indirectly by the engine, comprising supplying mechanical power to the dual mode component to drive the same and during rapid engine transients also supplying electrical power at the same time mechanical power is being supplied to the dual mode component to assist in driving the dual mode component. 
     
     
         16 . The method as set forth in  claim 15  further comprising determining when an engine of the vehicle system is accelerating at first rate or greater than the first rate, and if so, supplying electrical power to a dual mode component while the dual mode component is also being driven by mechanical power. 
     
     
         17 . A method of operating a vehicle system, the vehicle system including a battery and a dual mode component connect to the battery, measuring the remaining capacity of the battery to store additional energy, and if the remaining capacity is at or less than a first amount or capacity, then supplying electrical energy from the battery to the dual mode component to drive the dual mode component and to utilize a portion of the energy that was stored in the battery thereby freeing up capacity in the battery to store energy from mechanical and thermal energy recovery components. 
     
     
         18 . A method as set forth in  claim 17  wherein the dual mode component is being driven also by mechanical energy during the supplying electrical energy from the battery to the dual mode component to drive the dual mode component and to utilize a portion of the energy that was stored in the battery. 
     
     
         19 . A method of operating a vehicle system including at least one dual mode component comprising supplying electrical power and mechanical power at the same time to the at least one dual mode component to drive the same, the vehicle system comprising at least one of air conditioning system coolant compressor pump, an engine oil pump or a transmission oil pump operate connected to the dual mode component to be driven by the same. 
     
     
         20 . A vehicle system comprising a dual mode component constructed and arranged to be driven by mechanical power and electrical power, at least one of a radiator fan, coolant pump, air conditioning compressor pump, combustion engine lubricating oil pump, or transmission oil pump connected to the dual mode component to be driven by the same, and a controller constructed and arranged to control the operation of the dual mode component so that the dual mode component is driven by mechanical power and electrical power at the same time. 
     
     
         21 . A method of operating a vehicle system comprising a dual mode component constructed and arranged to be drive by mechanical power and electrical power, at least one of a radiator fan, coolant pump, air conditioning compressor pump, combustion engine lubricating oil pump, or transmission oil pump connected to the dual mode component to be driven by the same, comprising supplying both mechanical power and electrical power to the dual mode component at the same time to at least one of a radiator fan, coolant pump, air conditioning compressor pump, combustion engine lubricating oil pump, or transmission oil pump. 
     
     
         22 . A method of operating a vehicle system comprising a dual mode component constructed and arranged to be driven by mechanical power and electrical power, comprising controlling the dual mode component so that neither mechanical power nor electrical power is supplied during rapid engine transients and thereafter supplying both electrical power and mechanical power at the same time. 
     
     
         23 . A method of operating a vehicle system comprising a dual mode component constructed and arranged to be driven by mechanical power and electrical power, comprising supplying only electrical power to the dual mode during rapid engine transients and thereafter supplying both electrical power and mechanical power at the same time. 
     
     
         24 . A method of operating a vehicle system comprising a dual mode component constructed and arranged to be driven by mechanical power and electrical power, comprising supplying electrical power and mechanical power at the same time to the at least one dual mode component to drive the same, and thereafter, upon deceleration of the vehicle supplying only electrical power produced from an alternator to the dual mode component. 
     
     
         25 . A method of operating a dual mode cooling pump for a vehicle system comprising supplying electrical power by an electrical motor to the dual mode cooling pump to drive the same during a first period of operation, supplying mechanical power by an engine belt system to the dual mode cooling pump to drive same during a second period of operation, driving said cooling pump by an electric motor at a first speed;
 detecting that the rotation of said cooling pump is changing from electrical power to mechanical power;   detecting the speed of the engine belt system for rotating said cooling pump; said speed being a secure speed; and   minimizing the difference between said first speed and said second speed before changing the operation of rotation of said cooling pump from electrical power to mechanical power;   wherein a smoother transition from electrical power to mechanical power is effectuated.   
     
     
         26 . A method of operating a dual mode cooling pump for a vehicle system comprising supplying electrical power by an electrical motor to the dual mode cooling pump to drive the same during a first period of operation, supplying mechanical power by an engine belt system to the dual mode cooling pump to drive same during a second period of operation, actuating a friction clutch mechanism to selectively engage the engine belt system and supply mechanical power to the dual mode cooling pump, and changing the speed of the electrical motor to be substantially the same as the speed of the engine belt system prior to actuating said friction clutch mechanism, wherein a smoother transition from said electrical power to said mechanical power is effectuated;
 wherein the change from electrical power operation to mechanical power operation is made when said mechanical power operation has a higher cooling capacity than the electrical power operation.