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Charging System
General Information
Overview and Operation
Smart Regenerative Charging. Smart Regenerative Charging is an intelligent charge control system that calculates and regulates the set generator voltage.The basic idea of the system is to increase the generator charge voltage when the vehicle is decelerating and reduce it when it is accelerating.This means that during the acceleration phase, there is no additional energy demand as a result of having a high generator load; however generator load is increased when the vehicle is decelerating.This strategy enables further fuel savings to be achieved.
Battery Monitoring Sensor
The Battery Monitoring Sensor continuously monitors the condition of the battery.The sensor is equipped to vehicles which have Smart Regenerative Charging or Start-Stop. These systems require knowledge of the battery state of charge. The Battery Monitoring Sensor is the sensor used to provide this information.
Battery Monitoring Sensor connection
The Battery Monitoring Sensor is clamped directly to the negative terminal of the battery and grounds to the vehicle at the chassis ground connection point by means of a thick (25 to 35mm²) cable and eyelet. External customer loads must only be connected to the vehicle at the customer battery connection point. If the external customer load is connected at the negative battery post, the Battery Monitoring Sensor accuracy cannot be guaranteed. It is recommended that the Battery Monitoring Sensor pole clamp is not removed unless a battery replacement is required. Should the battery need to be isolated, this should be done by disconnecting the ground eyelet at the chassis ground.
Battery Monitoring Sensor reset
The Battery Monitoring Sensor also estimates losses in the battery capacity over time. The Battery Monitoring Sensor should be reset to factory default settings, when the battery is replaced. It is urgently recommended that the replacement battery has the exact same specification as the original battery. If it does not, the accuracy of the Battery Monitoring Sensor outputs will be compromised. The Battery Monitoring Sensor reset is part of the battery replacement procedure in IDS (Int egrated Diagnostic System). The Battery Monitor Sensor can also be reseted manually by using the following steps:
• Switch on the ignition.
• Press the high beam switch five times by pulling and releasing.
• Press and release the brake pedal three times.
• If the steps were successful, the warning indicator of the battery charging system in the IPC (instrument panel cluster) flashes three times within the next 15 s. If the sequence is interrupted by pressing other keys or pedals for any reason, repeat the above steps, starting from the beginning.
If the BMS reset procedure described above does not work, follow the procedure below (within 10 s)
•Switch on the ignition.
• Press the rear fog light switch five times.
• Press the hazard flasher switch three times.
• If the steps were successful, the warning indicator of the battery charging system in the IPC (instrument panel cluster) flashes three times within the next 15 s.
Smart Regenerative Charging
The largest element of the Smart Regenerative Charging Strategy is stored in the BCMmodule. It receives all of the important information relating to the battery condition sent by the battery monitoring sensor via the LIN (local interconnect network) data bus.The information obtained is used to calculate the required set value for generator charge voltage. This is sent by the BCM to the PCM via the HS-CAN (controller area network) data
bus. This then adjusts the value received if necessary and passes it on the generator via the LIN data bus. The charging voltage is adjusted depending on various parameters, such as the current level of engine efficiency.The smallest possible set value for the generator voltage is 12.2 V, while the maximum charging voltage may be anywhere between 14.5 and 14.9 V.However, when the battery is in a refresh phase, the voltage may occasionally reach up to 15.2 V. These refresh phases are required as the battery charge status is 80% over long periods of time, which increases the risk of sulfation in the cells.
Comparison of Smart Regenerative Charging and Conventional Charging
Conventional charging aims to charge the battery to the highest possible levels. During this process the battery temperature is monitored and the battery must not be overcharged.By comparison, Smart Regenerative Charging uses the information from the battery monitoring sensor to maintain the battery at a calibrated state of charge (approx. 80%) at all times. This means that the battery has a certain amount of extra charging capacity at all times.If the battery monitoring sensor detects that the charge status is above the calibrated value (approx. 80%), then the generator charging voltage is reduced in order to discharge the battery. If the opposite occurs and too low a value is detected, the charging value is increased in order to return the battery to the calibrated value.
Battery Monitor Sensor
The measures temperature, voltage and current throughput of the battery. It uses this information to calculate the battery SOC (State of Charge).To function with high accuracy, the BMS must be recalibrated at regular intervals. A recalibration occurs during a rest period when the battery quiescent current is less than 100mA. This rest period must last for at least 3 hours. The longer the rest period, the greater the accuracy.
The timeframe in which a recalibration must take place is seven days.If the system has been unable to carry out a recalibration within 7 days, the SOC accuracy cannot be guaranteed.This will result in the Start – Stop and SRC systems being deactivated.