Abstract: A compressed air supply apparatus for heavy vehicles includes a service reservoir, an air dryer in communication with the service reservoir, a purge reservoir in communication with the air dryer, a compressor for delivering compressed air through the air dryer preferentially to the purge reservoir and then to the service reservoir and a controller. The controller interrupts the charge cycle of the compressor in response to a moisture accumulation value being equal to or exceeding a wetness threshold value and the pressure in the service reservoir being within a predetermined pressure range. The controller then initiates a modified purge cycle of the air dryer, which includes iteratively regenerating the air dryer with air from the purge reservoir until at least one of the moisture accumulation value is less than the wetness threshold value and the pressure in the service reservoir is outside the predetermined pressure range.

Abstract: Various embodiments of a method and apparatus for an air charging system controller for an air braked vehicle are disclosed. The air charging system controller comprises an input for receiving conditions of the vehicle, an output for controlling a compressor in a normal mode and in a high demand mode and control logic. The control logic determines whether the vehicle meets a predetermined condition and controls the compressor in the high demand mode in response to the vehicle meeting the predetermined condition.

Abstract: A compressed air supply apparatus for heavy vehicles includes a service reservoir, an air dryer in communication with the service reservoir, a purge reservoir in communication with the air dryer, a compressor for delivering compressed air through the air dryer preferentially to the purge reservoir and then to the service reservoir and a controller. The controller interrupts the charge cycle of the compressor in response to a moisture accumulation value being equal to or exceeding a wetness threshold value and the pressure in the service reservoir being within a predetermined pressure range. The controller then initiates a modified purge cycle of the air dryer, which includes iteratively regenerating the air dryer with air from the purge reservoir until at least one of the moisture accumulation value is less than the wetness threshold value and the pressure in the service reservoir is outside the predetermined pressure range.

Abstract: A device for monitoring humidity in a compressed air system comprises a light emitter; a light sensor; and a hygromorphic element. The hygromorphic element is exposed to a source of compressed air and positioned between the light emitter and the light sensor. The hygromorphic element changes the amount of light passing between the light emitter and the light sensor as the humidity in the compressed air increases.

Abstract: Various embodiments of a method and apparatus for an air charging system controller for an air braked vehicle are disclosed. The air charging system controller comprises an input for receiving conditions of the vehicle, an output for controlling a compressor in a normal mode and in a high demand mode and control logic. The control logic determines whether the vehicle meets a predetermined condition and controls the compressor in the high demand mode in response to the vehicle meeting the predetermined condition.

Abstract: A device for monitoring humidity in a compressed air system comprises a light emitter; a light sensor; and a hygromorphic element. The hygromorphic element is exposed to a source of compressed air and positioned between the light emitter and the light sensor. The hygromorphic element changes the amount of light passing between the light emitter and the light sensor as the humidity in the compressed air increases.

Abstract: A controller apparatus is provided for a compressed air system. The controller apparatus comprises a control output for transmitting a control signal to interrupt a charge cycle of an associated compressor in a loading state. The controller apparatus further comprises control logic capable of initiating an interrupted charge cycle of the compressor based upon a moisture accumulation value indicative of the extent of moisture accumulated in an associated air dryer during the charge cycle of the compressor in the loading state.

Abstract: A controller for monitoring an air system in a vehicle comprises an input for receiving at least one pressure signal indicative of an air pressure in an air system an output for transmitting an alert to a vehicle operator; and control logic. The control logic is capable of determining an instant cut out time indicative of the time for the at least one air pressure signal to reach a cut out pressure value from a cut in pressure value; determining a difference between the instant cut out time to an average cut out time; and transmitting a leakage alert at the output in response to the instant cut out time being greater than or equal to a predetermined difference from the average cut out time. The control logic is also capable of changing the compressor operation in response to the alert.

Abstract: A controller for monitoring an air system in a vehicle comprises an input for receiving at least one pressure signal indicative of air pressure in an air system; and a processor having control logic. The control logic is capable of determining a volume of the air system at a first time based on the at least one air pressure signal and a vehicle factor; determining the volume of the air system at a second time based on the at least one air pressure signal and the vehicle factor; determining the difference between the volume at the first time and the volume at the second time; and transmitting an alert in response to a difference between the volume at the first time and volume at the second time. The control logic is also capable of changing the compressor operation in response to the alert.

Abstract: A method and controller for controlling the purge cycling of an air dryer assembly is disclosed. The controller includes a control output for transmitting a control signal for controlling the air dryer. The controller is capable of initiating an enhanced purge cycle for the air dryer based on a regeneration volume value. The regeneration volume value is based on the accumulated volume of air delivered to the air dryer for a first time or since a prior standard purge cycle.

Abstract: A method and controller for controlling the purge cycling of an air dryer assembly is disclosed. The controller includes a control output for transmitting a control signal for controlling the air dryer. The controller is capable of initiating an enhanced purge cycle for the air dryer based on a regeneration volume value. The regeneration volume value is based on the accumulated volume of air delivered to the air dryer for a first time or since a prior standard purge cycle.

Abstract: The described systems and methods relate to employing an Electric Air Charging System (EACS) to maintain a hybrid commercial vehicle (or the like) battery within a desired range of charge. The innovation facilitates reducing battery charge when the state of charge is too high, such as by adjusting air compressor cut-in and cut-out pressure thresholds to cause the air compressor to compress air for the brake system when there is excess charge in the battery, as well as triggering a brake regeneration protocol and/or other charge regeneration protocol(s) to restore charge to the battery when the state of charge of the battery is too low.

Abstract: A controller unit facilitates determining that a fast approaching forward vehicle has breached a fast approach threshold and may initiate brake regeneration to slow a commercial hybrid host vehicle in which the controller is employed. The controller determines whether there is capacity in the state of charge (SOC) of a high voltage battery to permit brake regeneration, and/or determines whether there is capacity in on board air tanks to permit a compressor motor to compress air, thereby drawing charge from the battery to create brake regeneration capacity. When battery SOC is below a predetermined threshold and a fast approaching vehicle breaches a fast approach threshold, the controller sends a brake regeneration command to a traction motor to act as a generator to supply charge to the battery, which in turn slows the vehicle.

Abstract: A motor controller unit facilitates modifying pressure thresholds for an air compressor motor in a hybrid commercial vehicle as a function of vehicle pitch and comprises a memory that stores computer-executable instructions for modifying compressor cut-in and cut-out pressure thresholds as a function of vehicle pitch, and a processor configured to execute the computer-executable instructions. The instructions comprise monitoring a pitch of the vehicle, and determining that the vehicle is on an uphill grade. The instructions further comprise reducing compressor cut-in and cut-out pressure thresholds for an on-board air compressor motor to conserve state-of-charge until the pitch of the vehicle falls below a predetermined level, and, once the pitch of the vehicle falls below a predetermined percentage of the maximum pitch detected on the uphill grade, increasing the compressor cut-in and cut-out pressure thresholds to increase available braking pressure and brake regeneration opportunities for the vehicle.

Abstract: A controller unit facilitates determining that a fast approaching forward vehicle has breached a fast approach threshold and may initiate brake regeneration to slow a commercial hybrid host vehicle in which the controller is employed. The controller determines whether there is capacity in the state of charge (SOC) of a high voltage battery to permit brake regeneration, and/or determines whether there is capacity in on board air tanks to permit a compressor motor to compress air, thereby drawing charge from the battery to create brake regeneration capacity. When battery SOC is below a predetermined threshold and a fast approaching vehicle breaches a fast approach threshold, the controller sends a brake regeneration command to a traction motor to act as a generator to supply charge to the battery, which in turn slows the vehicle.

Abstract: A motor controller unit facilitates modifying pressure thresholds and motor operation mode for an air compressor in a hybrid commercial vehicle as a function of vehicle air demand and comprises a processor configured to execute computer-executable instructions comprising monitoring vehicle air system pressure, calculating air demand generated by the vehicle air system, and determining that the vehicle air system air demand is greater than a predetermined air demand threshold. A cut-out pressure threshold for the compressor motor is increased and the air compressor motor is switched from an on/off mode to a continuous run mode wherein pressure is maintained in the air system to be between a cut-in pressure threshold and the increased cut-out pressure threshold. The compressor motor operates in the continuous run mode until air demand falls below the predetermined air demand threshold.

Abstract: The described systems and methods relate to employing an Electric Air Charging System (EACS) to maintain a hybrid commercial vehicle (or the like) battery within a desired range of charge. The innovation facilitates reducing battery charge when the state of charge is too high, such as by adjusting air compressor cut-in and cut-out pressure thresholds to cause the air compressor to compress air for the brake system when there is excess charge in the battery, as well as triggering a brake regeneration protocol and/or other charge regeneration protocol(s) to restore charge to the battery when the state of charge of the battery is too low.

Abstract: When controlling an air compressor (13) for a pneumatic braking system on a large hybrid commercial vehicle (e.g., a bus, a package delivery truck, etc.), PID control of an air compressor motor (12) is employed during normal system operation such as when the motor shaft is spinning, and state machine control is employed during startup or upon a system disturbance such as a shaft seizure or stall. In this manner, stalling events that occurs due to PID control inability to correct for unexpected disturbances are mitigated by employing state machine control.

Abstract: When controlling an air compressor (13) for a pneumatic braking system on a large hybrid commercial vehicle (e.g., a bus, a package delivery truck, etc.), PID control of an air compressor motor (12) is employed during normal system operation such as when the motor shaft is spinning, and state machine control is employed during startup or upon a system disturbance such as a shaft seizure or stall. In this manner, stalling events that occurs due to PID control inability to correct for unexpected disturbances are mitigated by employing state machine control.

Abstract: Controlling air compressors based on a temperature of air compressed by the air compressor. A temperature of air compressed by the air compressor is sensed. The sensed compressed air temperature is compared with a predetermined threshold temperature. The air compressor is deactivated when the sensed temperature exceeds the threshold temperature. The threshold temperature may be selected to inhibit carbon formation caused by oil thermal breakdown.