System and method for redistributing electronic fuses

Abstract

Systems and methods for reassigning electronic fuses (EFn). The method includes simultaneously receiving respective sensor data for a plurality (N) of EFn and comparing the sensor data to respective operating ranges. EFn exceeding their operating ranges are turned off. Where a preprogrammed configuration of a fuse harness defines a plurality (M) of clusters, the method identifies for each EFn within the operating range whether the EFn is a member of a cluster of the M clusters and the other members of the cluster. The method monitors the sensor data of each cluster member relative to a preprogrammed threshold and load current demand, classifying each EFn in each cluster as healthy, degraded, or failed. For failed EFn, a target EF with reassignment potential in the same cluster is identified and its fuse limit is modified according to the reassignment potential.

Description

Technical Field

[0001] This disclosure generally relates to automatic energy distribution in mobile platforms, and more specifically to systems and methods for redistributing electronic fuses (EF) implemented in vehicles, the electronic fuses being configured to drive fuse harnesses operatively connected to multiple loads. Background Technology

[0002] Smart electronic fuses (EFs) are sometimes used to meet load current requirements in vehicle applications. However, the technical challenge is that each vehicle model and variant may have its own load arrangement, and each load has its own load current requirements, which means that the smart EF array must be reconfigured for each new iteration of the vehicle.

[0003] In addition to addressing the related problems, the following disclosure also provides technical solutions to these technical problems. Furthermore, in conjunction with the accompanying drawings and the foregoing background, other desired features and characteristics of the system and method will become readily apparent from the following detailed description. Summary of the Invention

[0004] In one embodiment, a system for redistributing electronic fuses (EF) implemented on a vehicle is provided, the electronic fuses being configured to drive fuse harnesses operably connected to multiple loads. The system includes: an EF array comprising a plurality (N) of electronic fuses (EFn); a controller circuit including a processor operatively coupled to the EF array and programmed to simultaneously receive a corresponding load current (EFn_i) and temperature (EFn_T) for each EFn; for each EFn, comparing the corresponding EFn_i with the operating range of the EFn; shutting off each EFn whose EFn_i is outside the operating range, and generating a corresponding load current alarm in response; wherein a pre-programmed configuration of the fuse harness defines a plurality (M) clusters, and for each EFn_i within the operating range, determining whether the corresponding EFn is a member of a cluster among the M clusters; in response to determining that an EFn is a member of the cluster, identifying other members of the cluster; for each member of the cluster, performing a comparison of the corresponding EFn_i with a pre-programmed load current expectation and a comparison of the corresponding EFn_T with a pre-programmed temperature threshold during a pre-programmed duration; and, upon expiration of the pre-programmed duration, based on the EFn_i and the EFn... The comparison of _T classifies each EFn in the cluster as healthy, degraded, or faulty; for each EFn classified as degraded, a degrade alarm is generated for that EFn; and for each EFn classified as faulty, another member of the cluster is identified as a target EF, which has a redistribution potential consistent with the pre-programmed configuration of the fuse harness; and the fuse limit of the target EF is modified according to the redistribution potential.

[0005] In one embodiment, the redistribution potential includes the capacity to support the increased load current, and the controller circuitry is also programmed to modify the fusing limit of the target EF by increasing the load current of the target EF.

[0006] In one embodiment, the controller circuitry is also programmed to shut down the corresponding EFn classified as faulty after modifying the fuse limit of the target EF, and to generate an alarm indicating that the cluster has been modified.

[0007] In one embodiment, the controller circuitry is also programmed to reference pre-programmed EF data for each EFn to determine the pre-programmed load current expectation.

[0008] In one embodiment, the pre-programmed configuration of the fuse harness specifies the arrangement and location of each of the M clusters, and the arrangement and location of each of the M clusters is a function of the predefined load current demand from each of the multiple loads.

[0009] In one embodiment, the pre-programmed configuration of the fuse harness is designed to meet a predetermined load current requirement from at least one of a plurality of loads by combining two or more EFn_i.

[0010] In one embodiment, the controller circuit is also programmed to classify each EFn as degraded upon the expiration of a pre-programmed duration: in response to determining that EFn_i exceeds the pre-programmed load current expected by EFn but does not exceed a critical current threshold of EFn, while EFn_T is within a pre-programmed temperature threshold.

[0011] In one embodiment, the controller circuitry is also programmed to classify each EFn as a fault upon the expiration of a pre-programmed duration, in response to determining that EFn_T exceeds a pre-programmed temperature threshold.

[0012] In one embodiment, the controller circuit is also programmed to classify each EFn as a fault upon the expiration of the pre-programmed duration, in response to determining that EFn_i exceeds a critical current threshold of EFn.

[0013] In one embodiment, the load current alarm is a system alarm for the vehicle.

[0014] A method is also provided for reallocating electronic fuses (EF) within an EF array comprising multiple (N) electronic fuses (EFn) implemented in a vehicle, the method comprising: simultaneously receiving a corresponding load current (EFn_i) and temperature (EFn_T) for each EFn at a controller circuit including a processor programmed with programming instructions; and for each EFn, reallocating the corresponding EFn The EFn_i is compared with the operating range of the EFn; each EFn outside the operating range is shut off, and a corresponding load current alarm is generated accordingly; wherein the pre-programmed configuration of the fuse harness defines a plurality of (M) clusters, and for each EFn_i within the operating range, it is determined whether the corresponding EFn is a member of a cluster in the M clusters; in response to determining that an EFn is a member of the cluster, other members of the cluster are identified; for each member of the cluster, during the pre-programmed duration, a comparison is performed between the corresponding EFn_i and the pre-programmed load current expectation, and a comparison is performed between the corresponding EFn_T and the pre-programmed temperature threshold; at the end of the pre-programmed duration, each EFn in the cluster is classified as healthy, degraded, or faulty based on the comparison of the EFn_i and the EFn_T; for each EFn classified as degraded, a degraded alarm is generated for the EFn; and for each EFn classified as faulty, another member of the cluster is identified as a target EF with a redistribution potential consistent with the pre-programmed configuration of the fuse harness, and the fusing limit of the target EF is modified according to the redistribution potential.

[0015] In an embodiment, the redistribution potential includes the capacity to support the increased load current, and also includes modifying the fusing limit of the target EF by increasing the load current of the target EF.

[0016] In one embodiment, the method further includes: after modifying the circuit breaker limit of the target EF, shutting down the corresponding EFn that is classified as faulty, and generating an alarm indicating that the cluster has been modified.

[0017] In one embodiment, the method further includes: for each EFn, referencing pre-programmed EF data to determine the pre-programmed load current expectation.

[0018] In an embodiment, the pre-programmed configuration of the fuse harness specifies the arrangement and location of each of the M clusters, and the arrangement and location of each of the m clusters is a function of the predefined load current demand from each of the multiple loads.

[0019] In one embodiment, the pre-programmed configuration of the fuse harness is designed to meet a predetermined load current requirement from at least one of a plurality of loads by combining two or more EFn_i.

[0020] In one embodiment, the method further includes, upon the expiration of the pre-programmed duration: in response to determining that EFn_i exceeds the pre-programmed load current expected by EFn but does not exceed a critical current threshold of EFn, while EFn_T is within a pre-programmed temperature threshold, classifying each EFn as degraded.

[0021] In one embodiment, the method further includes classifying each EFn as a fault upon the expiration of the pre-programmed duration: in response to determining that EFn_T exceeds a pre-programmed temperature threshold.

[0022] In one embodiment, the method further includes classifying each EFn as a fault upon the expiration of a pre-programmed duration: in response to determining that EFn_i exceeds a critical current threshold of EFn.

[0023] A system for redistributing electronic fuses (EF) in an EF array, implemented on a vehicle, is also provided, the EF array being configured to drive fuse harnesses operatively connected to multiple loads. The system includes: a fuse communication module operatively communicating with the EF array, the EF array comprising multiple (N) electronic fuses, each individually referred to as EFn, the fuse communication module being configured to simultaneously receive and buffer the corresponding load current (EFn_i) and temperature (EFn_T) for each EFn; a current limit checker module connected to the fuse communication module and configured to: for each EFn, compare the corresponding EFn_i with the operating range of the EFn; and shut off each EFn whose EFn_i is outside the operating range, and generate a corresponding load current alarm; and a cluster membership determiner module connected to the current limit checker module and configured to: wherein a pre-programmed configuration of the fuse harness defines multiple (M) clusters, and for each EFn_i within the operating range, determine whether the corresponding EFn is a member of one of the M clusters; and respond to... The system includes: a health status determiner module connected to the cluster member determiner module, configured to: for each member of the cluster, perform a comparison of the corresponding EFn_i with a pre-programmed load current expectation and a comparison of the corresponding EFn_T with a pre-programmed temperature threshold for a pre-programmed duration; classify each EFn in the cluster as healthy, degraded, or faulty based on the comparison of EFn_i and EFn_T at the end of the pre-programmed duration; generate a degraded alarm for each EFn classified as degraded; and a fuse reallocation module connected to the health status determiner module, configured to: identify another member of the cluster as a target EF with a reallocation potential consistent with the pre-programmed configuration of the fuse harness; and modify the fusing limit of the target EF based on the reallocation potential. Attached Figure Description

[0024] Exemplary embodiments will be described below in conjunction with the accompanying drawings, wherein the same reference numerals denote the same elements, and wherein:

[0025] Figure 1-2 This is a schematic diagram illustrating a system for redistributing an electronic fuse (EF) according to various embodiments, the electronic fuse being configured to drive a fuse harness operatively connected to multiple loads implemented on a vehicle.

[0026] Figure 3This is an architectural block diagram of one or more application modules according to various embodiments, which can operate in a system for redistributing electronic fuses (EF), the electronic fuses being configured to drive fuse harnesses operably coupled to multiple loads implemented in a vehicle; and

[0027] Figure 4 A process flowchart is provided depicting an example method for reallocating an electronic fuse (EF) according to various embodiments, the electronic fuse being configured to drive a fuse harness operatively coupled to multiple loads implemented on a vehicle. Detailed Implementation

[0028] The following detailed description is merely exemplary in nature and is not intended to limit application or use. Furthermore, it is not intended to be bound by any express or implied theory presented in the foregoing technical field, background art, invention summary, or the following detailed description.

[0029] This document describes embodiments of the present disclosure in terms of functional and / or logical block components and various processing steps. It should be understood that such block components can be implemented by any number of hardware, software, and / or firmware components configured to perform specified functions. For example, embodiments of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which can perform various functions under the control of one or more microprocessors or other control devices.

[0030] As used herein, the term "module" may refer individually or in any combination to any hardware, software, firmware, electronic control components, processing logic, and / or processor device. In various embodiments, a module is one or more of the following: application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), electronic circuitry, a computer system including a processor (shared, dedicated, or grouped) and memory executing one or more software or firmware programs, combinational logic circuitry, and / or other suitable components that provide functionality attributable to the module.

[0031] For the sake of brevity, this document may not describe in detail conventional techniques related to signal processing, data transmission, signaling, control, machine learning models, radio radar, lidar, image analysis, and other functional aspects of the system (as well as the various operating components of the system). Furthermore, the connecting lines shown in the various figures included herein are intended to represent exemplary functional relationships and / or physical connections between various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in the embodiments of this disclosure.

[0032] As mentioned above, smart electronic fuses (EFs) are sometimes used to meet load current requirements in vehicle applications. However, a technical problem exists because each vehicle model and variant may have its own load arrangement, and each load has its own load current requirements, resulting in a lack of interchangeability. Reconfiguring the smart EF array for each new iteration of the vehicle is cumbersome and inefficient.

[0033] Exemplary embodiments provide a technical solution to this problem using systems and methods for reallocating electronic fuses (EFs) configured to drive fuse harnesses operatively coupled to multiple loads implemented in a vehicle. The embodiments utilize pre-programmed fuse harness configurations and match them to an EF array using connection schemes. The embodiments provide control and monitoring functions to dynamically reallocate EFs in response to detected faulty EFs and detected degraded EFs.

[0034] The embodiments provide configurable solid-state smart fuse solutions to create flexible energy distribution strategies. The embodiments provide a single connectivity system that utilizes a calibrable EF array and fuse harness to configure fuse distribution based on vehicle architecture and load requirements.

[0035] The provided system employs controller circuitry that controls EF parameters and their channels, enabling the controller circuitry to reconfigure fuse allocation based on the vehicle architecture requirements of the load and to dynamically reallocate EF. As described in more detail below, in addition to easily providing redundant power paths in the event of a faulty / failed EF, the embodiments advantageously support system optimization in scenarios such as component / wiring failures, load prioritization (power demand), and vehicle operating modes.

[0036] Figure 1This is a functional block diagram depicting an example mobility platform. The exemplary mobility platform is a vehicle 100 capable of moving, towing, and transporting passengers from one location to another. Vehicle 100 is depicted as a passenger car in the illustrated embodiment, but other vehicle types may also be used, including motorcycles, taxis, fleets, buses, cars, vans, trucks, sport utility vehicles, other automobiles, recreational vehicles (RVs), locomotives, and other vehicles. As generally understood, vehicle 100 may be embodied as a body, chassis, and wheels 20, each of the wheels 20 being rotatably coupled to the chassis near a corresponding corner of the body. Vehicle 100 is depicted as having four wheels 20, but in other embodiments, the number of wheels 20 may vary. Vehicle 100 may be autonomous or semi-autonomous. Vehicle 100 includes at least a battery management system 182 and collective functional blocks, a drive system 106, which typically includes known vehicle systems for vehicle operation, such as propulsion systems, transmission systems, steering systems, wheel actuators, and braking systems, and generates various signals, including vehicle speed and vehicle acceleration. In various embodiments, the battery management system 182 and the drive system 106 are operatively coupled to one or more vehicle components and systems via a communication bus 130. The battery management system 182 is understood to include a battery and provide power to the system for redistributing electronic fuses (EF) configured to drive fuse harness 180.

[0037] External source 150 includes one or more other mobile platforms (also referred to herein as “road participant”) located outside vehicle 100 in the environment surrounding vehicle 100.

[0038] A system (generally shown as system 102) for redistributing electronic fuses (EFs) configured to drive fuse harnesses 180 operably coupled to multiple loads includes controller circuitry 104 (also referred to as a smart electronic controller SEC) and an array of electronic fuses 122. In various embodiments, system 102 distributes power to other modules on vehicle 100. In various embodiments, controller circuitry 104 is communicatively coupled to onboard systems and components via a communication bus 130. Controller circuitry 104 can transmit commands, controls, and power for various onboard systems and components via communication bus 130. Controller circuitry 104 can acquire information from various road users and information about various road users via onboard camera system 118 and sensors and / or via transceiver 112.

[0039] Returning to vehicle 100, vehicle 100 may include one or more other components and / or onboard systems, each of which may typically communicate with controller circuitry 104 via communication bus 130. Non-limiting examples of onboard components include drive system 106, battery management system 182, central platform controller 108, user interface 114, transceiver 112, global positioning system (GPS) 116, camera system 118 and sensors, mapping system 110, navigation system 120, and fuse harness 180. The function and operation of each of these components are described in more detail below.

[0040] In various embodiments, the central platform controller 108 can receive and integrate communications from various modules and systems known to exist in the vehicle 100 described above. Therefore, in some embodiments, the inputs provided by the central platform controller 108 to the controller circuitry 104 may include or represent user inputs (including ALC requests), mobile application and system inputs, inputs from external communications (e.g., via transceiver 112), and inputs based on the Global Positioning System (GPS 116), navigation system 120, mapping system 110, camera system 118, sensors, and drive system 106.

[0041] User interface 114 can provide passengers in vehicle 100 with any combination of touch, voice / audio, cursor, button pressing, and gesture control. Therefore, user interface 114 may include display devices and audio devices, as known in the industry.

[0042] Transceiver 112 can be configured to enable communication between onboard components and systems and various external sources 150, such as cloud server systems. Therefore, in various embodiments, transceiver 112 includes hardware and software to support one or more communication protocols for wireless communication 151 (e.g., Wi-Fi and Bluetooth) between controller circuitry 104 and external sources such as routers, the Internet, cloud, satellites, communication towers, and ground stations.

[0043] GPS 116 is a globally recognized positioning system in the mobile platform industry. GPS 116 can interact with various external sources via transceiver 112 to provide information about the vehicle's position in three-dimensional space at any given time.

[0044] When the mapping system 110 is present on the vehicle 100, it includes a database for storing up-to-date and high-resolution maps of streets, environmental features, etc.

[0045] The navigation system 120 can acquire and process signals from various vehicle components to determine the current position, trajectory, speed, acceleration, etc., and coordinate with the central platform controller 108, GPS 116 and mapping system 110 to plan future position, trajectory, speed, acceleration, turning, etc.

[0046] The camera system 118 and sensors may include one or more cameras and sensors for detecting the position and movement of road participants and features around the vehicle. The sensors in the camera system 118 may be configured to transmit, receive, and process LiDAR, RADAR, or other signals to determine the position and movement of nearby road participants.

[0047] In various embodiments, such as Figure 1 As shown, the controller circuit 104 is implemented as an enhanced computer system, including a computer-readable storage device or medium, a memory 54 for storing instructions, algorithms, and / or programs 56, such as EF allocation algorithms and operating parameters 58, such as pre-programmed EF data (for each EFn in the EF array), including pre-programmed load current thresholds, critical current thresholds (fuse limits), voltage thresholds, and temperature thresholds, and pre-programmed fuse harness 180 configurations. The controller circuit 104 also includes a processor 50 for executing the program 56 and an input / output interface (I / O) 52. The computer-readable storage device or medium (memory 54) may include volatile and non-volatile storage, such as read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is a persistent or non-volatile memory that can be used to store various operating variables when the processor 50 is powered down. Memory 54 can be implemented using any of several known memory devices, such as PROM (Programmable Read-Only Memory), EPROM (Electrically Erasable PROM), EEPROM (Electrically Erasable PROM), flash memory, or any other electrical, magnetic, optical, or combined memory device capable of storing data, some of which represent executable instructions used by processor 50 when controlling vehicle 100. In various embodiments, processor 50 is configured to implement system 102. Processor 50 may also utilize memory 54 to cache data, temporarily store comparison and analysis results, etc. Information in memory 54 can be organized and / or imported from external sources during initialization or installment operations in the method; it can also be programmed via a user I / O interface.

[0048] Input / output interface (I / O) 52 can be operatively coupled to processor 50 via a bus and enables communication within and outside circuit 104. Input / output interface (I / O) 52 may include one or more wired and / or wireless network interfaces and may be implemented using any suitable methods and means. In various embodiments, input / output interface (I / O) 52 includes hardware and software to support one or more communication protocols for wireless communication between processor 50 and external sources such as satellites, clouds, communication towers, and ground stations. In various embodiments, input / output interface (I / O) 52 supports communication with technicians and / or one or more storage interfaces for direct connection to storage devices.

[0049] During operation of system 102, processor 50 loads and executes one or more algorithms, instructions, and rules embodied in program 56, and thus controls the general operation of system 102. During operation of system 102, processor 50 may receive data from communication bus 130 or external sources. In various embodiments of system 102, controller circuitry 104 may: perform operations belonging to system 102 according to algorithms; perform operations according to state machine logic; and perform operations according to logic in a programmable logic array.

[0050] While exemplary embodiments of system 102 are described in the context of controller circuitry 104 being implemented as a fully-featured enhanced computer system, those skilled in the art will recognize that the mechanisms of this disclosure can be distributed as a program product including program 56 and predefined parameters. Such a program product may include an arrangement of instructions organized into multiple interdependent program code modules, each configured to implement a separate process and / or perform a separate algorithmic operation, arranged to manage data flow through system 102. Each program code module may each include an ordered list of executable instructions for implementing the logical functions of the process performed by system 102. When executed by a processor (e.g., processor 50), the instructions in the program code modules cause the processor to receive and process signals and execute the logic, calculations, methods, and / or algorithms as described herein for automatically and in real-time performing vehicle-to-target localization and generating associated commands.

[0051] Once developed, the program code modules constituting the program product can be stored and distributed individually or together using one or more types of non-transitory computer-readable signal-bearing media (such as non-transitory computer-readable media), which can be used to store and distribute instructions. Such program products can take various forms, and this disclosure applies equally to the type of computer-readable signal-bearing media used for distribution. Examples of signal-bearing media include recordable media such as floppy disks, hard disks, memory cards, and optical disks, as well as transmission media such as digital and analog communication links. It should be understood that in some embodiments, cloud-based storage and / or other technologies can also be used as storage and time-based viewing license requests for the program product.

[0052] The fuse harness 180 connects multiple electronic fuses (EF) to multiple loads on the vehicle, thereby assisting system 102 in distributing power. Regarding the invention, and as will be described in more detail below, in various embodiments, some or all components and systems coupled to communication bus 130 can be considered as one of multiple loads operatively coupled to fuse harness 180. Additionally, in various embodiments, a "load" can also be a "source," such as a generator or APM module supplying power to a power bus within communication bus 130.

[0053] Figure 2The concepts of EF array 122, cluster, and load as used herein are illustrated. EF array 122 is an arrangement or grouping of electronic fuses. EF array 122 includes N electronic fuses EFn, such that n ranges from 1 to N (described as EF1, EF2, EF3…EFN). Each EFn has its own dedicated voltage output 202 (EFn_v to EFN_V), temperature output 206 (EFn_T to EFN_T), and load current output 204 (EFn_i to EFN_i). Each EFN also has its own ON / OFF control (Ctrl1 to CtrlN) for controlling its operating parameters, and its own ON / OFF control for controlling the load current (on / off1 to on / offN) through its channel. Regarding the operating parameters stored in memory 54, each EFn has a programmable threshold for its current limit versus time to simulate conventional fuses (i.e., slow-burning fuses and / or fast-burning fuses). Sensor bus 208 combines all voltage, temperature, and current outputs. The bus 105 that operatively connects the controller circuitry 104 to the EF array 122 is a combination of the control bus 210, the on / off bus 212, the power bus, and the sensor bus 208. The controller circuitry 104 continuously performs diagnostics / predictions on the load current drawn from each EFn and assesses the overall health of the system 102 based on the system 102 capacity to meet its fusing limits for each EFn.

[0054] In this example, multiple (P) loads (L) are depicted as L1, L2, L3, ... LP (individually, each load is Lp, since p ranges from 1 to P). Each load Lp can have a different load current requirement. The pre-programmed configuration of the fuse harness 180 simultaneously implements the predefined load current requirements 109 of multiple loads.

[0055] The pre-programmed configuration of fuse harness 180 is designed to meet a predetermined load current requirement from at least one of multiple loads by combining two or more EFn_i via clusters. The pre-programmed configuration of fuse harness 180 defines multiple (M) clusters (individually, each cluster is cluster_m, where m ranges from 1 to M). The pre-programmed configuration of fuse harness 180 specifies the arrangement and spatial location of each of the M clusters, which is a function of the predefined load current requirement from each of the multiple (P) loads (L).

[0056] Each cluster_m is used to sum the load current outputs from the electronic fuses in the EF array. The individual electronic fuses connected in cluster_m are called cluster members or members of cluster_m.

[0057] exist Figure 2 In a non-limiting example, the pre-programmed configuration of fuse harness 180 is defined as follows: EF1 is connected only to L1, EF2 is connected only to L2, cluster_1 combines the load current outputs from EF3, EF4 and EF5 to supply the load current demand of L3, and cluster_M combines the load current outputs from EFN-1 and EFN to supply the load current demand of LP.

[0058] like Figure 1-2 As shown, the fuse harness 180 is pre-programmed or pre-configured to meet the power and load current requirements 109 of multiple loads. Embodiments of this system 102 utilize information related to the programming of the fuse harness 180 to dynamically adjust the load current output 107 and the power of the EF array 122 to achieve more robust fuse harness 180 operation, more robust delivery of necessary current to loads on the vehicle, and an overall improved energy management strategy for the vehicle.

[0059] Now go to Figure 3-4 And continue to refer to Figure 1-2 It describes the various method steps of system 102 and associated exemplary application processing modules. Figure 3 It can be operated in system 102 and is compatible with... Figure 4 An architecture block diagram 300, which combines one or more application modules, illustrates the steps of a method for smoothing automatic lane-changing operations, typically shown as method 400.

[0060] In an application, each module can be implemented as one or more submodules, and modules and submodules can be distributed among and between various in-vehicle systems and components. In various examples, program 56 and stored variables, as well as preloaded custom data 58, implement the application process module of system 102.

[0061] For illustrative purposes, the following description of method 400 may be referenced in conjunction with the above. Figure 1-3 The mentioned components. In various embodiments, some portions of method 400 may be performed by different components of the described system 102. It should be understood that method 400 may include any number of additional or alternative operations and tasks. Figure 3-4 The tasks shown do not need to be performed in the order shown, and method 400 can be incorporated into a more comprehensive process or method, such as an energy-saving or security application, which has additional functionality not described in detail herein. Furthermore, if the intended overall functionality remains intact, it can be omitted from embodiments of method 400. Figure 3-4 One or more tasks are shown.

[0062] The fuse communication module 302 can manage the task of simultaneously receiving and caching sensor data from the sensor bus 208. This is represented at 402 by the task of receiving and caching data for each EFn of the EF array, with respect to the corresponding load current (EFn_i) and temperature (EFn_T).

[0063] The current limit checker module 304 can manage the following tasks for each EFn: comparing the corresponding EFn_i with the operating range load current for EFn to determine whether EFn_i exceeds the operating range of the load current (at 404). The current limit checker module 304 can perform channel control 306, which includes shutting down each EFn where EFn_i is not within the operating range. As used herein, shutting down (at 406) is equivalent to sending an "off" signal, blowing the fuse, and disconnecting the gate in the MOSFET device so that no load current can flow through that EF. In various embodiments, in response to shutting down EFN at 406, the current limit checker module 304 can perform a task 308 to generate a corresponding load current alarm. In various embodiments, the load current alarm can be a system alarm and can be placed on the communication bus 130 for use by other vehicle systems, such as the central platform controller 108. After 406, system 102 can return to 402 or terminate.

[0064] The cluster membership determiner module 310 can refer to the preloaded harness arrangement to perform a determination task (at 408) for each EFn_i within the operating range: whether the corresponding EFn is a member of cluster_m of the M clusters defined in the pre-programmed configuration of the fuse harness. At 410, in response to determining that EFn is a member of cluster_m, the cluster membership determiner module 310 can perform a task to identify all other members of cluster_m.

[0065] The EF health determiner module 312 can perform monitoring and classification tasks for cluster members. For example, for all members of cluster_m, during a pre-programmed duration, the EF health determiner module 312 can monitor EFn_i and perform a comparison of EFn_i with a pre-programmed expected load current (at 412) and a comparison of EFn_T with a pre-programmed temperature threshold. When the pre-programmed duration expires, at 414, the EF health determiner module 312 can classify each EFn of all members of cluster_m as healthy, degraded, or faulty based on the comparison of EFn_i and EFn_T. The EF health determiner module 312 can generate a degraded alarm for each EFn classified as degraded. In various implementations, the degraded alarm can be a system alarm and can be placed on the communication bus 130 for use by other vehicle systems, such as the central platform controller 108.

[0066] Finally, the fuse reallocation module 314 can perform the following tasks: for each EFn classified as faulty, at 416, identify the target EF among the other members of cluster_m as having a reallocation potential consistent with the pre-programmed configuration of fuse harness 180; and at 418, modify the fuse limit of the target EF according to the reallocation potential. After 418, system 102 can move to 406 and shut down the channel of the faulty EFn.

[0067] The redistribution potential includes the capacity of a given EFn to support the increased load current, and the controller circuit 104 is also programmed to modify the fusing limit of the target EF by correspondingly increasing the load current of the target EF.

[0068] To illustrate the above, the following non-limiting example is provided: There are three fuses (EF1, EF2, and EF3) in cluster_m to meet the load demand of 24 amps of load current for L1. Each EF can handle 12 amps, but is currently set to 8 amps. System 102 determines, via the method described above, that one of the fuses, EF1, has failed. In response to classifying EF1 as failed, system 102 analyzes the redistribution potential of EF2 and EF3. The redistribution potential of EF2 and EF3 allows each EF2 and EF3 to increase its fusing limit (via a corresponding control signal on control bus 210) to 12 amps, which continues to meet the load demand of 24 amps of load current. This is referred to as redistributing the load current to EF2 and EF3 of L1. While this example provides two target EFs in cluster_m that have been identified and modified, those skilled in the art will understand that the concept is applicable to other combinations of cluster members.

[0069] System 102 can also move from 418 to 402 and shut down the channel for EF1, and generate a system command / alarm indicating that the load L1 attached to the cluster_m is now limited to the new current limits from EF2 and EF3 (i.e., the cluster_m has been modified).

[0070] Returning to EF health determiner module 312, the degradation categories are now described. Upon the expiration of the pre-programmed duration, EF health determiner module 312 may classify each EFn as degraded in response to determining that EFn_i exceeds the pre-programmed load current expectation for EFn but does not exceed a critical current threshold for EFn, while EFn_T is within a pre-programmed temperature threshold.

[0071] To illustrate the above, the following non-limiting example of a degradation category is now provided. Returning to cluster_m above, consider the case where EF1 has not yet failed, but system 102 detects that, according to the pre-programmed configuration of fuse harness 180, EF1 and EF2 are providing 80% of the 24-amp load current demand, and the temperature of EF1 (EF1_T) is within the temperature threshold of EF1, instead of approximately 33% of the 24-amp load current demand for L1 (current usage profile) each for EF1, EF2, and EF3. This is an example of a degraded state for EF1.

[0072] In response to the detected degraded state of EF1, system 102 continues to monitor EF1_i and EF1_T. At some point in time, such as during the pre-programmed duration, EF1_T may exceed a temperature threshold, or the current usage profile of cluster_m may worsen; in either case, system 102 determines that EF1 has entered a fault state and is not operating correctly. In response to this determination, system 102 may proceed to step 414 above and may dynamically modify one or more target EFs in the EF array.

[0073] The ability to dynamically modify and shut down fuses and electronic fuses (EFs) is known as fuse reallocation. The fuse reallocation capability provided by these embodiments supports designs with precise power / fuse response during transient conditions and allows for load shedding to minimize the impact of any fuse allocation, thereby enabling flexible energy distribution strategies for solid-state smart EF solutions. The fuse reallocation capacity provided by these embodiments also enables redundancy to be incorporated into the power lines, allowing loads with high safety requirements to be powered without interruption or degradation based on a fault in one or both lines. The embodiments also simplify applications by eliminating the need for additional controllers.

[0074] Having described system 102, it will be understood that, in various embodiments, one or more controller circuits 104 (also referred to as intelligent electronic controllers (SECs)) connected to the same battery source in battery management system 182 may exist, each connected to a different load in the vehicle—this can occur when there are more loads in the system on vehicle 100 than the available outputs from the controller circuit 104 itself. For example, if the vehicle requires 50 clusters, it will comprise 150 individual eFuses, and each controller circuit 104 or SEC will have 100 eFuses. In this case, two controller circuits 104 or SECs would be needed to cover the electrical system of vehicle 100.

[0075] Therefore, the system 102 and method implemented on a vehicle for redistributing electronic fuses (EFs) configured to drive fuse harnesses operably connected to multiple loads provides a technical solution to the technical problems of available systems that rely on multiple smart EFs.

[0076] While at least one exemplary embodiment has been described in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing one or more exemplary embodiments. Various changes may be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A system for reallocating electronic fuses implemented in a vehicle, the electronic fuses being configured to drive fuse harnesses operably connected to a plurality of loads, the system comprising: An electronic fuse array, the electronic fuse array comprising a plurality of electronic fuses EFn; A controller circuit, comprising a processor operably coupled to the electronic fuse array and programmed to: For each EFn, the corresponding load current EFn_i and temperature EFn_T are received simultaneously. For each EFn, the corresponding EFn_i is compared with the operation range of EFn; Shut down each EFn that is not within the operating range, and generate a corresponding load current alarm in response to this; The pre-programmed configuration of the fuse harness defines multiple clusters. For each EFn_i within the operational scope, determine whether the corresponding EFn is a member of one of the plurality of clusters; In response to determining that EFn is a member of the cluster, other members of the cluster are identified; For each member of the cluster, during the preprogrammed duration, a comparison is performed between the corresponding EFn_i and the preprogrammed load current expectation, and a comparison is performed between the corresponding EFn_T and the preprogrammed temperature threshold. When the pre-programmed duration expires, each EFn in the cluster is classified as healthy, degraded, or faulty based on a comparison of EFn_i and EFn_T. For each EFn that is classified as degraded, generate a degrade alert for that EFn; as well as For each EFn classified as a fault, another member of the cluster is identified as the target electronic fuse, which has a redistribution potential consistent with the pre-programmed configuration of the fuse harness. as well as The fusing limit of the target electronic fuse is modified based on the redistribution potential; Each EFn has a programmable threshold for its current limit versus time to simulate a conventional fuse; The redistribution potential includes the capacity to support increased load current, and the controller circuit is also programmed to modify the fusing limit of the target electronic fuse by increasing the load current of the target electronic fuse.

2. The system according to claim 1, wherein, The controller circuit is also programmed to shut down the corresponding EFn classified as faulty after modifying the fusing limit of the target electronic fuse, and to generate an alarm indicating that the cluster has been modified.

3. The system of claim 1, wherein the pre-programmed configuration of the fuse harness specifies the arrangement and location of each of the plurality of clusters, and the arrangement and location of each of the plurality of clusters is a function of a predefined load current requirement from each of the plurality of loads.

4. The system of claim 3, wherein the pre-programmed configuration of the fuse harness is designed to meet the predefined load current requirement from at least one of the plurality of loads by combining two or more EFn_i.

5. The system according to claim 1, wherein, The controller circuit is also programmed to: In response to determining that EFn_i exceeds the pre-programmed load current expected for EFn but does not exceed the critical current threshold of EFn, while EFn_T is within the pre-programmed temperature threshold, each EFn is classified as degraded.

6. The system according to claim 1, wherein, The controller circuit is also programmed to: In response to determining that the EFn_T exceeds the pre-programmed temperature threshold, each EFn is classified as a fault, and In response to determining that EFn_i exceeds the critical current threshold of EFn, each EFn is classified as a fault.

7. A method for reallocating electronic fuses within an electronic fuse array comprising a plurality of electronic fuses EFn implemented in a vehicle, the method comprising: In the controller circuitry, which includes the processor programmed with programming instructions, For each EFn, the corresponding load current EFn_i and temperature EFn_T are received simultaneously. For each EFn, the corresponding EFn_i is compared with the operation range of EFn; Shut down each EFn that is not within the operating range, and generate a corresponding load current alarm in response to this; The pre-programmed configuration of the fuse harness limits the number of clusters. For each EFn_i within the operational scope, determine whether the corresponding EFn is a member of one of the plurality of clusters; In response to determining that EFn is a member of the cluster, other members of the cluster are identified; For each member of the cluster, during the preprogrammed duration, a comparison is performed between the corresponding EFn_i and the preprogrammed load current expectation, and a comparison is performed between the corresponding EFn_T and the preprogrammed temperature threshold. When the pre-programmed duration expires, each EFn in the cluster is classified as healthy, degraded, or faulty based on a comparison of EFn_i and EFn_T. For each EFn that is classified as degraded, generate a degrade alert for that EFn; as well as For each EFn classified as a fault, another member of the cluster is identified as the target electronic fuse, which has a redistribution potential consistent with the pre-programmed configuration of the fuse harness. as well as The fusing limit of the target electronic fuse is modified based on the redistribution potential; Each EFn has a programmable threshold for its current limit versus time to simulate a conventional fuse; The redistribution potential includes the capacity to support increased load current, and the controller circuit is also programmed to modify the fusing limit of the target electronic fuse by increasing the load current of the target electronic fuse.

8. The method according to claim 7, further comprising: After modifying the fusing limit of the target electronic fuse, the shutdown is classified as a fault in the corresponding EFn, and an alarm indicating that the cluster has been modified is generated.

Images