Dual output current sensor, system for providing short circuit protection, and associated method

Abstract

A dual output current sensor, a system providing short circuit protection, and an associated method are provided. For example, a dual output current sensor may include: a current sensing element for detecting a current; a current comparison circuit for determining whether the detected current exceeds a predetermined threshold current; a first output channel for outputting an indication of the detected current from the current sensor; a driving circuit for generating an amplified output of the current comparison circuit; and a second output channel for outputting the amplified output of the current comparison circuit from the current sensor.

Description

Technical Field

[0001] Embodiments of the present disclosure generally relate to sensing devices, and more particularly, to current sensors. Background Art

[0002] Short - circuit protection systems are important in electrical systems. For example, such short - circuit protection systems are used in electric vehicles to protect motors and batteries from short - circuits, which can expose sensitive components to very high currents.

[0003] Such short - circuit protection systems are plagued by technical challenges and limitations. Through effort, ingenuity, and innovation, many of these recognized problems have been solved through the development of solutions including those in the embodiments of the present disclosure, and many examples of the embodiments of the present disclosure will be described in detail herein. Summary of the Invention

[0004] Various embodiments described herein relate to dual - output current sensors, systems for providing short - circuit protection in electric vehicles, and associated methods for providing short - circuit protection.

[0005] According to various embodiments of the present disclosure, a system for providing short - circuit protection is provided. In some embodiments, the system includes a dual - output current sensor. The dual - output current sensor includes: a current sensing element for detecting a current; a current comparison circuit for determining whether the detected current exceeds a predetermined threshold current; a first output channel for outputting an indication of the detected current from the current sensor; a drive circuit for generating an amplified output of the current comparison circuit; and a second output channel for outputting the amplified output of the current comparison circuit from the current sensor.

[0006] In some embodiments, the current sensing element outputs a voltage proportional to the detected current, and the current comparison circuit includes an analog voltage comparison circuit that compares the voltage proportional to the detected current with a reference voltage corresponding to the predetermined threshold current.

[0007] In some embodiments, the current sensing element outputs a voltage proportional to the detected current, the current comparison circuit includes an analog - to - digital controller (ADC) and a controller, the ADC receives the voltage proportional to the detected current and converts the voltage proportional to the detected current into a digital value of the detected current, and the controller receives the digital value of the detected current and compares the digital value of the detected current with the predetermined threshold current.

[0008] In some embodiments, the system further includes: a battery management system; an electrical busbar that carries the detected current; and a normally closed pyrotechnic switch that is connected in-line with the electrical busbar. The first output channel outputs an indication of the detected current to the battery management system of the electric vehicle, and the second output channel outputs the amplified output of the current comparison circuit to the pyrotechnic switch so that the pyrotechnic switch opens and interrupts the detected current on the electrical busbar.

[0009] In some embodiments, if the detected current exceeds the predetermined threshold current, the current sensor receives a command to actuate the pyrotechnic switch from the battery management system, and in response to the current sensor receiving the command to actuate the pyrotechnic switch from the battery management system, the second output channel outputs the amplified output of the current comparison circuit to the pyrotechnic switch.

[0010] According to various embodiments of the present disclosure, a system for providing short-circuit protection in an electric vehicle is provided. In some embodiments, the system includes a battery management system, an electrical busbar, a normally closed pyrotechnic switch connected in-line with the electrical busbar, and a dual-output current sensor for detecting the current on the electrical busbar. The current sensor includes: a current sensing element for detecting the current on the electrical busbar; a current comparison circuit for determining whether the detected current exceeds a predetermined threshold current; a first output channel for outputting an indication of the detected current from the current sensor to the battery management system; a drive circuit for generating the amplified output of the current comparison circuit; and a second output channel for outputting the amplified output of the current comparison circuit from the current sensor to the pyrotechnic switch so that the pyrotechnic switch opens and interrupts the current on the electrical busbar.

[0011] According to various embodiments of the present disclosure, a method for providing short-circuit protection in an electric vehicle is provided. In some embodiments, the method includes connecting a dual-output current sensor to the electrical busbar of the electric vehicle; detecting the current on the electrical busbar by the current sensing element of the current sensor; determining whether the detected current exceeds a predetermined threshold current by the current comparison circuit of the current sensor; outputting an indication of the detected current from the first output channel of the current sensor to the battery management system of the electric vehicle; generating the amplified output of the current comparison circuit by the drive circuit of the current sensor; and outputting the amplified output of the current comparison circuit from the second output channel of the current sensor to the pyrotechnic switch of the electric vehicle so that the pyrotechnic switch opens and interrupts the current on the electrical busbar.

[0012] The foregoing illustrative overview and other exemplary objects and / or advantages of the present disclosure, as well as the manner of achieving them, will be further explained in the following detailed description and its accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The description of the illustrative embodiments may be read in conjunction with the accompanying drawings. It will be appreciated that, for the sake of simplicity and clarity of illustration, the elements illustrated in the figures are not necessarily drawn to scale unless otherwise described. For example, the dimensions of some of the elements may be exaggerated relative to other elements unless otherwise described. Embodiments incorporating the teachings of the present disclosure are shown and described with respect to the figures presented herein, in which:

[0014] Figure 1 is a block diagram of an example system for providing short-circuit protection in accordance with an example embodiment of the present disclosure;

[0015] Figure 2 is a block diagram of an example dual-output current sensor that can be used in a system in accordance with an example embodiment of the present disclosure Figure 1 is a block diagram of an example dual-output current sensor that can be used in a system in accordance with an alternative example embodiment of the present disclosure;

[0016] Figure 3 is a block diagram of an example dual-output current sensor that can be used in a system in accordance with an alternative example embodiment of the present disclosure Figure 1 is a block diagram of an example dual-output current sensor that can be used in a system in accordance with an alternative example embodiment of the present disclosure;

[0017] Figure 4 is a circuit diagram of an example drive circuit in an example dual-output current sensor that can be used in Figure 2 or an example dual-output current sensor that can be used in Figure 3 is a circuit diagram of an example drive circuit in an example dual-output current sensor that can be used in an example dual-output current sensor;

[0018] Figure 5 is a circuit diagram of an example comparison circuit in an example dual-output current sensor that can be used in Figure 3 and is a circuit diagram of an example comparison circuit in an example dual-output current sensor that can be used in an example dual-output current sensor; and

[0019] Figure 6 is a flowchart illustrating an example method for providing short-circuit protection in accordance with an example embodiment of the present disclosure. DETAILED DESCRIPTION

[0020] Some embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. In fact, these disclosures may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numerals refer to like elements throughout.

[0021] As used herein, terms such as "front", "rear", "top", "bottom", "left", "right", etc. are used for explanatory purposes to describe the relative positions of certain components or parts of components in the examples provided below. Additionally, as will be apparent to those of ordinary skill in the art, in accordance with the present disclosure, the terms "substantially" and "approximately" indicate that the referenced element or associated description is accurate within the applicable engineering tolerances.

[0022] As used herein, the term "comprising" means including but not limited to, and should be interpreted in the manner in which it is commonly used in the patent context. The use of broader terms such as "including", "comprising", and "having" should be understood to support narrower terms such as "consisting of", "consisting essentially of", and "substantially consisting of".

[0023] The phrases "in one embodiment", "according to one embodiment", "in some embodiments", etc. generally mean that the particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of the present disclosure and can be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

[0024] The phrases "in one example", "according to one example", "in some examples", etc. generally mean that the particular feature, structure, or characteristic following the phrase can be included in at least one example of the present disclosure and can be included in more than one example of the present disclosure (importantly, such phrases do not necessarily refer to the same example).

[0025] If the specification states that a component or feature "may", "can", "could", "should", "would", "preferably", "possibly", "typically", "optionally", "for example", "as an example", "in some examples", "often", or "might" (or other such language) includes or has a characteristic, it is not required that the particular component or feature includes or has that characteristic. Such a component or feature can optionally be included in some examples, or it can be excluded.

[0026] The word "example" or "exemplary" as used herein is used to mean "serving as an example, instance, or illustration". Any embodiment described herein as "example" or "exemplary" is not necessarily to be understood as being preferred or superior to other embodiments.

[0027] The terms "electrically coupled", "make an electrical coupling", "electrical coupling", "communicate with", "make an electrical communication with", or "connect" in the present disclosure refer to two or more elements or components being connected by a wired and / or wireless manner so that signals, voltage / current, data, and / or information can be transmitted to and / or received from these elements or components.

[0028] The term "component" may refer to an article, device, or apparatus, which may include one or more surfaces, parts, layers, and / or elements. For example, an exemplary component may include one or more substrates that may provide the underlying layer(s) for the component, and may include one or more elements that may form a part of the substrate and / or be disposed on top of the substrate. In the present disclosure, the term "element" may refer to an article, device, or apparatus that may provide one or more functions.

[0029] The term "sensor" or "sensing device" may refer to an article, device, or apparatus that measures a physical input from its environment and converts the input into data that can be interpreted by a human or a machine. Sensing devices may be utilized in various applications including measuring current.

[0030] The terms "sensing element", "sensor circuit", "sensing circuit", etc. may refer to one or more components, integrated circuits, etc. within a sensing device that interacts with the environment, detects the input to be detected (such as current), and provides an output (such as voltage) to another component to be interpreted within the sensing device. In an exemplary current sensing device, the sensing circuit may include an open-loop Hall effect sensor, a closed-loop Hall effect sensor, a fluxgate sensor, or any suitable sensing element.

[0031] Providing short-circuit protection in an electrical device is important, especially in an electric vehicle where a short circuit can result in a current of over 2000 amperes (amps or "A"). Such a high current can quickly damage sensitive electrical and electronic components. Fuses are often used for short-circuit protection, but fuses may take one to two seconds to open the circuit, which may be too slow to provide the desired protection. These fuses are often referred to as passive fuses. A pyrotechnic fuse is an explosive switch that can open the circuit faster than a passive fuse, but typically requires a very large current (such as 4000 A or higher) to actuate and open the circuit.

[0032] To address the challenges and limitations associated with conventional short-circuit protection, various examples of the present disclosure may be provided. For example, various examples of the present disclosure may provide exemplary dual-output current sensors, systems for short-circuit protection, and methods for short-circuit protection.

[0033] In various embodiments, an example dual-output current sensor provides current monitoring to detect a short circuit and provides two output terminals as described herein. Although embodiments of the present disclosure are described herein with respect to an electric vehicle, embodiments of the present disclosure can be used with any electrical device in which rapid short-circuit protection is desired.

[0034] In various embodiments, an example dual-output current sensor is connected to a busbar of an electric vehicle to measure a primary current on the busbar. In various embodiments, a first output terminal of the example dual-output current sensor provides an indication of the measured primary current to a battery management system (BMS) of the electric vehicle. In various embodiments, when the measured primary current exceeds a predetermined threshold, a second output terminal of the example dual-output current sensor provides a control signal to a pyrotechnic switch of the electric vehicle.

[0035] Now referring Figure 1 , a block diagram of an example system for providing short-circuit protection in accordance with various embodiments of the present disclosure is provided. As Figure 1 depicted therein, in various embodiments, such a system includes: an electrical busbar 105 for carrying current from a battery of an electric vehicle (e.g., which can be a large battery pack or multiple batteries connected together) to one or more load components (e.g., a drive motor); a pyrotechnic switch 110 connected in series with the busbar 105; a relay 115 connected in series with the busbar 105 for selectively enabling or disabling current flowing to the load component; and a dual-output current sensor 100 positioned to measure a primary current flowing through the busbar 105. In various embodiments, the current sensor 100 is configured to perform and implement the operations described herein. The relay 115 is an example component that can be damaged (e.g., blown due to a fuse) by a high-current short circuit.

[0036] In some embodiments, the current sensor 100 defines a substantially circular through-hole, and the current sensor 100 is positioned such that a portion of the busbar 105 protrudes through the through-hole in the current sensor 100 such that the current sensor 100 can detect and measure the current flowing through the busbar 105.

[0037] In various embodiments, the pyrotechnic switch 110 is normally closed and will explosively open within microseconds when subjected to a very high-current short circuit (e.g., greater than 4000 amperes). However, in cases where the current caused by the short circuit is high enough to damage components but not high enough to directly trigger the pyrotechnic switch 110, a similar rapid short-circuit protection is desired. Thus, when the measured primary current exceeds a threshold predetermined to be high enough to damage components but not high enough to directly trigger the pyrotechnic switch, current sensors of various embodiments of the present disclosure provide a control signal to actuate (i.e., open) the pyrotechnic switch.

[0038] In various embodiments illustrated as Figure 1 shown, the current sensor 100 has two output terminals: a first output terminal 120 that provides an indication of the measured primary current to the battery management system (BMS) of an electric vehicle; and a second output terminal 125 that provides a control signal to the pyrotechnic switch 110 to actuate (i.e., turn on) the pyrotechnic switch 110 when the measured primary current exceeds a predetermined threshold. In one exemplary embodiment, the threshold current is 2000 amperes, but any suitable threshold current may be used.

[0039] In various embodiments, the current sensor may have a digital version and an analog version. Now refer to Figure 2 , which illustrates a block diagram of a digital version of an exemplary dual-output current sensor according to an example embodiment of the present disclosure. As Figure 2 depicted, the dual-output current sensor 200 includes a current sensing element 205, a signal conditioning element 210, an analog-to-digital controller (ADC) 215, a processing element (such as a microcontroller unit) (MCU) 220, a transceiver 225, and a drive circuit 230. The current sensor 200 has two output channels: a first output channel 235 that provides an indication of the measured primary current to the BMS of an electric vehicle; and a second output channel 240 that provides a control signal to the pyrotechnic switch to actuate (i.e., turn on) the pyrotechnic switch when the measured primary current exceeds a predetermined threshold.

[0040] In various embodiments, the sensing element 205 may include a magnetic field current sensor that is magnetically coupled to a conductor (i.e., a busbar) and is configured to generate a magnetic field signal having an amplitude in response to the current flowing through the conductor. In various alternative embodiments, the sensing element 205 may include a shunt interface having a first input terminal and a second input terminal electrically coupled to ends of a shunt disposed along a conductor (i.e., a busbar) and is configured to generate a shunt signal having an amplitude in response to the current flowing through the conductor. In various embodiments, the sensing element 205 may include an open-loop Hall effect sensor, a closed-loop Hall effect sensor, a fluxgate sensor, or any suitable current sensing element.

[0041] In various embodiments, the sensing element 205 generates an analog voltage proportional to the primary current flowing through the busbar. In various embodiments, the signal conditioning element 210 includes an amplifier for amplifying the voltage from the current sensing element 205. In some embodiments, a signal conditioning element is not required.

[0042] In various embodiments, the ADC 215 converts an analog voltage from the current sensing element 205 (which may have been amplified by the signal conditioning element 210 if the signal conditioning element 210 is present) into a digital signal representative of the measured current. In various embodiments, the MCU 220 receives the digital signal from the ADC 215 and compares the signal to a predetermined and stored threshold. In various embodiments, the MCU 220 sends the representation of the measured current to the transceiver 225, and the transceiver 225 outputs the representation of the measured current to the BMS via the first output channel 235. In various embodiments of the digital version of the example dual-output current sensor, the representation of the measured current is a digital output of the measurement result.

[0043] In various embodiments, if the MCU 220 determines that the measured current exceeds a predetermined threshold, the MCU 220 outputs an overcurrent signal (e.g., a pulse-width modulation (PWM) signal) to the drive circuit 230. In various embodiments, the drive circuit 230 amplifies the overcurrent signal from the MCU 220 and outputs the amplified signal to the pyrotechnic switch via the second output channel 240, thereby causing the pyrotechnic switch to actuate. In an example embodiment, the drive circuit functionality is provided by a Bosch CG912 four-channel pyrotechnic fuse driver.

[0044] In various alternative embodiments, the decision to actuate the pyrotechnic switch is not made within the current sensor (such as within the MCU), but rather the decision to actuate the pyrotechnic switch is made within the BMS. In various alternative embodiments, if the BMS makes the decision to actuate the pyrotechnic switch, the BMS sends a control command to the current sensor, which is received by the current sensor via the transceiver 225, and the control signal is sent from the current sensor to the pyrotechnic switch via the second output channel 240. In various other alternative embodiments, if the BMS makes the decision to actuate the pyrotechnic switch, the BMS sends a control command directly to the pyrotechnic switch.

[0045] Now refer Figure 3 to Figure 3 FIG.

[0046] In various embodiments, the sensing element 305 can include an open-loop Hall effect sensor, a closed-loop Hall effect sensor, a fluxgate sensor, or any suitable current sensing element. In various embodiments, the sensing element 305 generates an analog voltage proportional to the primary current flowing through the bus bar. In various embodiments, the signal conditioning element 310 includes an amplifier for amplifying the voltage from the current sensing element 305. In some embodiments, the signal conditioning element is not required. In various embodiments, the analog voltage from the current sensing element 305 (which may have been amplified by the signal conditioning element 310 if the signal conditioning element 310 exists) is output to the BMS via the first output channel 325. In various embodiments of an exemplary dual-output current sensor in analog version, the representation of the measured current is proportional to the primary current.

[0047] In various embodiments, the analog voltage from the current sensing element 305 (which may have been amplified by the signal conditioning element 310 if the signal conditioning element 310 exists) is provided to the comparison circuit 315. In various embodiments, the comparison circuit 315 compares the analog voltage from the current sensing element 305 with a reference voltage that is selected to be equal to the value that the analog voltage from the current sensing element 305 would be when the primary current is equal to the threshold current. In various embodiments, if the analog voltage from the current sensing element 305 is higher than the reference voltage, the comparison circuit 315 will output a positive voltage to the drive circuit 320. In various embodiments, the drive circuit 320 amplifies the positive output voltage from the comparison circuit 315 and outputs the amplified signal to the pyrotechnic switch via the second output channel 330, thereby actuating the pyrotechnic switch.

[0048] The dual-output current sensor of embodiments of the present disclosure can use any suitable drive circuit that is capable of receiving a signal from an MCU (such as the MCU 220) or a comparison circuit (such as the comparison circuit 315) and amplifying the signal to the desired level required to actuate the pyrotechnic switch. Now refer to Figure 4 , which illustrates an exemplary drive circuit that can be used in an exemplary dual-output current sensor of Figure 2 or an exemplary dual-output current sensor of Figure 3 according to various embodiments of the present disclosure. As seen in Figure 4 , the drive circuit 400 includes a first resistor 405, a first transistor 415 (such as an NPN low-power silicon planar epitaxial transistor), a second resistor 420, a second transistor 425 (such as an NPN bipolar junction transistor), a diode 430, and a relay 435.

[0049] One end of the first resistor 405 is connected to the input of the drive circuit 400 to receive the input signal 410 (which results in an input voltage (Vin)) (e.g., from the MCU 220 or the comparison circuit 315), and the other end is connected to the base of the first transistor 415. The emitter of the first transistor 415 is connected to one end of the second resistor 420 and the base of the second transistor 425. The other end of the second resistor 420 and the emitter of the second transistor 425 are connected to ground. The collectors of the first transistor 415 and the second transistor 425 are connected to the anode of the diode 430 and one end of the relay 435. The cathode of the diode 430 and the other end of the relay 435 are connected to the power supply voltage (Vcc). The relay 435 is connected to the pyrotechnic switch 440 and drives the actuation of the pyrotechnic switch 440. In operation, when the driver circuit 400 receives a positive input signal 410 (eg, from the MCU 220 or the comparison circuit 315 ), indicating that an overcurrent has been detected, the input signal is amplified and actuates the relay 435 , which actuates the pyrotechnic switch 440 .

[0050] The dual output current sensor of the embodiments of the present disclosure may use any suitable comparison circuit capable of: receiving an analog voltage from a current sensing element (such as current sensing element 305); comparing the analog voltage to a reference voltage that is equal to the value that the analog voltage from the current sensing element would be if the primary current was equal to the threshold current; and outputting a positive voltage to a drive circuit (such as drive circuit 320) if the analog voltage from the current sensing element is higher than the reference voltage. Now referring to Figure 5 , which illustrates that various embodiments of the present disclosure may be Figure 3 A circuit diagram of an example comparator circuit used in an example dual output current sensor. Figure 5 As seen in FIG. 1 , the comparison circuit 500 includes: a first resistor 505 and a second resistor 510 connected in series between a power supply voltage (Vcc) and ground; and an operational amplifier 515. The negative input terminal of the operational amplifier 515 is connected between the first resistor 505 and the second resistor 510, and the positive input terminal of the operational amplifier 515 is connected to the analog voltage (Vin) from the current sensing element. The operational amplifier 515 is connected to the positive power supply voltage (Vcc) and the negative power supply voltage (V EE ). The output of the operational amplifier 515 is Vout. In various embodiments, the value of the first resistor 505 and the value of the second resistor 510 are selected so that the reference voltage V REFis the value that the analog voltage from the current sensing element would be in the case where the primary current equals a predetermined threshold current. In operation, when the analog voltage (Vin) from the current sensing element is greater than the predetermined threshold current, the output (Vout) of the operational amplifier 515 is positive. In various embodiments, this positive output is amplified by a drive circuit and actuates a pyrotechnic switch.

[0051] Although components are described in terms of functional limitations, it should be understood that at least some in a particular implementation necessarily involve the use of specific computing hardware. It should also be understood that in some embodiments, certain components described herein include similar or common hardware. For example, in some embodiments, both sets of circuitry optimize the use of the same processor(s), memory(ies), circuit(s), and / or similar devices to perform their associated functions such that each set of circuitry does not require duplicate hardware.

[0052] The MCU 220 can be embodied in a variety of different ways. In various embodiments, the use of the term "processor" or "processing circuit" should be understood to include a single-core processor, a multi-core processor, multiple processors within the current sensor 100, and / or one or more remote or "cloud" processors external to the current sensor 100. In some example embodiments, the MCU 220 can include one or more processing devices configured to execute independently. Alternatively or additionally, the MCU 220 can include one or more processors configured in series via a bus to enable independent execution of operations, instructions, pipelining, and / or multithreading.

[0053] In an example embodiment, the MCU 220 can be configured to execute instructions stored in a memory circuit (not shown) or otherwise accessible to the processor. Alternatively or additionally, the MCU 220 can be configured to execute hard-coded functions. Thus, whether configured by a hardware approach, a software approach, or a combination thereof, the MCU 220 can represent an entity (e.g., physically embodied as circuitry) capable of performing operations in accordance with embodiments of the present disclosure while being correspondingly configured. Alternatively or additionally, the MCU 220 can be embodied as an executor of software instructions, and the instructions can specifically configure the MCU 220 to perform various algorithms embodied by one or more operations described herein when such instructions are executed. In some embodiments, the MCU 220 includes hardware, software, firmware, and / or a combination thereof that performs one or more operations described herein.

[0054] In some embodiments, two or more sets of circuitry are combinable. Alternatively or additionally, one or more sets of circuitry perform some or all of the operations and / or functions described herein associated with another circuitry. In some embodiments, two or more sets of circuitry are combined into a single module embodied in hardware, software, firmware, and / or combinations thereof.

[0055] While the above description provides an example current sensor 100, it should be noted that the scope of the present disclosure is not limited to the above description. In some examples, an example current sensor 100 according to the present disclosure may be in other forms. In some examples, an example current sensor 100 may include one or more additional and / or alternative elements, and / or may be configured differently from the current sensor illustrated in Figure 2 and Figure 3 the current sensor illustrated in

[0056] Reference will now be made to Figure 6 which provides a flowchart illustrating example steps, processes, procedures, and / or operations in accordance with various embodiments of the present disclosure. The various methods described herein (including, for example, the method illustrated in Figure 6 the method illustrated in

[0057] Reference will now be made to Figure 6 which illustrates an example method 600. In some embodiments, the example method includes a method for providing short circuit protection using a dual-output current sensor. At step / operation 605, a dual-output current sensor (such as, but not limited to, the dual-output current sensor 200 described above in connection with Figure 2 or the dual-output current sensor 300 described above in connection with Figure 3 detects a primary current on an electrical busbar.

[0058] At step / operation 610, the dual-output current sensor (such as, but not limited to, the dual-output current sensor 200 described above in connection with Figure 2 or the dual-output current sensor 300 described above in connection with Figure 3 outputs an indication of the detected current to a battery management system via a first output channel.

[0059] At step / operation 615, the dual-output current sensor (such as, but not limited to, the dual-output current sensor 200 described above in connection with Figure 2 or the dual-output current sensor 300 described above in connection with Figure 3 determines whether the detected current exceeds a predetermined threshold current.

[0060] If it is determined at step / operation 615 that the detected current does not exceed a predetermined threshold current, method 600 returns to step / operation 605 and continues to monitor the primary current on the bus bar. If it is determined at step / operation 615 that the detected current does in fact exceed the predetermined threshold current, method 600 proceeds to step / operation 625.

[0061] At step / operation 625, a dual-output current sensor (such as but not limited to dual-output current sensor 200 described above in connection with Figure 2 or dual-output current sensor 300 described above in connection with Figure 3 outputs an overcurrent error to the battery management system via a first output channel and outputs a control signal to the pyrotechnic switch via a second output channel to actuate the pyrotechnic switch. In various alternative embodiments, the decision to actuate the pyrotechnic switch is made inside the BMS, and if the BMS makes the decision to actuate the pyrotechnic switch, the BMS sends a control command to the current sensor, and the current sensor receives the control command from the BMS (such as but not limited to, via transceiver 225 of dual-output current sensor 200 described above in connection with Figure 2 ). This portion of step / operation 625 in parentheses indicates that it is optional.

[0062] In some embodiments, method 600 repeats steps / operations 605-620 until an overcurrent is detected and the pyrotechnic switch is actuated.

[0063] The operations and processes described herein support combinations of devices for performing the specified functions and combinations of operations for performing the specified functions. It will be understood that one or more operations and combinations of operations can be implemented by a special-purpose hardware-based computer system for performing the specified functions or by a combination of special-purpose hardware and computer instructions.

[0064] In some example embodiments, as described below, certain operations herein can be modified or further augmented. Additionally, in some embodiments, additional optional operations can be included. It should be understood that each modification, optional addition, or augmentation described herein can be included in the operations herein either alone or in combination with any other of the features described herein.

[0065] The foregoing method and process descriptions are provided only as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. Those skilled in the art will understand that the steps in the foregoing embodiments can be performed in any order. Words such as "thereafter," "then," "next," and similar words are not intended to limit the order of the steps; these words are merely used to guide the reader through the description of the method. Additionally, any reference to a claim element in the singular (e.g., using the articles "a," "an," or "the") should not be construed as limiting that element to the singular, and in some cases, it may be construed in the plural.

[0066] Although various embodiments in accordance with the principles disclosed herein have been shown and described above, those skilled in the art may make modifications thereto without departing from the teachings of the disclosure. The embodiments described herein are merely representative and are not intended to be limiting. Many variations, combinations, and modifications are possible and are within the scope of the disclosure. Alternative embodiments resulting from the combination, integration, and / or omission of features of the (one or more) embodiments are also within the scope of the disclosure. Accordingly, the scope of protection is not limited by the description set forth above, but is defined by the claims that follow, which scope includes all equivalents of the subject matter of the claims. Each claim is incorporated into the specification as a further disclosure, and the claims are (one or more) embodiments of the disclosure. Additionally, any advantages and features described above may be associated with specific embodiments, but the application of the claims so issued should not be limited to processes and structures that achieve any or all of the above advantages or have any or all of the above features.

[0067] Furthermore, the section headings used herein are provided to be consistent with the recommendations of 37 C.F.R.§1.77 or to otherwise provide organizational cues. These headings should not limit or characterize the disclosure set forth in any claims that may result from this disclosure. For example, the description of the technology in the "Background Art" should not be construed as admitting that certain technology is prior art to any disclosure in this disclosure. The "Summary of the Invention" should also not be regarded as a limiting characterization of the disclosure set forth in the issued claims. Additionally, any reference in this disclosure to the "disclosure" or "embodiment" in the singular should not be used to argue that there is only a single novel point in this disclosure. Multiple embodiments of this disclosure can be set forth in accordance with the limitations of the multiple claims resulting from this disclosure, and such claims accordingly define this disclosure and its equivalents, which are thus protected. In all cases, the scope of the claims should be considered on their own merits in light of this disclosure, but should not be constrained by the headings set forth herein.

[0068] Additionally, without departing from the scope of the present disclosure, the systems, subsystems, devices, techniques, and methods described and illustrated as discrete or separate in various embodiments may be combined or integrated with other systems, modules, techniques, or methods. Other devices or components shown or discussed as being coupled or communicating with each other may be indirectly coupled through some intervening device or component, whether electrically, mechanically, or otherwise. Those skilled in the art may identify other examples of changes, substitutions, and alterations, and other examples of changes, substitutions, and alterations may be made without departing from the scope disclosed herein.

[0069] Many modifications and other embodiments of the disclosure set forth herein will come to mind to those skilled in the art to which these embodiments pertain, having the benefit of the teachings presented in the foregoing description and the associated drawings. Although the figures only show certain components of the devices and systems described herein, various other components may be used in conjunction with the components and structures disclosed herein. Accordingly, it is to be understood that the disclosure is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. For example, various elements or components may be combined, rearranged, or integrated into another system, or certain features may be omitted or not implemented. Additionally, the steps in any of the methods described above may not necessarily occur in the order depicted in the figures, and in some cases, one or more of the depicted steps may occur substantially simultaneously, or may involve additional steps. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

Claims

1. A system for providing short - circuit protection, comprising: A dual - output current sensor, comprising: A current - sensing element for detecting current; A current - comparison circuit for determining whether the detected current exceeds a predetermined threshold current; A first output channel for outputting an indication of the detected current from the current sensor; A drive circuit for generating an amplified output of the current - comparison circuit; and A second output channel for outputting the amplified output of the current - comparison circuit from the current sensor.

2. The system according to claim 1, wherein The current - sensing element outputs a voltage proportional to the detected current; and Wherein, the current - comparison circuit includes an analog voltage - comparison circuit that compares the voltage proportional to the detected current with a reference voltage corresponding to the predetermined threshold current.

3. The system according to claim 1, wherein The current - sensing element outputs a voltage proportional to the detected current; Wherein, the current - comparison circuit includes an analog - to - digital controller (ADC) and a controller; Wherein, the ADC receives the voltage proportional to the detected current and converts the voltage proportional to the detected current into a digital value of the detected current; and Wherein, the controller receives the digital value of the detected current and compares the digital value of the detected current with the predetermined threshold current.

4. The system according to claim 1, further comprising: A battery management system; An electrical bus bar for carrying the detected current; And A normally - closed pyrotechnic switch connected in series with the electrical bus bar; Wherein, the first output channel outputs an indication of the detected current to the battery management system; and Wherein, the second output channel outputs the amplified output of the current - comparison circuit to the pyrotechnic switch so that the pyrotechnic switch opens and interrupts the detected current on the electrical bus bar.

5. The system according to claim 4, wherein If the detected current exceeds the predetermined threshold current, the current sensor receives a command from the battery management system to actuate the pyrotechnic switch; And Wherein, in response to the current sensor receiving a command from the battery management system to actuate the pyrotechnic switch, the second output channel outputs the amplified output of the current - comparison circuit to the pyrotechnic switch.

6. A method for providing short - circuit protection in an electric vehicle, the method comprising: Connecting a dual - output current sensor to the electrical bus bar of the electric vehicle; Detecting the current on the electrical bus bar by the current - sensing element of the current sensor; Determining by the current - comparison circuit of the current sensor whether the detected current exceeds a predetermined threshold current; Outputting an indication of the detected current from the first output channel of the current sensor to the battery management system of the electric vehicle; Generating an amplified output of the current - comparison circuit by the drive circuit of the current sensor; And If the detected current exceeds the predetermined threshold current, an amplified output of the current comparison circuit is output from a second output channel of the current sensor to a pyrotechnic switch of the electric vehicle, so that the pyrotechnic switch is turned on and the current on the busbar is interrupted.

7. According to the method of claim 8, wherein The current comparison circuit includes an analog voltage comparison circuit; and wherein, the method further includes: outputting a voltage proportional to the detected current by the current sensing element; and comparing, by the analog voltage comparison circuit, the voltage proportional to the detected current with a reference voltage corresponding to the predetermined threshold current.

8. The method according to claim 8, wherein The current comparison circuit includes an analog-to-digital controller (ADC) and a controller; and wherein, the method further includes: outputting a voltage proportional to the detected current by the current sensing element; receiving, by the ADC, the voltage proportional to the detected current; converting, by the ADC, the voltage proportional to the detected current into a digital value of the detected current; receiving, by the controller, the digital value of the detected current; and comparing, by the controller, the digital value of the detected current with the predetermined threshold current.

9. The method according to claim 6, further comprising: if the detected current exceeds the predetermined threshold current, receiving, from a battery management system by a first output channel of the current sensor, a command to actuate the pyrotechnic switch; wherein, in response to receiving the command to actuate the pyrotechnic switch from the battery management system, the second output channel outputs the amplified output of the current comparison circuit to the pyrotechnic switch.

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