Contact protection interface for jump start

Abstract

Battery terminal, comprising: a first electrical contact (10) exposed to an external energy source; a second electrical contact (20) hard-wired to an electrical bus; a separating device (40) which is in physical contact with both the first electrical contact (10) and the second electrical contact (20), and which isolates the first electrical contact (10) from the second electrical contact (20) in response to a condition being met; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the isolating device (40) to electrically connect the second electrical contact (20) to the external power source when the condition is met, wherein the condition is met when the voltage of the external power source is above a predetermined low value and below a predetermined maximum value.

Description

FIELD OF EXPERTISE

[0001] The field concerns the electrical systems of vehicles in general, specifically an interface that protects an electrical system from an overvoltage when jump-starting the vehicle or in the case of reversed battery polarity. BACKGROUND

[0002] The electrical load on vehicles is growing and becoming increasingly complex. When all systems are operating simultaneously, a vehicle can consume more than 77 amps, which is a significant amount. Not only is the electrical load increasing quantitatively, but the complexity of the load is also increasing, with more and more processors and other electronic features and devices. Conventional methods for protecting electronic functions from surges and reverse polarity, such as diodes and input resistors, sometimes come with costs, particularly excessive power and / or fuel consumption.

[0003] DE 198 55 245 B4 relates to a redundant power supply for electrical consumers in a vehicle's electrical system, in particular for electric brakes. The redundant power supply has a generator that supplies two separate circuits, each containing a voltage-storing device, e.g., a battery, connected to the generator and the supplied load via corresponding switches. These switches are normally closed and are opened to disconnect a defective circuit from the generator and the load.

[0004] DE 199 51 095 A1 relates to a device for protecting an electrical network, in particular a battery-containing vehicle electrical system. The device has a switch-like disconnecting device near the network connection area, which is triggered in the event of a reaction. The disconnecting device has at least two associated, independent tripping units, each of which can cause the network to be switched off via the disconnecting device, responds to different drivers, and contains active tripping elements in series with tripping resistors.

[0005] US 2012 / 0 013 175 A1 relates to an auxiliary power supply system for an electrical load in a vehicle power system, comprising an auxiliary battery, a thermal converter in physical contact with the auxiliary battery, a charging circuit for controlling the charging process of the battery depending on at least a temperature of the auxiliary battery, and an output power supply circuit for supplying an electrical load with power under normal and emergency conditions. The auxiliary power supply system is housed in a thermally conductive housing in thermal communication with the charging circuit and the power supply circuit. The power output circuit selectively supplies power to the electrical output from both an electrical input terminal and the battery based on the magnitude of a voltage available at the electrical input terminal.

[0006] WO 01 / 21 445 A1 relates to a spool for a seat belt retractor comprising a cylindrical element with a cylindrical central portion and two end plates at opposite axial ends of the cylindrical portion. A channel having an outer wall and an inner wall is formed in the cylindrical central portion, defining a guide path for the seat belt webbing. The path circumscribes the spool axis substantially over the length of the central portion of the spool in a generally smooth curve. The path has a spool entry portion and a spool exit portion, and the acute angle formed by the entry portion of the path and the exit portion of the path with the spool axis is approximately 90 degrees. The spool may be hollow, with a torsion bar forming the inner wall of the channel.

[0007] Accordingly, it is desirable to protect the vehicle's electronics while reducing power consumption. Furthermore, it is desirable to eliminate the need for overvoltage and reverse polarity protection devices on each module and to reduce power consumption during normal vehicle operation. Furthermore, other desirable features and characteristics of the present invention will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and this background of the invention. SUMMARY A battery terminal for receiving power from an external source is provided having the features of patent claim 1. A system for receiving power from an external source is provided having the features of claim 7. A vehicle is provided which receives power from an external source with the features of patent claim 10. DESCRIPTION OF THE DRAWINGS

[0008] The embodiments are described below in conjunction with the following drawings, wherein like reference numerals designate like elements, and wherein: Fig. 1 is a simplified illustration of a vehicle according to one embodiment. Fig. 2 is a simplified schematic diagram of a protection interface according to one embodiment; Fig. 3A is a schematic diagram of an electrical control circuit of a separation device according to one embodiment; Fig. 3B is a schematic diagram of a second electrical control circuit of a separation device according to an embodiment; Fig. 3C is a schematic diagram of a third electrical control circuit of a separation device according to an embodiment; Fig. 4 is a simplified schematic diagram of an exemplary mechanical separation device and an exemplary control system according to one embodiment; Fig. 5 is another simplified schematic diagram of an exemplary mechanical separation device and an exemplary control system according to an embodiment; Fig. 6A and Fig. 6B are side and plan views of another exemplary mechanical separator according to an embodiment. DETAILED DESCRIPTION

[0009] Those skilled in the art will appreciate that the various exemplary logical blocks, modules, and algorithm steps described in connection with the presently described embodiments may be executable as electronic hardware, computer software executable on a processor, or combinations thereof. Some of the embodiments are described above as functional and / or logical block components (or modules) and various processing steps. It is understood that these block components (or modules) may be executable by a variety of hardware, software executable on a processor, and / or firmware components configured to perform the specified functions.

[0010] To clearly illustrate this interchangeability, various example components, blocks, modules, circuits, and steps may be described above generally in terms of their functions. Whether these functions are implemented in hardware or software depends on the specific application and the design constraints of the overall system. Those skilled in the art may implement the described functionality in various ways for each specific application; however, these implementation choices should not be construed as departing from the scope of the present invention. For example, an embodiment of a system or component may employ various integrated circuits, e.g., memory elements, digital signal processing elements, logic elements, lookup tables, etc., that can perform various functions under the control of one or more microprocessors or other control devices.Furthermore, it will be clear to those skilled in the art that the embodiments described herein are merely examples.

[0011] The various exemplary logic blocks, modules, and circuits described in connection with the various embodiments described herein may be implemented using a general-purpose processor, a digital signal processor (DSP), an ASIC (Application Specific Integrated Circuit), a FPGA (Field Programmable Gate Array), any programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination designed to perform the functions described herein. The general-purpose processor may be a microprocessor, but may alternatively be any conventional processor, microcontroller, or state machine. A processor may also be a combination of computers, e.g.A combination of a DSP and a microprocessor, a plurality of microprocessors, one or more microprocessors in conjunction with a DSP core, or any such configuration. As used herein, "exemplary" is to be understood solely as "serving as an example, instance, or illustration." An embodiment identified herein as exemplary is not necessarily to be construed as preferred or advantageous over other embodiments.

[0012] The steps of a method or algorithm described in connection with the presently described embodiments may be implemented directly in hardware, in a software module executed by a processor, or in a combination of both. A software module may be implemented in RAM, flash memory, ROM, EPROM, EEPROM, registers, a hard disk, a removable disk, a CD-ROM, or any known type of storage medium. An exemplary storage medium is coupled to the processor such that the processor can read data from and write data to the storage medium. Alternatively, the storage medium may be integrated with the processor. The processor and storage medium may be incorporated into an ASIC. The ASIC may be incorporated into a user's terminal device. Alternatively, the processor and storage medium may be discrete components of a user's terminal device.

[0013] In the present case, relational terms such as "first" and "second," etc., may be used merely to distinguish one object or act from another, without necessarily requiring or implying an actual relationship or sequence of those objects or acts. Ordinal numbers such as "first," "second," "third," etc., simply designate different elements of a plurality, without implying an order or sequence unless expressly stated in the claim language. The order of the wording of the respective claims does not imply that the method steps must necessarily occur in a temporal or logical order corresponding to that order, unless expressly stated in the claim.The process steps can be exchanged in any order without departing from the scope of the invention, as long as the exchange neither contradicts the wording of the claim nor is logically nonsensical.

[0014] Furthermore, terms such as "connect" or "couple" used to describe a relationship between different elements should not be interpreted, depending on the context, as implying a direct physical connection between the respective elements. For example, two elements may be connected physically, electronically, logically, or in any other way, through two or more additional elements.

[0015] The Fig. Figure 2 is a simplified diagram of an embodiment of a protection interface 5 according to the invention, which is used in conjunction with an electrical contact 2 of a jumper cable 3. As a non-limiting example, the cable may be a conventional jumper cable 3 having metallic crocodile clips 2 (e.g., made of copper) at each end. However, other existing or future cable and contact designs can also be readily adapted for use according to the invention without departing from the scope of the invention (see Figure 1). Fig. 6A).

[0016] To cover or electrically protect the actual contact, which is directly connected (i.e., hard-wired) to the vehicle's electrical system 70, a false contact is essentially used, also referred to herein as the "extra contact" 10. The actual contact to the vehicle's electrical system 400 is referred to herein as the "protected contact" 20. If necessary, the protected contact 20 is further protected from contact with the alligator clip by an insulating layer of material 30. However, this insulating layer 30 may be optional depending on the design and orientation of the protected contact 20.

[0017] According to the embodiment of the contactor interface 5 of the Fig. 2, the extra contact 10 and the protected contact 20 are separated by an electronically controlled isolating device 40. The isolating device 40 is a self-contained mechanical or electronic switch such that when the isolating device 40 detects that the voltage at the alligator clip 2 on the extra contact 10 is of the correct voltage level and polarity, the external power from the alligator clip 2 is electrically connected by the isolating device 40 via the extra contact 10 to the protected contact 20. If the voltage is incorrect, the connection is not made. The isolating device 40 can have any form factor and any method of operation, as long as the form factor is physically constructed from a non-conductive structural material capable of electrically isolating the extra contact 10 from the protected contact 20.

[0018] According to other embodiments, the isolation device may be a semiconducting silicone device. The silicone device isolates / separates the extra contact from the main contact when it is not biased in the on direction and would conduct if biased accordingly. According to some embodiments, the semiconducting silicone device may be a 1000 amp switch.

[0019] The Fig. 3A shows a non-limiting example electronic switch that may be used in the disconnect device 40 and is powered by the incoming voltage from the alligator clip 2 and / or the protected contact. The switch 50 includes a relay or solid-state switch 58, which may be any suitable relay known or developed in the future. The relay / switch 58 electrically connects the auxiliary contact 10 to the protected contact 20.

[0020] The switch / control circuit 50 includes a diode 51, a high-threshold Zener diode 54, a low-threshold Zener diode 55, and input resistors 52 and 53. The control circuit further includes a first transistor 56 and a second transistor 57.

[0021] During operation, if the polarity of the voltage applied by the crocodile clip 2 to the auxiliary contact 10 is negative or below a predetermined minimum value, the diode 51 and the base-emitter junctions of transistors 56 and 57 are reverse biased so that no current flows through the relay 58. Thus, the isolation device 40 does not allow a connection because the transistor 57 is not biased toward conduction.

[0022] When the voltage supplied by the crocodile clip 2 is above the predetermined low value and below the predetermined maximum value, the low-limit Zener diode becomes conductive, allowing a base current supplied to the transistor to trigger the second transistor 57, allowing current to flow through the relay 58 and closing the switch connecting the extra contact 10 to the protected contact 20.

[0023] If the voltage supplied by crocodile clip 2 exceeds the predetermined maximum value, the high-limit Zener diode breaks down, applying a base current to the first transistor 56, shorting the base of the second transistor 57 to ground, and interrupting the current through switch / relay 58. Thus, the protected contact 20 remains electrically isolated from the voltage at crocodile clip 2.

[0024] The Fig. Figure 3B is another embodiment of the switch / control circuit 50, but includes a transistor 63 and a resistor 64. The purpose of transistor 63 is to cause a larger change in the "on" current, resulting in a sharper turn-on voltage point.

[0025] The Fig. Figure 3C is yet another embodiment of the switch / control circuit 50, but includes a diode 62. The purpose of the diode 62 is to ensure that sufficient energy is supplied from the alligator clip 2 to turn on the relay 58.

[0026] Fig. Figure 4 is a simplified system diagram of a non-limiting alternative embodiment of the protection interface 5, wherein the disconnect device 40 comprises a mechanical device switch. As in the case of the embodiment of Fig. 2, the physical arrangement of the extra contact 10, the isolating device 40 and the insulator 30 is configured such that the crocodile clip 2 cannot come into contact with the protected contact 20, but only with the extra contact 10.

[0027] If the extra contact 10 comes into contact with the crocodile clip 2, the potential of the crocodile clip 2 is detected by the ECU (Electronic Control Unit) 100 via the lead 60. The control unit (ECU) 100 is a non-limiting example of a control unit and may comprise any suitable digital or analog circuit known or to be developed in the future.

[0028] The controller 100 is configured such that, if the polarity and voltage level are correct and within the limits, the controller 100 causes the actuator 200 to modify the disconnect device 40 to connect the extra contact 10 to the protected contact 20 to supply power to the vehicle. "Modify" is understood herein to mean a change in the physical state from a conductive state to a non-conductive state or from a non-conductive state to a conductive state.

[0029] The controller 100 can draw its power from the crocodile clip 2 via the extra contact 10 when the crocodile clip contacts the extra contact 10. Alternatively, the controller 100 can draw its power from the vehicle battery 25. The controller 100 has a ground 26.

[0030] According to equivalent embodiments of the protection interface 5, the interface may include a sensing resistor 27 arranged to detect the potential difference between the extra contact and the protected contact. The sensing resistor 27 is an optional element.

[0031] An advantage of the sensing resistor 27 is that it enables the safe parallel connection of the batteries 25 of two vehicles equipped with the protection interface 5. For example, a driver can activate a circuit or resistive switch 61 (e.g., circuit breaker) in the protection interface 5 of the vehicle with a good battery 25. The resistive circuit 61 connects the power from the protected contact 20 to the extra contact 10 to supply power to the extra contact, and thus to the dead battery. The sensing resistor 27 monitors to prevent overcurrent and, in the event of an overcurrent, opens the resistive circuit 61. With this power connection, the protection interface 5 of the dead battery would connect its extra contact 10 to its protected contact 20 in the normal manner, as described above.The protection interface 5 of the good battery would then connect its extra contact 10 to its protected contact 20 in the normal manner, as described above.

[0032] The Fig. 5 shows another equivalent embodiment of the protection interface 5. Here, the same components are identified by the same reference numerals as in the Fig. 4. According to the alternative embodiment of the Fig. 5, the resistor 27 is connected in series with the switch 61.

[0033] In the vehicle 400 (see Fig. 1) with the good battery 25 (see Fig. 1) Switch 61 is closed (manually or automatically) and applies voltage across resistor 27 to the extra contact. The same vehicle monitors the voltage difference across this resistor using controller 100 and opens switch 61 if the resulting current is excessive, as will be understood by those skilled in the art. Closing switch 61 applies voltage across resistor 27 so that the second vehicle with the dead battery can draw voltage from the good battery 25 and closes the electronically controlled disconnect device 40 in the manner described above. The sensing circuit on the vehicle 400 with the good battery is deactivated during this process until the voltage across resistor 27 has been verified and sufficient time has elapsed to ensure that the vehicle with the dead battery has had sufficient time to close its electronically controlled disconnect device 40.Non-limiting examples of switch 61 would be a resettable switch or a linear resistor that can increase its resistance in response to an overcurrent.

[0034] The Fig. 6A and Fig. 6B are simplified side and plan views of a non-limiting exemplary mechanical disconnect device 300 according to one embodiment. In these specific drawings, it is assumed that the jumper cable 3 includes a pin or rod 2' instead of the conventional alligator clip 2. However, the geometry of the disconnect device 300 may be substantially parallelepipedal rather than cylindrical, so that the alligator clip 2 can be inserted in the closed position in the same manner as the illustrated rod 2'.

[0035] The mechanical disconnect device 300 includes a hollow housing 310 having at least one open end 312, a protected contact 320, an extra contact 330, a controller 100, a piston 340 (or other physical barrier element) that penetrates the wall of the hollow housing and projects into the interior 311 of the hollow housing, and a solenoid 350. The controller 100 controls the solenoid 350 and thus also the position of the piston 340, thus placing it either in a retracted state with power supply or in an extended state in which power is normally not supplied.

[0036] In the normally de-energized state, the piston 340 is in the normally extended state when no jumper cable rod is present. In this position, the rod 2' cannot extend far enough into the hollow housing to contact the protected contact 320 due to the interference caused by the extended piston 340. However, the rod 2' can extend far enough to contact the extra contact 330. Once the rod 2' contacts the extra contact 330, the voltage polarity and voltage level are detected by the controller via lead 60 at the extra contact.When the voltage supplied by the rod has a positive polarity and is between a predetermined maximum and a predetermined minimum value, the controller 100 energizes the solenoid valve 350, which retracts the piston 340 from the interior 311 to allow the rod 2' to protrude further and contact the protected contact, thereby supplying power to the vehicle 400 via the current pickup. Examples Example 1. Battery terminal comprising: a first electrical contact exposed to an external energy source; a second electrical contact hard-wired to an electrical bus; a separating device in physical contact with both the first electrical contact and the second electrical contact, and conditionally isolating the first electrical contact from the second electrical contact; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the disconnect device to electrically connect the second electrical contact to the external power source when a condition is met. Example 2. The battery terminal of Example 1, wherein the first electrical contact is either a plate or a pin. Example 3. The battery terminal according to example 1 or 2, wherein the disconnecting device connects the first electrical contact to the second electrical contact via an electronic switch. Example 4. The battery terminal of any one of examples 1-3, wherein the isolating device comprises a physical barrier between the second electrical contact and the external energy source. Example 5. The battery terminal of example 4, further comprising an ECU that controls a position of the physical barrier based on the voltage of the external power source. Example 6. The battery terminal of example 5, wherein the disconnect device allows electrical and physical connection of the external energy source to the second electrical terminal by retracting the physical barrier. Example 7. A system for transmitting energy from an external energy source, comprising: an electric bus of a vehicle; a vehicle battery; and a battery terminal, the battery terminal comprising: a first electrical contact exposed to an external energy source, a second electrical contact hard-wired to an electrical bus of the vehicle and a separating device in physical contact with both the first electrical contact and the second electrical contact, and conditionally isolating the first electrical contact from the second electrical contact; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the disconnect device to electrically connect the second electrical contact to the external power source when a condition is met. Example 8. The battery terminal of Example 7, wherein the first electrical contact is either a plate or a pin. Example 9. The battery terminal of example 7 or 8, wherein the disconnecting device connects the first electrical contact to the second electrical contact via an electronic switch. Example 10. The battery terminal of any one of examples 7-9, wherein the isolating device comprises a physical barrier between the second electrical contact and the external energy source. Example 10. The battery terminal of any one of examples 7-10, further comprising an ECU that controls a position of the physical barrier based on the voltage of the external power source. Example 11. The battery terminal of example 11, wherein the disconnect device allows electrical and physical connection of the external energy source to the second electrical terminal by retracting the physical barrier. Example 12. Vehicle comprising: a body; a battery located inside the body; a battery terminal, the battery terminal comprising: a first electrical contact exposed to an external energy source, a second electrical contact hard-wired to an electrical bus, a separating device in physical contact with both the first electrical contact and the second electrical contact, and conditionally isolating the first electrical contact from the second electrical contact; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the disconnect device to electrically connect the second electrical contact to the external power source when a condition is met. Example 13. The battery terminal of Example 12, wherein the first electrical contact is either a plate or a pin. Example 14. The battery terminal of example 12 or 13, wherein the disconnect device connects the first electrical contact to the second electrical contact via an electronic switch. Example 15. The battery terminal of any one of examples 12-14, wherein the isolating device comprises a physical barrier between the second contact and the external power source. Example 16. The battery terminal of example 15, further comprising an ECU that controls a position of the physical barrier based on the voltage of the external power source. Example 17. The battery terminal of example 15 or 16, wherein the disconnect device allows electrical and physical connection of the external energy source to the second electrical terminal by retracting the physical barrier. Example 18. The battery terminal of any one of examples 12-17, wherein the disconnect device comprises a relay. Example 19. The battery terminal of any one of Examples 12-17, wherein the separator is a solid-state semiconducting device.

Claims

[1] Battery terminal, comprising: a first electrical contact (10) exposed to an external energy source; a second electrical contact (20) hard-wired to an electrical bus; a separating device (40) which is in physical contact with both the first electrical contact (10) and the second electrical contact (20), and which isolates the first electrical contact (10) from the second electrical contact (20) in response to a condition being met; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the isolating device (40) to electrically connect the second electrical contact (20) to the external power source when the condition is met, wherein the condition is met when the voltage of the external power source is above a predetermined low value and below a predetermined maximum value. [2] Battery terminal according to claim 1, wherein the first electrical contact (10) is either a plate or a pin. [3] Battery terminal according to claim 1 or 2, wherein the separating device (40) connects the first electrical contact (10) to the second electrical contact (20) via an electronic switch (50) of the separating device (40). [4] Battery terminal according to one of claims 1-3, wherein the isolating device (40) comprises a physical barrier between the second electrical contact (20) and the external energy source. [5] The battery terminal of claim 4, wherein the disconnect device (40) further comprises a controller (100) that controls a position of the physical barrier based on the voltage of the external power source. [6] The battery terminal of claim 5, wherein the disconnect device (40) allows electrical and physical connection of the external power source to the second electrical contact (20) by retracting the physical barrier. [7] System for transmitting energy from an external energy source, comprising: an electric bus of a vehicle (5); a vehicle battery (25); and a battery terminal, the battery terminal comprising: a first electrical contact (10) exposed to the external energy source, a second electrical contact (20) hard-wired to the electrical bus of the vehicle (5) and a separating device (40) in physical contact with both the first electrical contact and the second electrical contact, and isolating the first electrical contact from the second electrical contact in response to a condition being met; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the isolating device (40) to electrically connect the second electrical contact to the external power source when the condition is met, wherein the condition is met when the voltage of the external power source is above a predetermined low value and below a predetermined high value. [8] The system of claim 7, wherein the first electrical contact (10) is either a plate or a pin. [9] System according to claim 7 or 8, wherein the separating device (40) connects the first electrical contact (10) to the second electrical contact (20) via an electronic switch (50). [10] Vehicle (400), comprising: a body; a battery (25) arranged within the body; a battery terminal, the battery terminal comprising: a first electrical contact (10) exposed to an external energy source, a second electrical contact (20) hard-wired to an electrical bus, a separating device (40) which is in physical contact with both the first electrical contact (10) and the second electrical contact (20), and which isolates the first electrical contact (10) from the second electrical contact (20) in response to a condition being met; and an electrical circuit configured to detect a voltage of the external power source and to physically modify the isolating device (40) to electrically connect the second electrical contact (20) to the external power source when the condition is met, wherein the condition is met when the voltage of the external power source is above a predetermined low value and below a predetermined maximum value.

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