DIAGNOSTIC DEVICE AND MANUFACTURING METHOD

Abstract

Diagnostic device (100, 200) for diagnosing switching elements (101, 102, 201, 202, 220, 221) in a vehicle, comprising: a pluggable resistor module (104, 105, 204, 205, 222, 223) for each of the switching elements (101, 102, 201, 202, 220, 221), a diagnostic device (115, 215) which is electrically connected in series with the pluggable resistance modules (104, 105, 204, 205, 222, 223) and is configured to detect a current (117, 118, 217, 218) through the resistance modules (104, 105, 204, 205, 222, 223) and to diagnose the function of the respective switching element (101, 102, 201, 202, 220, 221) based on the respective detected current (117, 118, 217, 218), and a module carrier (103) which is configured to accommodate the resistor modules (104, 105, 204, 205, 222, 223) and to couple input terminals (106, 107) of the resistor modules (104, 105, 204, 205, 222, 223) with the corresponding switching element (101, 102, 201, 202, 220, 221) and to couple output terminals (108, 109) of the resistor modules (104, 105, 204, 205, 222, 223) with the diagnostic device (115, 215), wherein the resistance modules (104, 105, 204, 205, 222, 223) each have a resistor (110, 111, 210, 211, 224, 225) and a diode (112, 113, 212, 213, 226, 227) arranged in series with the resistor (110, 111, 210, 211, 224, 225), and wherein the module carrier (103) has electrical connections configured to couple at least two of the resistance modules (104, 105, 204, 205, 222, 223) electrically in parallel with a single diagnostic input (116, 216, 228) of the diagnostic device (115, 215).

Description

Technical field

[0001] The present invention relates to a diagnostic device for diagnosing switching elements in a vehicle. The invention further relates to a corresponding manufacturing method. State of the art

[0002] The present invention is described below mainly in connection with motor vehicles. However, it is understood that the present invention can be used in any application where switched electrical supply lines need to be diagnosed.

[0003] Modern vehicles utilize a variety of electrical components. These components can be permanently connected to the vehicle battery or supplied with electrical power via switched supply lines, known as terminals. In automotive electrical systems, terminal designations can include auxiliary numbers or letters to simplify connecting wires and troubleshooting using a wiring diagram. For example, terminal 30 is typically permanently connected to the positive terminal of the vehicle battery, while terminal 30g, for instance, might be a switched positive line.

[0004] The switched terminals are typically controlled via vehicle relays, which can be located, for example, in a fuse and relay holder. The relays can be controlled, for example, by a control module mounted on a power distribution board or fuse holder. However, this solution is not very flexible.

[0005] DE 102 57 589 A1 discloses a measuring device for mounting on a plug-in fuse and for measuring the current through the plug-in fuse. US 2006 / 0 017 540 A1 discloses a plug-in fuse with an LED arrangement. DE 40 24 082 C1 discloses a pluggable electrical test plug for establishing a connection with a plug socket. Description of the invention

[0006] One object of the invention is therefore to diagnose a switched power distribution in a vehicle using means that are as simple as possible in terms of construction.

[0007] The problem is solved by the subject matter of the independent claims. Advantageous embodiments of the invention are specified in the dependent claims, the description, and the accompanying figures. In particular, the independent claims of one claim category may also be further developed analogously to the dependent claims of another claim category.

[0008] As explained above, the control of relays for switched terminals in vehicles can be implemented, for example, on a power distribution board. Typically, the diagnostics of such relays are also implemented on the power distribution board using permanently soldered components.

[0009] The present invention is based on the understanding that permanently soldered components allow for only limited flexibility in their arrangement. Therefore, the present invention provides that the individual units for diagnosing the switching elements, e.g., vehicle relays, are arranged separately.

[0010] The resistor modules can couple an output of the respective switching element to the diagnostic device via a predefined resistance. If a switching element is switched on, i.e., conducting, a current flows through the resistor module to the diagnostic device, which can then be evaluated.

[0011] The module carrier can be, for example, a fuse and / or relay carrier in a vehicle. Such module carriers can be located in different places in the vehicle, such as in the engine compartment, the passenger compartment, and / or the trunk. The resistor modules can therefore be arranged very flexibly on any of the module carriers present in the vehicle.

[0012] The individual resistor modules can be connected to the diagnostic device, for example, via a cable harness or wiring harness attached to the module carrier. Cable harnesses or wiring harnesses are typically custom-made for a specific vehicle or even for each variant of a vehicle. Therefore, the position of the diagnostic device can be taken into account when manufacturing such a cable harness or wiring harness.

[0013] The diagnostic device can therefore be positioned very flexibly at any suitable location in the vehicle. In particular, the position of the diagnostic device is independent of the position of the module carrier or the resistor modules.

[0014] If the module carrier is also designed as a relay carrier, i.e., it also houses the switching elements, the individual resistor modules can be arranged very close to the respective switching elements.

[0015] In one embodiment, the diagnostic device can be configured to detect, in order to diagnose one of the switching elements, whether a current flows through the respective switching element when the respective switching element is switched on or controlled.

[0016] As previously explained, the resistor modules connect an output of the respective switching element to the diagnostic device via a predefined resistor. If the diagnostic device has information about the state of the switching elements, it can determine whether the respective switching element is functioning correctly based on the current flow. If the diagnostic device does not have this information, it can forward information about the current flow through the respective switching elements to, for example, a control unit in the vehicle that possesses the necessary information.

[0017] In one embodiment, the resistor modules can each have a resistor and a diode arranged in series with the resistor.

[0018] The resistors limit the current flow from the vehicle battery or alternator through the switching elements to the diagnostic device. The diode prevents current flow back to the respective switching element or to the electrical consumers it supplies.

[0019] The resistor and diode can each be implemented as discrete components with leads, which can be soldered directly together and housed in a package. Alternatively, the resistor and diode can be implemented as through-hole (THT) or surface-mount (SMD) components. A circuit board can accommodate the resistor and diode and also provide contact to the respective input and output terminals.

[0020] In one embodiment, the module carrier can have electrical connections configured to couple at least two of the resistance modules electrically in parallel to a single diagnostic input of the diagnostic device.

[0021] If several of the resistor modules are electrically connected in parallel to a single diagnostic input of the diagnostic device, the diagnostic device can diagnose several of the switching elements simultaneously via this single diagnostic input. The parallel connection can be achieved, for example, via a cable harness or via the module carrier. For instance, the module carrier can have a stamped grid enclosed by an injection-molded part. The stamped grid can provide the corresponding parallel connection.

[0022] In one embodiment, the resistances of the electrically parallel connected resistance modules can have different resistance values.

[0023] In order to differentiate which of the switching elements are activated when simultaneously diagnosing several switching elements via a single diagnostic input, the diagnostic device can, for example, detect the total current through the resistor modules.

[0024] When resistor modules are connected in parallel, the currents through the individual resistor modules add up at the diagnostic input. If each of the parallel-connected resistor modules has a different resistance value, the individual resistor modules contribute different amounts to the total current at the diagnostic input.

[0025] For example, one of the resistor modules can contribute 1 / 7, a second 2 / 7, and a third 4 / 7 of the total current. Therefore, if the diagnostic device detects only 1 / 7 of the total current, the first switching element is closed. If the diagnostic device detects 2 / 7 of the total current, the second switching element is closed. If the diagnostic device detects 4 / 7 of the total current, the third switching element is closed. If the diagnostic device detects 3 / 7 of the total current, the first and second switching elements are closed. If the diagnostic device detects 5 / 7 of the total current, the first and third switching elements are closed. If the diagnostic device detects 6 / 7 of the total current, the second and third switching elements are closed. Finally, if the diagnostic device detects 7 / 7 of the total current, all three switching elements are closed.

[0026] The individual resistors in the resistor modules can therefore be dimensioned such that unambiguous current values ​​are established in the diagnostic device in all control combinations. Typically, all switching elements are supplied from a common source, e.g., the vehicle battery or the alternator.

[0027] In one embodiment, the resistance modules can be designed externally as plug-in fuses, in particular as blade fuses.

[0028] The resistor modules therefore have housings that are externally identical to those of blade fuses. Such blade fuses, especially standard blade fuses, are commonly used in motor vehicles and can be designed as low-profile mini fuses, mini fuses, regular ATO fuses, or maxi fuses. Possible housing variants are also shown in the standards ISO 8820-3:2010 and ISO 8820-3:2015. It goes without saying that the resistor modules can have a housing analogous to any of the aforementioned fuse types. Instead of, for example, a fuse wire, a resistor and a diode can be arranged in the respective housing.

[0029] The resistor modules are mechanically identical, i.e., in their external shape, to standard automotive fuses and can be used in conventional fuse holders, which then serve as the module carrier. As explained above, the individual resistor modules can be connected to the diagnostic device, for example, via the vehicle's wiring harness. Parallel connection of individual resistor modules can also be achieved within the wiring harness using appropriate connectors.

[0030] In one embodiment, two resistance modules can each be arranged in a plug-in fuse housing with three electrical contacts.

[0031] For example, so-called "Micro3" fuses have three electrical contacts, the middle contact being a common contact. This design can therefore be used, for instance, to connect two resistor modules in parallel and arrange them in a single plug-in fuse housing. Each of the outer contacts is electrically coupled to one of the switching elements, and the middle contact is connected to the diagnostic input of the diagnostic device. In this way, two switching elements can be connected to the diagnostic device in a very space-saving manner using only one plug-in housing and two resistor modules.

[0032] In one embodiment, the diagnostic device can have a control output for each of the switching elements, which is coupled to a control input of the respective switching element.

[0033] The diagnostic device can therefore be used not only for diagnosis but also for controlling the switching elements. When diagnosing individual switching elements, the diagnostic device knows their current state. Thus, the diagnostic device can not only measure the current through the resistor modules but also simultaneously evaluate whether the individual switching elements are correctly activated. Brief character description

[0034] Advantageous embodiments of the invention are explained below with reference to the accompanying figures. These show: Fig. 1 a block diagram of an embodiment of a diagnostic device according to the present invention; Fig. 2 a block diagram of a further embodiment of a diagnostic device according to the present invention; and Fig. 3 a flowchart of an embodiment of a manufacturing process according to the present invention.

[0035] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are consistently identified by the same reference numerals. Detailed description

[0036] Fig. Figure 1 shows a block diagram of a diagnostic device 100 for diagnosing switching elements 101, 102. It is understood that the two switching elements 101, 102 are shown only as examples, and any number of switching elements can be diagnosed with the diagnostic device 100. The diagnostic device 100 has a resistor module 104, 105 for each of the switching elements 101, 102. The resistor modules 104, 105 of the diagnostic device 100 have housings similar to those of blade fuses for vehicles. The resistor modules 104, 105 are arranged in a module carrier 103, which can, for example, be designed as a fuse holder in a vehicle. It is understood that other housing configurations are also possible. For example, several resistor modules can also be arranged in a relay housing. Such housings can have a variety of connections, e.g. 3-8, and therefore accommodate 2-7 resistor modules in parallel.

[0037] Each input terminal 106, 107 of the resistor modules 104, 105 is coupled to an output of the corresponding switching element 101, 102. In the resistor modules 104, 105, a resistor 110, 111 and a diode 112, 113 are connected in series between the respective input terminal 106, 107 and the corresponding output terminal 108, 109. The diodes 112, 113 are forward-biased between the respective input terminal 106, 107 and the corresponding output terminal 108, 109. The output terminals 108, 109 are coupled to a diagnostic input 116 of a diagnostic device 115. Resistors 110, 111 and diodes 112, 113 can, for example, be mounted as SMD components on a carrier board, which is soldered to the corresponding input terminals 106, 107 and the corresponding output terminals 108, 109. A discrete construction is also possible.

[0038] When one of the switching elements 101, 102 is activated, the supply voltage 150 is applied across the resistors 110, 111 and diodes 112, 113 of the resistor modules 104, 105. Consequently, a current 117, 118 flows through the respective switching element 101, 102 into the diagnostic input 116. The diagnostic device 115 can use the current 117, 118 to diagnose whether the respective switching element 101, 102 is activated or not. A shunt resistor, for example, can be provided in the diagnostic device 115 for current measurement. The resistors 110, 111 can be dimensioned according to the desired current 117, 118 and the input voltage 150. With a typical input voltage of 12 V in vehicles, resistors 110 and 111 can, for example, be dimensioned as 10 kΩ resistors. This results in a current of 1.2 mA in each case. Regarding Fig. Section 2 explains why resistors 110 and 111 can also have different sizes.

[0039] Although not shown, it is understood that the actual loads can be connected to the switching elements 101 and 102 in parallel with the resistor modules 104 and 105. Such loads could be, for example, electrical consumers in a vehicle.

[0040] The diagnostic device 115 can, for example, be a control unit in a vehicle. The diagnostic device 115 can also be connected to other vehicle systems via a bus interface. Possible bus interfaces include, for example, LIN bus, CAN bus, FlexRay bus, Ethernet, or similar. The diagnostic device 115 can receive information from these systems about the current control state of the individual switching elements 101, 102 and compare it with the measured current 117, 118. If, for example, current flows even though the respective switching element 101, 102 is not energized, a fault has occurred. Likewise, a fault occurs if no current 117, 118 flows even though the respective switching element is energized.

[0041] Alternatively, the diagnostic device 115 can, for example, have a control output (not shown separately) via which it can control the individual switching elements 101 and 102. The diagnostic device 115 can also receive control instructions via a bus interface, for example, which instruct it to activate specific switching elements 101 and 102. The diagnostic device 115 can therefore perform both control and diagnostic functions.

[0042] Fig. Figure 2 shows a block diagram of another diagnostic device 200. The diagnostic device 200 has a diagnostic unit 215, which has two diagnostic inputs 216, 228. In contrast to the Fig. Each of the diagnostic inputs 216, 228 is coupled to two resistor modules 204, 205, 222, 223, which are electrically connected in parallel to the respective diagnostic input 216, 228. Each of the resistor modules 204, 205, 222, 223 is connected to the output of a relay 201, 202, 220, 221 in order to diagnose the respective output or relay 201, 202, 220, 221 in the diagnostic device 215. Furthermore, as already mentioned above, additional electrical loads can be arranged in parallel to the resistor modules 204, 205, 222, 223 (not shown).

[0043] When one of the relays 201, 202, 220, 221 is activated via its control input 230, 231, 232, 233, i.e., closed, the supply voltage 250 is applied to the respective resistor module 204, 205, 222, 223. Consequently, a current flows through the respective resistor module 204, 205, 222, 223. Since two of the resistor modules 204, 205, 222, 223 are connected in parallel to each of the diagnostic inputs 216, 228, the currents flowing through the resistor modules 204, 205, 222, 223 add up at the respective diagnostic input 216, 228 to the current 217, 218 to be measured in the diagnostic device 215.

[0044] In order to distinguish which of the parallel-connected relays 201, 202, 220, 221 is currently activated in the diagnostic device 215, the parallel resistors 210, 211, 224, 225 can each have different resistance values. This allows the diagnostic device 215 to differentiate the individual resistor modules 204, 205, 222, 223 based on the measured current 217, 218, as explained above.

[0045] Although in Fig. Since only two resistor modules 204, 205, 222, 223 are connected in parallel to one of the diagnostic inputs 216, 228, it follows that any number of resistor modules 204, 205, 222, 223 can be connected to a single diagnostic input 216, 228. The number of possible parallel resistor modules 204, 205, 222, 223 is limited only by the maximum current consumption capacity of the respective diagnostic input 216, 228 and the resolution of the current measurement in the diagnostic device 215.

[0046] For better understanding, the following section describes the device-related aspects. Fig. 1 and Fig. 2 reference symbols used to describe the process-related Fig. Keep 3.

[0047] Fig. Figure 3 shows a flowchart of a manufacturing process for a diagnostic device 100, 200 for diagnosing switching elements 101, 102, 201, 202, 220, 221 in a vehicle.

[0048] The manufacturing process provides in a first step S1 of provisioning the provision of a pluggable resistance module 104, 105, 204, 205, 222, 223 for each of the switching elements 101, 102, 201, 202, 220, 221. In a second step S2 of provisioning, a diagnostic device 115, 215 is provided, which is designed to detect a current 117, 118, 217, 218 across the resistance modules 104, 105, 204, 205, 222, 223 and, based on the respective detected current 117, 118, 217, 218, to diagnose the function of the respective switching element 101, 102, 201, 202, 220, 221. In a third step S3 of the arrangement, the resistance modules 104, 105, 204, 205, 222, 223 are arranged in a module carrier 103, which is designed to accommodate the resistance modules 104, 105, 204, 205, 222, 223.In a fourth step S4 of the coupling process, the input terminals 106, 107 of the resistor modules 104, 105, 204, 205, 222, 223 are coupled with the corresponding switching element 101, 102, 201, 202, 220, 221. Finally, in a fifth step S5 of the coupling process, the output terminals 108, 109 of the resistor modules 104, 105, 204, 205, 222, 223 are coupled with the diagnostic device 115, 215.

[0049] The manufacturing method may further include the arrangement of a current measuring device in the diagnostic device 115, 215, which is configured to diagnose one of the switching elements 101, 102, 201, 202, 220, 221 by detecting whether a current 117, 118, 217, 218 flows through the respective switching element 101, 102, 201, 202, 220, 221 when the respective switching element 101, 102, 201, 202, 220, 221 is switched on.

[0050] Furthermore, in the resistor modules 104, 105, 204, 205, 222, 223, a resistor 110, 111, 210, 211, 224, 225 can each be electrically arranged in series with a diode 112, 113, 212, 213, 226, 227.

[0051] Furthermore, at least two of the resistor modules 104, 105, 204, 205, 222, 223 can be connected in parallel to a single diagnostic input 116, 216, 228 of the diagnostic device 115, 215. When each resistor 110, 111, 210, 211, 224, 225 is coupled to a diode 112, 113, 212, 213, 226, 227, the resistances of the respective electrically parallel-connected resistor modules 104, 105, 204, 205, 222, 223 can be provided with different resistance values.

[0052] The resistance modules 104, 105, 204, 205, 222, 223 can be externally designed mechanically as plug-in fuses, in particular as blade fuses. Two of the resistance modules 104, 105, 204, 205, 222, 223 can each be arranged in a plug-in fuse housing with three electrical contacts.

[0053] In the diagnostic device 115, 215, an additional control output can be provided for each of the switching elements 101, 102, 201, 202, 220, 221 to control the switching elements 101, 102, 201, 202, 220, 221, which can be coupled with a control input 230, 231, 232, 233 of the respective switching element 101, 102, 201, 202, 220, 221.

[0054] Since the devices and methods described in detail above are exemplary embodiments, they can be modified extensively by a person skilled in the art without departing from the scope of the invention. In particular, the mechanical arrangements and the relative sizes of the individual elements are merely exemplary. REFERENCE MARK LIST 100, 200 diagnostic device 101, 102, 201, 202, 220, 221 switching element 103 module carriers 104, 105, 204, 205, 222, 223 Resistance module 106, 107 Input connection 108, 109 Output port 110, 111, 210, 211, 224, 225 resistance 112, 113, 212, 213, 226, 227 diode 115, 215 Diagnostic facility 116, 216, 228 Diagnostic entry 117, 118, 217, 218 Electricity 230, 231, 232, 233 Tax receipt 150, 250 supply voltage S1 - S5 Procedure steps

Claims

[1] Diagnostic device (100, 200) for diagnosing switching elements (101, 102, 201, 202, 220, 221) in a vehicle, comprising: a pluggable resistor module (104, 105, 204, 205, 222, 223) for each of the switching elements (101, 102, 201, 202, 220, 221), a diagnostic device (115, 215) which is electrically connected in series with the pluggable resistance modules (104, 105, 204, 205, 222, 223) and is configured to detect a current (117, 118, 217, 218) through the resistance modules (104, 105, 204, 205, 222, 223) and to diagnose the function of the respective switching element (101, 102, 201, 202, 220, 221) based on the respective detected current (117, 118, 217, 218), and a module carrier (103) which is configured to accommodate the resistor modules (104, 105, 204, 205, 222, 223) and to couple input terminals (106, 107) of the resistor modules (104, 105, 204, 205, 222, 223) with the corresponding switching element (101, 102, 201, 202, 220, 221) and to couple output terminals (108, 109) of the resistor modules (104, 105, 204, 205, 222, 223) with the diagnostic device (115, 215), wherein the resistance modules (104, 105, 204, 205, 222, 223) each have a resistor (110, 111, 210, 211, 224, 225) and a diode (112, 113, 212, 213, 226, 227) arranged in series with the resistor (110, 111, 210, 211, 224, 225), and wherein the module carrier (103) has electrical connections configured to couple at least two of the resistance modules (104, 105, 204, 205, 222, 223) electrically in parallel with a single diagnostic input (116, 216, 228) of the diagnostic device (115, 215). [2] Diagnostic device (100, 200) according to claim 1, wherein the diagnostic device (115, 215) is configured to diagnose one of the switching elements (101, 102, 201, 202, 220, 221) by detecting whether a current (117, 118, 217, 218) flows through the respective switching element (101, 102, 201, 202, 220, 221) when the respective switching element (101, 102, 201, 202, 220, 221) is switched on. [3] Diagnostic device (100, 200) according to claim 1, wherein the resistances of the electrically parallel connected resistance modules (104, 105, 204, 205, 222, 223) have different resistance values. [4] Diagnostic device (100, 200) according to one of the preceding claims, wherein the resistance modules (104, 105, 204, 205, 222, 223) are externally designed mechanically as plug-in fuses, in particular as blade fuses. [5] Diagnostic device (100, 200) according to claim 4, wherein two resistance modules (104, 105, 204, 205, 222, 223) are each arranged in a plug-in fuse housing with three electrical contacts. [6] Diagnostic device (100, 200) according to one of the preceding claims, wherein the diagnostic device (115, 215) has a control output for each of the switching elements (101, 102, 201, 202, 220, 221) which is coupled to a control input (230, 231, 232, 233) of the respective switching element (101, 102, 201, 202, 220, 221). [7] Manufacturing method for a diagnostic device (100, 200) for diagnosing switching elements (101, 102, 201, 202, 220, 221) in a vehicle, comprising the steps: Providing (S1) a pluggable resistor module (104, 105, 204, 205, 222, 223) for each of the switching elements (101, 102, 201, 202, 220, 221), Coupling one resistor (110, 111, 210, 211, 224, 225) and one diode (112, 113, 212, 213, 226, 227) electrically in series in the resistor modules (104, 105, 204, 205, 222, 223), Providing (S2) a diagnostic device (115, 215) electrically in series with the pluggable resistor modules (104, 105, 204, 205, 222, 223), which is configured to detect a current (117, 118, 217, 218) across the resistor modules (104, 105, 204, 205, 222, 223) and to diagnose the function of the respective switching element (101, 102, 201, 202, 220, 221) based on the respective detected current (117, 118, 217, 218), Arranging (S3) the resistance modules (104, 105, 204, 205, 222, 223) in a module carrier (103) which is designed to accommodate the resistance modules (104, 105, 204, 205, 222, 223), Coupling (S4) of input terminals (106, 107) of the resistor modules (104, 105, 204, 205, 222, 223) with the corresponding switching elements (101, 102, 201, 202, 220, 221), Electrically connect at least two of the resistance modules (104, 105, 204, 205, 222, 223) in parallel to a single diagnostic input (116, 216, 228) of the diagnostic device (115, 215), and Coupling (S5) of output terminals (108, 109) of the resistor modules (104, 105, 204, 205, 222, 223) with the diagnostic device (115, 215). [8] Manufacturing method according to claim 7, comprising arranging a current measuring device in the diagnostic device (115, 215), which is configured to diagnose one of the switching elements (101, 102, 201, 202, 220, 221) by detecting whether a current (117, 118, 217, 218) flows through the respective switching element (101, 102, 201, 202, 220, 221) when the respective switching element (101, 102, 201, 202, 220, 221) is switched on. [9] Manufacturing method according to claim 7, wherein when coupling a resistor (110, 111, 210, 211, 224, 225) and a diode (112, 113, 212, 213, 226, 227) the resistances of the respective electrically parallel connected resistance modules (104, 105, 204, 205, 222, 223) are provided with different resistance values. [10] Manufacturing method according to any one of the preceding claims 7 to 9, wherein the resistance modules (104, 105, 204, 205, 222, 223) are externally designed mechanically as plug-in fuses, in particular as blade fuses, in particular wherein two of the resistance modules (104, 105, 204, 205, 222, 223) are each arranged in a plug-in fuse housing with three electrical contacts. [11] Manufacturing method according to any one of the preceding claims 7 to 10, wherein in the diagnostic device (115, 215) a control output is provided for each of the switching elements (101, 102, 201, 202, 220, 221), which is coupled to a control input (230, 231, 232, 233) of the respective switching element (101, 102, 201, 202, 220, 221).

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