Multi-channel trigger sensor for pyrotechnic fuses

Abstract

To provide a multi-channel trigger sensor for electric automobile pyrotechnic fuses.SOLUTION: A current sensor 60 receives output from a Hall sensor 66 and one or a plurality of external sources, and outputs to a fuse module 10 through a trigger positive terminal 78 and a trigger negative terminal 79. A pyrotechnic igniter of the fuse module is connected between the trigger positive terminal 78 and the trigger negative terminal 79, and a signal for operating is transmitted from the trigger positive terminal and the trigger negative terminal. The current sensor has a low-dropout (LDO) voltage regulator 61 communicating with a 12V filter 62 and a power-good detector 63, and the 12V filter and the power-good detector communicate with a squib circuit 64. The current sensor also has a fault level shift device 65 communicating with the Hall sensor of the fuse module and an OR logic device 67, and the OR logic device communicates with the squib circuit 64, an optocoupler 68, and a second filter 69.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority to pending U.S. Provisional Patent Application No. 63 / 624,928, filed January 25, 2024, and U.S. Provisional Patent Application No. 63 / 666,777, filed July 2, 2024, which are incorporated by reference in their entireties.

[0002] The present disclosure relates generally to the field of circuit protection devices. More particularly, embodiments of the present disclosure relate to a multi-channel trigger sensor for pyrotechnic fuses. [Background technology]

[0003] Fuses are commonly implemented in electrical systems to provide overcurrent protection. Most fuses are "passive" devices that include a fuse element configured to carry a rated amount of current during normal operation. If the current flowing through the fuse element exceeds the fuse element's rated current, the fuse element melts, disintegrates, or otherwise separates, thereby blocking the current and preventing or mitigating damage to connected electrical components.

[0004] In some cases, it may be desirable to "actively" create a physical open in an electrical circuit regardless of the amount of current flowing through the circuit. For example, if an automobile is involved in a collision, it may be desirable to ensure that electrical circuits within the automobile are physically open to de-energize connected electrical components and reduce the risk of fire and / or electric shock following the collision.

[0005] To this end, so-called pyrotechnic interrupters (PIs) have been developed which can be selectively activated upon the occurrence of a specific event to interrupt the flow of current in a circuit.

[0006] For example, if a vehicle crashes, a controller (e.g., an airbag control unit, a battery management system, etc.) may send an activation signal to the PI, detonating a pyrotechnic igniter within the PI. The resulting increase in pressure within the PI forces a piston or blade to quickly sever a conductor extending through the PI, thereby interrupting current flow through the PI, and the piston, formed of a dielectric material, provides an electrically insulating barrier between the separated portions of the conductor to prevent electrical arcing between them.

[0007] In certain applications, it may be desirable to provide a multi-channel trigger sensor for a pyrotechnic fuse. With respect to these and other considerations, the present improvements may be useful. Summary of the Disclosure

[0008] This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is this Summary intended to aid in determining the scope of the claimed subject matter.

[0009] In one approach, the current sensor may comprise a multi-channel, input-triggered pyrotechnic fuse for electric vehicle (EV) applications that is fast, reliable, and operates with different trigger sources and different vehicle modes.

[0010] In another approach, a trigger sensor operable with a fuse module may include a programmable logic device and a diagnostic microcontroller unit operable to receive outputs from a Hall sensor and one or more external sources and to provide outputs to the fuse module. The trigger sensor may further include a plurality of mode-switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, wherein the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes.

[0011] In another approach, a multi-channel input-triggered pyrotechnic fuse for electric vehicle (EV) applications may include a programmable logic device and a diagnostic microcontroller unit operable to receive outputs from Hall sensors and one or more external sources and to provide outputs to a fuse module. The multi-channel input-triggered pyrotechnic fuse for EV applications may further include a plurality of mode-switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, wherein the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes.

[0012] In another approach, a multi-channel input-triggered pyrotechnic fuse for electric vehicle (EV) applications may include a programmable logic device and a diagnostic microcontroller unit operable to receive outputs from Hall sensors and one or more external sources and to provide outputs to a fuse module. The multi-channel input-triggered pyrotechnic fuse for EV applications may further include a plurality of mode-switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, where the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes, and where the programmable logic device and the diagnostic microcontroller unit determine an overcurrent detection response time. [Brief explanation of the drawings]

[0013] The accompanying drawings illustrate exemplary approaches currently devised for the practical application of these principles of the disclosed embodiments.

[0014] [Figure 1] 1 illustrates a perspective view of an active / passive fuse module according to an embodiment of the present disclosure.

[0015] [Figure 2] 2 is a circuit diagram of the active / passive fuse module of FIG. 1 including a multi-channel input trigger sensor according to an embodiment of the present disclosure.

[0016] [Figure 3] 2 is a circuit diagram of the active / passive fuse module of FIG. 1 including a multi-channel input trigger sensor according to an embodiment of the present disclosure.

[0017] The drawings are not necessarily to scale. The drawings are merely representational and are not intended to portray specific parameters of the present disclosure. The drawings are intended to illustrate exemplary embodiments of the present disclosure and therefore should not be considered limiting in scope. In the drawings, like reference numerals represent like elements.

[0018] Additionally, certain elements in some figures may be omitted or shown not to scale for clarity of illustration. Cross-sectional views may be in the form of "slices," or "close-up" cross-sections, and for clarity of illustration, certain background lines that would otherwise be visible in a "natural" cross-sectional view are omitted. Additionally, some reference numbers may be omitted in certain figures for clarity. DETAILED DESCRIPTION OF THE INVENTION

[0019] Assemblies, devices, systems, and methods according to the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which embodiments are shown. The assemblies, devices, systems, and methods may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Instead, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0020] Embodiments of the present disclosure are directed to a multi-channel, input-triggered pyrotechnic fuse for electric vehicle (EV) applications that is fast, reliable, and operates with different trigger sources. In some cases, triggering can occur within a few milliseconds to ensure current limiting, thereby protecting the HV system, including the battery. To enhance reliability, the trigger sensor can include diagnostics, including in-range supply voltage, loss of ground, Hall IC internal diagnostics, and squib resistance diagnostics, such as resistance measurements and short / open detection, using low-current (e.g., 50 mA), periodic (e.g., 10 ms) pulses to evaluate resistance. The results of all these diagnostics are continuously communicated to the EV's battery management system (BMS) or engine control unit (ECU) via a digital communication bus, pulse-width modulation (PWM) output, or other customer-selected means.

[0021] As described in more detail herein, different trigger sources enable protection based on a current trigger (or multiple internal triggers) internal to the trigger sensor via an internal current sensor that triggers a pyrotechnic fuse as soon as a certain predetermined level is exceeded, i.e., higher than the maximum current in any driving or charging condition. Different trigger sources may also enable external protection, for example, from a squib driver, which may be part of a BMS and can be controlled by an ECU via a controller area network (CAN) bus, for example, in the event of a crash where the battery needs to be disconnected regardless of current level. In yet another example, a trigger may be used via the system's main current sensor (or sensors) via its OCD (over current detection) output. In most cases, an external, non-current-dependent trigger is often used, but it is recognized that combinations of one or more of the above are possible.

[0022] Embodiments of the present disclosure further provide false triggering avoidance in the event of an EMI pulse, for example caused by lightning, by ignoring short current spikes that may not be caused by the busbar current itself, thereby ensuring that the power supply voltage is stable and within acceptable levels, otherwise the trigger function is disabled.

[0023] It is understood that more than one pyrotechnic squib can be connected in parallel and triggered in parallel, i.e. simultaneously, and the pyrotechnic squibs are also diagnosed, for example, if all are OK or at least one is not OK.

[0024] Referring to FIG. 1 , a cross-sectional view illustrating an active / passive fuse module 10 (hereinafter “fuse module 10”) according to an exemplary, non-limiting embodiment of the present disclosure is shown. Fuse module 10 may generally include a base 12, bus bars 14, and a pyrotechnic interrupter (PI) 18. Base 12 may be formed of an electrically insulating material such as a plastic, polymer, ceramic, or the like. The present disclosure is not limited in this regard. Base 12 may include a cavity 20 formed in an upper surface thereof.

[0025] The bus bar 14 may be formed from a single piece or length of conductive material (e.g., stamped from a single sheet such as copper) and may have the fuse element 22 and first and second terminal portions 26a, 26b extending from opposite ends of the fuse element 22. The bus bar 14 may be positioned on the top surface of the base 12 in a horizontal orientation with the fuse element 22 extending across the cavity 20. The first and second terminal portions 26a, 26b may extend outside or beyond the sides of the base 12 to facilitate connection of the fuse module 10 in a circuit.

[0026] The fuse element 22 may be configured to melt, disintegrate, or otherwise open when the current flowing through the busbar 14 exceeds a predetermined threshold, or "current rating," of the fuse module 10. In various examples, the fuse element 22 may include perforations, slots, thin or narrow segments, and / or various other features to make the fuse element 22 more likely to melt or open than other portions of the busbar 14. In a non-limiting example, the fuse element 22 may be configured to have a current rating ranging between 30 amps and 1000 amps. The present disclosure is not limited in this respect.

[0027] The PI 18 may have a housing 36 with a mounting flange 38 protruding from a lower portion thereof. The housing 36 may be positioned on the base 12 with mechanical fasteners 40 a, 40 b extending through the mounting flange 38 and into the base 12 for fastening the components together in a vertically stacked relationship. The housing 36 may include a hollow, vertically oriented shaft 43 extending therethrough. The shaft 43 may have an open lower end located directly above the fuse element 22 and cavity 20.

[0028] Housing 36 may include a movable piston or blade 42 (hereinafter "piston 42") disposed within a hollow shaft 43 located above cavity 20 in base 12. Housing 36 may further include one or more pyrotechnic igniters 44 disposed within shaft 43 and above piston 42.

[0029] In some embodiments, because the fuse element 22 begins to separate (e.g., melt) before the pyrotechnic igniter 44 explodes and drives the piston 42, the fuse element 22 is weakened (e.g., partially melted) before the piston 42 is driven therethrough, making it easier for the piston 42 to sever the fuse element 22. Thus, the fuse element 22 can be thicker / larger (and therefore able to handle higher currents) than would be possible if the piston 42 were required to sever an unweakened portion of the busbar 14 (i.e., the portion of the busbar 14 other than the partially melted fuse element 22), as in conventional fuse modules incorporating pyrotechnic interrupters.

[0030] 2 demonstrates that fuse module 10 is operable with current sensor 60. In various embodiments, current sensor 60 may be triggered via self-triggering by a current level measurement, via an external signal from a squib driver, or via an external signal from an overcurrent detection (OCD) signal from another current sensor. More specifically, current sensor 60 may be a multi-channel current sensor operable to receive output from Hall sensor 66 and one or more external sources and to provide output to fuse module 10 via a positive trigger terminal 78 and a negative trigger terminal 79. In some embodiments, pyrotechnic igniter 44 is connected between positive trigger terminal 78 and negative trigger terminal 79. More specifically, a signal to activate igniter 44 may be transmitted from current sensor 60 terminals, positive trigger terminal 78, and negative trigger terminal 79.

[0031] As shown, the current sensor 60 may include a low dropout (LDO) voltage regulator 61 in communication with a filter (e.g., 12V) 62 and a power good detector 63. The filter 62 and the power good detector 63 may be in communication with a squib circuit 64. As further shown, the current sensor 60 may include a fault level shifting device 65 in communication with a Hall sensor 66 of the fuse module 10 and an OR logic device 67. The OR logic device 67 may be in communication with the squib circuit 64, an optocoupler 68, and a second filter 69. In some embodiments, the Hall sensor 66 may be a coreless Hall sensor for very fast pyrotechnic triggering and a smaller form factor.

[0032] As further shown, current sensor 60 may include a diagnostic system 70 having a diagnostic microcontroller unit (MCU) 71 in communication with a Vcc monitor 72, a diagnostic current pulse driver 73, a differential amplifier 74, and a pulse width modulation (PWM) driver circuit 75. In some embodiments, diagnostic system 70 may be optional, while still allowing the primary functionality of current sensor 60; that is, current sensor 60 may be entirely analog.

[0033] Vcc 76 is connected between the EV's BMS, filter 62, and Vcc monitor 72; ground (GND) 77 is connected between the EV's BMS and filter 62; trigger positive 78 and trigger negative 79 are connected between the pyrotechnic fuse squib and squib circuit 64. As further shown, external trigger positive 80 and external trigger negative 81 are connected between the BMS or ECU and optocoupler 68. A resistor 83 (e.g., 2.1 ohms) may be connected between external trigger positive 80 and external trigger negative 81. As further shown, diagnostic 84 is connected between the BMS or ECU and PWM driver 75; and OCD trigger 85 is connected between the external current sensor with OCD functionality (e.g., based on voltage level or PWM) and filter 69.

[0034] In operation, the current sensor 60 may accommodate multiple inputs, for example, from the internal sensor 66, from an external squib driver, or from an external current sensor (PWM or voltage level). For example, a trigger may result from an OR function on three inputs, while an AND function may also be possible (e.g., two together for safety).

[0035] Current sensor 60 may further provide igniter emulation functionality for external trigger input. For example, optocoupler 68 may provide galvanic isolation and bidirectional current input from external trigger positive 80 and external trigger negative 81. This igniter resistor emulation further provides squib driver compatibility.

[0036] The current sensor 60 also provides diagnostics based on discrete electronics (analog + diagnostic MCU 71). In some embodiments, low-end MCU monitoring of multiple signals allows different diagnostic algorithms and customizable prioritization. For example, an algorithm may combine information about squib resistance, power supply voltage, and Hall diagnostics, while a PWM output signal allows automatic diagnosis of loss of ground via a pull-up resistor. Resistance measurements may be implemented via low-amplitude current pulses and a differential amplifier, and voltage level shifting may be adjusted to suit different circuits (5V MCU vs. 12V circuits).

[0037] As mentioned above, the current sensor 60 advantageously provides an analog sensing and triggering architecture that increases the speed from when the current is exceeded to trigger a signal (e.g., trigger positive 78) to the pyrotechnic fuse squib. The MCU 71 of the diagnostic system 70 can be digital only. In some cases, the igniter driver is based on discrete components, while false trigger prevention by power supply monitoring (power good detector 63) trigger function is disabled until power is stable. False trigger prevention by glitch filtering (e.g., second filter 69) is also provided, while additional filtering from filter 62 may protect against power supply voltage spikes.

[0038] As a result, faster response can be achieved compared to conventional squib drivers, a power bank (using a capacitor for power storage) can be provided for short power supply brownouts, and high current output via fully opening the MOSFET (achieved by using an additional MOSFET driver) can be possible, as can the ability to drive and diagnose two igniters in parallel.

[0039] FIG. 3 demonstrates that fuse module 10 can operate with another current sensor 160. Current sensor 160 may be similar in some respects to current sensor 60 described above. Therefore, for brevity, only certain aspects of current sensor 160 are described below. In various embodiments, current sensor 160 may be triggered via self-triggering by a current level measurement, via an external signal from a squib driver, or via an external signal from an overcurrent detection (OCD) signal from another current sensor. More specifically, current sensor 160 may be a multi-channel current sensor operable to receive output from Hall sensor 166 and one or more external sources and to provide output to fuse module 10 via a positive trigger terminal 178 and a negative trigger terminal 179. In some embodiments, pyrotechnic igniter 144 is connected between positive trigger terminal 178 and negative trigger terminal 179. More specifically, the signal to activate the igniter 144 may be transmitted from a terminal of the current sensor 160 , a positive trigger terminal 178 , and a negative trigger terminal 179 .

[0040] As shown, the current sensor 160 may include a low dropout (LDO) voltage regulator 161 in communication with a filter (e.g., 12V) 162 and a power good detector 163. The filter 162 and the power good detector 163 may communicate with a squib circuit 164. As further shown, the current sensor 160 may include an internal programmable logic device (PLD) 192 in communication with a Hall sensor 166 and an OR logic device 167 of the fuse module 10, where the PLD 192 interprets measurements to perform diagnostics for the selected OCD delay mode. The OR logic device 167 may communicate with the squib circuit 164, an optocoupler 168, and a second filter 169. In some embodiments, the Hall sensor 166 may be a coreless Hall sensor for very fast pyrotechnic triggering and a smaller form factor.

[0041] As further shown, current sensor 160 may include a diagnostic system 170 having a diagnostic microcontroller unit (MCU) 171 in communication with a Vcc monitor 172, a diagnostic current pulse driver 173, a differential amplifier 174, a pulse width modulation (PWM) driver 175, and a PWM filter 194. In some embodiments, diagnostic system 170 may be optional, while still allowing the primary functionality of current sensor 160; that is, current sensor 160 may be entirely analog.

[0042] Vcc 176 is connected between the EV's BMS, filter 162, and Vcc monitor 172; ground (GND) 177 is connected between the EV's BMS and filter 162; trigger positive 178 and trigger negative 179 are connected between the pyrotechnic fuse squib and squib circuit 164. As further shown, external trigger positive 180 and external trigger negative 181 are connected between the BMS or ECU and optocoupler 168. A resistor 183 (e.g., 2.1 ohms) may be connected between external trigger positive 180 and external trigger negative 181. As further shown, diagnostic 184 is connected between the BMS or ECU and PWM driver 175; and OCD trigger 185 is connected between the external current sensor with OCD functionality (e.g., based on voltage level or PWM) and filter 169.

[0043] In operation, the current sensor 160 may accommodate multiple inputs, for example, from the internal sensor 166, from an external squib driver, or from an external current sensor (PWM or voltage level). For example, a trigger may result from an OR function on three inputs, while an AND function may also be possible (e.g., two together for safety).

[0044] Current sensor 160 may further provide igniter emulation functionality for external trigger input. For example, optocoupler 168 may provide galvanic isolation and bidirectional current input from external trigger positive 180 and external trigger negative 181. This igniter resistor emulation further provides squib driver compatibility.

[0045] The current sensor 160 also provides diagnostics based on discrete electronics (analog + diagnostic MCU 171). In some embodiments, low-end MCU monitoring of multiple signals allows different diagnostic algorithms and customizable prioritization. For example, an algorithm may combine information about squib resistance, power supply voltage, and Hall diagnostics, while a PWM output signal allows automatic diagnosis of loss of ground via a pull-up resistor. Resistance measurements may be implemented via low-amplitude current pulses and a differential amplifier, and voltage level shifting may be adjusted to suit different circuits (5V MCU vs. 12V circuits).

[0046] As mentioned above, current sensor 160 advantageously provides an analog sensing and triggering architecture that increases the speed at which current exceeds a triggering signal (e.g., trigger positive 178) to the pyrotechnic fuse squib. The MCU 171 of diagnostic system 170 can be exclusively digital. In some cases, the igniter driver is based on discrete components, while false triggering prevention via power supply monitoring (power good detector 163) triggering is disabled until power is stable. False triggering prevention via a glitch filter (e.g., second filter 169) is also provided, while additional filtering from filter 162 may protect against power supply voltage spikes.

[0047] As a result, faster response can be achieved compared to conventional squib drivers, a power bank (using a capacitor for power storage) can be provided for short power supply dropouts, and high current output via fully opening the MOSFET (achieved by using an additional MOSFET driver) can be possible, as can the ability to drive and diagnose two igniters in parallel.

[0048] As further shown, because different operating modes may benefit from different OCD response times, the current sensor 160 may include a mode switch 190 to accommodate multiple vehicle operating modes, such as driving, charging, and accelerating. For example, a longer response time in driving mode helps avoid false triggers due to periphery malfunctions. The mode switch may be connected to a PMW filter 194, a diagnostic MCU 171, and a PLD 192. During use, input signal measurements from the PLD 192 and the MCU 171 are combined to determine and verify a mode-switching event, thereby increasing the robustness of the mode-switching event.

[0049] The mode switch 190 provides an additional input that indicates the current delay time, i.e., how long the current is allowed to exceed the threshold, to detect the requested mode. In some embodiments, the response time can be switched during vehicle operation by different mechanisms, such as via a received external communication request, allowing for a commanded response time for each operating mode. Additionally, the response time mode can be configurable, for example, based on an internally measured current direction. In some embodiments, different trigger level values can be used for each current polarity. This provides a significant advantage over prior art options in which the pyro trigger has the same OCD trigger time for both current directions and all vehicle operating modes.

[0050] More specifically, in some embodiments, multiple response time OCD delay configurations are possible for two (2) and more different delay options, for example, but not limited to, 10 us, 100 us, 1 ms, 10 ms, etc. Additionally, mode switch 190 may provide current polarity-based OCD response time delay selection as well as current polarity detection internally within the sensor. Without limitation, switch mode 190 may allow for external communication command-based OCD delay mode switching, for example, but not limited to, PWM, local interconnect networking (LIN), controller area network (CAN), voltage level, etc.

[0051] In summary, embodiments herein provide a novel approach to protecting electric vehicle HV circuits where sensors activate pyrotechnic fuses by using different input trigger sources and switching based on vehicle mode, and by providing a reliable, very fast, high current signal to an igniter.

[0052] As used herein, elements or steps described in the singular and preceded by the word "a" or "an" are not understood to exclude a plurality of elements or steps, unless the context explicitly states that such exclusion exists. Furthermore, references to "one embodiment" of the present disclosure are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features.

[0053] The use of "including," "comprising," or "having," and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. Thus, the terms "including," "comprising," or "having," and variations thereof, are open-ended and can be used interchangeably herein.

[0054] As used herein, the phrases "at least one," "one or more," and "and / or" are open-ended and are both conjunctive and disjunctive in operation. For example, the phrases "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" mean A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0055] All directional references (e.g., proximal, distal, upper, lower, upward, downward, left, right, lateral, longitudinal, front, rear, top, bottom, above, below, vertical, horizontal, radial, axial, clockwise, and counterclockwise) are used solely for identification purposes to aid the reader in understanding the present disclosure. The directional references do not impose any limitations on the position, orientation, or use of the present disclosure in particular. References to connections (e.g., attached, coupled, connected, and joined) should be interpreted broadly and may include intermediate members between a collection of elements and relative movement between the elements, unless otherwise indicated. Thus, references to connections do not necessarily imply that two elements are directly connected and in a fixed relationship to each other.

[0056] Furthermore, references of identity (e.g., primary, secondary, first, second, third, fourth, etc.) are not intended to imply importance or priority, but are used to distinguish one feature from another. The drawings are for illustrative purposes, and the dimensions, positions, order, and relative sizes reflected in the drawings accompanying this specification may vary.

[0057] While particular embodiments of the present disclosure have been described herein, the disclosure is not limited thereto, as the disclosure has the broadest scope permitted by the art and the specification may be read in the same manner. Therefore, the above description should not be construed as limiting. Rather, the above description is merely illustrative of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

1. 1. A trigger sensor operable with a fuse module, the trigger sensor comprising: a programmable logic device and diagnostic microcontroller unit operable to receive outputs from the Hall sensors and one or more external sources and to provide outputs to the fuse module; and a plurality of mode switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, wherein the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes; A trigger sensor comprising:

2. The trigger sensor of claim 1 , wherein the programmable logic device and the diagnostic microcontroller unit determine an overcurrent detection response time based on the determined vehicle operating mode.

3. 10. The trigger sensor of claim 1, wherein the programmable logic device and the diagnostic microcontroller unit determine an overcurrent detection response time based on an internally measured current polarity of the current.

4. The trigger sensor of claim 3 , wherein the overcurrent detection response time is the amount of delay allowed for the current to exceed a threshold.

5. 4. The trigger sensor of claim 3, wherein the overcurrent detection response time is switched between a plurality of different overcurrent detection response times without an external mode switching signal based on the internally measured current polarity of the current.

6. The trigger sensor of claim 1 , further comprising a pulse width modulation filter coupled to the plurality of mode-switching sources.

7. The trigger sensor of claim 6 , wherein the pulse width modulation filter is further connected to the diagnostic microcontroller unit and to the programmable logic device.

8. 2. The trigger sensor of claim 1, wherein the trigger sensor is operable to trip a fuse in the fuse module in response to at least one of the following: a current level measurement exceeding a predetermined threshold, an external signal from a squib driver, and an external signal from another current sensor indicating an overcurrent.

9. 1. A multi-channel input-triggered pyrotechnic fuse for electric vehicle (EV) applications, comprising: a programmable logic device and diagnostic microcontroller unit operable to receive outputs from the Hall sensors and one or more external sources and to provide outputs to the fuse module; and a plurality of mode switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, wherein the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes; 1. A multi-channel input trigger pyrotechnic fuse comprising:

10. 10. The multi-channel, input-triggered pyrotechnic fuse of claim 9, wherein the programmable logic device and the diagnostic microcontroller unit determine an overcurrent detection response time based on the determined vehicle operating mode.

11. 10. The multi-channel, input-triggered pyrotechnic fuse of claim 9, further comprising a pulse width modulated filter connected to said plurality of mode-switching sources.

12. 12. The multi-channel, input-triggered pyrotechnic fuse of claim 11, wherein the pulse width modulation filter is further connected to the diagnostic microcontroller unit and to the programmable logic device.

13. 10. The multi-channel, input-triggered pyrotechnic fuse of claim 9, wherein the multi-channel, input-triggered pyrotechnic fuse is operable to trip a fuse of the fuse module in response to at least one of the following: a measured current level exceeding a predetermined threshold, an external signal from a squib driver, and an external signal from another current sensor indicating an overcurrent.

14. 14. The multi-channel input trigger pyrotechnic fuse of claim 13, further comprising a resistor having the same resistance as a pyro-igniter used to mimic an igniter for external triggering from the squib driver.

15. 14. The multi-channel, input-triggered pyrotechnic fuse of claim 13, further comprising an optocoupler component, said optocoupler component being externally triggered from said squib driver.

16. 1. A multi-channel input-triggered pyrotechnic fuse for electric vehicle (EV) applications, comprising: a programmable logic device and diagnostic microcontroller unit operable to receive outputs from the Hall sensors and one or more external sources and to provide outputs to the fuse module; and a plurality of mode switching sources in communication with the programmable logic device and the diagnostic microcontroller unit, wherein the programmable logic device and the diagnostic microcontroller unit determine a vehicle operating mode from a plurality of vehicle operating modes, and wherein the programmable logic device and the diagnostic microcontroller unit determine an overcurrent detection response time based on the determined vehicle operating mode; 1. A multi-channel input trigger pyrotechnic fuse comprising:

17. 17. The multi-channel, input-triggered pyrotechnic fuse of claim 16, further comprising a pulse width modulation filter connected to said plurality of mode-switching sources.

18. 18. The multi-channel, input-triggered pyrotechnic fuse of claim 17, wherein the pulse width modulation filter is further connected to the diagnostic microcontroller unit and to the programmable logic device.

19. 17. The multi-channel, input-triggered pyrotechnic fuse of claim 16, wherein the multi-channel, input-triggered pyrotechnic fuse is operable to trip a fuse of the fuse module in response to at least one of the following: a measured current level exceeding a predetermined threshold, an external signal from a squib driver, and an external signal from another current sensor indicating an overcurrent.

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