Power management system for a winch of a vehicle

Abstract

The invention relates to a power management system (1 ) for a winch (11 ) of a vehicle (10). The system (1) includes a current sensor (2) for determining an operating current supplied to an electric motor (14) of the winch (11), an input means (18a, 18b) for receiving command signals and a processor (40) operatively connected to the current sensor (2) and the input means (18a, 18b). The processor (40) is configured to operate the electric motor (14) in first or second directions in response to command signals received by the input means (18a, 18b), to determine an operating condition based at least on the operating current while the electric motor (14) is operated in the first direction and to disable it in response to the operating condition exceeding a threshold. The processor (40) is configured to re¬ enable the electric motor (14) thereafter in response to receiving the second command signal.

Description

[0001] POWER MANAGEMENT SYSTEM FOR A WINCH OF A VEHICLE

[0002] This invention relates generally to power management and in particular to power management systems for winches. More specifically, although not exclusively, this invention relates to a power management system for a winch of a vehicle.

[0003] Power management systems for vehicle winches are known and generally include a current sensor that determines an operating current of the winch and provides an interrupt signal when the current is greater than a threshold value.

[0004] EP2280900A1 describes such a system in which a low voltage interrupt module is also included, which determines a voltage of a power source and provides a further interrupt signal when the voltage is less than a threshold value. This document includes these and other components in a common housing.

[0005] Whilst this arrangement is effective for preventing the winch from being overloaded, the inventors have determined that safety could be improved.

[0006] According to a broad aspect, a power management system is provided which is configured or operable to disable a winch in response to an operating condition exceeding a threshold.

[0007] Preferably, the system is configured or operable to disable a motor of a winch of a vehicle and engage a brake of the winch independently of disabling the motor.

[0008] The inventors have determined that, in some circumstances, simultaneous disabling of the motor and engaging of the brake can result in uncontrolled release of a load.

[0009] The system may comprise a current sensing means, e.g. for determining an operating current supplied to an electric motor of the winch. The current sensing means may comprise a current sensor, such as a hall effect sensor or any other suitable type of sensor for determining, calculating or measuring an operating current supplied to the electric motor. Hereinafter, this feature will be referred to as a current sensing means, but this term may be replaced with any of the aforementioned terms without departing from the scope of the invention. The operating condition may be based at least in part on the operating current. The system may be configured to determine or measure or calculate the operating condition, e.g. based at least in part on the operating current.

[0010] The system may comprise processing means. The processing means may comprise one or more processors or other suitable processing devices capable of carrying out the functions described herein. Hereinafter, this feature will be referred to as a processing means, but this term may be replaced with any of the aforementioned terms without departing from the scope of the invention.

[0011] The processing means may comprise or be operatively connected to memory means or a memory. The memory means or memory may comprise computer-readable software code means or code, which may be operable or configured to carry out one or more steps as outlined below.

[0012] The processing means may be operatively connected to the current sensing means. The processing means may be operable or configured to determine or measure or calculate the operating condition, e.g. based at least in part on the operating current.

[0013] The processing means may be operable or configured to disable the electric motor, for example in response to the operating condition exceeding a threshold. The processing means may be operable or configured to engage the brake, for example in response to the operating condition exceeding a threshold.

[0014] The system may comprise at least one output means or output, hereinafter output means but this term may be replaced with the term output.

[0015] The processing means may be operatively connected to the or each output means. The processing means may be configured to control the or each output means, for example to disable the electric motor and / or to engage the brake.

[0016] The system may comprise first and second output means. The first output means may be for selectively disabling the electric motor. The second output means may be for selectively engaging a brake of the winch. The processing means may be operatively connected to each of the first output means and the second output means. The processing means may be configured to control independently, e.g. in response to the operating condition exceeding a threshold, each of the first output means, such as to disable the electric motor, and the second output means, such as to engage the brake.

[0017] Another aspect provides a power management system, e.g. for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; first output means for selectively disabling the electric motor; second output means for selectively engaging a brake of the winch; and processing means operatively connected to each of the current sensing means, the first output means and the second output means; wherein the processing means is configured to determine, in use, an operating condition based at least in part on the operating current and to control independently, in response to the operating condition exceeding a threshold, each of the first output means to disable the electric motor and the second output means to engage the brake.

[0018] The processing means may be configured to control, in use, the second output means to engage the brake before controlling the first output means to disable the electric motor, e.g. in response to the operating condition exceeding the threshold. The second output means may comprise a binary output means, for example to selectively control the brake between engaged and released conditions. Alternatively, the second output means may comprise a variable, for example infinitely variable or stepwise, output means, e.g. to selectively control the brake at various levels of engagement between engaged and released conditions.

[0019] The system may comprise voltage sensing means, e.g. for determining a supply voltage and / or an operating voltage supplied to the electric motor. The voltage sensing means may comprise a voltage sensor, voltmeter or any other suitable device, hereinafter voltage means. The processing means may be configured to determine the operating condition based at least in part on the operating voltage and the operating current.

[0020] The threshold may comprise a threshold value for a predetermined period of time. The processing means may be configured to control independently, in response to the operating condition exceeding the threshold fora predetermined period of time, each of the first output means to disable the electric motor and the second output means to engage the brake. The system may comprise input means, e.g. for receiving at least one command signal. The processing means may be operatively connected to the input means. The system or processing means may be configured to operate the electric motor, e.g. in response to a command signal received by the input means. The input means may comprise an input or input device, such as a winch controller.

[0021] The system or processing means may be configured to operate the electric motor in a first direction, for example in response to a first command signal received by the input means. The system or processing means may be configured to operate the electric motor in a second direction, which may be opposite the first direction, e.g. in response to a second command signal received by the input means.

[0022] The processing means may be operable or configured to disable the electric motor, for example in response to the operating condition exceeding the threshold, while the electric motor is operated in the first direction. The processing means may be operable or configured to re-enable the electric motor, e.g. thereafter, such as in response to receiving the second command signal. The processing means may be operable or configured to control the first output means to re-enable or reset the electric motor, e.g. thereafter, such as in response to receiving the second command signal.

[0023] Another aspect provides a power management system for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; input means for receiving command signals; and processing means operatively connected to the current sensing means and the input means; wherein the processing means is configured to: operate the electric motor in a first direction in response to a first command signal received by the input means and in a second direction, opposite the first direction, in response to a second command signal received by the input means; determine an operating condition based at least in part on the operating current while the electric motor is operated in the first direction; disable the electric motor in response to the operating condition exceeding a threshold; and re-enable the electric motor thereafter in response to receiving the second command signal.

[0024] The operating condition may comprise an operating current or operating power. Where the operating condition comprises an operating power, the operating condition may be determined or calculated based at least in part on the operating current and / or the operating voltage.

[0025] The operating condition may comprise an instantaneous current or power. The operating condition may comprise an instantaneous operating condition, such as an instantaneous current or power.

[0026] The operating condition may comprise a predicted or projected (hereinafter predicted) current or power. The operating condition may comprise an predicted operating condition, such as a predicted current or power. The predicted current or power may be determined or calculated based upon a rate of change, e.g. a historical rate of change, of the or an instantaneous current or power. Other methods of forward estimating the operating condition are also envisaged and would be appreciated by the skilled person.

[0027] The processing means may be configured to re-enable the electric motor after a predetermined time, for example in the absence of receiving the second command signal. The processing means may be configured to re-enable the electric motor after a predetermined time following the electric motor being disabled in the absence of receiving the second command signal.

[0028] The processing means may be configured to cause the first output means to re-enable the electric motor after a predetermined time, for example in the absence of receiving the second command signal. The processing means may be configured to cause the first output means to re-enable the electric motor after a predetermined time following the electric motor being disabled in the absence of receiving the second command signal.

[0029] The processing means may be configured to disable the electric motor in response to the operating condition exceeding the threshold for a predetermined period of time.

[0030] The operating condition may comprise a cumulative operating condition, for example based on the operating current and / or operating voltage over a predetermined period of time. In addition to the instantaneous or predicted operating condition or in the alternative, the processing means may be configured to determine a cumulative operating condition, for example based on the operating current and / or the operating voltage over a predetermined period of time. The system may comprise two or more operating modes. The system or operating modes may comprise a first operating mode and / or a second operating mode and / or one or more further operating modes.

[0031] The processing means may be configured to disable the electric motor in response to the cumulative operating condition exceeding a threshold, e.g. a cumulative threshold. The processing means may be configured to disable the electric motor in response to the cumulative operating condition exceeding a first threshold, e.g. a first cumulative threshold, in the first operating mode. The processing means may be configured to disable the electric motor in response to the cumulative operating condition exceeding a second threshold, e.g. a second cumulative threshold, in the second operating mode.

[0032] The processing means may be configured to determine an instantaneous operating condition, for example based on the operating current and / or the operating voltage. The processing means may be configured to determine a predicted operating condition, for example based on the operating current and / or the operating voltage over a predetermined period of time. The processing means may be configured to determine a cumulative operating condition, for example based on the operating current and / or the operating voltage over a predetermined period of time. The processing means may be configured to control independently, in response to at least one of the instantaneous operating condition exceeding an instantaneous threshold, the predicted operating condition exceeding a predicted threshold or the cumulative operating condition exceeding a cumulative threshold, each of the first output means to disable the electric motor and the second output means to engage the brake.

[0033] The processing means may be configured to disable the electric motor in response to at least one of the instantaneous operating condition exceeding a first threshold in the first operating mode or a second threshold in the second operating mode; the predicted operating condition exceeding a first threshold in the first operating mode or a second threshold in the second operating mode; or the cumulative operating condition exceeding a first threshold in the first operating mode or a second threshold in the second operating mode. The processing means may be configured to re-enable the electric motor after a predetermined time, e.g. following the electric motor being disabled in response to the cumulative operating condition exceeding the threshold or the first or second threshold. The processing means may be configured to re-enable the electric motor only after a predetermined time, e.g. following the electric motor being disabled in response to the cumulative operating condition exceeding the threshold or the first or second threshold.

[0034] The processing means may be configured to re-enable the electric motor in response to receiving the second command signal if, e.g. only if, the electric motor was disabled either in response to the instantaneous operating condition exceeding the instantaneous threshold or the first or second instantaneous threshold or in response to the predicted operating condition exceeding the predicted threshold or the first or second predicted threshold. The processing means may be configured not to re-enable the electric motor in response to receiving the second command signal if the electric motor was disabled in response to the cumulative operating condition exceeding the cumulative threshold or the first or second cumulative threshold.

[0035] More specifically, the processing means may be configured to re-enable the electric motor in response to receiving the second command signal if the electric motor was disabled in response to the instantaneous operating condition exceeding the instantaneous threshold or in response to the predicted operating condition exceeding the predicted threshold, but not if the electric motor was disabled in response to the cumulative operating condition exceeding the cumulative threshold.

[0036] The processing means may be operable or configured to control the first output means to re-enable the electric motor.

[0037] The operating condition or the cumulative operating condition may, but need not, comprise a quantity of energy supplied to the electric motor, for example during a predetermined period of time.

[0038] The processing means may be configured to selectively supply power to the electric motor, e.g. thereby to operate or disable the electric motor. The processing means may be configured to control the output means or the first output means, for example to selectively supply power to the electric motor, thereby to operate or disable the electric motor. The processing means may be configured to operate the electric motor continuously, for example in response to a continuous command signal received by the input means. The processing means may be configured to operate the electric motor continuously until the operating condition exceeds the threshold. The processing means may be configured to operate the electric motor continuously until the operating condition exceeds the first or second threshold.

[0039] The system may comprise two or more operating modes, e.g. a first operating mode and / or a second operating mode and / or further operating modes, each of which may have different respective thresholds.

[0040] In the first operating mode, the processing means may be configured to disable the electric motor, for example in response to the operating condition exceeding a first threshold.

[0041] In the first operating mode, the processing means may be configured to control, in use, independently each of the first output means to disable the electric motor and the second output means to engage the brake, for example in response to the operating condition exceeding a first threshold.

[0042] In the second operating mode, the processing means may be configured to disable the electric motor, for example in response to the operating condition exceeding a second threshold, which may be different from the first threshold.

[0043] In the second operating mode, the processing means may be configured to control, in use, independently each of the first output means to disable the electric motor and the second output means to engage the brake, for example in response to the operating condition exceeding a second threshold, different from the first threshold.

[0044] Another aspect provides a power management system for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; and processing means operatively connected to the current sensing means and configured to determine, in use, an operating condition based at least in part on the operating current; wherein the system comprises: a first operating mode in which the processing means is configured to disable the electric motor in response to the operating condition exceeding a first threshold; and a second operating mode in which the processing means is configured to disable the electric motor in response to the operating condition exceeding a second threshold, different from the first threshold.

[0045] The operating modes may correspond to security modes of a vehicle within which the power management system is incorporated.

[0046] The operating modes comprise any two or more, for example each or all, of a blackout mode, a visible light mode and an infrared mode. The blackout mode may correspond to a security mode in which a lighting system of the vehicle is disabled. The visible light mode may correspond to a security mode in which the lighting system emits visible light. The infrared mode may correspond to a security mode in which the lighting system emits infrared light but not visible light.

[0047] Additionally or alternatively, the operating modes may comprise a further operating mode, e.g. an emergency mode, which may correspond to an emergency mode of the vehicle. The processing means may be prevented from disabling the electric motor, e.g. automatically, in the further operating mode.

[0048] Another aspect provides a power management system for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; and processing means operatively connected to the current sensing means and configured to determine, in use, an operating condition based at least in part on the operating current; wherein the system comprises: a first operating mode in which the processing means is configured to disable the electric motor in response to the operating condition exceeding a threshold; and a second operating mode in which the processing means is prevented from disabling the electric motor in response to the operating condition exceeding the threshold.

[0049] The processing means may, in the second operating mode, be either: configured to disable the electric motor in response to the operating condition exceeding a second threshold, different from the first threshold; or prevented from disabling the electric motor in response to the operating condition exceeding the first or second threshold. Another aspect provides a power management system for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; and processing means operatively connected to the current sensing means and configured to determine, in use, an operating condition based at least in part on the operating current; wherein the system comprises: a first operating mode in which the processing means is configured to disable the electric motor in response to the operating condition exceeding a first threshold; and a second operating mode in which the processing means is either: configured to disable the electric motor in response to the operating condition exceeding a second threshold, different from the first threshold; or prevented from disabling the electric motor in response to the operating condition exceeding the first or second threshold.

[0050] The processing means may, in the second operating mode, be either: configured to control, in use, independently each of the first output means to disable the electric motor and the second output means to engage the brake, in response to the operating condition exceeding a second threshold, different from the first threshold; or prevented from disabling the electric motor in response to the operating condition exceeding the first or second threshold.

[0051] The processing means may be operable or configured, in the second or further operating mode, to generate an alarm or warning signal, which may but need not be sent to the input means or another device, for alerting a user if the operating condition exceeds the threshold, e.g. the first or second threshold. The processing means may be operable or configured, in the second or further operating mode, to generate an alarm orwarning signal, which may but need not be sent to the input means or another device, for alerting a user of an overload or overwork condition.

[0052] The alarm or warning signal may be configured or intended to prompt the user to disable the electric motor, e.g. via the input means. The warning or alarm may be provided by an indicator. The indicator may comprise one or more of a visual light indicator, an infrared light indicator and a vibratory indicator. The indicator may be included or incorporated on or in the input means.

[0053] Where the system comprises first and second output means, the processing means may be configured to control independently each of the first output means, e.g. to disable the electric motor, and the second output means, e.g. to engage the brake, in response to a determined operating current exceeding the first or second threshold.

[0054] The processing means may also be configured to control the second output means to engage the brake before controlling the first output means to disable the electric motor, in response to the operating condition exceeding the first or second threshold.

[0055] The system may comprise a data output means. The data output means may be operable or configured to provide a signal indicative of operating parameters, for example at least one of the operating current determined by the current sensing means, the operating condition and an alarm indicative of the operating condition exceeding the threshold. The data output means may enable the power management system to be queried for information stored on the memory.

[0056] The system may comprise a display. The display may be operatively connected to the data output means, e.g. for displaying one or more of the operating current determined by the current sensing means, the operating condition and an alarm indicative of the operating condition exceeding the threshold.

[0057] Another aspect provides a winch system for a vehicle. The winch system may comprise the aforementioned power management system.

[0058] Another aspect provides a vehicle comprising the aforementioned power management system or the aforementioned winch system.

[0059] Another aspect provides a method of managing power supplied to a winch for a vehicle. The method may comprise determining an operating current supplied to an electric motor of the winch, e.g. using a current sensing means. The method may comprise determining an operating condition, for example based at least in part on the operating current. The method may comprise disabling an electric motor of the winch, for example in response to the operating condition exceeding a threshold.

[0060] The method may comprise engaging a brake of the winch, for example independently and / or before disabling an electric motor and / or in response to the operating condition exceeding a threshold. The method may comprise operating the electric motor in a first direction, for example in response to a first command signal received by input means. The method may comprise operating the electric motor in a second direction, which may be opposite the first direction, e.g. in response to a second command signal received by the input means. The method may comprise determine the operating condition while the electric motor is operated in the first direction. The method may comprise disabling the electric motor in response to the operating condition exceeding a threshold and may comprise re-enabling the electric motor thereafter in response to receiving the second command signal.

[0061] The method may comprise operating the a power management system in a first operating mode or in a second operating mode. In the first operating mode, the processing means may be configured to disable the electric motor in response to the operating condition exceeding a first threshold. In the second operating mode, the processing means may be configured to disable the electric motor in response to the operating condition exceeding a second threshold, which may be different from the first threshold.

[0062] For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. For example, any of the systems may comprise one or more features described in relation to any of the other systems. Equally, any of the systems may comprise any one or more features of the method relevant thereto or vice versa.

[0063] A further aspect of the invention provides a computer program element comprising computer readable program code means for causing a processor to execute a procedure to implement one or more steps of the aforementioned method.

[0064] A yet further aspect of the invention provides the computer program element embodied on a computer readable medium.

[0065] A yet further aspect of the invention provides a computer readable medium having a program stored thereon, where the program is arranged to make a computer execute a procedure to implement one or more steps of the aforementioned method.

[0066] A yet further aspect of the invention provides a control means or control system or controller comprising the aforementioned computer program element or computer readable medium. For purposes of this disclosure, and notwithstanding the above, it is to be understood that any processing means, controller(s), control units and / or control modules described herein may each comprise a control unit or computational device having one or more electronic processors. The controller may comprise a single control unit or electronic controller or alternatively different functions of the control of the system or apparatus may be embodied in, or hosted in, different control units or controllers or control modules. As used herein, the terms “control unit” and “controller” will be understood to include both a single control unit or controller and a plurality of control units or controllers collectively operating to provide the required control functionality. A set of instructions could be provided which, when executed, cause said controller(s) or control unit(s) or control module(s) to implement the control techniques described herein (including the method(s) described herein). The set of instructions may be embedded in one or more electronic processors, or alternatively, may be provided as software to be executed by one or more electronic processor(s).

[0067] For example, a first controller may be implemented in software run on one or more electronic processors, and one or more other controllers may also be implemented in software run on or more electronic processors, optionally the same one or more processors as the first controller. It will be appreciated, however, that other arrangements are also useful, and therefore, the present invention is not intended to be limited to any particular arrangement. In any event, the set of instructions described herein may be embedded in a computer-readable storage medium (e.g., a non-transitory storage medium) that may comprise any mechanism for storing information in a form readable by a machine or electronic processors / computational device, including, without limitation: a magnetic storage medium; optical storage medium; magneto optical storage medium; read only memory (ROM); random access memory (RAM); erasable programmable memory (e.g., EPROM ad EEPROM); flash memory; or electrical or other types of medium for storing such information / instructions.

[0068] Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and / or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and / or features of any embodiment can be combined in any way and / or combination, unless such features are incompatible. For the avoidance of doubt, the terms “may”, “and / or”, “e.g.”, “for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so- described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and / or incorporate any feature of any other claim although not originally claimed in that manner.

[0069] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

[0070] Figure 1 is a circuit diagram illustrating one example of a power management system for a winch of a vehicle; and

[0071] Figure 2 is a schematic representation of the power management system if Figure 1 incorporated in a vehicle.

[0072] Referring now to Figure 1 , there is shown a vehicle 10 comprising a winch system 11 for winching a load L by selectively drawing and releasing a winch cable C around a drum D. The winch system 11 incorporates a power management system 1 for protecting the winch system 11 against overload. The power management system 1 , shown in more detail in Figure 2, includes a current sensor 2 and an overload protection module 3.

[0073] The winch system 11 is supplied with power by a battery 12, which itself is charged by an alternator 13 operatively connected thereto. The winch system 11 includes an electric motor 14 for rotating the drum D and a brake control device 17, such as a solenoid valve, for selectively releasing a normally engaged brake (not shown) of the winch system 11 . The electric motor 14 is operatively connected to the battery 12 by first and second power cables 15, 16. More specifically, the first power cable 15 is electrically connected to a first input 14a of the motor 14 by an isolation device 15a, for example a solenoid relay, for selectively causing the motor 14 to rotate in a first, winch IN direction. The second cable 16 is electrically connected to a second input 14b of the motor 14 by an isolation device 16a, for example as a solenoid relay, for selectively causing the motor 14 to rotate in a second, winch OUT direction.

[0074] It will be appreciated by those skilled in the art that the first and second power cables 15, 16 may be provided within a single cable or sheath. Similarly, the solenoid relays 15a and 16a may be included within one device. Indeed, the solenoid relays 15a, 16a may be replaced with any other suitable isolation device.

[0075] The winch system 11 also includes a winch controller 18 powered by a branch off of the battery 12 and alternator 13 circuit and is configured to receive command signals from a user (not shown). Specifically, the winch controller 18 includes a winch IN button 18a and a winch OUT button 18b. The winch IN button 18a selectively provides power, via the overload protection module 3, to the solenoid relay 15a of the first power cable 15. The winch IN button 18a also selectively provides power to the brake control solenoid valve 17. The winch OUT button 18b selectively provides power directly to the solenoid relay 16a of the second power cable 16 and to the brake control solenoid valve 17. The winch controller 18 is configured in the usual way, whereby only one of the buttons 18a, 18b may be depressed at any given time.

[0076] As such, under normal working conditions a user depressing the winch IN button 18a actuates the brake control solenoid valve 17 to release the brake and causes the solenoid relay 15a to close the connection between the battery 12 and the motor 14 through the first power cable 15, thereby to cause the motor 14 to rotate in the winch IN direction. Similarly, a user depressing the winch OUT button 18b actuates the brake control solenoid valve 17 to release the brake and causes the solenoid relay 16a to close the connection between the battery 12 and the motor 14 through the second power cable 16, thereby to cause the motor 14 to rotate in the winch OUT direction.

[0077] Turning now to the power management system 1 , the purpose of the overload protection module 3 is to detect an overload condition in the supply of electrical power to the motor 14 of the winch system 11 , and to stop the operation of the motor 14 if such a condition is detected. This is done to prevent damage to and / or failure of the motor 14, the winch cable C or any other part of the winch system 11 . The current sensor 2 in this example is a hall effect sensor with a toroid surrounding the power supply cables 15, 16 for determining an operating current supplied to the electric motor 14. The overload protection module 3 includes a control unit 4, a first output 5, a second output 6 and, in this example, a first voltage sensor 7, a second voltage sensor 8 and a third voltage sensor 9. The control unit 4 includes a processor 40 operatively connected to a memory 41 and to the current sensor 2, the first and second outputs 5, 6 and the first, second and third voltage sensors 7, 8, 9. The overload protection module 3 also includes a data output port 42 for providing signals indicative of operating parameters and through which the power management system 1 may be queried for any information stored on the memory 41 .

[0078] The first output 5 includes a solenoid relay 50 for selectively disabling the motor 14 by disconnecting power from the winch IN button 18a of the winch controller 18 to the solenoid relay 15a of the first power cable 15. The second output 6 includes a solenoid relay 60 for selectively engaging the brake by disconnecting power from the winch IN button 18a of the winch controller 18 to the brake control solenoid valve 17. As a result, the overload protection module 3 is able to control the brake control solenoid valve 17 independently of the motor 14.

[0079] The inventors have determined that this can improve the safety of the winch system 11 , whereby the brake can be engaged prior to cutting the power to the motor 14. This should prevent an uncontrolled release of a load L. It is also envisaged that the second output 6 may be provided as a variable output, which would enable greater control of the braking function of the winch system 11 .

[0080] The first voltage sensor 7 is operatively connected to the power supply cables 15, 16 for determining the voltage supplied to the electric motor 14. The second voltage sensor 8 is operatively connected to the cable supplying the solenoid relay 15a of the first power cable 15 for detecting the presence of a voltage supplied thereto. The third voltage sensor 9 is operatively connected to the cable supplying the solenoid relay 16a of the second power cable 16 for detecting the presence of a voltage supplied thereto.

[0081] In use, the solenoid relay 50 of the first output 5 and the solenoid relay 60 of the second output 6 are both closed in a closed condition. As such, when a user depresses the winch IN button 18a, the brake control solenoid valve 17 is actuated to release the brake and causes the solenoid relay 15a to close the connection between the battery 12 and the motor 14 through the first power cable 15, thereby to cause the motor 14 to rotate in the winch IN direction. In this state, the processor 40 determines the current supplied to the motor 14 using the current sensor 2 and determines the voltage supplied to the motor 14 using the first voltage sensor 7.

[0082] The processor 40 calculates an instantaneous operating condition, which is in the form of power supplied to the motor 14 in this example, using these values. This instantaneous operating condition is indicative of the torque provided by the drum D and therefore the towing force applied to the load L by the winch cable C. This instantaneous operating condition is compared with a threshold saved in the memory 41 to determine whether there is an overload condition. If the instantaneous operating condition exceeds the threshold, the overload protection module 3 is put into an overload protection mode.

[0083] In addition or alternatively, the processor 40 may calculate a predicted operating condition, which may be in the form of a predicted power supplied to the motor 14. The predicted current or power may be determined or calculated based upon a combination of the instantaneous power and its rate of change. In some cases, predicted current or power may be determined or calculated based upon a historical rate of change, which may but need not employ a machine learning algorithm. Other methods of forward estimating the operating condition are also envisaged and would be appreciated by the skilled person.

[0084] In the overload protection mode, the solenoid relay 60 of the second output 6 the winch IN button 18a of the winch controller 18 from the brake control solenoid valve 17, which disables the brake release function and causes the brake to engage. Shortly thereafter, the solenoid relay 50 of the first output 5 disables the motor 14 by disconnecting the winch IN button 18a from the solenoid relay 15a of the first power cable 15, which stops the motor 14 from rotating in the winch IN direction.

[0085] In this example, the overload protection module 3 is configured to remain in the overload protection mode until the winch OUT button 18b is operated to reverse the rotation of motor 14. Operation of the winch OUT button 18b is detected by the third voltage sensor 9 and resets the overload protection module 3, taking it out of the overload protection mode and re-enabling the winch IN function. It is believed that this, reverse operation of the motor 14 in the winch OUT direction should release at least some tension in the winch cable C, thereby to enable the user to remove any obstructions that may have caused the overload. In addition or as an alternative to this functionality, it is also envisaged that the overload protection module 3 may be configured to be reset after a predetermined time period has elapsed.

[0086] A further optional feature is that the calculated power is measured and recorded onto the memory 41 overtime, that it is converted to a cumulative operating condition, corresponding to a cumulative work value, and that this cumulative operating condition is compared with a second threshold indicative of and overwork condition. If the cumulative operating condition exceeds the second threshold, the overload protection module 3 may be put into an overwork protection mode. The overload protection module 3 may then be configured to remain in the overwork protection mode until a predetermined time has elapsed, which may be much longer than the predetermined time required to reset from the overload protection mode. In such examples, resetting of the overload protection module 3 using the winch OUT button 18b may be prevented. Other approaches are also envisaged.

[0087] In some cases, the power management system 1 may be incorporated in a winch system 11 of a military vehicle 10. In such applications, the military vehicle 10 may include a control system (not shown) having multiple modes, such as a blackout mode (e.g. in which all lights and electronic or electrical displays are disabled), an infrared mode (e.g. in which only lights that emit infrared light are enabled) and a visible light mode (e.g. in which visible lights are enabled). The power management system 1 may, in such applications, also include multiple modes.

[0088] For example, the power management system 1 may include a first, blackout operating mode and / or a second, infrared operating mode and / or a third, visible light operating modes. In the first operating mode, the processor 40 may be configured to disable the electric motor 14 in response to the instantaneous operating condition, the predicted operating condition or the cumulative operating condition exceeding a first threshold (or respective first threshold). In the second operating mode, the processor 40 may be configured to disable the electric motor 14 in response to the instantaneous, predicted or cumulative operating condition exceeding a second threshold (or respective second threshold), which may be different from, for example lower or higher than, the first threshold. In the third operating mode, the processor 40 may be configured to disable the electric motor 14 in response to the instantaneous operating condition or the cumulative operating condition exceeding a third threshold (or respective third threshold), which may be different from, for example lower or higher than, each of the first and second thresholds.

[0089] Additionally or alternatively, the power management system 1 may include an emergency mode, which may correspond to an emergency mode of the vehicle 10. In the emergency mode, the overload protection module 3 may be prevented from disabling the motor 14 automatically. More specifically, on detection of an overload or overwork condition the power management system 1 may provide a warning or alarm to a user and prompt the user to release the winch IN button 18a. The warning or alarm may be provided by one or more of a visual light indicator, an infrared light indicator and a vibratory indicator on the winch controller 18. In the case of a military vehicle 10, it may be beneficial for the warning or alarm to be provided by a vibratory indicator in case the vehicle 10 is to be operated in a blackout mode.

[0090] The data output port 42 in this example is configured to be connected to a display (not shown) for displaying one or more of the operating current determined by the current sensor 2, the voltage determined by the voltage sensor 7, the instantaneous and / or predicted and / or cumulative operating conditions and an alarm indicative of the overload protection module 3 being in an overload protection mode or an overwork protection mode. As mentioned above, the data output port 42 may also be used to query the power management system 1 for any information stored on the memory 41 , such as energy usage (e.g. based upon the cumulative operating condition) and / or previous alarms and / or maximum values.

[0091] The power management system 1 may also include a display (not shown) connected to the data output port 42.

[0092] It will be appreciated by those skilled in the art that several variations to the aforementioned embodiments are envisaged without departing from the scope of the invention.

[0093] It will also be appreciated by those skilled in the art that any number of combinations of the aforementioned features and / or those shown in the appended drawings provide clear advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1. CLAIMS1 . A power management system for a winch of a vehicle, the system comprising: current sensing means for determining an operating current supplied to an electric motor of the winch; input means for receiving command signals; and processing means operatively connected to the current sensing means and the input means; wherein the processing means is configured to: operate the electric motor in a first direction in response to a first command signal received by the input means and in a second direction, opposite the first direction, in response to a second command signal received by the input means; determine an operating condition based at least in part on the operating current while the electric motor is operated in the first direction; disable the electric motor in response to the operating condition exceeding a threshold; and re-enable the electric motor thereafter in response to receiving the second command signal.

2. The power management system of claim 1 , wherein the operating condition comprises an instantaneous or predicted current or power.

3. The power management system of claim 2 comprising voltage sensing means for determining an operating voltage supplied to the electric motor, wherein the processing means is configured to determine the operating condition based at least in part on the operating voltage and the operating current.

4. The power management system of claim 2 or claim 3, wherein the processing means is configured to re-enable the electric motor after a predetermined time following the electric motor being disabled in the absence of receiving the second command signal.

5. The power management system of any one of claims 2 to 4, wherein the processing means is configured to disable the electric motor in response to the operating condition exceeding the threshold for a predetermined period of time.

6. The power management system of any one of claims 2 to 5, wherein the processing means is configured to: determine an instantaneous operating condition based at least in part on the operating current; determine a predicted operating condition based at least in part on the operating current over a predetermined period of time; determine a cumulative operating condition based at least in part on the operating current over a predetermined period of time; and disable the electric motor in response to at least one of the instantaneous operating condition exceeding an instantaneous threshold, the predicted operating condition exceeding a predicted threshold or the cumulative operating condition exceeding a cumulative threshold.

7. The power management system of claim 6, wherein the processing means is configured to re-enable the electric motor in response to receiving the second command signal if the electric motor was disabled in response to the instantaneous operating condition exceeding the instantaneous threshold or in response to the predicted operating condition exceeding the predicted threshold but not if the electric motor was disabled in response to the cumulative operating condition exceeding the cumulative threshold.

8. The power management system of any one of claims 2 to 7, wherein the processing means is configured to selectively supply power to the electric motor, thereby to operate or disable the electric motor.

9. The power management system of any one of claims 2 to 8, wherein the processing means is configured to operate the electric motor continuously in response to a continuous command signal received by the input means, until the operating condition exceeds the threshold.

10. The power management system of any one of claims 2 to 9 comprising: first output means for selectively disabling the electric motor; and second output means for selectively engaging a brake of the winch;wherein the processing means is operatively connected to the first and second output means and is configured to control independently each of the first output means to disable the electric motor and the second output means to engage the brake, in response to the operating condition exceeding the threshold.11 . The power management system of any claim 10, wherein the processing means is configured to control the second output means to engage the brake before controlling the first output means to disable the electric motor, in response to the operating condition exceeding the threshold.

12. The power management system of any one of claims 2 to 11 comprising two or more operating modes each with different respective thresholds.

13. The power management system of any one of claims 2 to 12 comprising: a first operating mode in which the processing means is configured to disable the electric motor in response to the operating condition exceeding a first threshold; and a second operating mode in which the processing means is either: configured to disable the electric motor in response to the operating condition exceeding a second threshold, different from the first threshold; or prevented from disabling the electric motor in response to the operating condition exceeding the first or second threshold.

14. The power management system of claim 14, wherein the processing means is prevented, in the second operating mode, from disabling the electric motor, but is configured to generate and send to the input means an alarm signal if the operating condition exceeds the first or second threshold, thereby to prompt the user to disable the electric motor via the input means.

15. The power management system of any one of claims 12 to 14, wherein the operating modes correspond to security modes of a vehicle within which the power management system is incorporated.

16. The power management system of claim 14, wherein the operating modes comprise any two or more of a blackout mode, corresponding to a security mode in which alighting system of the vehicle is disabled, a visible light mode, corresponding to a security mode in which the lighting system emits visible light, an infrared mode, corresponding to a security mode in which the lighting system emits infrared light but not visible light and an emergency mode.

17. The power management system of any preceding claim comprising a data output means configured to provide a signal indicative of at least one of the operating current determined by the current sensing means, the operating condition and an alarm indicative of the operating condition exceeding the threshold.

18. The power management system of claim 17 comprising a display operatively connected to the data output means for displaying one or more of the operating current determined by the current sensing means, the operating condition and an alarm indicative of the operating condition exceeding the threshold.

19. A winch system for a vehicle, the system comprising the power management system of any preceding claim.

20. A vehicle comprising the power management system of any one of claims 1 to 18 or the winch system of claim 19.

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