Relay Controller Power Management for Quiescent Draw Reduction

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Solution Overview

Problem

Multiple electronic controllers in machines lead to significant quiescent power draw, depleting batteries when the engine is off and making it difficult to start the machine.

Innovation Solution

A relay controller is used to manage power distribution by disconnecting electronic controllers from the power source through a main power relay and a low current mode relay, reducing power draw by switching to a low current mode when the engine is off or during automatic shutdown.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple electronic controllers are used to provide precise control to various systems, then control precision and system functionality are improved, but quiescent power draw increases significantly

Engineering Contradiction:

Improvecontrol precisionVSAvoidquiescent power draw

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

The patent segments the power supply to electronic controllers by introducing multiple relays (main power relay, low current mode relay, and individual controller relays) that can independently control power delivery to each controller. This allows the system to divide power distribution into different modes (full power, low current, or completely off) based on operational needs, thereby reducing quiescent power draw while maintaining control precision when needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system dynamically adjusts power delivery to electronic controllers based on real-time operational conditions. The relay controller receives status signals from electronic controllers and automatically switches between different power states (key-on, key-off, sleep modes) without manual intervention. This dynamic power management ensures controllers receive full power during operation and minimal or no power during idle periods, resolving the contradiction between maintaining control capability and reducing power consumption.

Inventive Principle:

Principle #15Dynamics

2Speed

If electronic controllers remain powered during key-off to maintain readiness, then system responsiveness is improved, but battery life is reduced

Engineering Contradiction:

Improvesystem responsivenessVSAvoidbattery life

Core Design Contradiction:

SpeedVSDuration of action of moving object

Solution Approach 1:

The system performs preliminary actions by maintaining a minimal power state through the low current mode relay during key-off conditions, allowing electronic controllers to remain in a low-power sleep mode rather than completely shutting down. This preliminary power maintenance enables faster wake-up and system responsiveness when the key is turned on, while still significantly extending battery life compared to full power operation. The relay controller pre-configures the power state based on anticipated operational needs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the power supply parameters to electronic controllers by switching between different voltage and current states using multiple relays. During key-off, the system transitions controllers from full power mode to low current mode or complete power cutoff, adjusting electrical parameters dynamically. This parameter change allows the system to balance between maintaining minimal responsiveness and preserving battery charge, resolving the contradiction between system readiness and battery life.

Inventive Principle:

Principle #35Parameter changes

3Use of energy by moving object

If all electronic controllers are disconnected from power to reduce quiescent draw, then power consumption is reduced, but system reliability during startup may be compromised

Engineering Contradiction:

Improvepower consumptionVSAvoidsystem reliability

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The relay controller serves as an intermediary between the power source and electronic controllers, intelligently managing power distribution based on system needs. During key-off periods, it selectively disconnects power to minimize quiescent draw while maintaining the capability to rapidly restore power to all controllers when startup is required. The relay controller monitors system status and ensures that critical controllers receive power in the correct sequence during startup, thereby maintaining system reliability while achieving significant power reduction during idle periods.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system implements periodic power cycling through the relay controller, which rhythmically switches power states based on operational cycles (key-on, key-off, sleep, wake). During normal operation, controllers receive full power; during idle periods, power is reduced or cut off periodically. This periodic action pattern allows the system to achieve low average power consumption while ensuring controllers are fully powered and reliable when actually needed, resolving the contradiction between power reduction and system reliability.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS7977813B2System and method for reducing quiescent power draw and machine using same

Publication Date: 2011.07.12 CUMMINS TURBO TECH

AI summary

A machine includes a plurality of electronic controllers electrically connected to an electrical power source along a first electrical circuit through a first relay and along a second electrical circuit through a second relay. A relay controller is directly connected to the electrical power source along a third electrical circuit, and is in communication with the first relay and the second relay. The relay controller is configured to open or close the first relay or the second relay in response to a power requirement indication.