Input Output Device for Vehicle Controllers Reducing Connector Size
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Solution Overview
Problem
The size and weight of connectors in vehicle controllers are excessive, limiting design freedom and increasing costs, particularly in high-voltage battery applications like electric vehicles and fuel cell vehicles, due to the large number of components required.
Innovation Solution
An input/output device with an integrated circuit that selectively determines the communication target between a limit switch and a sensor using two input/output terminals, minimizing the number of necessary parts and terminals by activating only the required circuits based on measured voltage values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large number of connectors are used to connect high-voltage electrical components, then the electrical connection capability is improved, but the number of components increases, the price increases, and the controller package size increases
Solution Approach 1:
The input/output device is designed to support multiple communication modes (CAN, LIN, FlexRay) and can adapt to different communication targets (limit switch or sensor) through integrated circuit switching. This multi-functionality allows a single device to replace what would traditionally require multiple specialized connectors and components, thereby reducing the total number of components while maintaining comprehensive electrical connection capability.
2Reliability
If the size of the connector is increased to accommodate more components, then the electrical connection capability is improved, but the weight increases and the degree of freedom in designing the controller package is reduced
Solution Approach 1:
The patent combines multiple functional circuits (limit switch forward signal input circuit, limit switch backward signal input circuit, sensor power generation circuit, and sensing signal input circuit) into a single integrated input/output device. This merging of functions into one compact unit reduces the overall connector size and weight while maintaining all necessary electrical connection capabilities for both limit switches and sensors.
3Reliability
If the number of parts such as housing and terminal in the connector is increased, then the electrical connection capability is improved, but the manufacturing cost increases
Solution Approach 1:
The input/output device is designed as a universal interface that can communicate with both limit switches and sensors using the same physical connector and circuitry. The integrated circuit selectively activates appropriate signal processing paths based on the communication target, eliminating the need for separate dedicated connectors for each device type. This universality reduces the total number of parts required (housing, terminals, etc.) while maintaining full electrical connection capability, thereby reducing manufacturing costs.
Data Source
AI summary
Proposed are an input/output device and a control method for the same, the device including a first input/output terminal that receives a forward signal from a limit switch or outputs power to a sensor; a second input/output terminal that receives a backward signal from the limit switch or receives a sensing signal from the sensor; and an integrated circuit unit that determines a communication target for exchanging a signal through the first input/output terminal and the second input/output terminal, and selectively receives or outputs the forward signal, the backward signal, the power of the sensor and the sensing signal based on the determination result.