MOTOR VEHICLE BATTERY DISCONNECT SWITCH CIRCUITS

• US 20050001587A1
• Filed: 07/01/2003
• Published: 01/06/2005
• Est. Priority Date: 07/01/2003
• Status: Active Grant

• Current Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Original Assignee: International Truck Intellectual Property Co. LLC (Volkswagen AG)
• Inventors: Bender, Burnell L.
• Granted Patent: US 6,836,094 B1
• Time in Patent Office: Days
• US Class Current: 320/116
• CPC Class Codes: B60R 16/03 for supply of electrical power to vehicle subsystems or for circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: F02N 11/0862 characterised by the electrical power supply means, e.g. battery
• CPC Class Codes: H02J 2310/46 for ICE-powered road vehicles
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence

Abstract

A disconnect switch (30, 30SA) is placed in circuit between a battery bank (12) and a distribution point (30B) for the entire electrical system load except the engine cranking motor (24). This allows the circuit between the battery bank and a cranking motor solenoid (22) that operates the cranking motor to be switch-free. A switch-free circuit allows a continuous cable to connect the battery bank to the cranking motor solenoid, significantly reducing the electrical resistance between the battery bank and the cranking motor solenoid.

Claims

1. An engine-powered land vehicle comprising:

a chassis comprising an engine and a drivetrain through which the engine propels the vehicle on land;

a body disposed on the chassis and comprising a driver'"'"'s compartment for a driver of the vehicle;

a battery bank comprising one or more D.C. storage batteries;

an electric cranking motor that draws current from the battery bank to crank the engine at starting when a cranking motor solenoid is energized;

a main control switch that can be placed selectively in any one of multiple positions by the driver to selectively control the delivery of current from the battery bank to multiple circuit protection devices for distributing current to individual circuits in the vehicle, including a cranking motor solenoid circuit through which the cranking motor solenoid is energized;

a disconnect switch in circuit between the battery bank and the multiple circuit protection devices for selectively connecting and disconnecting the multiple circuit protection devices to and from the battery bank; and

a switch-free electric circuit for providing continuity between the battery bank and a terminal of the cranking motor solenoid, both when the disconnect switch is connecting the multiple circuit protection devices to the battery bank and when the disconnect switch is disconnecting the multiple circuit protection devices from the battery bank, for carrying current from the battery bank to a terminal of the cranking motor solenoid that is connected through a closed contact in the solenoid to the cranking motor when the cranking motor solenoid circuit is energizing a coil in the cranking motor solenoid that is forcing the contact in the solenoid closed.

2. A vehicle as set forth in claim 1 in which the disconnect switch is disposed within the driver'"'"'s compartment for manual operation by the driver.

3. A vehicle as set forth in claim 2 in which the disconnect switch comprises an actuator that turns about an axis to respective positions for connecting and disconnecting the multiple circuit protection devices to and from the battery bank.

4. A vehicle as set forth in claim 3 in which the actuator comprises a lock that can be placed in a locking condition to prevent disconnect switch operation out of the position disconnecting the multiple circuit protection devices from the battery bank.

5. A vehicle as set forth in claim 1 in which the disconnect switch comprises an electric actuator for operating the disconnect switch from the position disconnecting the multiple circuit protection devices from the battery bank to the position connecting the multiple circuit protection devices to the battery bank, and in which the vehicle comprises a further switch that is operable by the driver for operating the electric actuator.

6. A vehicle as set forth in claim 5 in which the further switch comprises a momentary-contact, spring-return switch.

7. A vehicle as set forth in claim 6 in which the further switch is disposed within the driver'"'"'s compartment.

8. A vehicle as set forth in claim 7 in which the main control switch can be placed selectively in an OFF position for preventing the delivery of current from the battery bank to the multiple circuit protection devices, an ACCESSORY position for allowing delivery of current from the battery bank to circuits of a first group of the individual circuits to which group current is distributed through a first group of the circuit protection devices, and an IGNITION position for allowing delivery of current from the battery bank to circuits of the first group of the individual circuits and also to a second group of the individual circuits to which second group current is distributed through a second group of the circuit protection devices,

in which operation of the momentary-contact, spring-return switch, while the main control switch is in ACCESSORY position and the disconnect switch is in the position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and one of the circuits in the first group of circuits comprises a sealing circuit to the electric actuator for sealing the electric actuator energized upon release of the momentary-contact, spring-return switch,

in which operation of the momentary-contact, spring-return switch, when the main control switch is in IGNITION position and the disconnect switch is in position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and one of the circuits in the second group of circuits comprises a sealing circuit to the electric actuator for sealing the electric actuator energized upon release of the momentary-contact, spring-return switch, and

including a diode network for preventing a back-feed from each sealing circuit to the other sealing circuit.

9. A vehicle as set forth in claim 8 in which the main control switch, after having been placed in the IGNITION position, can be placed in a START position for energizing the cranking motor solenoid without interruption of delivery of current from the battery bank to the second group of the individual circuits to which current is distributed through the second group of the circuit protection devices, but with interruption of delivery of current from the battery bank to the first group of the individual circuits to which current is distributed through the first group of the circuit protection devices.

10. A vehicle as set forth in claim 6 further including an electrical component that monitors battery bank voltage to distinguish a range of higher battery bank voltages from a range of lower voltages by producing a voltage output at an output terminal when battery bank voltage is in the higher range and not producing the voltage output when battery bank voltage is in the lower range, and a sealing switch connected in circuit between the output terminal and the electric actuator, and

in which operation of the momentary-contact, spring-return switch while the disconnect switch is in the position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and upon release of the momentary-contact, spring-return switch, the coincidence of battery bank voltage in the higher range and the sealing switch being closed, seals the electric actuator energized until either battery bank voltage enters the lower range or the sealing switch opens.

11. A vehicle as set forth in claim 1 in which the vehicle comprises a tractor for hauling a trailer, the body comprises a truck cab mounted on the chassis rearward of an engine compartment that houses the engine, the battery bank, the cranking motor, and the cranking motor solenoid, and the disconnect switch is disposed within the truck cab.

12. A vehicle as set forth in claim 11 in which the disconnect switch is mounted on an instrument panel of the truck cab and comprises an actuator disposed for manual operation by the driver.

13. A vehicle as set forth in claim 12 in which the disconnect switch actuator turns about an axis to respective positions for connecting and disconnecting the multiple circuit protection devices to and from the battery bank.

14. A vehicle as set forth in claim 13 in which the disconnect switch actuator comprises a lock that can be placed in a locking condition to prevent disconnect switch operation out of the position disconnecting the multiple circuit protection devices from the battery bank.

15. A vehicle as set forth in claim 1 in which the vehicle comprises a tractor for hauling a trailer, the body comprises a truck cab mounted on the chassis rearward of an engine compartment that houses the engine, the battery bank, the cranking motor, and the cranking motor solenoid, the disconnect switch comprises an electric actuator for operating the disconnect switch from the position disconnecting the multiple circuit protection devices from the battery bank to the position connecting the multiple circuit protection devices to the battery bank, and including a further switch that is disposed within the truck cab for actuation by the driver to operate the electric actuator.

16. A vehicle as set forth in claim 15 in which the further switch comprises a momentary-contact, spring-return switch.

17. A vehicle as set forth in claim 16 in which the main control switch can be placed selectively in an OFF position for preventing the delivery of current from the battery bank to the multiple circuit protection devices, an ACCESSORY position for allowing delivery of current from the battery bank to circuits of a first group of the individual circuits to which group current is distributed through a first group of the circuit protection devices, and an IGNITION position for allowing delivery of current from the battery bank to circuits of the first group of the individual circuits and also to a second group of the individual circuits to which second group current is distributed through a second group of the circuit protection devices,

in which operation of the momentary-contact, spring-return switch, while the main control switch is in ACCESSORY position and the disconnect switch is in the position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and one of the circuits in the first group of circuits comprises a sealing circuit to the electric actuator for seating the electric actuator energized upon release of the momentary-contact, spring-return switch,

in which operation of the momentary-contact, spring-return switch, when the main control switch is in IGNITION position and the disconnect switch is in position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and one of the circuits in the second group of circuits comprises a sealing circuit to the electric actuatol for sealing the electric actuator energized upon release of the momentary-contact, spring-return switch, and

including a diode network for preventing a back-feed from each sealing circuit to the other sealing circuit.

18. A vehicle as set forth in claim 17 in which the main control switch, after having been placed in the IGNITION position, can be placed in a START position for energizing the cranking motor solenoid without interruption of delivery of current from the battery bank to the second group of the individual circuits to which current is distributed through the second group of the circuit protection devices, but with interruption of delivery of current from the battery bank to the first group of the individual circuits to which current is distributed through the first group of the circuit protection devices.

19. A vehicle as set forth in claim 16 further including an electrical component that monitors battery bank voltage to distinguish a range of higher battery bank voltages from a range of lower voltages by producing a voltage output at an output terminal when battery bank voltage is in the higher range and not producing the voltage output when battery bank voltage is in the lower range, and a sealing switch connected in circuit between the output terminal and the electric actuator, and

in which operation of the momentary-contact, spring-return switch while the disconnect switch is in the position disconnecting the multiple circuit protection devices from the battery bank, energizes the electric actuator to cause the disconnect switch to operate to the position connecting the multiple circuit protection devices to the battery bank, and upon release of the momentary-contact, spring-return switch, the coincidence of battery bank voltage in the higher range and the sealing switch being closed, seals the electric actuator energized until either battery bank voltage enters the lower range or the sealing switch opens.

20. An electrical system in an engine-powered land vehicle comprising:

a battery bank comprising one or more D.C. storage batteries;

an electric cranking motor that draws current from the battery bank to crank the engine at starting when a cranking motor solenoid is energized;

a disconnect switch in circuit between the battery bank and a distribution point for the entire electrical system load except the engine cranking motor for selectively connecting and disconnecting the entire electrical system load except the engine cranking motor to and from the battery bank; and

a switch-free electric circuit for providing continuity between the battery bank and the cranking motor solenoid independent of the disconnect switch and for carrying current for operating the cranking motor.

21. An electrical system as set forth in claim 20 in which the switch-free electric circuit comprises a length of continuous conductor cable having a terminal at one end fastened to the battery bank and a terminal at another end fastened to a terminal of the cranking motor solenoid.

22. An electrical system as set forth in claim 21 in which the disconnect switch comprises a manual actuator.

23. An electrical system as set forth in claim 22 in which the actuator comprises a lock that can be placed in a locking condition to lock the disconnect switch in position disconnecting the entire electrical system load except the engine cranking motor from the battery bank.

24. An electrical system as set forth in claim 21 in which the disconnect switch comprises an electric actuator for operating the disconnect switch from the position disconnecting the entire electrical system load except the engine cranking motor from the battery bank to the position connecting the entire electrical system load except the engine cranking motor to the battery bank, and a further switch for operating the electric actuator.

25. An electrical system in an engine-powered land vehicle comprising:

a battery bank comprising one or more D.C. storage batteries;

an electric cranking motor that draws current from the battery bank to crank the engine at starting when a cranking motor solenoid is energized;

a disconnect switch in circuit between the battery bank and a main distribution point through which current is delivered from the battery bank to all electrical devices in the electrical system except the cranking motor and a normally open switch that, when operated closed, energizes a solenoid coil that operates the disconnect switch from an OFF position disconnecting all the devices except the cranking motor and the normally open switch from the battery bank to an ON position connecting all the devices except the cranking motor and the normally open switch to the battery bank; and

a switch-free electric circuit that provides continuity between the battery bank and the cranking motor solenoid and that carries current for operating the cranking motor and current for energizing the solenoid coil that operates the disconnect switch from OFF position to ON position when the normally open switch is operated closed.

26. An electrical system as set forth in claim 25 in which the normally open switch comprises a bias spring biasing the switch to normally open.

27. An electrical system as set forth in claim 25 in which a circuit that carries current that has passed through the main distribution point once the disconnect switch has assumed its ON position seals the solenoid coil that operates the disconnect switch from OFF position to ON position energized.

28. An electrical system as set forth in claim 27 in which the circuit that seals the solenoid coil that operates the disconnect switch from OFF position to ON position is opened by operation of a main control switch shutting off the engine, thereby unsealing the sealed solenoid coil concurrent with shutting off the engine.

29. An electrical system as set forth in claim 27 in which the circuit that seals the solenoid coil that operates the disconnect switch from OFF position to ON position is opened to unseal the solenoid coil either by opening of a sealing switch or by battery bank voltage falling below a predetermined voltage.

30. An electrical system as set forth in claim 29 in which the circuit that seals the solenoid coil that operates the disconnect switch from OFF position to ON position is unaffected by operation of a main control switch shutting off the engine.

31. A method for avoiding draining a battery bank of one or more storage batteries in an engine-powered land vehicle to a point where the battery bank is incapable of operating an electric cranking motor to crank the engine at starting while providing a switch-free path for current flow from the battery bank to the cranking motor during engine cranking:

placing a disconnect switch that can be operated to respective ON and OFF positions in circuit between the battery bank and multiple circuit protection devices that distribute current to individual circuits in the vehicle, including a cranking motor solenoid circuit through which a cranking motor solenoid is energized to connect the cranking motor to the battery bank for operating the cranking motor to crank the engine at starting, so that the circuit protection devices are connected to the battery bank when the disconnect switch is in ON position and disconnected from the battery bank when the disconnect switch is in OFF position; and

connecting the cranking motor solenoid to the battery bank through a switch-free current path for delivering cranking current from the battery bank to the cranking motor via the solenoid when the disconnect switch is in ON position and the cranking motor solenoid is being energized by the cranking motor solenoid circuit.