Power management assembly

• US 6,642,633 B1
• Filed: 06/27/2001
• Issued: 11/04/2003
• Est. Priority Date: 06/27/2001
• Status: Expired due to Fees

• Current Assignee: Yazaki North America Incorporated (Yazaki Corporation)
• Original Assignee: Yazaki North America Incorporated (Yazaki Corporation)
• Inventors: Yang, Shenghua
• Primary Examiner(s): Toatley, Jr., Gregory J.
• Assistant Examiner(s): DeBeradinis, Robert L
• Application Number:
  US09/891,519
• Time in Patent Office: 860 Days
• Field of Search: 307/18, 307/9.1, 307/10.1, 307/10.6, 307/10.8, 307/48, 307/147
• US Class Current: 307/147
• CPC Class Codes: H01R 9/226 comprising a plurality of conductive flat strips providing connection between wires or components H01R9/2425 takes precedence
• CPC Class Codes: Y02E 60/10 Energy storage using batteries

Abstract

A power management system comprises a busboard for selectively managing the power from a forty-two volt source and a fourteen volt source in a vehicle dual voltage electrical system. The busboard has a lower plate with recesses for receiving variously configured busbars. The busbars have upright terminals for electrical connection with the voltage sources. The power from the voltage sources is directed along the busbars to other terminals extending at assorted locations from the busboard. An upper cover fits over the lower plate and covers the recesses. The upper cover has an area accommodating the forty-two volt source and housings for partially enclosing the other terminals. One of the housings forms a forty-two volt jump start post. Another of the housings forms a fourteen volt jump start post. The terminal in the fourteen volt jump start post is connected through a DC/DC converter to the forty-two volt source so power from a vehicle having a fourteen volt electrical system can be converted to forty-two volts and used to charge the dual voltage system. A relay mounted on the busboard is actuated to provide power to a vehicle starter when the batteries are charged. An additional housing provides a connection port for electrically connecting the busboard to a vehicle alternator. Two further terminals on the busboard enable connection of forty-two volt power and fourteen volt power to a junction box requiring each of the separate voltages for serving different sets of electrical components.

Claims

1. A power management assembly comprising:

a first power source for supplying power at a first voltage and a second power source for providing power at a second, higher voltage;

a junction box for distributing power to a first set of electrical components and a second set of electrical components;

a busboard for electrically connecting the junction box to the first power source for providing power at the first voltage to the first set of electrical components and electrically connecting the junction box to the second power source for providing power at the second voltage to the second set of electrical components, the busboard comprising a plurality of busbars mounted on a single plate, the busbars having terminals through which the first and second power sources and the junction box are directly, electrically connected to the busboard; and

means for supporting the first power source, second power source and junction box on the busboard to provide a compact assembly.

2. The power management assembly of claim 1 wherein each busbar receives power from the first or second power source at the first or second voltage and directs the power to at least one output terminal.

3. The power management assembly of claim 2 wherein the junction box has a first bus for distributing power to the first set of electrical components and a second bus for distributing power to the second set of electrical components, the first bus being electrically connected to a terminal of the busboard busbar to which the first voltage has been directed and the second bus being electrically connected to a terminal of the busboard busbar to which the second voltage has been directed.

4. The power management assembly of claim 1 wherein a DC/DC converter is mounted on the second power source and is electrically connected to the first and second power sources through the busboard to connect the first and second voltages to the junction box.

5. The power management assembly of claim 1 wherein the second power source comprises three batteries electrically connected together in series through the busboard.

6. The power management assembly of claim 5 wherein the first power source comprises a fourth, separate battery electrically connected to the busboard.

7. The power management assembly of claim 1 wherein the busboard further comprises a pair of terminals, one of the terminals of the pair being electrically connected with the second voltage and the other of the terminals of the pair adapted to be electrically connected with a vehicle starter.

8. The power management assembly of claim 1 further comprising a jump start housing directly extending from the busboard and allowing access to a terminal of a busbar electrically connected to the first voltage source and a second terminal adapted to be electrically connected to a vehicle starter.

9. A power management assembly comprising:

means for supplying power at a first voltage and a second, higher voltage;

a junction box for distributing power to a first set of electrical components and a second set of electrical components;

a busboard for electrically connecting the junction box to the power supply means for providing power at the first voltage to the first set of electrical components and providing power at the second voltage to the second set of electrical components, the junction box and power supply means being supported on the busboard, the busboard having a section for housing a jump start terminal extending from the busboard, the busboard further including a pair of terminals, one of the terminals of the pair being electrically connected with the second voltage and the other of the terminals of the pair adapted to be electrically connected with a vehicle starter; and

a DC/DC converter supported on the power supply means and electrically connected between the jump start terminal of the busboard and the power supply means, wherein lower voltage provided to the jump start terminal is converted to the second, higher voltage to charge the power supply means.

10. The power management assembly of claim 9 further comprising a case for enclosing the busboard, junction box, power supply means and DC/DC converter, whereby the entire assembly system is compact and positionable in a single location.

11. The power management assembly of claim 9 further comprising a control module connected to a relay, the relay mounted on the busboard in electrical connection with the power supply means and adapted to be electrically connected with a vehicle starter, the control module being connected to the converter and operable to actuate the relay to power the starter when enough energy is stored in the power supply means.

12. The power management assembly of claim 9 wherein the busboard has connection means adapted for electrically connecting the power supply means with a vehicle alternator.

13. The power management assembly of claim 12 wherein the DC/DC converter is also electrically connected between the alternator connection means and the power supply means.

14. A busboard providing power management for a dual voltage electrical system, the busboard comprising:

an electrically non-conductive bottom plate having recesses;

a plurality of busbars for being laid into the recesses of the plate;

terminals attached to the busbars, each terminal extending at an angle from the busbars for direct electrical connection to first and second voltage sources of the dual voltage electrical system;

an upper cover for covering the recesses, the upper cover having an area for accommodating the first voltage source of the dual voltage electrical system immediately adjacent the busboard as it electrically engages some of the busbar terminals; and

a jump start housing extending from the upper cover and allowing access to a terminal of a busbar electrically connected to the first voltage source and a second terminal adapted to be electrically connected to a vehicle starter.

15. The busboard of claim 14 further comprising a relay mounted on the busboard, the relay having a first side electrically connected to a terminal of a busbar electrically engaged with the first voltage source and a second side adapted to be electrically connected with a vehicle starter.

16. The busboard of claim 14 wherein the jump start housing is configured to permit access to the terminals by a jump start connector in only one orientation, whereby incorrect connection is prevented.

17. The busboard of claim 14 further comprising a DC/DC converter electrically connected to the dual voltage electrical system through the busboard.

18. The busboard of claim 17 further comprising a second jump start housing extending from the upper cover and allowing access to a terminal electrically connected through the DC/DC converter to the dual voltage electrical system.

19. The busboard of claim 14 wherein one of the plurality of busbars has a terminal for electrically connecting the first voltage source with a junction box attached to the busboard, and another of the plurality of busbars has a terminal for electrically connecting a second voltage source of the dual voltage electrical system with the junction box.

20. The busboard of claim 14 wherein the first voltage source comprises multiple batteries connected in series by the positions of the engaging terminals.