Integrated overload and low voltage interrupt module

• US 8,076,885 B2
• Filed: 05/15/2008
• Issued: 12/13/2011
• Est. Priority Date: 05/15/2008
• Status: Active Grant

• Current Assignee: Warn Industries Incorporated (LKQ Corporation)
• Original Assignee: Warn Industries Incorporated (LKQ Corporation)
• Inventors: Heravi, Oliver, Clohessy, Kip E., Ewer, Fred L.
• Primary Examiner(s): Benson, Walter
• Assistant Examiner(s): Paul, Antony M
• Application Number:
  US12/121,244
• Publication Number:
  US 20090284877A1
• Time in Patent Office: 1,307 Days
• Field of Search: 318/280, 318/433, 318/434, 318/783, 318/800, 318/400.38, 180/7.5, 180/65.1, 198/320, 242/903, 172/12, 172/103, 100/346, 100/147, 310/49.02, 335/40, 320/128, 320/134, 320/136, 320/152, 320/156, 320/164, 320/165, 212/323
• US Class Current: 318/434
• CPC Class Codes: B66D 1/58 responsive to excess of load
• CPC Class Codes: H02H 7/085 against excessive load H02H6/00 takes precedence
• CPC Class Codes: H02H 7/0855 avoiding response to transient overloads, e.g. during starting
• CPC Class Codes: H02H 7/09 against over-voltage; against reduction of voltage; against phase interruption
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence

Abstract

A power management module for a winch system comprises an overload and low voltage interrupt module within a housing. The overload interrupt determines operating current for the winch system and provides an interrupt signal when the current is greater than a threshold. The low voltage interrupt determines voltage of a power source and provides an interrupt signal when the voltage is less than a threshold. A method of operating the power management module comprises determining operating current of the winch system with an overload interrupt module and voltage of a vehicle power source with a low voltage interrupt module. The overload and low voltage interrupt modules are located within a housing. The overload interrupt provides an interrupt signal when the operating current is greater than a threshold. The low voltage interrupt provides an interrupt signal when the voltage is less than a threshold.

Claims

1. A power management module for an electrical winch system of a vehicle, the power management module comprising:

an overload interrupt module that determines an operating current of the winch system and that provides a first interrupt signal when said current is greater than a threshold current, wherein said overload interrupt module includes a toroid that, to detect said operating current, encircles a wire that provides said operating current from a power source of said vehicle;

a low voltage interrupt module that determines a voltage of said power source and that provides a second interrupt signal when said voltage is less than a threshold voltage; and

a housing, wherein each of said overload interrupt module, said toroid, and said low voltage interrupt module are located within said housing;

a printed circuit board (PCB) located within said housing, wherein;

said PCB includes said low voltage interrupt module; and

said PCB has an annular shape and encircles said wire; and

a Hall Effect sensor that generates an output voltage indicative of said operating current, wherein;

said toroid includes an air gap; and

said Hall Effect sensor is located on said PCB within said air gap.

2. The power management module of claim 1 wherein a relay module interrupts said operating current based on at least one of said first interrupt signal and said second interrupt signal.

3. The power management module of claim 1 further comprising an indicator that indicates one or more states associated with the power management module.

4. The power management module of claim 3 wherein said indicator includes at least one light emitting diode (LED).

5. The power management module of claim 4 wherein said LED is located within said housing and said housing includes an aperture that is located based on said LED.

6. The power management module of claim 1, wherein said housing has a toroid shape and encircles said wire.

7. A method of operating a power management module for an electrical winch system of a vehicle, the method comprising:

determining an operating current of the winch system with an overload interrupt module;

providing a first interrupt signal when said operating current is greater than a threshold current;

determining a voltage of a power source with a low voltage interrupt module;

providing a second interrupt signal when said voltage is less than a threshold voltage;

locating each of said overload interrupt module and said low voltage interrupt module within a housing;

detecting said operating current of the winch system with a toroid; and

encircling a wire with said toroid, said wire providing said operating current from a power source of the vehicle;

locating a printed circuit board (PCB) having an annular shape within said housing;

arranging said low voltage interrupt module on said PCB;

encircling said wire with said PCB;

locating a Hall Effect sensor on said PCB within an air gap of said toroid; and

using said Hall Effect sensor, generating an output voltage indicative of said operating current.

8. The method of claim 7 further comprising:

interrupting said operating current with a relay module based on at least one of said first interrupt signal and said second interrupt signal.

9. The method of claim 7 further comprising:

indicating one or more states associated with the power management module.

10. The method of claim 9 wherein said indicating includes indicating with at least one light emitting diode (LED).

11. The method of claim 10 wherein said LED is located within said housing and said housing includes an aperture based on said LED.

12. The method of claim 7, wherein said toroid is located within said housing.

13. The method of claim 7, wherein said housing has a toroid shape and encircles said wire.