Intelligent battery disconnect

• US 9,156,356 B2
• Filed: 02/08/2012
• Issued: 10/13/2015
• Est. Priority Date: 02/08/2012
• Status: Active Grant

• Current Assignee: GTR Development LLC
• Original Assignee: GTR Development LLC
• Inventors: Rini, Guy T., Groeller, Charles J., Henningson, Dale B.
• Primary Examiner(s): Fureman, Jared
• Assistant Examiner(s): Pham, Duc M
• Application Number:
  US13/368,409
• Publication Number:
  US 20130200690A1
• Time in Patent Office: 1,343 Days
• Field of Search: 307/10.7
• US Class Current: 1/1
• CPC Class Codes: B60L 1/00 Supplying electric power to auxiliary equipment of vehicles circuit arrangements for charging batteries H02J7/00
• CPC Class Codes: B60L 2200/26 Rail vehicles
• CPC Class Codes: B60L 3/0007 Measures or means for preventing or attenuating collisions
• CPC Class Codes: B60L 3/0046 relating to electric energy storage systems, e.g. batteries or capacitors
• CPC Class Codes: B60L 3/04 Cutting off the power supply under fault conditions protective devices and circuit arrangements in general H01H; H02H
• CPC Class Codes: B60L 50/53 in combination with an external power supply, e.g. from overhead contact lines
• CPC Class Codes: B60L 50/60 using power supplied by batteries in combination with fuel cells B60L50/75
• CPC Class Codes: B60L 58/14 Preventing excessive discharging
• CPC Class Codes: B60L 58/15 Preventing overcharging
• CPC Class Codes: B60L 58/16 responding to battery ageing, e.g. to the number of charging cycles or the state of health [SoH]
• CPC Class Codes: B60L 58/18 of two or more battery modules
• CPC Class Codes: B60L 58/22 Balancing the charge of battery modules
• CPC Class Codes: H02J 2310/48 for electric vehicles [EV] or hybrid vehicles [HEV]
• CPC Class Codes: H02J 7/00302 Overcharge protection
• CPC Class Codes: H02J 7/00304 Overcurrent protection
• CPC Class Codes: H02J 7/00306 Overdischarge protection
• CPC Class Codes: H02J 7/0031 using battery or load disconnect circuits H02J9/002 takes precedence
• CPC Class Codes: H02J 7/16 Regulation of the charging current or voltage by variation of field
• CPC Class Codes: Y02T 10/70 Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 90/16 Information or communication technologies improving the operation of electric vehicles

Abstract

The present invention is an electronically controlled battery contactor that opens (disconnects) or closes (connects) the battery circuit from the other parts of a motor vehicle electrical system based on measured or sensed data derived from monitoring the electrical system, communicating with other on-board control units, and pre-programmed requirements specific to the vehicle operation. The primary functions are to protect the battery from excessive current drain when the vehicle is parked, protect against short circuits across the main electrical feed, and provide emergency disconnect for vehicle impact, rollover or sensed thermal events. A programmed delay function controls the opening of the contactor in conjunction with other electronic control units that may require electrical power for a period of time after vehicle shutdown. A master electrical disconnect switch is provided for manual override for servicing the vehicle or during an emergency.

Claims

1. A battery disconnect apparatus for monitoring and controlling the battery to electrical load circuit completion or interruption based upon vehicle electrical system states comprising:

a battery for supplying electrical power to the vehicle circuits;

an alternator to maintain electrical power while the engine is operating and to recharge the battery;

a key switch for initiating the starting of the vehicle engine and completing the electrical circuits to switched electrical vehicle loads;

a battery contactor interposed in the vehicle electrical system between the battery and the vehicle electrical devices and loads, including switched and unswitched electrical loads; and

a controller module for sensing the state of the battery contactor and sensing the state of the key switch by initiating a voltage pulse through the voltage output of the battery contactor and sensing and comparing the voltage input from the key switch and issuing electrical control signals to the battery contactor to close upon sensing key closure.

2. The vehicle electrical system monitoring apparatus of claim 1 further comprising a master vehicle electrical system switch having a first manual control state for disconnecting the vehicle electrical circuits from the battery and a second automatic control state connected to said controller module, said controller module being capable of detecting and determining the state of the master switch for automatic operation of the vehicle electrical system.

3. The vehicle electrical system monitoring apparatus of claim 1, wherein said controller module further senses electrical system faults by continually monitoring vehicle electrical system voltages and currents by comparing battery voltage with voltage output of the battery contactor and the key switch against predetermined voltage values and constants including low battery charge, battery overcharging, normal battery charging, low battery voltage and electrical system short circuit.

4. The battery disconnect apparatus of claim 1, wherein said controller module further provides a timed delay of electrical system shut down by delaying the opening of said battery contactor by predetermined conditions or time period after sensing a key switch open condition.

5. The battery disconnect apparatus of claim 1, wherein said controller module maintains at least one communications link with another vehicle data collection device to share vehicle status information and data, to store or log vehicle information status or data on said another vehicle data collection device, said communication link being wired or wireless.

6. The battery disconnect apparatus of claim 1, wherein said controller module further records certain electrical faults and provides a fault status indication as well as logging such fault or status internally and for communicating such fault or status to other on-board or external data collection devices.

7. The battery disconnect apparatus of claim 1, wherein said controller module continually monitors data received from at least one other on board data collection device concerning vehicle status and responds to detected vehicle fault conditions including impact, rollover, engine compartment smoke or fire, operator compartment smoke or fire, and electrical system fault by automatically initiating vehicle electrical system shut down by opening the battery contactor disconnecting the battery from the electrical system.

8. The battery disconnect apparatus of claim 2, wherein said master switch being switched to said first manual state permits the operator to manually override automatic control opening the battery contactor to disable the vehicle electrical system and being switched to said second automatic control state permits the operator to initiate or resume automatic control of the vehicle electrical system.

9. The battery disconnect apparatus of claim 1, wherein said controller module in initiating battery disconnect will provide an alarm to the vehicle operator that may be visual, audible, or both.

10. A method for monitoring and controlling the battery to electrical load circuit completion or interruption based upon vehicle electrical system states comprising the steps of:

providing a battery contactor interposed in the vehicle electrical system between the battery and the vehicle electrical devices and loads, including switched and unswitched electrical loads;

providing a key switch for initiating the starting of the vehicle engine and completing the electrical circuits to switched electrical vehicle loads;

providing a controller module for sensing the state of the battery contactor and sensing the state of the key switch;

determining the open/closed status of the battery contactor;

if the battery contactor is determined to be open, periodically initiating a voltage pulse through the voltage output of the battery contactor and sensing and comparing the voltage input from the key switch; and

,

issuing electrical control signals to the battery contactor to close upon sensing key closure creating a closed circuit between the battery and the vehicle electrical devices and loads.