Note: Descriptions are shown in the official language in which they were submitted.
q 3
Description
Smart Power Conneator
Technical Field
This invention relates generally to a load
multiplexing network and more particularly, to an
electrical connector for controlling the flow of
electrical current from the electrical power network
to a peripheral device in a vehicle smart power
multiplexing system.
Background
Various multiplexing systems are implemented
today, especially on vehicles where a number of
components and peripheral devices require electrical
connection to a power source. Some type of electrical
connection is used in these systems, which typically
enable the electrical connection of a vehicle
peripheral device to a multiplexing system containing
a central control module. The peripheral device
control module controls the flow of electrical current
from the power network to the peripheral device in
response to a condition prescribed by the central
control module.
Examples of a vehicle multiplexing system
are described in U.S. Patent No. 4,302,841 issued to
McCulloch on Nov. 24, 1981, and in UOS. Patent No.
} 4,528,662 issued to Floyd et al. on 3uly 9, 1985. In
each example a vehicle electrical system is disclosed
including a central power network with a central
control module and a plurality of peripheral device
control modules and their attached associated
peripheral devices. The central control module
generates a control signal in response to a switch
~3'~!~)'7
2--
setting at a console. The control signal is
transmitted to the peripheral device control modules
which then control the peripheral devices to perform a
function as specified by the received contrvl signal.
~ultiplexed power networks significantly
reduce the number and length of wires used and greatly
simplify the wiring harnsss on a vehicle, but they are
not without problems. Current practice prescribes
connecting the modules which are physically separate
of the harness by splicing the network wires. One
recognized problem with such multiplexing network
connections are difficulties in the initial assembly
and installation o~ the vehicle power harness. The
resultant power network is also inflexible in its
configuration. Difficulties arise when the network
layout is to be altered, such as the addition or
deletion of a control module or peripheral device.
Limitations are placed on netwoxk reconfiguration due
to the fixed lengths of harnesses already in place and
the method of hard wiring electrical connection. The
network implemented this way is not easily expanded to
accommodate more control modules or devices.
Multiplexing systems for earthmoving
equipment operate in harsh environments. The control
modules and the peripheral devices are located
throughout the vehicle, where they may be exposed to a
wide temperature range, moisture, pollutants and
vibration. Consequently, The control devices have a
relatively high failure rate. Therefore, device fault
detection and diagnosis are essential to ensure
vehicle reliability.
The instant invention is directed to
overcome the problems and satisfy the requirements as
set forth above.
)C)~ 7
Disclosure of the Invenkion
An obJect of the invention i8 to provide an
electrical connector for controlling the flow of
electric power to a plurality of peripheral devices in
a vehicular loop network. The network includes a
plurality of data and power lines, and is controlled
by a main controller module.
In one aspect of the present invention, the
smart power connector includes a printed circuit board
having electrical components mounted thereon. The
connector further includes a first housing portion
ha~ing first and second connecting means for
electrical connection to the vehicular network, and
third connecting means for electrical connection to
the plurality of peripheral d~vices. A second housing
portion retains the printed circuit board and heat
conducting element, the second housing portion being
adapted to overlie the first housing portion. The
connector also includes a plurality of electrical
terminals disposed in the second housing portion and
adapted for electrical connection to the first, second
and third connecting means when the first and second
housing portions are aligned and closed together. The
smart power connector is constructed so that the
first, second and third connecting means each has
first and second end portions, the first end portions
being securely mounted to said first housing portion,
and the second end portions being detachable from said
first end portion, and are electrically connectable
with one another.
In another aspect of the present invention,
the smart power connector includes first and second
body portions. The first body portion includes first,
second and third inline connectors. Also included are
a plurality of first conductors electrically coupling
the first and second inline connectors. The first
conductors are electrically coupled to a plurality of
first terminals. A plurality o~ second conductors
electrically couple a plurality of second terminals
and the third inline connector. The fir~t and second
inline connectors are coupled to the power and data
lines of the networkl and the third inline connector
is connectable to peripheral devices. The second body
portion includes a plurality of third terminals
adapted to electrically mate with the plurality of
first terminals, and another plurality oX fourth
terminals adapted to electrically mate with the
plurality of second terminals. The terminals are
aligned when the first and second body portions are
aligned at all four corners, and are electrically
connected as the two portions are pressed close and
remain connected as the body portions are fastened
together.
The connector further includes a printed
circuit board mounted in the second body portion. The
circuit advantageously includes means for selectively
controlling the flow of electric power to the
peripheral devices. This includes voltage regulating
means for converting the vehicle power voltage level
to integrated circuit voltage level, communication
means for receiving commands on the data lines,
processing means for selectively delivering an on/off
signal or a pulse width modulated signal in response
to the commands, and power switches for delivering
power to the peripheral devices. Peripheral device
diagnostics are also performed and fault indication
messages relayed back to the main controller moduleO
Another feature of the smart power connector
advantageously includes potting material for
electrical isolation of the conductors and the
3'~
electrical circuit, and a hsat sink for heat
dissipation.
The instant invention provides an electrical
connector capable of smart power switching, and is
easily attached to or detached from the multiplexed
power network for reconfiguration or repairing. Any
change in accessories can al~o be ea ily accommodated.
The electrical aonnQctor is also packaged to withstand
the harsh environment typical of vehicular
applications. The invention also includes other
features and advantages which will become apparent
from a more detailed study of the drawings and
specification.
Brief Description of The Drawi~qs
For a better understanding of the present
invention, reference may be made to the accompanying
drawings, in which a preferred embodiment is
illustrated:
Fig. 1 is a schematic view of a multiplexing
network containing a main controller module, smart
power connectors, and interconnecting power and data
lines;
Fig~ 2 is a schematic of an electric circuit
in a smart power connector;
Fig. 3 is an i~ometric view of the first
body portion of a smart power connector;
Fig. 4 is an isometric view of the second
body portion of the smart power connector, oriented
above the first body portion to show alignment;
Fig. 5 is a fragmentary sectional view
through the mated body portions and showing one
embodiment of circuit board mounting;
'7~'7
--6--
Fig. 6 is a fragmentary sectional view
through the mated body portions and howing a heat
sink arran~ement;
Fig. 7 is a fraqmentary sectional view
through the mated body portion6 and showing electrical
contact between the first and second body portions.
Best Mode For Carryinq Out The In ention
Fig. 1 shows a schematic of a load
multiplexing network 12. The network is controlled by
a main controller module 14, which issues commands in
response to operator input or to a preselected
condition input on lines 21. A plurality of smart
power connectors 10 are located throughout a vehicle
(not shown) and interconnected by power lines 18,18',
and data lines 16,16'. Advantageously, at least two
sets of power lines 18,1~' carry electrical power to
different parts o~ the vehicle to prevent total power
outage in the event of a short or open circuit. The
preferred embodiment includes at least four such
multiplexed networks on a single vehicle. The data
lines 16 consist of a twisted pair of RS485 serial
lines, but alternatives such as optical fiber links
can also be used. The data loop carries commands and
diagnostic information between the main controller
module 14 and the smart power connectors 10.
Peripheral devices and vehicle components (not shown)
are connected to the smart power connectors 10 via
load lines 20. Climate control components, solenoids,
head lamps, and windshield wiper motors are examples
of vehicle components that can be monitored and
controlled by the smart power connectors 10.
Fig. 2 is a schematic representation of the
electric circuit 21 in the smart power connector. A
voltage regulating means 26 converts the vehicle
Z0~)3~7~ 7
accessory voltage level on lines 32,32', typically 24
volts, to a lower level, such as 5 volts, to support
the integrated circuit 21 in the connector. The data
on the data lines 30,30' are received and transmitted
through two ports 34,35 of the communication means 28.
A communication means 2~ receives commands on the data
lines 30,30' at one of the two ports 34,35, ~nd passes
the commands to a processing means 24. The processing
means 24 decodes the destination address containsd in
the command and determines if it matches its own
address. If the address does not match, the
processing means 24 retransmits the command via the
communication means 28, and the command is put back on
the data lines 30,30~ in the same direction in the
loop as the previous transmis~ion, i . e. if the command
was received at port one, it is retransmitted at port
two, and vice versa. In the case of an address match,
the processing means 24 directs one of the power
switches 22 to "turn on" its load (not shown) as
specified by the received command. The power switch
22 in turn returns a status signal for the loads
reflecting load abnormalities such as open circuit,
short circuit, temperature exceeding a preset limit,
and output voltage under a preset limit. These power
switches are commercially available.
Fig. 3 and Fig. 4 are isometric views of the
smart power connector 10 with two body portions 40,42
oriented to show mating alignment~ First and second
body portions 40,42 are advantageously aluminum
castings, but other materials and construction such as
a potting brick are also feasible. The first body
portion 40 includes first and second inline connectors
44,46 which enable electrical coupling between the
smart power connector and the power and data lines
18,18',16,16'. The first and second inline connectors
;~037~)~7
44,46 each consist of two end portions 44,45',47,47'.
In the preferred em~odiment of the apparatus 10, end
portions 45',~7'are electrically connectable with one
another. The ability to connect the end portions
45',47' provides a way to easily reestablish
electrical continuity if the connestor 10 i deleted
from the network. The third inline connector 48 on
the first body portion 40 enables electrical
connection between the peripheral devices and the
lo smart power connector 10, and can accommodate up to
four devices. The number of devices per connector is
variable depending on system configuration and
speci~ications. The third inline connector 48 also
has first and second end portions 49,49' which enable
easy connection and disconnection o~ the connector 10
to the peripheral device wiring harness 70. The
inline connectors 44,46,48 each have a plurality of
electrical terminals for the power and data
connections. In the preferred embodiment, the inline
connectors include electrical terminals of different
sized gauges for power and data transmission. The
inline connectors 44,46,48 as described are
commercially available.
In the smart power connector 10, the
electrical terminals of the first and second inline
connectors 44,46 are electrically coupled by four
conductors 58. The conductors 58 are preferably
strips of metal stamped on the inner-bottom side of
the first body portion 40, and electrically insulated
from the rest of the connector in potting material.
In instances where flexible wires are used instead of
the stamped metal strips, the potting material
immobilizes the wires to prevent breakage in addition
to providing electrical insulation. Also set in the
pot inside the connector 10 are electrical t~rminals
~ )3~)7
.9_
50,51,52. The terminals 50,51 provide for eleckrical
connections between the power and data lines of the
power network to the smart power connector circuit 21.
The terminals 50,51 consist of two types of terminals
for power and data transmission. The two power
terminals 50 electrically couple the the metal strips
carrying power to the smart power connector circuit
21. The data terminals 51 are of two portion
construction, each portion connected to one data line
of one of the inline connectors 44,46. This is so
that the connector circuit 21 is included in the data
loop with a data port at each side of the terminal 51.
An electrical insulation is preferably installed
between the forked portions of the data terminals 51.
The other terminals 52 of the first body portion
provide for electrical connections between the smart
power connector circuit 21 and the peripheral device
harness 70. Each peripheral device load requires two
power lines to the smart power connector 10, one power
and one ground, for a total of eight terminals.
The second body portion 42 of the smart
power conn~ctor 10 includes a printed circuit board 66
mounted and potted therein. The printed circuit board
66 contains the electric circuit 21 shown in Fig~ 2.
One set of terminals 54 of the second body portion 42
consists of four male terminals adapted to
electrically couple with the power and data terminals
50,51 of the first body portion 40. The peripheral
device terminals 56 in the second body portion 42
consists of eight male terminals adapted to
electrically couple with the eight terminals 52 in the
first body portion 40. Advantageously, the printed
circuit board 66 and the terminals 54,56 are potted
for electrical insulation and vibration protection.
The terminals 54,56 of the second body portion 42 are
--10~
aligned with th~ terminals 50,51,52 of the first body
portion 40 when the two body portions 40,42 are
oriented and aligned one on top of another. The male
and female terminals 50,51,52,54,56 further are
electrically engaged when the two body portions 40,42
are aligned and pressed together. Fastening means
62,64 secures the body portions 40,42 to~ether, and
vehicle mounting means 72 mounts the smart power
connector 10 to the vehicle.
Fig. 5 is a fragmentary sectional ~iew
through the mated two body portions showing an
embodiment for mounting the printed circuit board 66
to the second body portion 42. An attachment eye 75
is formed on the inner region of the second body
portion 42, and adapted to receive a screw 74. Other
conventional methods for mounting a circuit board
inside a housing known in the art can also be used.
Fig. 5 additionally shows the location of the potting
material with respect to the circuit board 66 and the
electrical components 78.
Referring to Fig. 6, a printed circuit board
66 mounted with a heat sink 80 is shown. The power
stage components B 2 such as power switches and drivers
are attached to the heat sink 80 and the circuit board
66 with a screw 74. The heat sink 80 in addition is
in contact with the second body portion 42 wall and
secured thereto with another screw 84. This is
repeated at the other end of the heat sink. Aluminum
is the preferred metal for a heat sink because of its
light weight and heat conducting properties.
Accordingly, heat from the power stage components 82
is dissipated through the laryer surface areas of the
heat sink 80 and the housing. Advantageously, the two
mounting methods as shown in Figs. 5 and 6 are
combined in one embodiment. Typically, in the art cf
electronic packaging, a circuit board is mounted to a
housing at five points: in the center and at ~our
corners. The heat sink method as shown in Fig. 6 can
be implemented at one of ~our corners of the housing
and a conventional mounting method such as shown in
Fig. 5 can be implemented at the three other corners
and in the center.
Fig. 7 is a fragmentary 6ectional view of
the two mated body portions 40,42 showing electrical
engagement of a female and male power terminal 52,56.
Ths data male and female terminals 54,51 are similarly
coupled. The male terminals 54,56 are advantageously
mounted on a circuit board 66 and soldered thereon to
provide for electrical connection to the circuit. The
female terminals 51,52 are preferably set in pot
within the first body portion 40.
Industrial ~pplicability
The operation of the smart power connector
10 is best described in relation to its use in a
vehicular multiplexed network having data and power
lines and controlled by a central control module,
where power is carried to a number of of vehicle
components and devices.
In a vehicle, many peripheral devices are
controllable by the operator ~rom within the cab on an
instrument panel. These devices may include head
lamps, back up indicator lamp, air conditioning fan,
windshield wiper motor, and cab light. Many other
vehicle components such as sensors and solenoids are
not directly controlled by the operator, but
nevertheless are indirectly activated. It can be
appreciated that both types of components and devices
as enumerated above may be connected to the smart
633'~
-12-
power connector to be included in the multiplexing
network.
As the vehicle operator turns on the fan and
sets the speed to high, this setting is relayed to the
central control module. The central control module
issues a ~'high fan speed" command in response to the
operator input and transmits the command onto the
multiplexing networ~ via the data lines. This command
message is passed around the loop network until the
smart power connector connected to the ~an receives
the command and finds a match between the destination
ID in the message and its own ID. That connector
thereafter delivers a pulse width modulated signal to
the fan to switch it on high. A different type of
load that does not offer varying speeds such as head
lamps are switched in the same fashion, except for the
difference of delivering simply an on/off signal to
the device.
The smart power connector acts essentially
as a T-connector, providing connection between the
peripheral devices and components and the multiplexing
network. The smart power connector physically breaks
the data loop and buffers the messages coming across
it. on the other hand, thP power loops are
continuous. The connection as provided by the smart
power connector is easily detachable at all three
connection points, so that network loop continuity is
easily reestablished.
The multiplexing network as implemented with
the smart power connectors is easily reconfigurable at
the dealer's facility to accept additional or
different accessory options~ In the event o~ a smart
power connector failure, the first body portion
containing all of the electronics can be easily
removed from the connector and repaired or exchanged.
;~ 3~
,
-13-
Peripheral device and p2ripheral device
harness failures can be detected by the gmart power
connectors and relayed back to the central control
module. Failures ~uch as ope~ circuit, short circui~,
over temperature, under voltage of the device loads
are readily detected. This peripheral device
diagnostic information can be relayed back to the
central aontrol module to be displayed or to activate
a visual or audio signal to alert the operator or
vehicle service personnel.
Other aspects, objects, and advantages of
this invention can be obtained from a study of the
drawings, the disclosure, and the appended claims.
