Load Current Management System for Automotive Vehicles

1. Technical Field

The present invention relates to electrical power delivery and more particularly to a system for the delivery of electrical power to various loads in a vehicle, such as an automotive vehicle.

2. Background Art

Efforts are being made to reduce the wiring harness requirements associated with the delivery of electrical power and the control of various electrical loads in automobiles and similar vehicles. One technique receiving considerable attention involves the use of multiplex wiring methods to reduce the bulk and routing complexities of traditional wiring harnesses. Recent examples of such multiplex systems are disclosed in U.S. Pat. No. 4,534,025 issued Aug. 6, 1985 to W. M. Floyd for "Vehicle Multiplex System Having Protocol/Format For Secure Communication Transaction" and U.S. Pat. No. 4,528,662 issued July 9, 1985 to W. M. Floyd et al for "Multiplex Control System Having Enhanced Integrity". Both of these applications are owned by the assignee of the present application. Such multiplex systems typically transform the vehicle electrical wiring system to an input/output system as a consequence of separating the power switching function from the logic switching function. The input system is concerned with the ergonomic aspects of the input switch design as well as the logical processing of the commands supplied by the vehicle's operator and/or passengers. The output system is concerned with directing power to the various loads and involves details such as distribution of the 12 volt power supply, remote switch electrical stresses and load device diagnostics.

Prior to the development of multiplex-wired vehicles, traditional power deliver systems had relied upon sizing the conductors sufficiently large to handle the total requirement of a plurality of loads all energized simultaneously. For instance, if a plurality of loads were connected to the end of a power conductor, it was necessary to establish the load current required by each load, the length of the conductor, the permissible IR drop at each load and then to select a wire gauge that would meet all of the requirements. Similarly, any switch connected to the power conductor for controlling delivery of current to the loads was designed to exceed the current-carrying capacity of the conductor connected to it.

In multiplex-wired vehicle systems, it is an objective that the overall volume and weight of conductor wires be reduced. Typically, the multiplex-wired vehicle employs single wire feeds to remote regions containing various functions. Due to the uncertainty of simultaneous load operation, it is difficult to predict the power feed wire size. Moreover, it is desirable to minimize the size or gauge of such power feed wire to the extent possible.

Accordingly, it is an object of the present invention to provide an electrical power delivery system for a vehicle, such as an automobile, which allows minimum gauge power conducting wire to be utilized.

It is a further object to provide such a power delivery system which is particularly suited for use in an output multiplex system.

It is yet a further object to provide such an electrical power delivery system having a plurality of loads of differing functions.

It is another object to provide a current monitoring system capable of separately monitoring an electrical operating condition of each load for diagnostic purposes.

In accordance with the present invention there is provided an improved electrical power delivery system for a vehicle, such as an automobile. The power delivery system is conveniently associated with a vehicle multiplex control system of the type employing a centralized multiplex control computer and one or more remote multiplex units (REMUX) each serving a particular region of the vehicle and responsible for controlling loads in that region. Within a particular region, the several controlled loads may typically provide different functions, as for instance, window actuation, door lock actuation, heat control and/or indicator lamp illumination. A power conductor extends from a power supply to respective power switches in the region, each switch being associated with a respective one of the loads in that region. Since multiple use of the various functions within a region rarely occurs simultaneously, the power conductor wire need not be sized so large as to accommodate the current occasioned by simultaneous operation of all of the loads. However, to accommodate those periods of simultaneous load demand within the region, provision is made for recognizing such intervals of excessive current demand and for establishing temporary load priority selection to maintain the current within a predetermined limit. The load priority selection may be varied so quickly that the operator of the vehicle does not realize the loads are being pulsed to limit current flow through the power conductor.

Specifically, a power conductor, as for instance a single wire, extends from a power supply to a region of the vehicle where current is selectively conducted through various loads via the controlled actuation of respective power switches in that region. Control of the respective power switches in a region and in turn connected via a data bus with a centralized multiplex control computer. The power conductor to the region is of a predetermined limited current-carrying capacity which is less than that required to simultaneously deliver full current to all of the loads in that region. Monitoring circuitry associated with the power conductor determines whether or not the current exceeds a threshold level and provides a signal indicative of such determination. That signal is monitored by the control circuitry of the REMUX and in turn by the control circuitry of the multiplex control computer. Once the current approaches or exceeds the threshold level the multiplex control computer acts to inhibit actuation of preselected loads of a lower priority in order to maintain the current through the power conductor below the predetermined threshold. Actuation of a particular load is typically controlled via an enabling signal applied to a power switch connected in series with the load and the power conductor. The various loads are prioritized based on a variety of factors such as current required, importance to operation of vehicle, and expected duration of operation of the load.

The multiplex control computer may also be used to identify the proposed current draw of each load or combination of loads being energized. This information may be utilized to select a current profile for that combination of loads such that the threshold level may be varied for each combination of loads. Additionally, by providing an adjustable threshold to a comparator serving as part of the current monitor, the adjustment of the current profile for the specific combination of loads is easily accomplished. This adjustable threshold may further be used to monitor on a selected basis the current flow to individual loads. The multiplex control computer may be utilized to selectively energize appropriate loads and to set the adjustable threshold for each load such that a sequential diagnostic evaluation may be performed on each load by comparing the current profile for the load with the current actually detected.

FIG. 1 is a generalized diagrammatic illustration of a multiplex system for controlling delivery of electrical power to various loads in various regions of an automotive vehicle;

FIG. 2 is a more detailed diagrammatic illustration of a portion of the system of FIG. 1 illustrating the system for current management to the loads in that region in greater detail;

FIG. 3 is a generalized diagrammatic illustration of one of the power switches depicted in FIGS. 1 and 2.

FIG. 4 is a generalized diagrammatic illustration of a current monitor depicted in FIG. 2.

Referring now to the drawings and particularly to FIG. 1, there is illustrated a generalized body electrical system for an automotive vehicle and utilizing a multiplex control system generally of the type disclosed in aforementioned U.S. application Ser. Nos. 469,591 and 540,581, which are incorporated herein by reference. A body electrical system, generally designated 10, includes various operator-actuated input switches and sensors for controlling the operation of various electrical loads. The loads may take a variety of forms including window lift motors, power door lock motors, seat-adjustment motors, interior lighting, exterior lighting, indication lamps, heater elements and the like. Electrical power to actuate the various loads is provided by a 12 volt DC power supply, such as battery 12. A central multiplex control computer 14 includes a microprocessor 15 and complementary-acting master multiplex circuitry 16 and monitor multiplex circuitry 17 for sending and receiving serially multiplexed data to various regions of an automobile via a data wire comprising one of the wires in a four-wire multiplex bus 18. Bus 18 includes a data line, a clock line, and two lines for delivering the supply potentials to the associated logic. The multiplex bus 18 extends to various regions of a vehicle and a respective remote multiplexer (REMUX) 20 is connected to bus 18 at each such region. For purposes of identification, the various regions have been identified by respective alphabetical subscripts to the reference numerals, i.e. 20.sub.a, 20.sub.b . . . 20.sub.j, 20.sub.k. Each region typically includes a plurality of inputs to the system from respective switches and outputs to various, typically diverse, loads.

A representative region might comprise the door of a two or four-door vehicle. It might include inputs from a coded vehicle entry switch as well as from a window control switch, a mirror heater switch and possibly a mirror control switch. The loads associated with that region might include a window actuation motor, a door lock actuator, illumination lamps, heaters and the like. The electrical energy for energizing the various loads at respective regions of the vehicle is distributed to that region by a "star" distribution arrangement in which a respective single wire conductor 22.sub.a, 22.sub.b . . . 22.sub.j, 22.sub.k extends to each of the respective regions from the power source 12. The several power conductors 22.sub.a -22.sub.k extend to respective groups of remote power switches 24.sub.a -24.sub.k at the respective regions.

Referring to FIG. 2 in which one of the regions, "j", is depicted in greater detail, it will be seen that a plurality of generally diverse loads 26.sub.j1 . . . 26.sub.jn receive their energizing electrical power from conductor wire 22.sub.j via respective power switches 24.sub.j1 . . . 24.sub.jn. The conducting state of a respective power switch 24.sub.j1 . . . 24.sub.jn is determined by an enabling control signal appearing on respective lead 28.sub.j1 . . . 28.sub.jn provided at a respective output from the REMUX 20.sub.j. A representative input switch 21.sub.a is here illustrated as being associated with REMUX 20.sub.a for providing a command to one of the loads 26.sub.j1 . . . 26.sub.jn in the "j" region. The input switch 21 might instead have been located in the "j" region, and might serve to command the turn-on or turn-off of a "j" function, such as a mirror heater or the like.

In accordance with the invention and referring to FIG. 3, a representative power switch 24.sub.j1 comprises a solid state power switch such as power MOSFET 30 and associated logic 32. The power MOSFET 30 is capable of conducting 10 amperes of current with a maximum voltage drop of 0.5 volts when in the "on" condition. In the "off" condition, the MOSFET 30 can withstand 60 volts applied to its terminals with very low "leakage" current. The associated logic 32 typically uses low-power CMOS technology. The logic 32 responds to an enabling control signal on lead 28.sub.j1 from the REMUX 20.sub.j to normally turn on or turn off power FET 30, thereby normally providing or preventing conduction of an energizing electrical current to the load 26.sub.j1 from the supply 12 via power conductor 22.sub.j. The logic 32 may also provide for short circuit detection, over load detection, over voltage detection and/or thermal sensing so as to protect the power FET 30 in one of those abnormal conditions. Logic 32 also includes provision for recognizing such an abnormal condition and communicating it to the REMUX 20.sub.j in the form of a STATUS BIT appearing on line 34.sub.j1. The multiplex control computer can access this information via REMUX 20.sub.j for ongoing diagnostic purposes. Assuming the power MOSFET 30 is connected in the so-called "high-side" configuration illustrated in FIGS. 2 and 3 in which its drain is connected to the relatively higher potential of the 12 volt power source 12, the circuitry of power switch 24.sub.j1 will also include a charge pump for applying a potential to the gate greater than that of the 12 volt supply voltage.

Returning to a consideration of the invention as depicted in FIG. 2, all of the electrical current required to power the several loads 26.sub.j1 . . . 26.sub.jn is provided via a single wire conductor 22.sub.j. A fuse 40.sub.j is illustrated as being connected in series with the power conductor 22.sub.j to protect that conductor and the circuitry and loads downstream thereof in the event of relatively large current excursions. However, it is generally desirable to size the power conductor wire 22.sub.j as small as possible to minimize its weight, volume and cost in such automotive vehicle applications. Because the several loads 26.sub.j1 . . . 26.sub.jn in a particular region "j" may not normally be simultaneously energized, it is possible in accordance with the invention to reduce the size or gauge of the conductor wire 22.sub.j below that which would otherwise be required to accommodate the simultaneous steady-state current drain of all of the loads 26.sub.j1 . . . 26.sub.jn. Moreover, in those instances in which the normal demands for energization of loads at a particular region would exceed the steady-state current-carrying capacity of the conductor 22.sub.j, provision has been made for temporarily preventing or delaying energization of selected ones of the loads until the current demands of other ones of the loads have been satisfied and are terminated. Characteristically, this function may be provided by assigning certain priorities to the various loads, dependent upon their respective functions. For example, a command to energize a window motor may be accorded a greater priority than one to energize a heater element or a nonessential indicator lamp during the relatively brief interval of several seconds required for window actuation. While it might be possible to profile the anticipated current drains of each of the loads with sufficient accuracy and detail as to attain the desired current management solely through the programming of the multiplex computer 15 without actually determining the magnitude of the current in conductor 22.sub.j, a more reliable arrangement involves the actual monitoring of that current.

A current sensing or monitoring arrangement is provided by placing a resistive element 50.sub.j, such as a resistance wire or the like, in series with power conductor 22.sub.j between power supply 12 and the several power switches 24.sub.j1 . . . 24.sub.jn. Appropriate current monitoring circuitry 60.sub.j is connected across the resistor 50.sub.j to sense the magnitude of the current flowing in conductor 22.sub.j. The output of current monitor 60.sub.j is a signal indicative of whether the magnitude of the current in conductor 22.sub.j is above or below some predetermined threshold. That current threshold is typically below the rated current capacity of the selected wire 22.sub.j. In one example, the rated capacity of wire 22.sub.j may be 20 amperes and the threshold may be 15 amperes. The output signal from current monitor 60.sub.j is extended via lead 68.sub.j to an appropriate input to REMUX 20.sub.j for relay to the multiplex control computer 15. The program of computer 15 is structured to disregard temporary over-current conditions caused by in-rush currents during start-up operation of a load. Typically such intervals are less than 320 milliseconds. Thereafter, if an over-current condition remains, the program is operative to disable or inhibit the enabling signal extended to the power switches 24.sub.j associated with one or more of the lower priority loads 26.sub.j. The system periodically monitors the current level signal appearing on line 62.sub.j and following its return to a normal condition below the threshold, the previously-applied command for energization of the temporarily disconnected load is reapplied to reenergize that load. If multiple commands for energization have been temporarily inhibited, the loads are enabled based on a predetermined priority schedule.

FIG. 4 is a diagrammatic circuit view of current monitor 60.sub.j. Power is supplied from a 12 volt source through fuse 40.sub.j through wire 22.sub.j to the appropriate loads. Resistor 50.sub.j is a section of resistance wire located within the wire 22.sub.j such that a predetermined resistance is achieved. The voltage drop across this resistor is measured to indicate the current flow to the loads through power conductor 22.sub.j. First stage operational amplifier 62.sub.j is connected to wire 22.sub.j on both sides of the resistive portion 50.sub.j. Operational amplifier 62.sub.j generates an output which is conducted through wire 65.sub.j to the positive input of a second operational amplifer 66.sub.j which operates as a comparator. A feedback loop 63.sub.j is provided about first stage operational amplifier 62.sub.j. The output from comparator 66.sub.j is either zero or 5 volts to give an effective digital signal, depending on whether the voltage on lead 65.sub.j from amplifier 62.sub.j is above or below a current threshold established by the potential applied to the negative input of the comparator via lead 67.sub.j. In a basic embodiment, the threshold may be a fixed value. This digital signal is conducted via wire 68.sub.j to REMUX 20.sub.j which determines from that signal whether or not the threshold level of the current flowing through wire 22.sub.j has been exceeded.

Additionally shown in FIG. 4, is a programmable or adjustable threshold 70.sub.j. Programmable threshold 70.sub.j is located to supply a threshold signal to comparator 66.sub.j to determine the current threshold above which a logic 1 appears on line 68.sub.j. A series of connections 72.sub.j are provided between REMUX 20.sub.j and programmable threshold 70.sub.j such that a three-bit signal may be provided from the regional muxtiplex computer REMUX 20.sub.j to the programmable threshold to vary the threshold level applied to comparator 66.sub.j on line 67.sub.j.

By utilizing programmable threshold 70.sub.j, additional features may also be achieved with the herein-described circuit. The various loads each have an associated current profile and the operation of a combination of the loads results in a combination profile achieved by adding the various profiles of each load.

The central multiplex computer knows which loads are being energized and can look up in a table the respective load profile for each load. Additionally, the central multiplex computer can provide an appropriate signal to the appropriate regional REMUX to indicate what that load profile should be. The REMUX can then provide a signal over wires 72.sub.j to programmable threshold 70.sub.j to adjust the threshold voltage applied to the comparator 66.sub.j such that the current threshold level detected on power conductor 22.sub.j is adjusted to be the threshold level corresponding to the load profile for the specific loads being energized. Hence, the threshold level may be adjusted based on the profile of the loads being energized and an over-current situation may be detected at less than the threshold level based on the current-carrying capacity of the wire.

The use of programmable threshold 70.sub.j also provides the capability of providing diagnostics within the multiplex circuit. The multiplex control computer can be programmed to sequentially energize each load in a region through the appropriate REMUX. The central multiplex computer also can look up in a table the load profile for the appropriate load being energized and can provide appropriate signals such that the programmable threshold can be adjusted to detect a threshold level based upon the load profile for that specific load. A comparison of the two can then be utilized to determine whether or not the load is performing as designed. The fact that no current is flowing is utilized to indicate an open circuit. High current can either indicate a failure in the load or a short circuit occurring at some location. Other specific variations from the load profile can additionally be evaluated.

It is contemplated that the central multiplex computer will include appropriate logic for achieving the desired functions. It is anticipated that an overall cycle time of 1.44 seconds could be utilized having a 320 millisecond start-up period during which functions will be allowed to be enabled until an over-current condition exists, and it will not be utilized to disable any other function. Two additional time periods each being 560 milliseconds in length are thereafter utilized. The functions are appropriately enabled and disabled at 80 millisecond increments within each of these cycles. If a specific load is indicated to be disabled due to an over-current situation for multiple time increments, as for instance following a second indication of over-current after the first such indication at the end of the 320 millisecond interval, it is then disabled for the entire remaining length of the 560 millisecond interval.

The basic premise of the logic is that, within an overall cycle, if an over-current condition occurs, functions will be disabled until the over-current condition is cleared. Once an over-current condition is cleared, the functions are then reenabled. However, if two successive over-current situations are sensed, a corresponding bypass is arranged. The bypass arrangement will then function to disable but not reenable during the 560 millisecond interval. This allows the lower priority function to be enabled even though a high priority function is disabled if the higher priority function repeatedly caused an over-current condition when reenabled with the lower priority function disabled. The functions are enabled and disabled in order of priority such that they are enabled from highest to lowest priority and disabled from lowest to highest priority. This is accomplished by prioritizing all the functions in a specific region in a table and by logically proceeding in a specific order through the table to either enable or disable the functions. The current management function ends when all functions are enabled and the over-current condition is not present at the end of a cycle time period. By "enabling" all the functions is simply meant they are permitted to occur, not that they are necessarily energized.

Although no flow chart is given herein, it is to be understood that a specific subroutine in the multiplex computer is utilized. the subroutine in a normal manner sets all initial conditions to zero and may thereafter at 80 millisecond intervals check for an over-current situation. Various flags are set to indicate the appropriate conditions of different portion of the circuit. A current management flag is set to indicate that the logic is in a current management condition. On each occasion of the 80 millisecond period elapsing and a current management flag being set, the current condition will be checked and a function enabled or disabled as required. Additional flags are set which determine the first 320 milliseconds of the cycle which elapse without further disabling functions and to indicate which of the second two 560 millisecond time periods the logic is in.

Once the logic is in the over-current sensing mode the logical question of whether or not the current-sensing bit is energized is asked. This is a bit in the REMUX for each region which is set in response to the signal generated by the current monitor. If this bit is not set, the logic can flow to the enable function subroutine which acts to enable additional functions as long as the over-current condition is not achieved. If the current-sensing bit is energized, then the logic flows to a diable function subroutine which acts to sequentially disable functions until the over-current condition is cleared. Appropriate subroutines are provided for looking up on an appropriate map or table the various functions and determining their priority such that they may be enabled and disenabled in their appropriate order. The specific programming to accomplish these referenced functions is within the skill in the art.

Although the invention has been described in relation to a particular embodiment it is to be understood by those skilled in the art that variations and modifications can be made within the spirit and scope of the invention.