Abstract:
A current discharge system is provided to supply a specified amount of high current to a device, such as a battery management system. The current may be used, for example, to simulate a short circuit to ensure that the batter management system properly isolates the batter from the circuit. The system can also be used to handle nearly any desired amount of current. The system enables the control of high current through a number of fixed resistors and programmable resisters to obtain a desired current.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. The Field of the Invention 
         [0002]    The present invention relates generally to a system for testing and/or controlling current discharge. In one application, the present invention relates to a system for testing a battery management system to ensure that the battery management system is functioning properly. 
         [0003]    2. State of the Art 
         [0004]    There are numerous situations in which it is important to test the flow of current in a system. For example, some battery management systems are used to ensure that a battery is not over charged or over discharged and to isolate the battery from the circuit in the event of a short circuit. Over charging or over discharging can cause over-heating, fires, reduced battery life damage to other electrical components, and damage to the battery. 
         [0005]    While many batteries discharge relatively small amounts of current, there are other situations wherein large current spikes are needed. For example, when starting an automobile, a short current spike of about 600 amps may be needed to start the engine. In large trucks and other vehicles which use large gasoline or diesel engines, the amperage required to turn over the engine may be several times that of an automobile. Thus, for example, it is not uncommon for the tractor of a semi-trailer to draw 2400 to 2800 amps when starting. In order to test the battery management system, the test system will be required to handle more than 2800 amps to ensure that the battery management system properly limits the amperage pulled from the batter. Testing such high amperage, however, typically requires very large systems and can be quite expensive. 
         [0006]    Thus, there is a need for a programmable current discharge system which can handle high current while remaining relatively compact and economical. 
       SUMMARY OF THE INVENTION 
       [0007]    According to one aspect of the present disclosure, a current discharge test system is provided. The current discharge system includes a plurality of resistors and a plurality of current control modules to test current discharge up to a desired threshold. 
         [0008]    According to one aspect of the disclosure, first, fixed resistor, such as an ultra-high current compact resister (hereinafter “HCCR”) may be provided. The compact resistor may be configured to handle a very high current (e.g. 100 to 1000 amps) without damage to the resistor. The compact resistor may include a compact resistor core which allows a high resistance in a relatively small space. Additionally the compact resistor may include a cooling system for limiting heat build-up due to the large current flowing through the resistor and to maintain a desirable temperature range for optimal resister performance. 
         [0009]    According to another aspect of the disclosure, an ultra-high power programmable current control module (hereinafter “CCM”) may be provided, which effectively forms a digital potentiometer/ resistor. The CCM may be provided which allows the current discharge test and regulation system to control the amount of current to be discharged. By providing multiple CCMs together, the system can be used to provide a desired current output. Such can be provided, for example, to test a battery management system to ensure that the battery management system is properly controlling current draw out of the battery. If the battery management system fails to properly control the current discharge, the battery management system will exceed its limits and be destroyed. Obviously, it is preferable that such happens during quality control rather than during use, where failure could result in a fire or other damage to the vehicle. 
         [0010]    In accordance with one aspect of the invention, the CCM includes Hall effects sensor for detecting current flow through a conductor. The Hall effects sensor sends a signal to a micro-control unit which processes the signal and creates an output based on the sensed current. The output from the micro-control unit that then forwarded to an OP amplifier which controls a plurality of MOSFETs. By regulating the voltage, the current flow can be regulated. Thus, for example, a feedback loop can be established with one CCM having 10, 20 or more MOSFETs and the current passing through the CCM regulated to achieve desired amperage. 
         [0011]    In accordance with another aspect of the disclosure, a plurality of HCCRs and a plurality of CCMs can be disposed in communication with a high current source, such as a battery. Each HCCR can be paired with a CCM on a leg to provide a desired amount of the total current needed. Because the HCCR will only allow a certain amount of current to pass through to the CCM, additional current is forced to pass through additional legs of the circuit, thereby reducing the risk of a CCM blowing due to too much current. 
         [0012]    In accordance with another aspect of the disclosure, each of the legs of the circuit are disposed to minimize the distance between the input conductor and the MOSFETs so that the MOSFETs get to a common current load as quickly as possible. 
         [0013]    According to one aspect of the present disclosure, the system includes a wireless master control system to prevent magnetic fields created within the CCMs from interfering with control. 
         [0014]    According to another aspect of the present disclosure, a master control may be provided which allows selecting control of each HCCR and CCM to thereby achieve a desired current draw. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]    Various embodiments of the present disclosure are shown and described in reference to the numbered drawings wherein: 
           [0016]      FIG. 1  shows a perspective view of an HCCR in accordance with the principles of the present disclosure. 
           [0017]      FIG. 2  shows an exploded view of the HCCR of  FIG. 1 ; 
           [0018]      FIG. 3  shows a top view of the HCCR of  FIG. 1 ; 
           [0019]      FIG. 4  shows an end view of the HCCR of  FIG. 1 ; 
           [0020]      FIG. 5  shows a front perspective view of a CCM in accordance with the present disclosure; 
           [0021]      FIG. 6  shows a rear perspective view of the CCM of  FIG. 5 ; 
           [0022]      FIG. 7  shows an exploded view of the CCM of  FIG. 5 ; 
           [0023]      FIG. 8  shows a top view of the CCM of  FIG. 5 ; 
           [0024]      FIG. 9  shows a bottom view of the CCM of  FIG. 5 ; 
           [0025]      FIG. 10  shows a schematic of the current discharge test and regulation system; 
           [0026]      FIG. 11  shows a schematic view of the programmable feedback look of the CCM of  FIG. 5 ; 
           [0027]      FIG. 12  shows a top view of a bank of HCCRs  10  and CCMs; 
           [0028]      FIGS. 13 through 15  show alternate configurations of buses and MOSFETs; and 
           [0029]      FIGS. 16 and 17  are schematics of one CCM/variable resistor and a cooling system in accordance with one application of the present invention. 
       
    
    
       [0030]    It will be appreciated that the drawings are illustrative and not limiting of the scope of the invention which is defined by the appended claims. The embodiments shown accomplish various aspects and objects of the invention. It is appreciated that it is not possible to clearly show each element and aspect of the invention in a single figure, and as such, multiple figures are presented to separately illustrate the various details of the invention in greater clarity. Similarly, not every embodiment need accomplish all advantages of the present invention. 
       DETAILED DESCRIPTION 
       [0031]    The invention and accompanying drawings will now be discussed in reference to the numerals provided therein so as to enable one skilled in the art to practice the present invention. The skilled artisan will understand, however, that the methods described below can be practiced without employing these specific details, or that they can be used for purposes other than those described herein. Indeed, they can be modified and can be used in conjunction with products and techniques known to those of skill in the art in light of the present disclosure. For example, while the description often discusses applications for arthroscopic surgery, the technique is not limited to that field and may apply to other types of surgery as well. The drawings and descriptions are intended to be exemplary of various aspects of the invention and are not intended to narrow the scope of the appended claims. Furthermore, it will be appreciated that the drawings may show aspects of the invention in isolation and the elements in one figure may be used in conjunction with elements shown in other figures. 
         [0032]    Reference in the specification to “one embodiment,” “one configuration,” “an embodiment,” or “a configuration” means that a particular feature, structure, or characteristic described in connection with the embodiment may be included in at least one embodiment, etc. The appearances of the phrase “in one embodiment” in various places may not necessarily limit the inclusion of a particular element of the invention to a single embodiment, rather the element may be included in other or all embodiments discussed herein. 
         [0033]    Furthermore, the described features, structures, or characteristics of embodiments of the present disclosure may be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of products or manufacturing techniques that may be used, to provide a thorough understanding of embodiments of the invention. One skilled in the relevant art will recognize, however, that embodiments discussed in the disclosure may be practiced without one or more of the specific details, or with other methods, components, materials, and so forth. In other instances, well-known structures, materials, or operations may not be shown or described in detail to avoid obscuring aspects of the invention. 
         [0034]    Before the present invention is disclosed and described in detail, it should be understood that the present invention is not limited to any particular structures, process steps, or materials discussed or disclosed herein, but is extended to include equivalents thereof as would be recognized by those of ordinarily skill in the relevant art. More specifically, the invention is defined by the terms set forth in the claims. It should also be understood that terminology contained herein is used for the purpose of describing particular aspects of the invention only and is not intended to limit the invention to the aspects or embodiments shown unless expressly indicated as such. Likewise, the discussion of any particular aspect of the invention is not to be understood as a requirement that such aspect is required to be present apart from an express inclusion of the aspect in the claims. 
         [0035]    It should also be noted that, as used in this specification and the appended claims, singular forms such as “a,” “an,” and “the” may include the plural unless the context clearly dictates otherwise. Thus, for example, reference to “a spring” may include an embodiment having one or more of such springs, and reference to “the layer” may include reference to one or more of such layers. 
         [0036]    As used herein, the term “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result to function as indicated. For example, an object that is “substantially” enclosed would mean that the object is either completely enclosed or nearly completely enclosed. The exact allowable degree of deviation from absolute completeness may in some cases depend on the specific context, such that enclosing the nearly all of the length of a lumen would be substantially enclosed, even if the distal end of the structure enclosing the lumen had a slit or channel formed along a portion thereof. The use of “substantially” is equally applicable when used in a negative connotation to refer to the complete or near complete lack of an action, characteristic, property, state, structure, item, or result. For example, structure which is “substantially free of” a bottom would either completely lack a bottom or so nearly completely lack a bottom that the effect would be effectively the same as if it completely lacked a bottom. 
         [0037]    As used herein, the term “about” is used to provide flexibility to a numerical range endpoint by providing that a given value may be “a little above” or “a little below” the endpoint while still accomplishing the function associated with the range. 
         [0038]    As used herein, a plurality of items, structural elements, compositional elements, and/or materials may be presented in a common list for convenience. However, these lists should be construed as though each member of the list is individually identified as a separate and unique member. 
         [0039]    Concentrations, amounts, proportions and other numerical data may be expressed or presented herein in a range format. It is to be understood that such a range format is used merely for convenience and brevity and thus should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. As an illustration, a numerical range of “about 1 to about 5” should be interpreted to include not only the explicitly recited values of about 1 to about 5, but also include individual values and sub-ranges within the indicated range. Thus, included in this numerical range are individual values such as 2, 3, and 4 and sub-ranges such as from 1-3, from 2-4, and from 3-5, etc., as well as 1, 2, 3, 4, and 5, individually. This same principle applies to ranges reciting only one numerical value as a minimum or a maximum Furthermore, such an interpretation should apply regardless of the breadth of the range or the characteristics being described. 
         [0040]    Distal and proximal, as used herein, are from the perspective of the person using the currently control system. Thus, proximal means nearer to the user and distal means farther from the person using the system. 
         [0041]    Turning now to  FIG. 1 , there is shown a perspective view of a first, fixed resistor, such as an HCCR, generally indicated at  10 , which may be used to regulate very high amperage (i.e. 100+ amps). The HCCR  10  may include an attachment socket  14  for connecting the HCCR to power conductors  18  which carries current to the HCCR. As shown the attachment socket  14  includes two holes  22  for inserting the power conductors  18  and fasteners  24  for securing the power conductors in the attachment socket. Secondary fasteners  26  may be used to hold the attachment socket  14  to the remainder of the HCCR  10 . 
         [0042]    The attachment socket  14  is in electrical communication with a resistive element  30 . It will be appreciated that the resistance of the resistive element is inversely proportional to the cross-sectional area of the resistive element. Additionally, the material from which the resistive element is made and the length of the resistive element also have a significant impact on resistivity. 
         [0043]    Disposed on either side of the resistive element  30  is a non-conductive isolation layer  34 . The non-conductive isolation layer  34  is designed to electrically isolate the resistive element  30  from a plurality of cooling elements  38 , such as heat sinks, disposed on either side of the resistive element. Because the heat of the resistive element  30  will also affect resistivity, the non-conductive isolation layer prevents current from passing into the cooling elements and effectively by-passing the resistive element. 
         [0044]    Also shown in  FIG. 1  is a fan  42 . The fan may be selectively driven to pull heat out of the cooling elements  38  to ensure that the HCCR  10  is operating within a desired temperature band to obtain the desired resistivity. 
         [0045]    Turning now to  FIG. 2 , there is shown an exploded view of the HCCR  10  of  FIG. 1 . The lower cooling element  38   a  may be formed from various metals or other materials which are known in the art. The lower cooling element  38   a  is shown spaced apart from a lower non-conductive isolation layer  34 , which may be formed from silicone or other suitable non-conductive material which will substantially prevent the current from traveling out the resistive element  30  and into the lower cooling element  38   a.    
         [0046]    In accordance with one aspect of the present disclosure, the resistive element  30  is made from a layer of graphite. The graphite may be anywhere from 1/16 th  of an inch to greater than an inch in thickness. In one current embodiment, the layer of graphite is between about ¼ inch and ½ inch in thickness. Because the resistivity of the resistive element  30  is in part a function of a cross-sectional area of the resistor, the graphite may be formed or cut with a plurality of slots or notches  46 . The notches  46  effectively change a sheet of graphite into a serpentine resistor wherein the cross-sectional area of the resistor is the distance between the notch and either an end or adjacent notch in the graphite times the thickness of the graphite. Thus, for one representative example used for testing a semi-truck battery management system, the resistive element  30  may have a length which is ¼ th  to ½ inches in thickness and between 1 and 2 inches in width, thereby providing a cross-sectional area of between about ¼ th  sq. in. to 1 sq. inch. As shown in  FIG. 2 , section  30   a  of the resistive element  30  may be wider than the other sections to accommodate for the two holes  52  shown therein. 
         [0047]    The attachment sockets  14  are attached at opposing ends of the resistive element  30  by the secondary fasteners  26 . Power conductors  18  may extend from both ends of the resistive element  30 . Thus, to pass through the power conductors  18 , the current must pass through the resistive element  18 . As will be explained in additional detail below, the resistive element  30  limits the amount of the current which may be directed to a digitally programmable resistor in the form of the CCM. 
         [0048]    Disposed above the resistive element  30  another electrically non-conductive isolation layer  34  may be used to electrically isolate the resistive element  30  from the upper cooling element  38   b.  The fan  42  is shown attached to the upper cooling element. It will be appreciated that a variety of cooling elements may be used and a fan is not required. For example, a hydraulic cooling system could be used. 
         [0049]      FIG. 3  shows a top view of the HCCR  10 . The elements which are visible are given common numbering with that used in  FIGS. 1 and 2 .  FIG. 4  shows an end view of the HCCR  10  including the cooling elements  38 , the attachment socket  14 , fasteners  22 , secondary fasteners  26 , the resistive element  30 , the non-conductive isolation layers  34  and the fan  42 . 
         [0050]    Turning now to  FIG. 5 , there is shown a perspective view of a digitally programmable resistor in the form of a current control module (CCM), generally indicated at  60 . One problem with using a digitally programmable resistor in a high current situation is that the current can damage the circuitry. Use of the HCCR with the CCM can prevent such damage. 
         [0051]    The CCM  60  may include a Hall effects sensor  64  which determines the current passing through the power conductors  18  (shown in dashed lines). The power conductors  18  are attached to a first bus bar  70 . The first bus bar  70  may be made from copper or a variety of other materials. The first bus bar  70  may be columnated so that the current is directed along two or more columns. In conventional circuit boards, a plurality of MOSFETs is typically arranged in the linear array. Current passing down a power line will engage the MOSFETs in sequential order. While such a scenario works well in low current configurations, in high current situations is common to burn out the first MOSFET before the current can equalize across the array of MOSFETs. 
         [0052]    In accordance with one aspect of the present invention, the first bus bar  70  is attached to a plurality of semi-conductor switches, for example, MOSFETs  74  (most visible in  FIG. 7 ). Other types of semi-conductor switches may also be used. Because the first bus bar  70  is columnated, the first two MOSFETs  74  receive the current at approximately the same time, thereby cutting the current load of any particular MOSFET in half. The current continues down the first bus bar  70  until all of the MOSFETs are receiving current. 
         [0053]    Because the MOSFETs  74  receive a substantial amount of current, substantial heat is created. Additionally, temperature changes can affect MOSFET performance. Thus, a cooling (temperature regulation) element  78  may be disposed above the MOSFETs  74  to prevent the MOSFETs from other heating and to keep the MOSFETS in a desired temperature range. The cooling element  78  may be connected to a fan  82  or other cooling element. 
         [0054]    Also shown in  FIG. 5  is a wireless controller  84  which allows a wireless master control (not shown in  FIG. 5 ) to selectively control the MOSFETs  74  to regulate the amount of current being allowed to pass. Also shown in  FIG. 5  is a circuit board  86  or other substrate on which the MOSFETs  74  and the first bus bar are mounted. 
         [0055]      FIG. 6  shows a rear view of the CCM  60  and is number in accordance with the description above.  FIG. 6  also shows displays  88  and  92  for displaying the temperature of the CCM  60  and the current being passed through the CCM. A plurality of switches  92  may be used identify an individual CCM from a group of CCMs. 
         [0056]      FIG. 7  shows an exploded view of the CCM  60 . The various parts are numbered in accordance with the discussion of  FIGS. 5 and 6 . As can be seen, a number of MOSFETs  74  are attached to the first bus bar  70 . The first two MOSFETs  74   a  are spaced equidistant from the attachment points where the power conductors  18  are attached to the first bus bar  70  as represented by arrows  100 . The next two MOSFETs  74  then receive the current and so on. By columnating the array of the MOSFETs  74  (i.e. putting them in columns), each of the MOSFETs receives power more closely in time than a conventional linear array. It will be appreciated in accordance with the present disclosure that the columnated design could use three, four or more columns so that three, four, etc., MOSFETs receive current at substantially the same time, thereby reducing the risk of a MOSFET being overloaded. 
         [0057]    Turning now to  FIG. 9 , there is shown a bottom view of the CCM  60  shown in  FIG. 5 . The MOSFETs  74  may be disposed on the circuit board  86  and have leads  74   c,  etc., which are connected to a second bus board  104 . The second bus board  104  may also be columnated, although doing so is not necessary. The current passing from the MOSFETs  74  is collected and so that the current coming out of the MOSFETs  74  is collected and passed to the load. 
         [0058]    Also shown on the bottom is a pair of switches  110 ,  112  which may be MOSFETs, which are used to control whether the MOSFETs are active or shut down. Also shown is a micro-controller  114  which is used to regulate the MOSFETs to control the amount of current passing into the second bus bar  104 . 
         [0059]    Turning now to  FIG. 10 , there is shown a schematic of the feedback loop which is used in the CCM  60 . Current passes through the Hall effects sensor  64  via the power conductor(s)  18 . The Hall effects sensor  64  may send a signal to a micro-controller unit  114  which processes the signals and generates an output signal. Communication line  116  to the micro-controller unit  114  may include an analog-to-digital converted and the communication line from the micro-controller unit may include a digital to analog converted. The signal from the micro-controller unit  114  regulates an OPAMP  116 . The OPAMP  116  adjusts the voltage in the MOSFETs  74  and thereby controls the current passing out of the MOSFETs  74 . 
         [0060]    Also shown in  FIG. 10  are switches  110  and  112 , which may be MOSFETs, for selectively turning off or turning on the MOSFETs  74 . A wireless master control  120  is provided because the fields within the feedback loop can interfere with control. 
         [0061]    Turning now to  FIG. 11 , there is shown a schematic of the system, generally indicated at  130 . Current passes into the power conductor  18  and is passed down a number of legs  18   a,    18   b,    18   n,  etc. Each of the legs  18  includes a first, fixed resistor, such as HCCR  10 . The first, fixed resistor  10  is provided to provide a first, generally fixed resistance range (resistance will vary somewhat based on temperature, etc.) so that a current within a desired range passes to the digital potentiometer/resister formed by the CCM  60 . Thus the first leg may produce a given amount of current, which may be constantly changing within a general range. Likewise, the second leg and each other leg may produce a given amount of current, which may be constantly changing. The master feedback control  120  controls each leg  18   a,    18   b,    18   n  by regulating the CCM  60  disposed along that leg in light of temperature and other current affecting factors so that the sum of the currents (I1-In) produce a desired current. Thus, the system may be programmed to obtain a desired current within a substantial range and the system can be adjusted to handle nearly any range desired by adding additional legs. 
         [0062]      FIG. 12  shows a top view of a bank of HCCRs  10  and CCMs  60  consistent with the description above. As many legs  18   a,    18   b,    18   n  may be used as necessary to handle the amount of current desired in the system. Thus, for example, ten HCCRs and CCMs could be used to handle a current of 5000 amps. 
         [0063]    Turning now to  FIGS. 13 through 15  there are shown three alternate configurations of a bus bar  170  and MOSFETs  174 . By columnating the MOSFETs  174  the risk that the first MOSFETs will fail under the high current is reduced. 
         [0064]      FIG. 16  shows a detailed schematic of a CCM/variable resistor. Claim  17  shows a schematic of a cooling system. 
         [0065]    There is thus disclosed an improved current discharge test system and method of use. It will be appreciated that numerous changes may be made to the present invention without departing from the scope of the claims.