Abstract:
A high voltage connector assembly is provide which may include a first connector having a first adapter and a first portion of an identification mark and a second connector having a second portion of the mark and a second adapter which may be configured to engage the first adapter. The first and second portions may be arranged on the connectors such that the portions are aligned to define the mark when the adapters are completely engaged and not aligned otherwise. The mark may include one or more electronically readable indicators identifying each of the first and second connectors. The mark may include indicia indicative of adapter engagement or adapter mis-engagement.

Description:
TECHNICAL FIELD 
     This disclosure relates to electrical connectors for high voltage battery systems utilized in vehicles. 
     BACKGROUND 
     Vehicles such as battery-electric vehicles (BEVs), plug-in hybrid-electric vehicles (PHEVs), mild hybrid-electric vehicles (MHEVs), or full hybrid-electric vehicles (FHEVs) contain a traction battery, such as a high voltage (HV) battery, to act as a propulsion source for the vehicle. The HV battery may include components and systems to assist in managing vehicle performance and operations. The HV battery may include one or more arrays of battery cells interconnected electrically between battery cell terminals and interconnector busbars. The HV battery and surrounding environment may include a thermal management system to assist in managing temperature of the HV battery components, systems, and individual battery cells. 
     SUMMARY 
     A high voltage connector assembly includes a first connector including a first adapter and a first portion of an identification mark and a second connector including a second portion of the mark and a second adapter configured to engage the first adapter. The first and second portions are arranged on the connectors such that the portions are aligned to define the mark when the adapters are completely engaged and not aligned otherwise. The mark may include one or more electronically readable indicators identifying each of the first and second connectors. The connectors may electrically connect a first vehicle component in communication with the first adapter and a second vehicle component in communication with the second adapter when the adapters are completely engaged. The mark may be electronically readable when the adapters are completely engaged and not electronically readable otherwise. The mark may include indicia indicative of adapter engagement or adapter mis-engagement. 
     A service disconnect assembly for a HV battery includes an interlock in electrical communication with a battery cell of the HV battery and having a first portion of an identification mark. The assembly also includes a body having a pivotable member mounted to the body for rotation and translation between a plurality of positions including an engaged position. The assembly also includes an interlock switch having a second portion of the mark, secured to the pivotable member, and configured to engage with the interlock when the pivotable member is in the engaged position. The first and second portions are arranged such that the portions align to define the mark only when the interlock and the interlock switch are engaged. The mark may include one or more electronically identifiable indicia indicative of instructions for an external device. The electronically identifiable indicia may be readable by the external device only when the interlock and interlock switch are engaged. The mark may include indicia indicative of interlock to interlock switch engagement or mis-engagement. 
     A high voltage connector assembly includes a first connector including a male adapter and an identification mark and a second connector including a female adapter to mate with the first connector and defining an alignment window. The mark and window are arranged such that the mark is readable through the window by an external device only when the connectors are fully mated to one another. The mark may include one or more electronically readable indicators identifying each of the first and second connectors. The indicators may be electronically readable by an external device. The first connector may include a feature configured to prevent access to the identification mark if the connectors are not fully mated to one another. The second connector may include a supplemental mark arranged to align with the identification mark and form an electronically readable indicator when the connectors are fully mated to one another. The electronically readable indicator may include indicia indicative of whether the connectors are fully mated to one another. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic illustration of a plug-in hybrid vehicle. 
         FIG. 2  is a perspective view of a high voltage connector assembly showing a first and second connector disengaged. 
         FIG. 3  is a plan view of the high voltage connector assembly of  FIG. 2 . 
         FIG. 4  is a plan view of the high voltage connector assembly of  FIG. 2  showing the first and second connector engaged. 
         FIG. 5  is a perspective view of another high voltage connector assembly showing a first and second connector disengaged. 
         FIG. 6  is a plan view of the high voltage connector assembly of  FIG. 5 . 
         FIG. 7  is a plan view of the high voltage connector assembly of  FIG. 5  showing the first and second connector engaged. 
         FIG. 8A  is a perspective view of a manual service disconnect shown in a first position prior to engagement with a portion of a traction battery. 
         FIG. 8B  is a perspective view of the manual service disconnect from  FIG. 8A  shown in a second position prior to engagement with the portion of the traction battery. 
         FIG. 8C  is a perspective view of the manual service disconnect from  FIG. 8A  shown in a third position engaged to the portion of the traction battery. 
         FIG. 9  is a flow chart of an algorithm for testing an engagement state of a high voltage connector assembly. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments can take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures can be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations. 
       FIG. 1  depicts a schematic of a typical plug-in hybrid-electric vehicle (PHEV). A typical plug-in hybrid-electric vehicle  12  may comprise one or more electric machines  14  mechanically connected to a hybrid transmission  16 . The electric machines  14  may be capable of operating as a motor or a generator. In addition, the hybrid transmission  16  is mechanically connected to an engine  18 . The hybrid transmission  16  is also mechanically connected to a drive shaft  20  that is mechanically connected to the wheels  22 . The electric machines  14  can provide propulsion and deceleration capability when the engine  18  is turned on or off. The electric machines  14  also act as generators and can provide fuel economy benefits by recovering energy that would normally be lost as heat in the friction braking system. The electric machines  14  may also provide reduced pollutant emissions since the hybrid-electric vehicle  12  may be operated in electric mode or hybrid mode under certain conditions to reduce overall fuel consumption of the vehicle  12 . 
     A traction battery or battery pack  24  stores and provides energy that can be used by the electric machines  14 . The traction battery  24  typically provides a high voltage DC output from one or more battery cell arrays, sometimes referred to as battery cell stacks, within the traction battery  24 . The battery cell arrays may include one or more battery cells. The traction battery  24  is electrically connected to one or more power electronics modules  26  through one or more contactors (not shown). The one or more contactors isolate the traction battery  24  from other components when opened and connect the traction battery  24  to other components when closed. The power electronics module  26  is also electrically connected to the electric machines  14  and provides the ability to bi-directionally transfer electrical energy between the traction battery  24  and the electric machines  14 . For example, a typical traction battery  24  may provide a DC voltage while the electric machines  14  may require a three-phase AC voltage to function. The power electronics module  26  may convert the DC voltage to a three-phase AC voltage as required by the electric machines  14 . In a regenerative mode, the power electronics module  26  may convert the three-phase AC voltage from the electric machines  14  acting as generators to the DC voltage required by the traction battery  24 . The description herein is equally applicable to a pure electric vehicle. For a pure electric vehicle, the hybrid transmission  16  may be a gear box connected to an electric machine  14  and the engine  18  may not be present. 
     In addition to providing energy for propulsion, the traction battery  24  may provide energy for other vehicle electrical systems. A typical system may include a DC/DC converter module  28  that converts the high voltage DC output of the traction battery  24  to a low voltage DC supply that is compatible with other vehicle loads. Other high-voltage loads, such as compressors and electric heaters, may be connected directly to the high-voltage without the use of a DC/DC converter module  28 . In a typical vehicle, the low-voltage systems are electrically connected to an auxiliary battery  30  (e.g., 12V battery). 
     A battery energy control module (BECM)  33  may be in communication with the traction battery  24 . The BECM  33  may act as a controller for the traction battery  24  and may also include an electronic monitoring system that manages temperature and charge state of each of the battery cells. The traction battery  24  may have a temperature sensor  31  such as a thermistor or other temperature gauge. The temperature sensor  31  may be in communication with the BECM  33  to provide temperature data regarding the traction battery  24 . The temperature sensor  31  may also be located on or near the battery cells within the traction battery  24 . It is also contemplated that more than one temperature sensor  31  may be used to monitor temperature of the battery cells. 
     The vehicle  12  may be, for example, an electric vehicle such as a PHEV, a FHEV, a MHEV, or a BEV in which the traction battery  24  may be recharged by an external power source  36 . The external power source  36  may be a connection to an electrical outlet. The external power source  36  may be electrically connected to electric vehicle supply equipment (EVSE)  38 . The EVSE  38  may provide circuitry and controls to regulate and manage the transfer of electrical energy between the power source  36  and the vehicle  12 . The external power source  36  may provide DC or AC electric power to the EVSE  38 . The EVSE  38  may have a charge connector  40  for plugging into a charge port  34  of the vehicle  12 . The charge port  34  may be any type of port configured to transfer power from the EVSE  38  to the vehicle  12 . The charge port  34  may be electrically connected to a charger or on-board power conversion module  32 . The power conversion module  32  may condition the power supplied from the EVSE  38  to provide the proper voltage and current levels to the traction battery  24 . The power conversion module  32  may interface with the EVSE  38  to coordinate the delivery of power to the vehicle  12 . The EVSE connector  40  may have pins that mate with corresponding recesses of the charge port  34 . 
     The various components discussed may have one or more associated controllers to control and monitor the operation of the components. The controllers may communicate via a serial bus (e.g., Controller Area Network (CAN)) or via discrete conductors. 
     The battery cells, such as a prismatic cell, may include electrochemical cells that convert stored chemical energy to electrical energy. Prismatic cells may include a housing, a positive electrode (cathode) and a negative electrode (anode). An electrolyte may allow ions to move between the anode and cathode during discharge, and then return during recharge. Terminals may allow current to flow out of the cell for use by the vehicle. When positioned in an array with multiple battery cells, the terminals of each battery cell may be aligned with opposing terminals (positive and negative) adjacent to one another and a busbar may assist in facilitating a series connection between the multiple battery cells. The battery cells may also be arranged in parallel such that similar terminals (positive and positive or negative and negative) are adjacent to one another. For example, two battery cells may be arranged with positive terminals adjacent to one another, and the next two cells may be arranged with negative terminals adjacent to one another. In this example, the busbar may contact terminals of all four cells. 
     Various battery pack configurations may be available to address individual vehicle variables including packaging constraints and power requirements. HV connectors may be used to connect different components within the different battery pack configurations and the components proximate thereto. Various operating requirements and conditions may be considered when determining a suitable type of HV connector for a particular circumstance. For example, an operating voltage, an environment of the connector, and assembly/installation considerations may be examined to assist in designing a male and female portion for the particular HV connector. When assembling electrical circuits within vehicles, incomplete connections of HV connectors, wire harnesses, or other similar connectors may sometimes result. These incomplete connections may occur due to operator error. The operator may not be able to determine whether the connector is fully seated. While it may be possible to utilize certain test methods to examine the connection, the time associated with such testing may not be acceptable in an assembly and/or installation environment. Additionally, while the electrical circuit between the mating connectors may be complete and thus pass a traditional connectivity test, the connectors may not be fully seated, engaged, or mated from a structural standpoint and as such, could eventually separate during vehicle operating conditions to create a failure or fault condition. Further, in an assembly setting it may be desirable to not only track parts and components throughout the installation processes, but also to track whether certain connectors fully mate and to provide a signal to operators indicating the same. 
       FIGS. 2 through 4  show an example of a HV connector assembly. A HV connector assembly  200  may include a male connector  202  and a female connector  204 . The male connector  202  may include one or more pins  206 . The female connector  204  may include one or more receiving wells  208 . A female receptacle (not shown) may be included within the receiving wells  208 . The receiving wells  208  may be configured to receive the corresponding pins  206  and to assist in completing an electrical circuit between the pins  206  and the female receptacle. In this example, the HV connector assembly  200  may be utilized to form an inline circuit connecting two separate wire harnesses from two vehicle components such as a charge port and a power conversion module. For example, an inline connection may be used to connect the charge port  34  with the power conversion module  32  of  FIG. 1 . 
     The male connector  202  may include an identification mark  210  secured to or defined by a housing  212  of the male connector  202 . The mark  210  may include one or more digitally identifiable items which may be read by an external device (not shown). For example, the mark  210  may include information relating to the male connector  202  such as a part number or instructions for the external device. The mark  210  may be in the form of an identification signature, a quick response code (QR code), or a bar code. Other forms for the mark  210  are available which may include digitally identifiable items. The external device may be a scanning device and include a sensor to capture and/or read the mark  210 . In one example, the external device may scan the mark  210  and access one or more sets of instructions included within the mark  210 . A set of instructions may direct the external device to trigger a signal, such as an audio or visual signal, indicating that the male connector  202  is engaged, seated or mated with the female connector  204 . Another set of instructions may direct the external device to trigger a signal indicating that the male connector  202  and the female connector  204  are not seated or mated with one another. Yet another set of instructions may direct the external device to trigger a signal to be sent to a server indicating the male connector  202  and the female connector  204  are engaged or whether a fault condition is present. It is contemplated that other examples of the external device which utilize a sensor may be available to read the mark  210 . 
     The female connector  204  may be configured to mate with the male connector  202  and include a housing  218  which may define an alignment window  220 . The alignment window  220  may be sized according to the identification mark  210  of the male connector  202  and may optionally include one or more blockers  221 . For example, the alignment window  220  may be such that the identification mark  210  is readable by the external device only when the male connector  202  and the female connector  204  are fully mated. In this example, the identification mark  210  may not be readable unless the blockers  221  are covering a portion of the identification mark  210 . Conversely, the housing  218  may include a feature to prevent access to the identification mark  210  when the male connector  202  and the female connector  204  are partially mated. Optionally, the female connector  204  may include a supplemental mark  224  located adjacent to the alignment window  220 . In this example, the supplemental mark  224  and the identification mark  210  may include digitally identifiable items which may only be readable by the external device when the supplemental mark  224  and the identification mark  210  are properly aligned. For example, the supplemental mark  224  and the identification mark  210  may together include a set of instructions which may direct the external device to trigger a signal indicating that the male connector  202  and the female connector  204  are fully mated as shown in  FIG. 4 . 
       FIGS. 5 through 7  show another example of a HV connector assembly. A HV connector assembly  300  may include a male connector  302  and a female connector  304 . The male connector  302  may include an adapter such as one or more pins  306 . The female connector  304  may include one or more receiving wells  308 . A female adapter, such as a female receptacle (not shown) may be included within the receiving wells  308 . The receiving wells  308  may be configured to receive the corresponding pins  306  and to assist in completing an electrical circuit between the pins  306  and the female receptacle. In this example, the connector assembly  300  may be located at a battery pack to facilitate an electrical connection to a high voltage harness leading to a power conversion module, such as the battery pack  24  and power conversion module  32  of  FIG. 1 . 
     The male connector  302  may include a first portion  310  of an identification mark secured to or defined by a housing  312  of the male connector  302 . The female connector  304  may be configured to mate with the male connector  302 . The female connector  304  may include a second portion  314  of the identification mark secured to or defined by a housing  316  of the female connector  304 . The first portion  310  and the second portion  314  may together form the identification mark in this example when the male connector  302  and the female connector  304  are fully mated. The first portion  310  and the second portion  314  may include one or more digitally identifiable items which may be read by an external device (not shown). 
     For example, the mark may include information relating to the male connector  302  and/or the female connector  304  such as a part number or instructions for the external device. The mark may be in the form of an identification signature, a QR code, or a bar code. Other forms for the mark are available which may include digitally identifiable items. The external device may be a scanning device and include a sensor to capture and/or read the first portion  310  and the second portion  314 . In one example, the external device may scan the first portion  310  and the second portion  314  and access one or more sets of instructions included therein. A set of instructions may direct the external device to trigger a signal, such as an audio or visual signal, indicating that the male connector  302  is engaged or mated with the female connector  304 . Another set of instructions may direct the external device to trigger a signal indicating that the male connector  302  and the female connector  304  are not mated to one another. Yet another set of instructions may direct the external device to trigger a signal to be sent to a server indicating the male connector  302  and the female connector  304  are engaged or whether a fault condition is present. Optionally, a label  317  may be secured to the housing  312  adjacent to the first portion  310 . The label may be visible only when the first portion  310  and second portion  314  are not fully mated. The label  317  may include an identifier, such as a color, which when read by the external device triggers a signal indicating a fault condition. Other examples of identifiers may be available. 
     A manual service disconnect is another example of an HV connector utilized in battery electric vehicles. Manual service disconnects may include a mechanical switch configured to disconnect the high voltage in an electrical bus of a HV battery when removed. An interlock switch may be disconnected during the process of removing the service disconnect switch to break the high voltage in the electrical bus. Optionally, an access cover may house two HV battery cable connection points at a battery bus electric center module. The cover may include features to prevent removal of the cover prior to removal of the service disconnect switch. A combination of the service disconnect switch and the cover may assist in preventing exposure to the high voltage during operation. 
       FIGS. 8A through 8C  show another HV connector assembly  400  which may include a service disconnect  402 . The service disconnect  402  may include a body  403 , an electrical connector (not shown), and a pivotal member  406 . The pivotal member  406  may include an interlock switch  408  which may engage with an interlock  410 . When installed in the connector assembly  400 , the interlock switch  408  and the electrical connector complete an electrical circuit. The pivotable member  406  may be mounted to the body  403  for rotation and translation. The pivotable member  406  may also include a handle  412  to assist in manipulating the pivotable member  406 . 
     The body  403  may include a first portion  420  of an identification mark secured to or defined by the body  403 . The pivotable member  406  may include a second portion  422  of the identification mark secured to or defined by the pivotable member  406 . The pivotable member  406  and handle  412  may translate along a body groove  405 . The first portion  420  and the second portion  422  may together form the identification mark in this example when the interlock  410  and the interlock switch  408  are fully engaged. The first portion  420  and the second portion  422  may include one or more digitally identifiable items which may be read by an external device (not shown) when properly aligned to form the identification mark. 
     For example, the identification mark may include information relating to the components of the service disconnect  402  such as part numbers or instructions for the external device. The mark may be in the form of an identification signature, a QR code, or a bar code. Other forms for the mark are available which may include digitally identifiable items. The external device may be a scanning device and include a sensor to capture and/or read the first portion  420  and the second portion  422 . In one example, the external device may scan the first portion  420  and the second portion  422  and access one or more sets of instructions included therein. A set of instructions may direct the external device to trigger a signal, such as an audio or visual signal, indicating that the first portion  420  and the second portion  422  are aligned and thus the interlock switch  408  is engaged with the interlock  410 . Another set of instructions may direct the external device to trigger a signal indicating that the interlock switch  408  is not engaged with the interlock  410 . For example, the first portion  420  and second portion  422  may each include this type of instructions such that a signal indicating a fault condition is triggered unless the first portion  420  and the second portion  422  are properly aligned. Yet another set of instructions may direct the external device to trigger a signal to be sent to a server indicating the interlock switch  408  and the interlock  410  are engaged or whether a fault condition is present. 
     In  FIG. 8A , the pivotable member  406  is shown in a first position in which the pivotable member  406  is oriented substantially perpendicular to the body  403 . In this first position, the interlock switch  408  and the interlock  410  are not engaged and the first portion  420  and the second portion  422  are not aligned to form the identification mark. Optionally and as described above, the first portion  420  and the second portion  422  may each separately include instructions to trigger a signal indicating a fault condition when either portion is scanned or read separately. In  FIG. 8B , the pivotable member  406  is shown in a second position in which the pivotable member  406  is rotated from the first position and is oriented substantially parallel to the body  403 . In this second position, the interlock switch  408  and the interlock  410  are not engaged and the first portion  420  and the second portion  422  are not aligned to form the identification mark. In  FIG. 8C , the pivotable member  406  is shown in a third position in which the interlock switch  408  and the interlock  410  are engaged, connecting the interlock switch  408  and the interlock  410  to complete the electrical circuit. In this third position, the first portion  420  and the second portion  422  are aligned such that when scanned as the complete identification mark, the external device may access the instructions included therein which may trigger one or more signals indicating full engagement as described above. 
     Now referring to  FIG. 9 , an algorithm is generally indicated by reference numeral  500 . Operation  502  may include inserting a first connector including a first portion of an identification mark into a second connector including a second portion of the identification mark. As described above, the first and second connectors may be HV connectors. The identification mark may include digitally identifiable items. The identification mark may be in the form of an identification signature, a quick response code (QR code), or a bar code. Other forms for the identification mark are available which may include digitally identifiable items. In operation  504 , a user may check to determine whether the first portion and second portion of the identification mark are aligned. For example, the user may use an external device, such as a scanner, to scan the first and second portions of the identification mark. If the first portion and second portion of the identification mark are not properly aligned, the user may be directed back to operation  502  to reinsert the first connector to the second connector. If the first portion and second portion of the identification mark are properly aligned, the scanner may read one or more digitally identifiable items included within the identification mark and send a corresponding signal to a server in operation  506 . The digitally identifiable items may include, for example, instructions which may direct the external device to trigger a signal to be sent to a server indicating the first connector and the second connector are engaged or whether a fault condition is present. 
     Optionally, another set of instructions may direct the external device to trigger a signal, such as an audio or visual signal, indicating that the first connector has mated with the second connector. Another set of instructions may direct the external device to trigger a signal indicating that the first connector and the second connector are not mated to one another. Additionally, the one or more digitally identifiable items of the first portion and second portion of the identification mark may only be readable by the external device when the connectors are mated or engaged. 
     The processes, methods, or algorithms disclosed herein can be deliverable to/implemented by a processing device, controller, or computer, which can include any existing programmable electronic control unit or dedicated electronic control unit. Similarly, the processes, methods, or algorithms can be stored as data and instructions executable by a controller or computer in many forms including, but not limited to, information permanently stored on non-writable storage media such as ROM devices and information alterably stored on writeable storage media such as floppy disks, magnetic tapes, CDs, RAM devices, and other magnetic and optical media. The processes, methods, or algorithms can also be implemented in a software executable object. Alternatively, the processes, methods, or algorithms can be embodied in whole or in part using suitable hardware components, such as Application Specific Integrated Circuits (ASICs), Field-Programmable Gate Arrays (FPGAs), state machines, or other hardware components or devices, or a combination of hardware, software and firmware components. 
     While various embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes can be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments can be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics can be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes can include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and can be desirable for particular applications.