Abstract:
A battery monitoring system that may be used to measure/monitor any number of battery operating conditions, including those associated with a vehicle battery. The system may be configured to interconnect a battery post that receives energy from the battery and a cable that electrically connects the battery to a vehicle.

Description:
TECHNICAL FIELD 
       [0001]    The present disclosure relates to battery diagnostic sensors, such as the type for connecting to battery posts and having capabilities for sensing and/or reporting battery operating conditions. 
       BACKGROUND 
       [0002]    Hybrid and non-hybrid vehicles may be equipped with energy storage devices, such as batteries for powering the vehicle and other devices. A battery monitoring system (BMS) may include a battery diagnostic sensor unit that may be connected to a battery post and configured to sense battery operating conditions. These type of battery diagnostic sensor units may be employed in automotive vehicles having lead-acid or some other type of battery or similar energy storage device. The battery diagnostic sensor units may be advantageous in reporting the battery operating conditions to a junction box or other vehicle system controller. 
       SUMMARY 
       [0003]    One or more embodiments of the present disclosure are directed to a battery monitoring system for use with a battery used to power electronic devices within a vehicle. The battery may have a ledge proximate to a battery post. The system may comprise a battery clamp including a terminal adapter at one end and a shunt adapter at another end. The terminal adapter may have a compressively tightened connection to electrically connect to the battery post. 
         [0004]    The system may further comprise a shunt having a first conductive portion, a second conductive portion, and a resistive portion disposed between the first conductive portion and the second conductive portion. The first conductive portion of the shunt may be attached to a first end of the shunt adapter and the second conductive portion of the shunt may be attached to a conducting portion of a vehicle cable. The cable may be used to carry energy between the battery and the vehicle. 
         [0005]    The system may further comprise a printed circuit board (PCB) having a battery monitoring circuit configured to measure a voltage drop between the first conductive portion and the second conductive portion of the shunt. The system may further comprise a housing enclosing the PCB and at least a portion of the shunt. The housing may include a tab slot that receives a tab formed at a second end of the shunt adapter. 
         [0006]    The first conductive portion of the shunt may be attached to the first end of the shunt adapter using a soldering process, a welding process, or a brazing process. The system may further include a signal connector attached to the PCB and in communication with the battery monitoring circuit. The signal connector may provide an interface that sends signals to and receives signals from a network vehicle element. 
         [0007]    The tab may be co-planar with the second end of the shunt adapter. Alternatively, the tab may be angled downward from a main plane of the shunt adapter. The housing may be formed from an epoxy molded compound molded around the PCB and the portion of the shunt. The shunt adapter may include a bend between the first end and the second end such that the first end and the second end of the shunt adapter are in offset, parallel planes. 
         [0008]    One or more additional embodiments of the present disclosure are directed to a battery diagnostic sensor (BDS) unit for use between a vehicle battery and a vehicle cable. The vehicle cable may be used for transferring energy between the vehicle battery and one or more electronic devices included within a vehicle. The BDS unit may comprise a shunt, a printed circuit board (PCB), a signal connector, a housing, and a battery clamp. 
         [0009]    The shunt may have a resistive portion disposed between a first conductive portion and a second conductive portion. The second conductive portion may be connected to an electrically conducting portion of the vehicle cable. The PCB may have first and second footprints respectively connected to the first and second conductive portions of the shunt. The PCB may include a battery monitoring circuit measuring a voltage drop between the first and second footprints. The signal connector may be attached to the PCB and in communication with the battery monitoring circuit. The signal connector may provide an interface that sends signals to and receives signals from a network vehicle element. The housing may enclose the PCB and at least a portion of the shunt. 
         [0010]    The battery clamp may be composed of a continuous piece of material. The battery clamp may include (i) a terminal adapter having a cylindrically shaped, compressively tightened portion to electrically connect to a post of the battery; and (ii) a shunt adapter extending from the terminal adapter. The shunt adapter may affix the battery clamp to a remainder of the BDS unit at a first fixation point and a second fixation point. The shunt adapter may have a first end electrically connected to the first conductive portion of the shunt at the first fixation point and a second end having a tab inserted into a corresponding tab slot in the housing at the second fixation point. 
         [0011]    The first end of the shunt adapter may be electrically connected to the first conductive portion of the shunt using one of a soldering, welding, or brazing process. The tab may be co-planar with the second end of the shunt adapter. Alternatively, the tab may be angled downward from a main plane of the second end of the shunt adapter. The housing may be formed from an epoxy molded compound molded around the PCB and the portion of the shunt. The shunt adapter may include a bend between the first end and the second end such that the first end and the second end of the shunt adapter are in offset, parallel planes. 
         [0012]    The second conductive portion of the shunt may be connected to an electrically conducting portion of the vehicle cable via a connecting element. The connecting element may have a proximal end including at least a first clamping portion secured to the electrically conducting portion of the vehicle cable. The connecting element may have a distal end electrically connected to the second conductive portion of the shunt. 
         [0013]    One or more additional embodiments of the present disclosure are directed to a method for assembling a battery diagnostic sensor (BDS) unit. The method may comprise providing a PCB having at least a battery monitoring circuit; soldering a shunt and a signal connector to the PCB; forming a housing around the PCB and at least portions of the shunt and the signal connector using a moldable compound; and attaching a battery clamp to the BDS unit at a first fixation point and a second fixation point, wherein only one of the first and second fixation points includes an electrical connection to the shunt. 
         [0014]    Attaching the battery clamp to the BDS unit may include inserting a tab formed in a battery clamp into a tab slot formed in the housing at the second fixation point and electrically connecting a shunt adapter to the shunt at the first fixation point. The shunt adapter may be electrically connected to a first conductive portion of the shunt. The method may further comprise electrically connecting a vehicle cable to a second conductive portion of the shunt. The first conductive portion and the second conductive portion of the shunt may be separated by a resistive portion of the shunt. Electrically connecting the shunt adapter to the shunt may comprise one of soldering, welding, or brazing the shunt adapter to the shunt. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view of a battery monitoring system, according to one or more embodiments of the present disclosure; 
           [0016]      FIG. 2  is an exemplary, exploded view of a battery diagnostic sensor (BDS) unit, according to one or more embodiments of the present disclosure; 
           [0017]      FIG. 3 a    is a perspective view of the BDS unit with an overmold housing, according to one or more embodiments of the present disclosure; 
           [0018]      FIG. 3 b    is a perspective view of the BDS unit in  FIG. 3 a    showing a battery clamp without the overmold housing; 
           [0019]      FIG. 4  is a perspective view of an alternate battery clamp for a BDS unit, according to one or more embodiments of the present disclosure; 
           [0020]      FIG. 5  is a top plan view of the battery clamp in  FIG. 4  secured to a housing, according to one or more embodiments of the present disclosure; 
           [0021]      FIG. 6  is a perspective view illustrating the assembled BDS unit with the battery clamp shown in  FIG. 4 , according to one or more embodiments of the present disclosure; and 
           [0022]      FIG. 7  is a flow chart illustrating an assembly process of a BDS unit, according to one or more embodiments of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0023]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may 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. 
         [0024]      FIG. 1  illustrates a battery monitoring system (BMS)  10  in accordance with one or more objects of the present disclosure. A battery diagnostic sensor (BDS) unit  12  may be included and configured for connecting to a battery post  14  of a battery  16 , such as a lead-acid or other battery commonly employed within vehicles. The battery  16  is used to power electronic devices within a vehicle. The BDS unit  12  may be securely connected to the battery post  14  with a battery clamp  18  via compressive tightening of a terminal adapter  20  at one end of the battery clamp  18  or through another suitable connection. The BDS unit  12  may be configured or otherwise programmed to support any number of sensor operations, such as but not limited to measuring/sensing current, voltage, and temperatures associated with the battery  16 . 
         [0025]    The battery clamp  18  may comprise a continuous piece of tinned brass or other material suitable for conducting electricity from the battery  16 . The battery clamp  18 , as described below in more detail, may extend relative to an outward clamping end that hosts the terminal adaptor  20  used to connect to the battery post  14 . The terminal adapter  20  is configured for attachment to a cylindrical battery post  14  for exemplary purposes. Accordingly, the terminal adapter  20  may include a cylindrically shaped, compressively tightened portion  22 . However, any type of connection to the battery  16  may be used. 
         [0026]    The BDS unit  12  may interface with a cable, wire, or other element  26  suitable for conducting electricity to another element within the vehicle, such as a vehicle chassis (not shown), grounding element, etc. The cable  26  may be suitable for use in conducting energy between the battery  16  and the vehicle element. The cable  26  may include an outer insulated portion  28  surrounding a copper or other suitable electrically conducting material  30 . 
         [0027]    The BDS unit  12  may further include a signal connector  32  that provides a network interface for interfacing signals with a network vehicle element (not shown), such as to a vehicle system controller, junction box, bus, network etc. The signal connector  32  may be used to interface any number of signals between the BDS unit  12  and the vehicle system controller or other network vehicle element, i.e., any element not intended to exchange current directly with the battery  16 . For example, one or two-way communications may be established with the BDS unit  12  to facilitate any number of operations, such as but not limited operations associated with sensing and measuring current, voltage, temperature, and other operating parameters of the battery  16 . 
         [0028]    As shown in  FIG. 1 , the BDS unit  12  may be sized and shaped to fit within a ledge or niche  34  of the battery  16 . The BDS unit  12  may rest within the ledge  34  so that no portion of the BDS unit  12  extends above a top side of the battery  16 . This can be helpful in reducing packaging and limiting space restrictions and help prevent rotation when mounting the BDS unit  12 . As also shown, the terminal adapter  20  may include an adapter screw  36 , which is slightly angled in an upright direction to facilitate tightening. The adapter screw  36  may be angled in any direction, both laterally and vertically and is not intended to be limited to the illustrated positions. 
         [0029]      FIG. 2  is an exemplary, exploded view of the BDS unit  12 . As shown, the BDS unit  12  may further include a shunt  40 , a printed circuit board (PCB)  42 , and a housing  44 . The shunt  40  may comprise any material having properties sufficient to facilitate electrical connectivity between the battery clamp  18  and the cable  26 . The shunt  40  is shown as a bi-metallic object having a first conductive portion  46 , a second conductive portion  48 , and a resistive portion  50 . The first and second conductive portions  46 - 48  may comprise a conductive copper alloy, while the resistive portion  50  may comprise a resistive copper alloy, such as manganin. The first and second conductive portions  46 - 48  correspond with the ends of the shunt  40  and the resistive portion  50  may be arranged therebetween such that current must flow from through the first conductive portion  46 , through the resistive portion  50 , and finally through the second conductive portion  48 . 
         [0030]    The resistive portion  50  may be used as a measuring element suitable for conducting high currents. Sensing features may be included within or outside the boundaries of the resistive portion  50  for use in facilitating sensing of a voltage drop therebetween. The known resistive characteristics of the resistive portion  50 , such as the resistive copper alloy, may be used in conjunction with the voltage drop to determine current flow through the shunt  40 . In this manner, the BDS unit  12  is able to sense voltage and current associated with the battery  16 . The known resistivity of the resistive portion  50  can be helpful in assuring the accuracy and consistency of the current calculations. Of course, the shunt  40  may utilize any number of other suitable materials as well, including making the shunt  40  out of a single material/composition, i.e., without the bi-metallic composition. 
         [0031]    The PCB  42  may be used to assess battery operations. Accordingly, the PCB  42  may be electrically connected to the shunt  40 . According to one or more embodiments, the PCB  42  may be directly connected or welded to the shunt  40 , for example, using a reflow soldering process. Alternatively, the PCB  42  may include connection tabs (not shown) that can be welded or otherwise electrically secured to the shunt  40 . The PCB  42  may include footprints extending over a portion of the first and second conductive portions  46 - 48  of the shunt  40  to facilitate measuring the voltage drop across the resistive portion  50 . 
         [0032]    The PCB  42  may include any number of sensors and circuitry or other electrical components to form a PCB sub-assembly  52 . For the sake of simplicity, reference to the PCB  42  may be considered a reference to the PCB sub-assembly  52  with electrical components  54  attached. The sensors and circuitry of the PCB  42  may form at least a battery monitoring circuit  56 . Accordingly, the PCB  42  may perform any number of logical functions associated with determining the operating conditions of the battery  16  or other operations associated with or based on the BDS unit  12  and its function and performance. For example, the PCB  42  may include a temperature sensor (not shown) for sensing connector temperature and/or battery temperature. A pair of connector pins  58  may be integrated with the signal connector  32  to facilitate an electrical connection to the BDS unit  12  via the PCB  42 . 
         [0033]    The temperature sensor may be used to sense the battery temperature as a function of the terminal adapter temperature. This may include establishing a thermal coupler or other element (not shown) between the terminal adapter  20  and the PCB  42  so as to facilitate temperature sensing. A negative or positive temperature coefficient element may be included proximate the thermal coupler to facilitate sensing the temperature. The PCB  42  is illustrated for exemplary purposes and without intending to limit the scope and contemplation of the present disclosure. The present disclosure fully contemplates the use of any type of logically functioning processing element, such as but not limited to a discrete or integrated circuit, having properties sufficient to facilitate determining battery operating conditions, which may or may not be included on a PCB  42 . 
         [0034]    The housing  44  may be included around the PCB  42  and at least the resistive portion  50  of the shunt  40 . The housing  44  may also enclose a portion  60  of the signal connector  32  containing the connector pins  58 . The housing  44  may comprise a non-conducting material configured for covering a portion of the battery clamp  18  and shunt  40  extending between the battery post  14  and the vehicle cable  26 . For instance, the housing  44  may be formed from a moldable compound once the shunt  40  and signal connector  32  are soldered to the PCB  42 . For example, an epoxy molding compound may be used to form the housing  44 . The housing  44  may be used to electrically isolate the shunt  40  and battery clamp  18 . 
         [0035]      FIG. 3 a    is a perspective view of the BDS unit  12  with the overmold housing  44 , while  FIG. 3 b    shows the same view without the overmold housing present for illustrative purposes.  FIGS. 3 a  and 3 b    illustrate the shunt  40  connected to the battery clamp  18  in accordance with one or more embodiments of the present disclosure. The battery clamp  18  may further include a shunt adapter  62  adjacent to the terminal adapter  20 . The first conductive portion  46  of the shunt  40  may be connected, such as by welding, soldering, brazing, or other fastening, to a first end  64  of the shunt adapter  62 . The second conductive portion  48  of the shunt  40  may be connected directly to the cable  26  or indirectly to the cable  26  via a connecting element,  66  as shown in  FIG. 1 . In the case of a direct connection, wire strands from the cable  26  may be soldered to the second conductive portion  48  of the shunt  40 . A soldering machine or other soldering or welding element may be configured to compress the wires from their circular shape within the cable  26  to a flatter shape more suitable for fastening to the shunt  40 . Once the wires are fastened to the shunt  40 , or in the same assembly process, the wires may be bent to form the right angle with the shunt  40 . 
         [0036]    Referring back to  FIG. 1 , the electrical connection between the cable  26  and shunt  40  via the connecting element  66  is illustrated. The connecting element  66  is formed from an electrically conductive material. The connecting element  66  may include a proximal  68  end having at least a first clamping portion  70  that may be connected to the conducting material  30  of the cable  26  that extends beyond the insulated portion  28 . The first clamping portion  70  may include opposed fingers  72  defining an opening for receipt of the cable  26 . The first clamping portion  70  may be bendable, with a crimp tool or other feature, to compressively connect to the inner, conducting material  30  of the cable  26 . 
         [0037]    The proximal end  68  of the connecting element  66  may further include a second clamping portion  74  that may be connected to the insulated portion  28  of the cable  26 . The second clamping portion  74  may also include opposed fingers  76  defining an opening for receipt of the cable  26 . The second clamping portion  74  may likewise be bendable, with a crimp tool or other feature, to compressively connect to the insulating portion  28  of the cable  26 . This connection may help reduce vibratory susceptibility of the connecting element  66 . The second clamping portion  74  is shown to include the opposed fingers  76  for exemplary purposes only. The second clamping portion  74  may include any shape or configuration suitable to providing a compressive or other connection between the connecting element  66  and the cable  26 . For example, the second clamping portion  74  may include a C-shaped configuration where the outer portions of the C-shape are compressed against the cable  26 . 
         [0038]    The connecting element  66  may further include a distal end  78  having a connecting surface  80  for electrically connecting to the second conducting portion  48  of the shunt. Similar to the shunt adapter  62 , the connecting element  66  may be electrically connected to the shunt  40  by a welding, soldering, brazing, or other fastening operation. According to one or more embodiments, the connecting element  66  may include a bend  82  between the proximal end  68  and the distal end  78 , such as the 90 degree bend shown in  FIG. 1 . The bend  82  in the connecting element  66  may orient the cable  26  in close proximity to the battery  16  and avoid interference with other vehicle components. 
         [0039]    In addition to the connection methods described above, other methods may be employed for connecting the vehicle cable  26  to the shunt  40 . For instance, the second conductive portion  48  of the shunt  40  may include an orthogonally extending screw  84  ( FIG. 6 ). Accordingly, the vehicle cable  26  may be attached to the shunt  40  via a connective element, such as a terminal, adapted to be secured to the screw  84  (not shown). 
         [0040]    The battery clamp  18  may be electrically connected at one end to the battery post  14  via the terminal adapter  20 . At the other end of the battery clamp  18 , the first end  64  of the shunt adapter  62  may be electrically connected to the first conductive portion  46  of the shunt  40 . The battery clamp  18  and the shunt  40  may be connected to the vehicle chassis or other ground element by cable  26 , as previously described, namely via a direct or indirect connection between the cable  26  and the second conductive portion  48  of the shunt  40 . This allows the BDS unit  12  to exchange current between the vehicle cable  26  and the battery post  14  by way of the shunt  40  and the battery clamp  18 , but without any direct electrical connection between the terminal adapter  20  and the vehicle cable  26 . 
         [0041]    As previously described, the housing  44  may be included around a portion of the shunt  40  and the PCB  42  used to assess battery operations. The housing  44  may comprise a non-conducting material configured for covering a portion of the shunt adapter  62  and shunt  40  extending between the battery post  14  and the vehicle cable  26 . For instance, the housing  44  may be formed from an epoxy molding compound once the shunt  40  and signal connector  32  are soldered to the PCB  42 . The housing  44  may be used to electrically isolate the shunt  40  and battery clamp  18 , except where the shunt  40  is electrically fastened to the shunt adapter  62  of the battery clamp  18 . 
         [0042]    The battery clamp  18  may be a stamped from a single sheet of electrically conducting material into the illustrated configuration. Alternatively, the battery clamp  18  may be forged from die-cast materials. According to one or more embodiments, the battery clamp  18  may be shaped so that only one soldering point is needed for fixation to the BDS unit  12 . As previously described, the sole soldering point may occur at an interface  86  (or first fixation point) between the first end  64  of the shunt adapter  62  and the first conducting portion  46  of the shunt  40 . 
         [0043]    As shown in  FIGS. 3 a  and 3 b   , the battery clamp  18  may be further secured to the remainder of the BDS unit  12  at a second fixation point  88  that is not soldered or welded to the shunt  40 . The second fixation point  88  may be realized by fitting a tab  90  formed at a second end  92  of the shunt adapter  62  into a corresponding tab slot  94  formed in the overmold housing  44 . Accordingly, the second end  92  of the shunt adapter  62  is not affixed directly to the shunt  40 . This avoids a second soldering/welding step, screw process step, riveting step, or the like. The two fixation points  86 - 88  described adequately secure the battery clamp  18  to the BDS unit  12  using, for example, a single soldering step. 
         [0044]    As shown in  FIG. 3 b   , shunt adapter  62  may include a bend  96  between its first end  64  and second end  92 . This may permit the second end  92  of the shunt adapter  62  to extend above the PCB  42  and shunt  40  in a plane generally parallel to the shunt  40 . Accordingly, the first end  64  of the shunt adapter  62  and the second end  92  of the shunt adapter  62  may extend along offset, yet parallel planes. The second end  92  of the shunt adapter  62  may include a cutout region  98  that forms the tab  90 . The tab  90  may be aligned with the tab slot  94  in the housing  44 . During assembly, the tab  90  may be inserted into the tab slot  94  to form the second fixation point  88  for securing the battery clamp  18  to the BDS unit  12 . The first end  64  of the shunt adapter  62  may be subsequently soldered or welded to the first conducting portion  46  of the shunt  40  to form the first fixation point  86 . 
         [0045]    As shown in  FIGS. 3 a  and 3 b   , the tab  90  is generally rectangular and is generally co-planar with the second end  92  of the shunt adapter  62 . According to one or more alternate embodiments of the present disclosure, the tab shape, angle and/or direction may be varied without departing from the scope of the present disclosure. Various tab configurations may result in corresponding adaptations to the tab slot  94  in the housing  44  so that it remains in alignment with the tab  90 . Accordingly, the tab  90  and tab slot  94  may be configured in such a way that the tab  90  may be inserted into the tab slot  94  regardless of tab orientation. 
         [0046]      FIGS. 4-6  illustrate an exemplary, alternative tab configuration according to one or more embodiments of the present disclosure.  FIG. 4  is a perspective view of an alternate battery clamp  118  having a terminal adapter  120  and a shunt adapter  162 . The terminal adapter  120  and a first end  164  of the shunt adapter  162  may be similar to corresponding elements in the battery clamp  18  illustrated in  FIGS. 1-3   b . The second end  192  of the shunt adapter  162  may include the alternate tab configuration. In particular, the second end  192  of the shunt adapter  162  may include a tab  190  formed into an L-shaped leg that extends downward from a main plane  102  of the shunt adapter  162  in the direction of the shunt. 
         [0047]      FIG. 5  is a top plan view of the battery clamp  118  secured to a housing  144 . As shown in  FIG. 5 , the housing  144  may include a corresponding tab slot  194  in which an extension  104  of the L-shaped leg may be inserted for securing the battery clamp  118  to the BDS unit  12  at a second fixation point  188 .  FIG. 6  is a perspective view illustrating the assembled BDS unit  12  with the battery clamp  118  having the alternate tab configuration.  FIG. 6  also illustrates an alternate shunt configuration where, as previously described, a second conductive portion  148  of a shunt  140  includes a screw  84  that may be employed for connecting the shunt  140  to the vehicle cable  26 , which in turn may be connected to the vehicle chassis or other grounding element of the vehicle. 
         [0048]    The shunt described above in all embodiments of the present disclosure is shown to be a relatively planar shunt. However, any type of shunt having any type of shape, including a shunt having a cylindrical shape, may be employed. Further, the present disclosure fully contemplates any number of connection methods to facilitate electrically connecting the PCB  42  to the shunt  40  and the use of any type of connector or soldering method to facilitate connecting to a cylindrical, planar, or other shaped shunt. 
         [0049]    With reference to  FIG. 7 , an exemplary method  700  of assembly of the BDS unit  12  is illustrated. At step  710 , electrical components  54  (e.g., sensors and circuitry) are mounted to the PCB  42  to form the PCB sub-assembly  52 . The electrical components  54  may be surface mount components, through hole components, or a combination of both. Moreover, the electrical components  54  may be attached to the PCB  42  by reflow soldering, wave soldering, or manual soldering. Once the PCB sub-assembly  52  is assembled, the shunt  40  and signal connector  32  may be soldered to the PCB sub-assembly  52  using, for example, reflow soldering, as provided at step  720 . 
         [0050]    At step  730 , the housing  44  made from an epoxy molded compound may be formed around the PCB  42  and portions of the shunt  40  and signal connector  32 . The housing  44  may vibrationally and electrically isolate and waterproof the PCB  42 , which is beneficial in enhancing system integrity against contaminates, water, debris, etc. The housing  44  may enclose the PCB  42  and at least the resistive portion  50  of the shunt  40 . It may also encase the connector pins  58  attaching the signal connector  32  to the PCB  42 . The housing  44  may be injection molded to form a particular shape around the PCB  42 . The housing  44  may be molded such that it includes the tab slot  94  for receiving the tab  90  of the battery clamp  18  at the second fixation point  88 . 
         [0051]    To that end, the battery clamp  18  may be attached to the shunt  40  at step  740 . In particular, the tab  90  at the second end  92  of the shunt adapter  62  may be inserted into the tab slot  94  in the housing  44 . The first end  64  of the shunt adapter  62  may then be electrically affixed to the first conductive portion  46  of the shunt  40  as previously described (e.g., using a soldering, welding, or brazing process, etc.). Next, the vehicle cable  26  may be attached to the shunt  40 , at step  750 . For example, the proximal end  68  of the connecting element  66  may be crimped to the cable  26  as previously described. The distal end  78  of the connecting element  66  may then be soldered to the second conductive portion  48  of the shunt  40 . Alternatively, the cable  26  may be directly soldered to the second conductive portion  48  of the shunt  40  or attached to a screw  84  as previously described. 
         [0052]    While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.