Abstract:
A vehicle power system may include a signal driver system electrically connected with a signal receiver system, and a traction battery electrically connected with contactors responsive to the signal receiver system. The electrical connections may be routed through a common interface. A voltage associated with a control signal commanding the signal receiver system to cause the contactors to close and driven into the electrical connection between the signal driver and signal receiver systems by the signal driver system may indicate whether the electrical connection between the traction battery and contactors at the common interface is faulty.

Description:
TECHNICAL FIELD 
       [0001]    This disclosure relates to interlock detection of automotive power system connectors. 
       BACKGROUND 
       [0002]    An electrified vehicle often includes a power storage unit, such as a traction battery, arranged to provide power for moving the vehicle. Power modules and wiring harnesses may form portions of the electrical path between the traction battery and the various high-voltage electrical loads electrically connected with the traction battery. The power modules and wiring harnesses may include connectors that interface with other components disposed along the electrical path. These connectors, on occasion, may not have a complete connection with their mating components. 
       SUMMARY 
       [0003]    The electrical connections between primary and secondary controllers, and a traction battery and switch associated with the secondary controller may be routed through a common interface. A voltage associated with a control signal driven into the electrical connection between the primary and secondary controllers may indicate whether the electrical connection between the traction battery and switch at the interface is faulty. 
         [0004]    A vehicle may include a traction battery, a primary controller, a secondary controller including a switch, and a wiring harness arrangement. The wiring harness arrangement may define at least a portion of a first electrical path connecting the traction battery and switch, and a second electrical path connecting the primary and secondary controllers. The wiring harness arrangement may include an electrical connector assembly through which the first and second electrical paths are routed. The primary controller may generate a control signal commanding the secondary controller to close the switch. The secondary controller may close the switch in response to the control signal if a voltage associated with the control signal falls within a predetermined range of voltages indicative of a non-faulty electrical connection between the primary and secondary controllers at the electrical connector assembly. 
         [0005]    A vehicle power system may be controlled by generating, by a signal driver system, a control signal, for a signal receiver system, commanding the signal receiver system to close contactors to enable current flow between a traction battery and an electric machine, and closing the contactors if a voltage associated with the control signal falls within a predetermined range of voltages indicative of a non-faulty electrical connection between the signal driver and receiver systems. 
         [0006]    An assembly for a vehicle may include a traction battery, a primary controller including a signal driver system, and a secondary controller including a signal receiver system and contactors responsive to the signal receiver system. The assembly may further include an interface electrically connecting the traction battery with the contactors, and the signal driver system with the signal receiver system. The signal driver system may generate a control signal commanding the signal receiver system to cause the contactors to close. The signal receiver system may cause the contactors to close in response to the control signal if a voltage associated with the control signal falls within a predetermined range of voltages. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIGS. 1-3  are block diagrams of automotive power systems. 
           [0008]      FIG. 4  is an exploded assembly view of one of the connectors of  FIG. 3 . 
       
    
    
     DETAILED DESCRIPTION 
       [0009]    Embodiments of the present disclosure are described herein; however, it is to be understood that the disclosed embodiments are merely examples and other embodiments may take 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. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may 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, may be desired for particular applications or implementations. 
         [0010]    Referring to  FIG. 1 , a power system  10  for an automotive vehicle  12  includes a high-voltage module  14 , a high-voltage contactor module  16 , and a high-voltage wiring harness  18  electrically connected there between. The high-voltage module  14  is electrically connected with a traction battery (not shown) and distributes electric current received from the traction battery to the high-voltage contactor module  16  via the high-voltage wiring harness  18 . The high-voltage contactor module  16  distributes electric current received from the high-voltage module  14  to various high-voltage electrical loads, such as an electric machine (not shown), electrically connected therewith. 
         [0011]    The high-voltage wiring harness  18  includes connectors  20 ,  22 , high-voltage wiring  24 , and low-voltage wiring  26 . The connectors  20 ,  22  respectively electrically interface with the high-voltage module  14  and high-voltage contactor module  16 . The high-voltage wiring  24  electrically connects the connectors  20 ,  22  and forms a high-voltage circuit that carries high-voltage electric current between the modules  14 ,  16 . The low-voltage wiring  26  also electrically connects the connectors  20 ,  22  and completes an interlock detection circuit, which includes a loop back portion  28  within the high-voltage module  14  and a terminal portion  30  within the high-voltage contactor module  16 , when the connectors  20 ,  22  are properly respectively connected with the modules  14 ,  16 . 
         [0012]    The high-voltage contactor module  16  includes a sensor (not shown) configured to detect a voltage across the terminal portion  30  and contactors (not shown) that electrically connect the high-voltage circuit and various high-voltage electrical loads (not shown). The contactors are opened/closed based on the detected voltage. That is, the quality of the connections between the connectors  20 ,  22  and their respective modules  14 ,  16  may be determined based on the voltage across the terminal portion  30 . The contactors are closed (the connections are assumed to be proper) if the detected voltage falls within some expected range indicative of a complete interlock detection circuit. The contactors are opened (the connections are assumed to be improper) if the detected voltage falls outside of the expected range. If the contactors are closed, high-voltage electric current from the high-voltage module  14  may flow to the various high-voltage electrical loads (not shown) mentioned above. If the contactors are open, high-voltage electric current may not so flow. 
         [0013]    Referring to  FIG. 2 , a power system  32  for an automotive vehicle  34  includes a high-voltage module  36 , a high-voltage contactor module  38 , and a high-voltage wiring harness  40  and communications line  42  each electrically connected between the modules  36 ,  38 . The high-voltage module  36  is operatively arranged with a traction battery (not shown) in a manner similar to that described with reference to the high-voltage module  14  of  FIG. 1 . Likewise, the high-voltage contactor module  38  is operatively arranged with various high-voltage electrical loads (not shown) in a manner similar to that described with reference to the high-voltage contactor module  16  of  FIG. 1 . 
         [0014]    The high-voltage wiring harness  40  includes connectors  44 ,  46  and high-voltage wiring  48 . The connectors  44 ,  46  respectively electrically interface with the high-voltage module  36  and high-voltage contactor module  38 . The high-voltage wiring  48  electrically connects the connectors  44 ,  46  and forms a high-voltage circuit that carries high-voltage electric current between the modules  36 ,  38 . The connector  44  includes a loop back portion  50  and the high-voltage module  36  includes a terminal portion  52  that together form an interlock detection circuit when the connector  44  is properly connected with the module  36 . 
         [0015]    The high-voltage module  36  includes a sensor (not shown) configured to detect a voltage across the terminal portion  52  and a communications interface (not shown) operatively arranged with the sensor and communications line  42 . The high-voltage contactor module  38  includes contactors (not shown) that electrically connect the high-voltage circuit and various high-voltage electrical loads (not shown), and a control interface (not shown) operatively arranged with the contactors and communications line  42 . 
         [0016]    The contactors are opened/closed based on the detected voltage. That is, the quality of the connection between the connector  44  and the module  36  may be determined based on the voltage across the terminal portion  52 . If the detected voltage falls within some expected range indicative of a complete interlock detection circuit, the communications interface sends a command to the high-voltage contactor module  38  to close the contactors. If the detected voltage falls outside of the expected range, the communications interface does not send such a command (and/or sends a command to the high-voltage contactor module  38  to open the contactors). The control interface of the high-voltage contactor module  38  opens or closes the contactors in response to the command. In other examples, the high-voltage contactor module  38  may detect its own continuity in a manner similar to the high-voltage module  36 . 
         [0017]    Referring to  FIG. 3 , a power system  54  for an automotive vehicle  56  may include a controller  58 , a high-voltage contactor module  60 , a traction battery  62 , and an electric machine  64 . The electric machine  64 , in the example of  FIG. 3 , is arranged to transform electrical energy from the traction battery  62  to mechanical energy to move the vehicle  56 . The controller  58  may include duty cycle control logic  66 , signal driver circuitry  68 , and a voltage sensor  70  arranged to detect a voltage associated with the signal driver circuitry  68 . The high-voltage contactor module  60  may include signal receiver circuitry  72 , a voltage sensor  74  arranged to detect a voltage associated with the signal receiver circuitry  72 , and contactors  76  (or any other suitable/known switch). The arrangement and operation of these components are described in further detail below. 
         [0018]    The power system  54  may further include wiring harnesses  78 ,  80 ,  82 . The wiring harness  78 , in this example, includes a high-voltage connector  84  and low-voltage connectors  86 ,  88 . It also includes high-voltage wiring  90  electrically connecting the traction battery  62  and high-voltage connector  84 , low-voltage wiring segment  92  electrically connecting the signal driver circuitry  68  and the low-voltage connector  86 , and low-voltage wiring segment  94  electrically connecting the low-voltage connectors  86 ,  88 . In other examples, the wiring harness  78  may instead comprise two separate wiring harnesses: a high-voltage harness including the high-voltage connector  84  and high-voltage wiring  90 , and a low-voltage harness including the low-voltage connectors  86 ,  88  and the low-voltage wiring segments  92 ,  94 . The wiring harness  80 , in this example, includes a high-voltage connector  96  and a low-voltage connector  98 . It also includes high-voltage wiring  100  electrically connecting the high-voltage connector  96  and contactors  76 . The low-voltage connector  98  includes a loop back portion  102  electrically connecting the low-voltage wiring segments  92 ,  94 . The wiring harness  82 , in this example, includes a low-voltage connector  104  and low-voltage wiring segment  106  electrically connecting the low-voltage connector  104  and the signal receiver circuitry  72 . 
         [0019]    The high-voltage wiring  90 ,  100  form a high-voltage circuit, if the high-voltage connectors  84 ,  96  are properly connected to each other, that carries high-voltage electric current between the traction battery  62  and the contactors  76 . If the contactors  76  are closed, high-voltage electric current from the traction battery  62  may flow to the electric machine  64 . If the contactors  76  are open, such current may not flow. Closing the contactors  76  if the high-voltage connectors  84 ,  96  are improperly connected with each other (or not connected at all) may be undesirable. The high-voltage contactor module  60  determines whether to close the contactors  76  based on information from the voltage sensor  74  as described in more detail below. 
         [0020]    The low-voltage wiring segments  92 ,  102 ,  94 ,  106  form a low-voltage circuit that carries a low-voltage communication signal between the signal driver circuitry  68  and the signal receiver circuitry  72  if (1) the high-voltage connectors  84 ,  96  are properly connected to each other, (2) the low-voltage connectors  86 ,  98  are properly connected to each other, and (3) the low-voltage connectors  88 ,  104  are properly connected to each other. That is, a voltage associated with the communication signal (originating from the duty cycle control  66 ) will fall within some expected range if the connections described above are proper; the voltage will fall outside of the expected range if the connections are improper or faulty. Hence, the voltage detected by the voltage sensor  74  (or possibly  70 ) may be used to determine the quality of the connection between the high-voltage connectors  84 ,  96  (as well as the quality of the connections between the low-voltage connectors  86 ,  98  and  88 ,  104 ). 
         [0021]    In other examples, the low-voltage wiring segments  94 ,  106 , loop back portion  102 , and low-voltage connectors  88 ,  104  may be omitted. A low-voltage wiring segment  108  may instead electrically connect the low-voltage connector  98  and the signal receiver circuitry  72 . This arrangement may present isolation issues if the low-voltage wiring segment  108  is routed between the connectors  96 ,  98  and contactors  76  in close proximity to the high-voltage wiring  100 . Any suitable/known circuit isolation technology, however, may be used to ensure isolation between the wiring  100  and wiring segment  108 . The arrangement described in previous paragraphs may not present such isolation issues as the low-voltage wiring segments  94 ,  106 , loop back portion  102 , and low-voltage connectors  88 ,  104  allow the low-voltage circuitry formed thereby to be routed some distance away from the high-voltage wiring  100 . Other arrangements, of course, are also contemplated. 
         [0022]    The duty cycle control logic  66  may cause the signal driver circuitry  68 , which in this example includes a transistor  110  connected with the low-voltage wiring segment  92  and a resistive element  112  connected to the transistor  110  and chassis ground, to drive a signal carrying command and/or communication information for the high-voltage contactor module  60  on to the low voltage circuit formed by the low-voltage wiring segments  92 ,  102 ,  94 ,  106 . The signal receiver circuitry  72 , which in this example includes a transistor  112  connected with the low-voltage wiring segment  106 , a resistive element  114  connected to the transistor  112  and chassis ground, and a resistive element  116  connected to the low-voltage wiring segment  106  and operatively arranged with the voltage sensor  74 , may receive the signal carrying command and/or communication information. If the voltage sensor  74  detects a voltage, for example, in the 1 V to 12 V range associated with the received signal, the high-voltage contactor module  60  may close the contactors  76 . Otherwise, the high-voltage contactor module  60  may not close the contactors  76 . 
         [0023]    Referring to  FIG. 4 , the high-voltage connector  96  may define a cavity  118  and include male terminal portions  120  that reside within the cavity  118  and that are electrically connected with the high-voltage wiring  100 . The low-voltage connector  98  may define a cavity  122  and include male terminal portions (associated with the loop back portion  102 ) that reside within the cavity  122 . 
         [0024]    The high-voltage connector  84  may include tracks  124  extending away from a surface intended to be adjacent to the low-voltage connector  86  when assembled. The high-voltage connector  84  may further include female terminal portions (not shown) that receive the male terminal portions  120  and that are electrically connected with the high-voltage wiring  90 . The low-voltage connector  86  may include recessed portions  126  formed in a surface intended to be adjacent to the high-voltage connector  84  and that receive the tracks  124  when assembled. The low-voltage connector  86  may further include female terminal portions (not shown) that receive the mail terminal portions associated with the loop back portion  102  and that are electrically connected with the low-voltage wiring segments  92 ,  94 . 
         [0025]    The high-voltage connector  84  may first be inserted into the cavity  118  to electrically connect the high-voltage wiring  90 ,  100 . The low-voltage connector  86  may then be inserted into the cavity  122  along the tracks  124  (thus engaging the high-voltage connector  84 ) to electrically connect the low-voltage wiring segments  92 ,  94  via the loop back portion  102 . In this embodiment, the high-voltage connector  84  supports the low-voltage connector  86 . That is, the connectors  84 ,  86  are arranged in a known fashion such that if an attempt is made to connect the low-voltage connector  86  before the high-voltage connector  84 , the low-voltage connector  86  would likely fall out of the cavity  122 . For example, the high-voltage connector  84  may include a tab portion (not shown) arranged in a known fashion that holds the low-voltage connector  86  in place. If the low-voltage connector  86  does not engage the tab portion because, for example, the high-voltage connector  84  is not disposed within the cavity  118 , the low-voltage connector  86  is free to fall out of the cavity  122 . To remove the low-voltage connector  86  from the cavity  122  (if properly installed), the tab portion would need to be disengaged. Other suitable/known connecting/locking technology may also be used. 
         [0026]    While exemplary 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 may be made without departing from the spirit and scope of the disclosure and claims. As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments may 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 may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may 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 may be desirable for particular applications.