Patent ID: 12247569

DETAILED DESCRIPTION OF THE DRAWINGS

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

FIG.1illustrates a system including a valve100and a pump150, according to some embodiments. In the illustrated embodiment, the valve100is a three-way valve. The valve100includes a housing105, a main chamber within the housing105, a first tube110, a second tube115A, and a third tube115B. The first tube110, the second tube115A, and the third tube115B are in communication with the main chamber of the housing105to define passageways for fluid and/or gas to flow through the valve100. The valve100also includes an electrical port120. In the illustrated embodiment, the electrical port120includes a pinout configuration125with a plurality of electrical connectors. In some embodiments, the valve100is mechanically coupled to an external device via the electrical port120and is electrically coupled to the external device via the pinout configuration125. The pullout configuration125receives and transmits control signals from the external device to the components of the valve100. In some embodiments, the pinout configuration125receives and transmits power to the valve100. In some embodiments, the valve100is a component making up part of a fluid system and is fluidly coupled to the pump150. The pump150may be a component of a vehicle system. In other embodiments, the valve100is physically and/or operatively connected the pump, a fan, a compressor, or any other suitable component of the vehicle system mechanically via the electrical port120. The valve100is physically and/or operatively connected the pump, a fan, a compressor, or any other suitable component of the vehicle system electrically via the pullout configuration125.

The pump150includes a pump housing155and an outlet tube160. As described above, the pump150is a component making up part of the vehicle system and the outlet tube160is fluidly coupled to the first tube110of the valve100. In some embodiments, the pump150includes an electrical port (further described below in reference toFIGS.2-3) similar to the electrical port125described above with respect to the valve100. The electrical port of the pump150includes a pinout configuration with a plurality of electrical connectors (further described below in reference toFIGS.2-3) similar to the pinout configuration125described above with respect to the valve100. The pump150is designed to increase the flow rate and static pressure of a fluid and/or gas and direct the fluid and/or gas to the valve100. The pump150may be, for example, a positive-displacement pump, a centrifugal pump, an axial-flow pump, or any other suitable pump for use in a vehicle system.

FIG.2is a block diagram of a vehicle system for controlling a pump200A, according to some embodiments. In some embodiments, the pump200A is similar to the pump150described above in reference toFIG.1. The pump200A is a component making up part of the vehicle system such as, for example, a cooling system of the vehicle. The vehicle system may be a fuel system, cooling system, bleed air system, or the like. The vehicle may be an automobile, an electric automobile, a motorcycle, a truck, a bus, and others. The pump200A includes a motor controller230and a motor235in electrical contact with the pinout configuration (e.g., similar to the pinout configuration125). The motor235and motor controller230may be positioned within the pump housing155. The motor235is configured to perform an operation (e.g., an error operation or failsafe operation) of the pump200A based on a control signal received from the motor controller230. For example, the motor235decreases speed in response to receiving the control signal to decrease flow rate and static pressure of the fluid and/or gas based on a control failure. In other examples, the motor235maintains speed in response to receiving the control signal to maintain a current flow rate and static pressure of the fluid and/or gas based on the control failure. In some embodiments, the control failure results in the absence of one or more control signals received by the motor controller230. In other embodiments, the control failure is a loss of power. The motor235is an electrical motor, such as but not limited to a direct-current motor operable at variable speeds. In some embodiments, the motor235is a brushless direct-current (BLDC) motor. In other embodiments, the motor235can be a variety of other types of motors, including but not limited to a brush DC motor, a stepper motor, a synchronous motor, or other direct-current or alternating-current motors.

The motor controller230is electrically connected to the motor235and provides one or more control signals to operate the motor235. The motor controller230includes a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the motor controller230and/or the motor235. For example, the motor controller230includes, among other things, a processing unit (e.g., a microprocessor, a microcontroller, or another suitable programmable device) and a memory unit. In some embodiments, the motor controller230is implemented partially or entirely on a semiconductor (e.g., a field-programmable gate array [“FPGA”] semiconductor, an application specific integrated circuit [“ASIC”], or other programmable semiconductor devices as appropriate for a given application) chip, such as a chip developed through a register transfer level (“RTL”) design process. In one example, upon receiving a control signal, the motor controller230controls and/or operates the switching of a plurality of electronic switches (e.g., FETs), in order to selectively drive the motor235at a speed and/or direction. In some embodiments, the motor controller230and the motor235form a single unit. In other embodiments, the motor controller230and the motor235are individual components of the pump200A.

The pump200A includes a plurality of electrical connectors (e.g., inputs, outputs, input/outputs [e.g., general purpose input/output “GPIO”], etc.). In some embodiments, the plurality of electrical connectors (for example, electrical contacts) includes a battery positive connector A, a battery negative (e.g., ground) connector B, a control signal connector C, an enable signal connector D, and an operation (e.g., error operation) connector E.

FIGS.2-3illustrate the pinout configuration which includes the plurality of electrical connectors A-E (e.g., pins, inputs, outputs, input/outputs, etc.). In some embodiments, the plurality of electrical connectors A-E includes the battery positive connector A, the battery negative connector B, the control signal connector C, the enable signal connector D, and the operation connector E. Although shown inFIG.2as connectors A, B, C, D, and E, each connector of the pinout configuration may be assigned to any one of the associated connectors shown in any order. The control signal connector C is configured to be electrically connected to a system controller250via electrical contact with a system controller bus255. In reference toFIG.2, although the control signal connector is shown as connector C, the control signal connector C may be any one of the plurality of connectors. The system controller bus255is configured to be in electrical contact with the pump200A, a first device200B, and a second device200C. The first device200B and the second device200C are other components of the vehicle system, for example, a compressor, a fan, or any suitable vehicle component. In some embodiments, the first device200B and the second device200C include a similar pinout configuration to the pump200A. The system controller bus255may use one or more known control bus protocols, such as a Controller Area Network (CAN) bus protocol, a Local Interconnect Network (LIN) bus protocol, or other control bus protocol types as required for a given application. In some embodiments, the system controller250may be configured to communicate using multiple control bus protocols.

With continued reference toFIG.2, the control signal connector C connects to the system controller bus255of the vehicle for communication of control protocol of the pump200A. In one embodiment, the system controller250and system controller bus255are the same as a CAN controller and CAN bus and/or LIN controller and LIN bus. In other embodiments, the system controller250and system controller bus255are separate from the vehicle's CAN controller and CAN bus and/or LIN controller and LIN bus. In some embodiments, the control signal connector C may connect directly to a CAN bus or LIN bus of the vehicle. In some embodiments, the LIN bus may be a sub-bus of the CAN bus of the vehicle. The operation connector E may be connected to a power source (e.g., a vehicle battery). In some embodiments, the operation connector E is connected to the system controller250or the system controller bus255to receive power. In some embodiments, a resistor is electrically connected between the operation connector E and the power source (further described below in reference toFIG.3). The operation connector E receives and transmits one or more signals to the system controller250related to the operation (e.g., an error operation or a failsafe operation) and an address selection of the pump200A. The connection of the operation connector E determines the address selection of the pump200A and the operation of the pump200A in the event of control failure (i.e., no control signal from the system controller250is received via the control signal connector C or a loss of power occurs). For example, if the operation connector E is connected to a first resistor with a first resistance value, the pump200A is assigned a first address. If the operation connector E is connected to a second resistor with a second resistance valve, the pump200A is assigned a second address. Therefore, the address selection may be dependent on the electrical connection of the operation connector E. The battery positive connector A is electrically connected to a positive terminal of the vehicle battery to provide power to the pump200A. In some embodiments, the battery positive connector A is electrically connected to the system controller450or the system controller bus455to receive power. The battery negative terminal B is electrically connected to a negative terminal of the vehicle battery to ground the pump200A. In some embodiments, the battery negative terminal B is electrically connected to a ground terminal of the system controller450or the system controller bus455to ground the pump200A. The enable signal connector D is electrically connected to the system controller450or the system controller bus455to allow the control signal connector C to receive control signals from the system controller450. For example, the enable signal connector D allows control signals to be received and transmitted by the control signal connector C when the pump200A is receiving power.

The system controller250can include a plurality of electrical and electronic components that provide power, operational control, and protection to the components and modules within the system controller250and/or the pump200A. For example, the system controller250includes, among other things, a processing unit (e.g., a microprocessor, a microcontroller, or another suitable programmable device) and a memory. In some embodiments, the system controller250is implemented partially or entirely on a semiconductor (e.g., a field-programmable gate array [“FPGA”] semiconductor, an application specific integrated circuit [“ASIC”], or other programmable semiconductor devices as appropriate for a given application) chip, such as a chip developed through a register transfer level (“RTL”) design process.

The memory includes, for example, a program storage area and a data storage area. The program storage area and the data storage area can include combinations of different types of memory, such as read-only memory (“ROM”), random access memory (“RAM”) (e.g., dynamic RAM [“DRAM”], synchronous DRAM [“SDRAM”], etc.), electrically erasable programmable read-only memory (“EEPROM”), flash memory, a hard disk, an SD card, or other suitable magnetic, optical, physical, or electronic memory devices. The illustrated processing unit is connected to the memory and executes software instructions that are capable of being stored in a RAM of the memory (e.g., during execution), a ROM of the memory (e.g., on a generally permanent basis), or another non-transitory computer readable medium such as another memory or a disc. Software included in some implementations of the pump200A can be stored in the memory of the system controller250. The software can include, for example, firmware, one or more applications, program data, filters, rules, one or more program modules, and other executable instructions. The system controller250is configured to retrieve from memory and execute, among other things, instructions related to the control processes and methods described herein. In other constructions, the system controller250includes additional, fewer, or different components.

In operation, the system controller250outputs a control signal to the motor controller230. The motor controller230receives the control signal and operates the motor235based on the control signal. In some embodiments, the control signal is a pulse-width modulated signal. The pulse-width modulated signal can have a duty cycle (e.g., 10%, 50%, 100%, etc.). In some embodiments, the duty cycle corresponds to an operating speed of the motor235(e.g., 10% of full speed, 50% of full speed, 100% of full speed, etc.).

The system controller250may further include a communications module. The communications module provides analog and/or digital communications from the system controller250to outside devices. In some embodiments, the communications module outputs diagnostic information concerning the system controller250and/or other components of the cooling system. The communications module may include an output driver in the form of a digital driver such as SAE J1939, CAN bus, or LIN bus for communicating directly to the vehicle's data bus, or the communications module may generate another suitable analog or digital signal depending on the needs of the specific application. The communication module may further be configured to receive data from one or more data buses within the vehicle, such as SAE J1939, CAN bus, and/or LIN bus.

FIG.3is a table300of a standard CAN communication protocol used with a FBFF (FD Base Frame Format) data frame including 11-bit identifiers for addressing the pump200A via the system controller250or system controller bus255, according to some embodiments. In one embodiment, the system controller250and system controller bus255are the same as a CAN controller and CAN bus and/or LIN controller and LIN bus. In other examples, the system controller250and system controller bus255are separate from the vehicle's CAN controller and CAN bus and/or LIN controller and LIN bus. Although the identification of the pump200A is shown inFIG.3as using the CAN communication protocol via the FBFF data frame, the communication protocol between the pump200A and the system controller250or system controller bus255may encompass various types of communication protocols. For example, the communication protocol may include SAE J1939, ISO 11898, or any CAN2.0data frames. In the illustrated embodiment, the pump pullout configuration (e.g., similar to the pinout configuration125) includes a single connection for the error operation and the address selection (e.g., the operation connector E). The single pin connection is advantageous for allowing more options for electrical connection selection and saving on wiring cost and space. Although described relative to the pump200A, the illustrated embodiment may be used in multiple applications, including but not limited to pumps, fans, compressors, blowers, and any fluid moving devices.

As described above, the pump200A is in electrical communication with the system controller250or system controller bus255via the control signal connector C, in which the pump200A receives a control signal from the system controller250or system controller bus255indicative of a control operation and a control address. In some embodiments, a resistor is electrically connected in line (e.g., in series) with the operation connector E (e.g., Pin A inFIG.3). In some embodiments, such as row305, the operation connector E is left open (e.g., not electrically connected to an external connection). In such embodiments, the system controller250determines that the operation connector E is electrically open and identifies the pump200A based on the operation connector E being left open and assigns the pump200A an address. For example, the system controller250determines that the resistor is not electrically connected to the operation connector E. In some embodiments, such as row310, the operation connector E is electrically connected to the power source terminal. In such embodiments, the system controller250determines that the operation connector E is only connected to the power source terminal and identifies the pump200A based on the operation connector E being connected to the power source terminal and assigns the pump200A an address. In some embodiments, a first end of the resistor is connected to the operation connector E and a second end of the resistor is connected to a terminal of the power source as shown by rows315,320,325. A resistance value of the resistor is measured by the system controller250to identify the pump200A based on the resistance value. For example, row315has a first resistor with a first resistance value, row320has a second resistor with a second resistance value, and row325has a third resistor with a third resistance value. Accordingly, the pump200A in row315is assigned a first address, the pump200A in row320is assigned a second address, and the pump200A in row325is assigned a third address based on the respective resistance value of the resistor.

In some embodiments, the resistance value of the resistor is based on a voltage level detected at the operation connector E connection point to the resistor. In other embodiments, the resistance value of the resistor is based on a measured current flowing through the resistor. Additionally, combinations of voltages across the resistor and/or current through the resistor may be used to determine a resistance value of the resistor. In some examples, the system controller250determines the resistance of the resistor. The pump200A may be identified based on the measured value of resistance and perform an operation (e.g., the error operation) based on any control signal received via the operation connector E. In some embodiments, a plurality of pumps can be connected to the system controller250via the system controller bus255. Therefore, each pump of the plurality of pumps includes a different resistor with a different resistance value. The different resistance value of each resistor allows for identification of each pump.

FIG.4is a flow chart of a method400for controlling a pump (e.g., the pump200A) of a vehicle, according to some embodiments. Although the method400is described herein with reference to the pump200A, the method400may be executed to control the pump150. The order of the steps disclosed in the method400could vary. For example, additional steps may be added to the process and not all of the steps may be required, or steps shown in one order may occur in a second order. In one embodiment, the system controller250is configured to execute the method400. In other embodiments, the system controller250is configured to execute the method400in combination with the motor controller230. The method400begins at step405when the pump200A receives power. For example, the system controller250determines that the pump200A is energized based on the electrical connection of the battery positive terminal A. The method400then proceeds to step410.

At step410, the system controller250determines that the operation connector E is operable by the system controller250. For example, the system controller250determines that the operation connector E is energized or power is detected by the system controller250on the operation connector E. If the operation connector E is not determined to be operable by the system controller250, the method400returns to step405. The method400then proceeds to step415. At step415, the system controller250determines that the pump200A is connected to the system controller bus455. For example, the system controller250determines that the control signal connector C is energized and operable by the system controller250. The method400then proceeds to step420.

At step420, the system controller250determines whether a resistor is detected in line with the operation connector E. For example, the system controller250measures the voltage and/or current at the operation connector E. If the system controller250determines a difference from an expected voltage and/or current at the operation connector E, the system controller determines that the resistor is in line with the operation connector E. In response to determining that the resistor is not detected in line with the operation connector E, the method400returns to step415. The method400proceeds to step425in response to the system controller450determining that the resistor is in line with the operation connector E.

At step425, the resistance value of the resistor is measured. For example, the system controller250may measure combinations of voltages across the resistor and/or current through the resistor may be used to determine a resistance value of the resistor. The method400proceeds to step430. At step430, the pump200A is identified by the system controller250based on the determined resistance value. The system controller250assigns an address (via the system controller bus255) to the pump200A based on the identification of the pump200A. For example, the system controller250assigns the first address to the pump200A based on determining the first resistance value, assigns the second address to the pump200A based on determining the second resistance value, and so on. The system controller250assigns the address to the pump200A based on a CAN communication protocol, as described above. In some instances, the system controller250determines that the operation connector E is electrically open. In such instances, the system controller250identifies the pump200A and assigns an address to the pump200A based on determining that the operation connector E is electrically open. For example, the system controller250determined that the operation connector E is electrically open and assigns a default address to the pump200A to the pump200A. The default address assigned to the pump200A when the operation connector E is electrically open is different than any address assigned to the pump200A when the resistor is determined to be in line with the operation connector E. When the operation connector E is electrically open, the pump200A may not perform an error operation via the motor235. In some instances, the system controller250determines that the operation connector E is electrically connected to the power source terminal without a resistor. In such instances, the system controller identifies the pump200A and assigns an address to the pump200A based on determining that the operation connector E is electrically connected to the power source terminal. The address assigned to the pump200A when the operation connector E is electrically connected to the power source terminal is different than any address assigned to the pump200A when the resistor is determined to be in line with the operation connector E or the operation connector E is electrically open. The method400then proceeds to step435.

At step435, the system controller250determines whether the operation needs to be enabled. For example, the system controller250determines that an error operation (e.g., no control signal from the system controller250is able to be sent via the control signal connector C or a loss of power occurs) is occurring. In response to determining that the operation needs to be enabled, the method400proceeds to enable (e.g., activate) the operation at step440. In some instances, the operation is an error operation, as described above. In response to the system controller250determining that no operation is needed, the method returns to step430. At step440, the system controller250transmits a control signal to the motor controller230to control the operation. The motor controller230enables the operation of the pump200A based on the motor controller230receiving the control signal. The method400then proceeds to step445in which the method400ends.

Although the invention has been described with reference to certain preferred embodiments, variations and modifications exist within the scope and spirit of one or more independent aspects of the invention as described.