AU2015258190A1 - Current sensing electrical converter - Google Patents

Current sensing electrical converter Download PDF

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Publication number
AU2015258190A1
AU2015258190A1 AU2015258190A AU2015258190A AU2015258190A1 AU 2015258190 A1 AU2015258190 A1 AU 2015258190A1 AU 2015258190 A AU2015258190 A AU 2015258190A AU 2015258190 A AU2015258190 A AU 2015258190A AU 2015258190 A1 AU2015258190 A1 AU 2015258190A1
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Australia
Prior art keywords
signal
wire
vehicle
towing vehicle
electrical
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Abandoned
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AU2015258190A
Inventor
Chandrakumar D. Kulkarni
Douglas R. Motts
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Horizon Global Americas Inc
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Cequent Performance Products Inc
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Priority claimed from AU2012322015A external-priority patent/AU2012322015A1/en
Application filed by Cequent Performance Products Inc filed Critical Cequent Performance Products Inc
Priority to AU2015258190A priority Critical patent/AU2015258190A1/en
Publication of AU2015258190A1 publication Critical patent/AU2015258190A1/en
Priority to AU2017203868A priority patent/AU2017203868B2/en
Abandoned legal-status Critical Current

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Abstract

An electrical converter assembly includes a sensing device coupled to one or more wires of a towing vehicle. The sensing device is configured to detect the current How in the one or more wires and generate a signal in response to the current flow. M The converter assembly further includes an electrical component in communication with the sensing device. The electrical component may generate a signal to a towed vehicle in response to the current flow detected by the sensing device. The sensing device may be a non-invasive sensing device. The non-invasive sensing device may detect current flow in the one or more wires of the towing vehicle without direct contact with the conducting element of the wires V-4865164:1 XV( 2013/05683 PI/I"US2QIZ/0001)8 C> C> -------

Description

1 CURRENT SENSING ELECTRICAL CONVERTER [0001] This is a divisional of Australian Patent Application No. 2012322015, the entire contents of which are incorporated herein by reference. FIELD OF INVENTION [0002] The present invention relates generally to an electrical converter and, more particularly, to a current sensing electrical converter. BACKGROUND [0003] When a towing vehicle tows a towed vehicle, such as a trailer, lighted signals arc often maintained on the towed vehicle, which indicate the movement status of the towing vehicle and towed vehicle. For example, left and right turn signal lights indicate a present or impending movement of the vehicles in the indicated direction. As another example, brake lights indicate application of the towing vehicle's brakes by the operator. It is, therefore, useful that the towed vehicle light indicators generally match those of the towing vehicle. [0004] A converter or circuitry may be used to detect an active input signal on the left, right, stoplight and tail channels of the towing vehicle and send a signal to a towed vehicle to operate a corresponding light on the towed vehicle. Converters typically utilize voltage measurements, such as hard-wired connections, to detect the presence of the applicable input signal. [0005] The installation of a typical converter is often cumbersome and time consuming. The input connections are often made by either providing connectors on the vehicle harness and providing mating connectors on the converter or using insulation displacement connectors or self-striping electrical tap connectors, such as for example Scotchlok type connectors. Both of these approaches are hard-wired connections and can be time consuming and unique to the V-4865164:1 WO 2013/056083 PCIUS2012/060008 towing and/or towed vehicle Stil further, once the instalaion is complete it is difficult to remove and port the converter to a different towing or towed vehicle, especially one of a different make or model. iO6)f The converters are connected directly to the electrical system of thetowing vehicle. Such asor example, through splicing he wires to detected voltage in the wiresThis direct electrical connecton imparts electrical load on the towing vehicle's electronics This load may result in Wtiggering a diagnostic code in the electronic systein, which may resut in setting off an alarm on the ton vehicle, Doing this may necessitate taking the towing vehicle to the dealer for to eso ll further these connections nay void the warranty of the towing chicle andor damage the electronics in the towing vehicle [00071 Ahenatively the electrical connections between the towing and towed vehicles aten utilize a custom approach In these svstets the towing vehicle manufacturer provides the harness with connectors to plug into and the converter provides he mating connectors in its harness thereby making a hard-wired connection between the converter and the electrical system of the towing vehicle. Since the harness and coinectios can vary with each make/model, a custom hamess with mating connemtors must be con figured for each applicable, make and model of vehicle; [0008] There is a need, therefore; for a conveyer that is portable and can be used with any vehicle regardless of the make or nodel of the vehicle. There is a need for a converter that does not direety connect to the towing vehicle's eleetrica system SUMMARY [0009] An electrical converter assembly is genrally presented. The converter assembly includes a sensing devie coupled to one or more wires of a towing vehicle. The sensing device is confiured to detect the current flow in the one or more wires and generate a signal in response to he current flow. The converter assembly further includes an electrical component in communication with the sensing device. The eectrical component tnay geneate a signa. to a towed vehicle in response o the current fko detected by the sensing device., 00101 In an embodiment the sensing device may be a nonlinvasve sensing device. The non invasive sensing device may detect cwrent flow in the one or more wires of towing vehicle without direct contact with the conducdag element of the wtres DESCRIPTION OlF THES DRA WINOS [010I Operation of the invention may be better understood by reference to the following detailed description taken in connection with the follow n g illustrations, wherein: WO 2013/056083 PCIUS2012/060008 10012 Fignre I is a top View of an embodiment of an electrical converter with a pluralty of sensor assembles. [0131 Figure 2 is a perspective view of an embodiment of a sensor assembly lbr an electrical convre in" man openi positi on. [0014] Figure 3 is a perspective viw ofan embodiment of the sensor assembly for an electrical converter in a closed position. 1001ir] g is a perspective view of a portion of a sensor assembly for m electrical contvefi XXith a houisin'g in phainm [00161 Figure 5 is a perspecte viewv of a portion of a sensor assembly for an electrical converter: 10017j Firm 6 is an electrical schematic of an embodiment of a sensr assembly f an electrical converter [0O18] Figure 7 is a graph of an output and amplified output of an eombodiment of a sensor assembly or an electrical converter 00191 Figure 8 is an electric schematic of an embodiment of a sensor assembly for an electrical convert. 100.201 Fipnre 9 is a graph of' ationtput and amplified output of another embodiment of a sensor assembly for an electrical converter. [0021j Figure 10 isan electrical schemnais of an embodiment of an electrical conventer 100221 Fgm fI is a graphical representation of an exemplary tiring chart of the powering and sampling ot a sensor assembly for an electrical converter. [0023] Nigures 1246 are confi gurations of a sensor assembly. [00241 Figure 17 is an electrical schematie of an embodiment of an electrical converter DETAIEED DESCRIPTION [0025] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustraed in the accompanying drawings s sto be understood that other embodiments may be utilized and structural Mid functional changes may be made without departteg from the scope of the invention Moreover features of the various embodimetts may be combined or altered without departing Don the scope of the invemion. As such the following description is presented by vay of llistration only and should not imit in WO 2013/056083 POT/US2012/064008 any way the various alternatives and nodifications that may be made to the illustrated enmhodiments anid still be within the spirit anid scope of the invemtion. NO261 An embodiment of -an electrical converter 20 is shown in Fiure 1, 'ie electrical converter 2.0 naay be connected to an electrical system of a towing vehicle whereby the electrical converter 20 may be operatively coupled with a ightig system of the towing vehicle When it is desired to tow a towed vehicle the subservient lighting system of the towed vehicle may be connected to the converter 20. Converter 20 can activate the appropriate lights or lamps on the towed Vehicle in response to the operational characteristics of te towing vehicle based on sensing the operational characteristics, as described below Connecting the lighting systems of the towing and towed vehicles through converter 20 may alow the lamps ofthe towed vehicle to operate consistently with the lamps ofthe towing vhicle. By way of a nonIinriting example f the left trin signal of the tving vehicle is initiated y an operator of the owing vehicle, the electrical converter 20 may sense the signal of the IeN tuni signal and initiate a Sianal on the towed vehicle to operate its left turn signal This may occur fe at least one of the left and riaht turn signals, the brake lights, and the tail channels of the towing vehicle. Moreover, this nay occur in any appropriate comonination of the left andright tum i al, the brake lights and the tail channels of the towing vehicle. Stil further, this may occur for reverse or any other appropriate signals he present teachings are not limited to tie signals set forthi herein and nay apply to ary appropriate signalon the towing vehicle and towed vehicle, ,PO27 , The eIectricai converter 20 may be of any apprpriate configuration. Exemplary embodiments of an deetrica convener 20 are shown and described herenT The present teachings may apply to any appropriate electrical converter and arc not limited to those shown and described herein Bv way of a nonlimiting example. the electical conveyer 20 may include a housing 25 that may have enclosed therein the relevant operative electrical components, which may consist of an appropriately configured circidt board assenm bly, The electrical conponetstt may be operatively connected with a power cord 28 and a ground wire 29. The power cord 28 may be operatively connectedwith a power source on the toving v-hicle and tihe round wirc 29 may be operatively connected with a ground source of the toing vehicle, such as the vehicle franre, 100281 TIe electrica converter 20 may further include a plurality of sensor assemres 100 operatively coupled with the electrical components within housing 2$, By wax of a nonImning example, each of the sensor assemblies 100 (described further below) may be operatively coupled to the electrical components of the electrical converter 2 -tgh a plurality of wires 140(described further below Converter 20 may include a ground wire. 36 and a power cord 38 4 WO 2013/056083 PCTUS2012/060008 that may be capable or connecting directly to the power source of the towing vehich such as by way of a non-IMiing example directly to the battery ot the towing vehicle, O429J Tlh electrical converter 20 iy also include an output device 40 that may be operatively coupled to the electrical components in housing 25 and to the electricJal system of the towed vehicle, such as the towed vehicle lighting system by way of noniing example The output device 4C' may include a plurality of wires 42 coupled to a connector 50 that is coni gured to connect with the fighting system of the towed vehicle. Any appropriate n er of wires 4 m1ay be used and connector 50 may be of ary appropriate shape and size The present teachings are not limited to a specific coector 50y y of a non-limiting example. the connector 50 may include a 4A-way, 5-way. 6-way, 7--way or any appropriate connector that may be capable of connecting with the towed vehicle electrical system and more specifically to the lighting system of the towed vehicle. The output device 40 may be configured to interfaces with a conunnicafions bus of a towed vehicle. The communications bus may use any appropriate communications protocol suCh as AIt UN, HSCAN o any other protocol. 003 in opeatko each sensor assemly 100 may detect electric current fk through an associated wire of the towing vehicle cect-ial system, the electric current flow being indicative an operating characteristic of the towing vehicle Electrical converter 20 may use the detected electric current flow to activate or trigger a response in the electrical system of the towed vehicle. By way of a non-imiting cx-apie, sensor assembly 100 ay detect electric current flow that isindicatve of the operation of the lef righu taillight reverse brake light, backup; auxiliary orhe like the he towingehicle; or ay combination of such. The sensor assemblies 100 may detect any appropriate input or activation of a system of the towing vehicle This detection may then be used by converter 20 to operate or activate a corresponding response in the ekctricaIsystem of the towed vehicle such as in the towed vehicles lighting system. {0031] Each sensor assembly 100 may sense and identify the activation of a predetermined signal on the towing vehicle An exemplary embodiment of a sensor assembly 100 is shown in Figures 2 and 3 The construction of the sensor assembly 10 however, is not limited to that shown and described and may be of any appropriate construction The sensor assembly 00 may be operadvey coupled with the electrical converter 20, stich as through wires 140 or any other appropriate manner uch th the sensor asset y 00 ny sndn appropriate signal to the electrical converter 20 upon an occurrence of a predetenined event. Such events may be by way of a non-Mlimiting example a. left turn signal being initiated on the towing vehicle a right tur signal being initiated on. the toin Iclea stoplight being stated on the towing vehicle. a taillight being initiated on the towing vehicle a backup signal being initiated 0n the towing 5 WO 2013/056083 PCTUS2012/060008 vehicle, an auxiliary signal being intiated on the towing vehicle or a battery charger signal on a trailer battery channel Sll further, such events nay be a combination of a turn signal (right or left being initiated on the towing vehicle, a stopght being initiated on the towing vehicle, and/or a taillight being initiated on the towSig vehicle. Still further, such event nay be a reverse light beiin sniated on the towing vehicle or any other appropriate signal from the electrical system of the towing veh tele, It should be understood that the present teaching are notimied to any number of nputs and oupus Ansuch nnber of inputs and outputs may be sensed by the sensor assemblies 100 10032) The electrical converter 20 may he used with any appropriate lighting systern of the towing and towed vehicle, such as two and three-wire systems, By way of a non-limiting example, the converter 20 may be operatively used with a three wire system of the towing vehicle to a twwvre system. of the towed vehicle In these configtrationsere may be three hlt inpls fron one sie ofte towing vehicle and three lightinputs from the oiher side of the towine vehle.The electrical converter 20 may be operatively engaged with the lighung systems of both sides of the towing vehicle and may be capable of activating or triggering the appropriate signal on.the towed vehicle. For example. tail stop and turn (left or right) in ay he in one wire of the towing vehicle and the electrical converter 20 may be operatively coupled to such. In addition or in the aiterhatve the electrical converter 20 may he ued with a twowire ystemt of the towing vehicle and a two-wire system of the towved vehicle Similadl in these configuranons. the electrical converter 20 may be operatively engaged with the lighting systems of both sides of the towing vehicle and my be capable of activating or riggering the appropriate signal on the towed vehicle For ex-ample stbop atd turn (left or right) may be in one wire of the towing vehicle and the electcal converter 20 may be operatively coupled to such, It will be further appreciated that the electrical converter 20 may be used with systems that utilize, one or more pulse width modulated PWM) signal wires. The electrical converter 20 may sense the PWM sign on One or more wres and may appropriately convert the signal to the towed vehicle 1033] The sensor assembly 100 may be sti-ucured such that it may be noninvasive or contactless with the electrically conductive elements of the electrical systern or lighting system of the towing vehicle. orespecificalvy the sensor assembly 100 may be secured to the lighting system or other systems of the towing vehicle without having to utilize: making connectors that are specific to the connectors of the vehicle hamess; insulation displacement connects; or self striping electrical tap connectors, such as for example Scotchlok type connectors, The sensor assembly 100 may be capable of engaging or coupliag with the applicable wire W of the electrical system of the towing vehicle without having to splce. displace or otherwise be 6 WO 2013/056083 PCIUS2012/060008 inserted through the insulation of the wire W, A non-invasive sensor 00 may be cofigured to sense any number of signals in a multi signal system. For example, a noninvasiv sensor may bo arranged to sense the current in a single Wie of a t rs wo oa three wire sysIem, or only a PWM signal wire of aiy wiring systent be appreciated that any number of non,-invasive sensors may be used as desired to provide the appropriate signal detection, [00341 The electrical conveyer 20 may include any appropriate number of sensor assemblies 100. In one nonlimiting example four sesor assemblies 100may be used with the eleerical converter 20 In these embodiments, each senor assembly 100 may sense or detct a predetermined activation ot a signal indicativee of an operating characteristic) on the towing vehicle, For example, one sensor assembly 100 may sense activation ot the left turn signal of the towing vehicle; another sensor assembly 100 may sense actvation of the right turn signal of the towing vehicet, another sensor assembly 100 may sense activation of the stop lights) of the towing vehicle, and another sensor assembly 100 May sense activation of the taillights) ofthe towing vehicle. Each such sensor assembly 100 may be engaged with or otherwise in close proximity to the ire used in activation of such signal. O3] nri somne enbodiment the sensonassembly 100 may include a housing 102 The housing 102 may be made oftany appropriate mateal, such as by way of a nonimitng example plastic, rbber or the like. he housing 102 may be of any appropriate shape, such as f rexamnp le.it may bea general parallelepiped. 10036i The sensor assembly I 00,r more specifically, the hoping 102, may be made of two compliets hatmaybe eemd tgeter n ay appropriate manner, such as by way of a noni components. tha may be- secureod together in ay:~oiN10)a " f limiting example, with a screw or clip or othemechanical means. In these embodiments the housing 102 may include a body 106 and a cap I11 The cap 110 may be pivotally attached to the body 106, or in the alerative may be'selectively detachable from the body 106. The cap 110 being capable of pivoting relative to the body 106 may open and close the housing 102 as needed to engage and/or disengage te wire NV. The cap 110 may be pivotally attached the body 106 in any appropriate manner, suchas fr example, one end may be integrally formed with the body 106, one end may be fstenedwelded, or the like to the body 106 Altematively, the housing 102 may be an integrally formed member. 10037 The housing 102 may further include a wire holding portion such as channel 116. The channel 11 6 may be of a shape and size to generally hold an appropriate towing vehicle wire W as shown in Figures 2 and Still further, the cap 110 may be able to pivot towards the body 106 and close, around the wire W to generally hold the wire W within the housing 102 so as to secure WO 2013/056083 PCTUS2012/060008 the sensor assembly 100 on to the wire W. ihe housing 102 may generally be capable of holing the sensor assembly 100 in close proximity to the wire V OO381 The sensor assembly 100 may include a locking device 120 that may generally prevent the cap I10 from pivoting open or otherwise disenaging from the body 106 so that the vehicle wire W may remain held within the sensor assembly 100 or more specifcallywitin the housi 102 0n somc embodiments, the locking device 120 may inchide a tab 124 that may be attached to the body 106. The tab 124 may be attached in any appropriate manner By way of a non himitig example the tab 124 nay be integrally formed with the body 1,06, fesened, welded o the like to the body 106 Still further, the locking device 120 may be of any appropriate construction, an example of which may include any kind of mechanical lock. 1,391 The locking device 120 may include a looking aperture 128 that may be positioned on the cap 110 The locking aperue 128 may be integrally formed with the cap 110 or may be added through asubsegunt operation: The locking aperure 128 may be shaped and sized to engage the tab 124 when the cap 110 is pivoted toward the body 106 i these embodiments, he ockintg aperturea 128 may engage the tab 124 to generally prevent the cap 110 from pivoting away from o otherwise being removed from the body 16 i other embodimentshe locking device 120 may be any appropriate mechanism that may general kp the cap 10 in position on the body 106 and may otherwise generally keep the wire W operatively engaged with the sensor assembly 100. 10040] The sensor assembly 100 nay ftirther Ilude a core 134 made of a materialthat may have a generally high magnetic permeability, such as by way of a nat-limiting example ferriteliron, The ferrite core 1.34 may generally be positioned itn the housing 102. som'e ebodimea, the ferrite core 134 may be of a generally toroid shape and may include a first ferrite cre portion 136, a second ferrite core portion i813, and a third territe core portion 139, The ferite core 134, however may beo appropriate shape and is not lited to having a generally toroid shape. such as for example, generally circular, rectangular squareoval or any other appropriate shape The shape of the ferrite core 134 may be determined by mamufacttuin processes available packaging to be used, or the like. The ft ferrite core portion 136 may generaiy be positoined within the cap 110 The second and third ferrite core portions 138, 139 may generally be positioned within the body 106. This may result in the frt second and third. errite core portions 136 138, 139 being adjacent when the cap 110 is pi'oted toward the bod.y 106 frming the generally toroid shape. The first, second, and third ferrite core portions 136. 138, 139 may be attached to the cap 110 and body 106 respectively in any appropriate manner. tn some embodiments, the first ferrite core portion 136 may be muolded into the cap 110 and the 8 WO 2013/056083 PCTUS2012/060008 second and third ferrite core portions 138, 139 may sinilarly be moled into the body 106, While threc ferrite core portions 13, 138, aand 139 are shown, any appropriate unber of ferrite cores may be used, such as for example. two, four; five or the like. [0041] Thee scr ssmbly 100 may include an output member that may operauvely couple the sensor assembly 100 with the components within housing 25 of electrical converter 20, such as for example a pluralty of wires 1404 shown in Figurs 2 and 3 three such wires 141, 142 and 143 may form the pluality 140 and may extend from the body 106 to the components within housing 25, Ahternatixely any appropriate nmnber of wires may extend from thc body 106, [00421 In some emnbodimnts the wire .40 may include a three-ribbon wire that nay extends from the body 106 The ribbon wire 140 may be inserted into the body 106 or alternatively, may be formed with the body 106, such as molding it therewith, in these embodiments and as shown in figures 2, 3 and 5, the ribbon wire 140 may include a first wire 141 that supplies pover to sensor assembly 100, a second wi 142 that may be a ground, and a third wire 143 that may transfer an output from sensor assembly 100 hewires 1 40 however, are not limited to this configuration and nmay be any appropriate configuration. in some embodiments, the wires 140 may ilncde four or live wires, some of which nay be operaively coupled with a comnarumation and/or data line or data bus. [00431 As shown in Figure 5, the sensor assembly 100 may include a printed circuit board 144 that may be operatively coupled to the wires 140 in these embodiments the printed circuit board 144 may be held within the housing 102, or nore specifically it may be held within the body 106 The printed Arcuit boards 144 may include the required electric configuration so that the sensor assembly 100 may operte as intended. [00441 The sensor assembly 100 may further include a current sensing device 148 that may be positioned within the housing 102.. l some embodiments, the current sensing device 14$ may be positioned wihin a slot or gap 15.5 of the ferrite core 134 and may be operaively coupled w ith the printed circuit board 144. The current sensing device 14S mag be capable of sensinga magnetic field produced by electric current flowing in the wire W. Which May indicate the activation on the .owinsthice, such as by way of a nonliming example, the left urn signal. The current sensing device 148 umyrbe positioned in a magnetic path created through the ferrite core 134 in response to the current flowing in the wire V. The magnetic field may be increased by utilizing the ferried core 134 foroonduction of the magnetic field, which may also reduce the reluctance. The current sending device 148 may, therefore he generally surrounded by the ferrite core 134. The current sensing device 148 may produce a 9 WO 2013/056083 PCIUS2012/060008 signalor output in response to detecting the current flow in wire W i'e signal or put may be used by converter 40 to activate or trniger a response in the electric system of the towed vehicle. (045] The current sensing device 148 may be any appropriate device that may be capable of sensing the presence of a current without having to invade the wire W such as a transducer. in some embodMents the current sensingr device 1 43 may be a linear Hall Effect sensor Thelinear Hail Efect sensor may be any appropriately sensitive linear Hall Effect sensor i semc embodiments, a Hail Effet sensor that many be capable of detecting the magnetic field produced by very small amounts of current may be used, In other embodiments, a digital Hall Etect sensor may be used. The digital Hal Effect sensor man be capable of detecting the presence of current in the wire W and produce an outpt signal of on or off In other embodiments, an analog Hall Efect sensor may be used The analog Hall Effet sensor may detect current flow in wire NW and have an output in the proportion to the current flow in the wire W. Stil further. a smart 1-ali Effect sensor may be used, The smart Hall Effect sensor may be capable of serial or parallel communication with a communication bus to convey the presence of current flow in wire . to the converter or other electrical system of Towingr or Towed vehicle [0046 The current sensing device 148 however, is not limited to the Hall Effet sensor shown and described. The current sensing device 1.48 may unlike any appropriate transduction technique using the magnetic field produced by the current in the wire W when the appropriate signals are active, such as the leftight stop and tail signals. By way of a non i citing example, the current sensing device 148 may be a magnetoresrstv sensor. or a device otherwise inductively coupling a magnetic field produced by the current in the wire -W or any other appropriate method or device to sense the magnetic feld produced by the current flow in the wire NW 10047 j some embodiments, a plurality of current sensing devices 148 may be used, which tmay permit thesensor assembly 100 to sense lower amounts of current flow in the vare W . By way of a non-miting example, two Hal Eect sensors may be used, I these exemplary embodiments, the two Flil Effetsensors may be positioned within the slot 155of the ferrite core 1.34. Still further, additional current sensing devices 14s may be used in the sensor assembin 100 such that the sensor assembly100 may detect even lower amounts ot current flow. {00481 In the embodiments shown, the Hall Effet sensor 148 may be operatily coupled the inted circuitboard 144, The ferrite core 134 may be generally positioned around the Hail Effhct sensor 148 such that the lail EffIect sensor may be positioned in the slot/gap 1S of the ferrie core 134 and a wire (not shown) that may be positioned through the channel 116 in the ferried core 134 in these enbodinments, the Hail Effect sensor may be positfioned in the slot/gap 10 WO 2013/056083 PCIUS2012/060008 15 of' the ferrite core 134 in such a mnner that it may he exposed to a maximum magneiclux density as a result of the magnetic field resulting from the current fow in the wire W. f'his may help maxinize the output from the Hall Effect sensor which may help provide an improved sgnaltonoise ratio, h. ferrite core 134 may be capable of corncerating the flx sothat it is in thre range required for an .tput with good sigal-to-noise ratio from the Hall Effect sensor 148. 100491 As shown in Figure 4 the sensor assembly 100 may be formed thrgh any appropriate proassuc asby ay f nn-lmutinig examples, pOtting ijection nioldi ngo COmpression piv~em, stCk as by way of non -iifn molding. insert molding or any appropriate molding process The sensor assembly 100 is not limited to any specific forcing process insome embodjments the houssing 102 of the sensor assembc y100 may be formed through an insert molding/overmoiding process embodiments/ the sensor assembly 100 may include an inner overnid 200 he inner oermoid 200 made be formed to hold the ferrite core 134 and Hall Effect sensor 148 in the appropriate position witin the housing 12 The printed ciit board 144 may be immediately below the inner overmold 2. or ahtematively may be held within the inner overmold 200. A top core 204 may be formed where the top core 204 may include the top ferrite core portion 136 of the ferrite core 134 and may be positioned generally above the inner overnold 200. A bottom and top overmoid 210. 214 may be formed to encompass the. inner overmold 200 printed circuit board 144 territe core 134and wires 140 The bottom and top overnmd 210, 214 may generally form the housing 102 or more specificaly Ifay form the body 106 and the cap 110, While the ovemolking process has been shown and. described the present teachings are not limited to this process Any approrate process may be used to form the sensor assembly 100, [00501 In operation, the sensor assembly 100 may sense or otherwise detect the presence of an active input signal from the electrical system of tie towing vehicle and may output an appropriate signal that the electrical converter 20 uses to activate or trigger a corresponding response in the electrical system of the towed vehicle By way of a non-liming example, the sensor assembly 100 may detect the presence of an activc input signal on lef. right stoplight, reverse. and tail channels (or any other appropriate input signal) of the electrical system of the towing vehicle by detecting the current flowt through the applicable wire W1 of thetWding vehicle The sensor assembly 100 may detect DC currents and pulse. width modulated (PWM) currents, which is described in more detail in US. Publication No20/0088 which is hereby iin by reference, Moreover, the sensor assembly 100 may detect the current flow regardless of the towing vehicle lamp load being an incandescent light or light emoting diode (LED), The dynamic range of the sensor's 100 ability to detect a current may be at it may accommodate the difkrence in loads betWeen ar incandescent light and an il WO 2013/056083 PCTUS2012/060008 LED, For example, an icandesent light may cr m uch more current such as 2A or 20A, wich would make detectingA the current flow eaer wh an LED light may carry less current; such as 50mV which may be more difficult to detect. Te sensor assembly 100, therefore, may he configured to have the ability to detect current for both art incandescent light and art LED ightAlternatively, wo different sensors 100 may be configured- one for incanOescent load and one fo lED loads on a towing vehicle. In these embodiments, the electrical converter 20 may include tvo sets of sensor assemblies 100 where one set of sensor assemblies 100 is used for incandescent brad and one set of sensor assemblies 100 is used for lED load in addition, the seitsor- ma inld two curn sesn de as Sassembly100 m i de t current seeing devices t415 such as for example two Hail Effect sensors, which may create enough sensitivity to detect the current flow in LED lighting systems The single flal sensor assembly may be capable of sensing current over 150 iA or 05 A. Still further any appropria.. nmber of current sensing devices 148 may be used within the sensor assembly 100 depending upon the appropriate sensitivity that may be required for the sensor assembly 100. in addition, the electrical conver20 may utilize any appropriae number ot sensor assemblies 00 to accomplish the approprate scnsitivty required for the electrical converter 20, 00511 Figure 6 shows an electrical schematic of an implementation of the sensor assenKi y 100. whikchnay be specifically used for sensing incandescent loads As shown, element 300 identifies the current sensing device 148 such as a linear Hail Effec sensor Te sensor assembly 100 may also include an operational amplifier 310 that may amplify the signal fromi he i-ball Effect sensor 148 Finally, the amplified output of the Hall Effect sensor 142 is shown as 320 The sensor assembly 100 is not limited to fhat showing Figure 6 he sensor assembly 100 may be formed using any appropriate electrical centfggiration. 0052 Shown in Figure 7 is a graphical represeniation of the output 390 of a sensor assenibly 100 that utilized a single current sensing device 1 4, or more specifically utilized a single Hail Effect sensurIn this embodiment the Hall Effect sensor was directional and had an output 392 as shown, The operaional amplifier 310 may amplify the output 392 as shon.s the current was detected by the il Effect senso the output of sensor assembly 1.00 iay be sent to the elecurical component in housing 25 and used by the electrical converter 2.0 to activate or trigger a desired response in the electrical system of the towed vehicle This signal may indicate the activation of a particular signal on (or operating characteristic off the towing vehicle. 10053j Figure 8 shows aa st'eat sive exemplary electrical schematic of another embodiment of the sensor assembly 100. 1his exemplary schematic may be particularly useful for sensing -ED roads, As shon the sensorassembix 100 may inclu-dc a. first and second current sensing device, 12 WO 2013/056083 PCIUS2012/060008 such as first and second Hall Effect sensors 410 414. The sensor assembly 100 may also include an operational amplifier 420 that may anmlifv the signals from the first and second Hall Effect sensors 410, 414, The HallEffect sensors 410, 414 may be configured such that the voltage on the output of the first flai Efftect sensor 41 0 increases when the current flow in wire W increases and the voyage on the output of the second Hall Effect sensor 414 decreases when the current flow in wire W increases. These two outputs may be connected in a differential mode and may be amplified by the operational amplifier 420 into a single output 425 The output of the arnptiter 420 may thus be increased versus using just one Hall Effect sensor. This may incirase the signal moonoise ratio of the output signal, The amplification stage may further provide filtering. In these embodiments, the Hall Efflect sensors may be positioned inenerally opposite directions with eachther with outputs connected in diffierential rmode for furher amplification. In some other embodiments one or more of such pairs of Hail effect sensors positioned i opposite direction may be arranged with their amplified outputs summed to achieve further improvement in signaltonoise ratio As ai alternative, the Hall Effect Sensors may be posRtioned so their outputs chance in the same direction and the outpus then summed foi further amplificaion.One or more of such pairs of H1ail effect sensors posined in same direction may be argeod with their amnplified outputs summed to achieve further improvement in signaifo noise ratio, 1054] Shown in Figure 9 is a graphical representation of at output. 690 of a ensor assembly 100 that uilized tvo current sensing devices 148 or more specifically utiized two d 1-lal Effect sensors. As previously noted thi configuration is particularly suited for use with LD lights. ln this embodment. the Hall Effect sensors are bidirectional The Hail Effect sensors 41, 414 may be conigured such that the vohage on the output 692 of the frste-lal Efect sensor 410 increases when the current flow in wire W increases and the voltage on the output 694 of the second Hal Effect sensor 414 decreases when the current flow in the wire. W increases These two outputs 692. 694 may be connected in a differential mode arid may be amplified bythe amplifier 420 to produce output 690, The output 690 of the amplifier 420 may thus increase versus usinglJust one HaliEffect sensor as shown compare Figures 7 and 9), T he signal 42$ may be sent to electrical components in housing 25 fr use by the electrical converter 20. If the value of this signal is over a threshold, it may indicate the activation of a particular signal on the towing vehicle and ekectrical converter 20 nay activate or trigger a. responding response in the electrical system of the towed vehide 10055 The output voltage of the sensor assembly 100 umay vary as a function of the current flowing in the wirc I A voltage comparator (not shown) may be included in the sensor 13 WO 2013/056083 PCIUS2012/060008 assembly 100 or more specifically. may be included in the priimed circuit board 144, The voltage comparator may he used to compare the voltage from the sensor assembly 100 before detecting current flow in wire W and after deng current flow in the wire N. The voltage at the output of the current sensing device 148 before detecting current flow in wire W plus a fixed volage may be used as a treshold voltage hat converter 20 may use as an indicator to activate or trigger a response in the eectrical system of the towed vehicle. The output of the comoarator may turn on when the output of the current sensing device 148 exceeds the threshold voltage By way of a nonl-initing example, the output 425 of the Hai Effect sensor assembly 148 nay be compared with dhe threshold. to determine, that sensor assembly 100 has detected a current tiow in the wire V of greater than O0M5 Amps. This threshold, however, may be any approprialevel and is quoted herein for reference only. The detection of thethreshold may be acconpished by the electrical converer 20 and mtay be in hardware using a comparator or in sofhvare using an ank~ ipu'o a inic ro-controlier, by way of non-I mitinug example. analog iu of ywyo [00561 Figure 10 is an electrical schematic of an embodiment of the electrical converter to sing sensor assemblies 100. i this embodiment, there may be four sensor assemblies 10) used By way of a non-limiting example, a first sensor assembly 1.00A may be secured to a wire of the electrical system of the towing vehicle to detect activation of tne right turn signal, a second sensor assembly 100B i may he secured to a wire of the electrical system of the towing vehicle to detect aivation of the brake light signal a third sensor assembly 00(may be secered to a wire of the electrical sYstem of the twing vehicle to detect activation (If theleft turn signal, and a fourth sensor assembly 100D may be secured to a Wire of theeVectrical system of the towing vehicle to detect activation of the tail channel In some embodiments, the electrical converter 20 may utilize three sensor assemblies 100 that may include a singe current sensing device 148 and a fourth sensor assembly 100 that may utilize two current sensing devices 18. in these embodiments, th three sensor assemblies 100 may be used to detect Operation of the left and right turn signals and the stoplight and the fourth sensor assembly 100 may be utilized to detect the taillight, which may require detection of 0:05A, by way of non-iming ex ample, 160571 In those embodiments of the electrical converter 20 in which there may be a plurality of sensors 100, if those sensors are left continously on, the current draw of electrical conyelter 20 may cause t undestable drain on tlie battery of the towing, vehicle over time. To preit this the senso assemblies 100 may be sampled, or more specifically the current sensing devices 148 may be smed By way of a non-imiig exame power to tie currentdevics 48 such -as the Hall Effet sensors 148, may be powered off after sainpling them. The current sensing devices 148 may then be turned on prior to sampling. Doing this may reuce the average 1 4 WO 2013/056083 PCIUS2012/060008 powercAurrent used. By way of a non-inisting example, a switch 504 nay be utilized to switch the power outputs to sensor assemblies 100 on and Of Swtcuing the. power outputs may be done to cause the average quiescent current of the cifire assembly including all sensors 100, to be less than 1 mA, In an embodiment, switching the power outputs ruay cause the average quiescent current of the entire assembly, including all sensors 100 to be less than 100 uA, The quiescent current of the Hall Effect sensor is typically 5- 10 mA. Further, power to each sensor can be turned onoff individualvy and not all the same time as shoving in the illustrative schematic. [00581 A graphical representation of this sampling is sho in Figure 11, The timing ohart shown is an example of the Hall Effect sensor 148 being powered and sampled periodically so that it may reduce the average current consumption As shown, the average current consumption equals I module+ 4 x 1 sensor x I'on--' tot. I moduI is the current consumption of the control module", which also uses 'peridic wakeAp techniques or other siinilar methods, such as the use of interrupts, to keep the average current do n nsor is he current drawn by one sensor assembly 100. i on s the time the power toIhe sensor mode is ON. T tot is the total sampling ine. {00591 FIG. 17 shows an electrical schematic of an implementation of the sensor assembly 100 that m.ay adaptivelv adjust or null the offet to accomplish high gain in the sensor to sense the low currents of liD lamps in te towing vehicle The signal 606 front the convertor module may be a PWN control signal that is altered by a resistor 600 and a capacitor 602. The average voltage may then be sent to an inverting input of an operational amplifier 604, Normally, the ampifier is biased to a guaranteed positive output. The output can be set at a fixed level by monitoring the output of signal 612 output when there is no current flowing in the sensor and varying signal 606 until a known output is obtained at the otput signal 612 This naulls the offset of sensor and operational amplifier 604. Under these coitions, a igh gain can be obtained ith the amplifier 60. T.'his vill allow sensing low currents, thus increasing the sensitviy of the circuit This will facilitate detecting turning ON/OFF of L latmp ircuits in the vehicle I will be appreciated that the sensor assembly 100 is not limited to that shown in Figure 7, and the sensor assernM l 100 may be formed using any aicticsl configuration {0060] The nulm ing of the ottset may be done during manufacturingThe value of signal 606 rno the converer module required to obtain the nuing of tle offet described above can be stored in EEPROM tr use at alter time. never, adaptive training of the offset can he done in real time for further al ustments for changes of offset with temperature and other factors [0061 lIn. an embodiment, the electrical converter 20 may include at least one sensor 100 to monitor the break light or tail light of the toving vehicle Tlhe sensor 100 will thus detect a 15 WO 2013/056083 PCIUS2012/060008 current flow when the brakes of the towing vehicle are applied and a tail or brake light is lit. The electrical converter 20 may then send a signal to the brakes of the towed vehicle. For example. the electrical converter 20 may receive additional inpuIs, such as an accelerometer input from the towing vehicle. Based on the additional inputs, the elecrical converter 20 may calculate the appropriate braking signal to send to the towed vehicle. The signal may be sent o the towing vehilde via discrete wire signals or over a commnicatons bus Such braking control is further described in 1S Patent Appijation No i241690 filed on October 11 2005 and ,S. Patent Applicaton No. 1/247010 filed on October It 200 each of which is incorporated by reference in its entirety. 100621 Athough the embodients of the present invention have been illustrated in the accompanying drawings and described in the foregoing detailed description, it is to be understood that the present invention is not to be united to just the emrbodinents disclosed. bti that the invenion described herein is capable of numerous rearrangements modificaions and substitutions without departing i'om the scope of the caims hereafter The cWaims as follovwsare intended to inchide all modifications and alterations insofar as they come within the scope of the claims or the equivalent thereof 16

Claims (10)

  1. 6. The electrical converter assembly of claim 5, wherein the converter is capable of sending the second signal through an electrical system of the towed vehicle to operate at least one of left turnght irn stophght tail lamps; backup signal or ar auxiliary signal of the towed vehicle. The electrical converter assembly of claim 6, wherein a, non-invasive current sensor is applied to only the stoplight signial of the towing vehicle.
  2. 8. The electrical converter assembly of caim I. further comprising a housing securable to the wire ofh towing vehicle, wherein the curretusensing device is held within the housing 9 The electrical converter assembly of Claim, wherein the converter receives power fIrom the moving vehicle.
  3. 10. The electrical converted assembly of claim 9, wherein te power is rec eived diretly from a battery of the towing vehicle. ii. A method of converting an electrical. signal from a towing vehicle to a towed vehicle, the method comprising sensing a. current flow in a wire of the towing vehicle; generating a first signal based on the sensed current flow, the first signal indicative of an operative condition of the towing vehicle; 17 WO 2013/056083 PCIUS2012/060008 generating a second signal based on the flirt signalI and activating an operattIn on the towed vehicle in rsponse to the second signal
  4. 12. The method of claim 11, ,wherein acovatiug includes activating a predetermined light on the twed vehicle.
  5. 13. The method of claim i. 1, wherein the current flov issensed by a nonoinvasive sensor applied to the wire of the towing vehicle,
  6. 14. The method of claiti 13, wherein the non-invasive current sensor is applied to a single wire of a .notiwire system.
  7. 15. The method of claim i wherein the wire of a towing vehicle is a left turn, right turn, stopiht tail backup, or auxiliary channels wire of the towing vehicle.
  8. 16. The method of claim 15, wherein the second signal is sent to the left turn right tur, stoplight tail lamps, backup signal or an tailiary sigal of the towed vehicle 17 1he method of daim 1i further comprising adaptively adjusting an offset to sense a low current condition on the wire of tlhe towing vehicle 18, A converter assembly comprising a current sensing deve capable of nvasingly engaging a wire of the twing vehicle the current sewing device capable of detecting current flow in the wire and generating a first sgnal in response to the detection; an electrical component in operable communication with the current sensin device, the electrical component generating a second signal that triggers a response in an electrical system of a towed vehicle in response to the first signal ofthe current sensing device. 1 The conventer assenbv of claim 18 wherein tie noninvasive curent sensor is applied to single wire of a multi-wire sstern
  9. 20. 'The converter assembly of claim 18 herein the wire of a towing vehicle, is a left turn, right turn, stoplight ail backup or auxiliary channels wire of the towing vehicle.
  10. 21. The converter assembly of claim 18" where 0he second sigal. is sent to the left tur, right turn, stoplight., tail Iaps, backup signal or an auxiliary signal of the towed vehicle. 22 The conveertr assembly of claim 18 wherein the second signal is sent to the towed vehicle through a communications bus of the. towed vehicle 2. The converter assembly of claim 22, wherein the second signal uses a CAN, IN or SCAN comminunications protocol. 18
AU2015258190A 2011-10-12 2015-11-17 Current sensing electrical converter Abandoned AU2015258190A1 (en)

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US4115764A (en) * 1974-09-27 1978-09-19 Nippon Soken, Inc. Diagnostic system employing a magnetic field responsive apparatus
US4064413A (en) * 1975-09-22 1977-12-20 Chrysler Corporation Relay adapter circuit for trailer lamps
US6039410A (en) * 1997-01-10 2000-03-21 Hayes Lemmerz International, Inc. Electronic trailer brake controller
AU2002351063A1 (en) * 2002-02-04 2003-09-02 Elizabeth Mary Ward A vehicle accessory
US7145442B1 (en) * 2003-10-14 2006-12-05 Yu Hei Sunny Wai Vehicle operation display system
JP2006038799A (en) * 2004-07-30 2006-02-09 Tamura Seisakusho Co Ltd Detector
US8746812B2 (en) * 2004-10-08 2014-06-10 Marcia Albright Brake control unit
US8179142B2 (en) * 2008-03-11 2012-05-15 Cequent Electric Products Trailer signal converter
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