AU2020200985A1 - Vehicle junction box - Google Patents

Vehicle junction box Download PDF

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Publication number
AU2020200985A1
AU2020200985A1 AU2020200985A AU2020200985A AU2020200985A1 AU 2020200985 A1 AU2020200985 A1 AU 2020200985A1 AU 2020200985 A AU2020200985 A AU 2020200985A AU 2020200985 A AU2020200985 A AU 2020200985A AU 2020200985 A1 AU2020200985 A1 AU 2020200985A1
Authority
AU
Australia
Prior art keywords
junction box
trailer
side marker
data
connector
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
AU2020200985A
Inventor
Robert Nelson Cartwright
Arnold Christian
Nigel John Greig
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hella New Zealand Ltd
Original Assignee
Hella New Zealand Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2019900434A external-priority patent/AU2019900434A0/en
Application filed by Hella New Zealand Ltd filed Critical Hella New Zealand Ltd
Publication of AU2020200985A1 publication Critical patent/AU2020200985A1/en
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B45/00—Circuit arrangements for operating light-emitting diodes [LED]
    • H05B45/50—Circuit arrangements for operating light-emitting diodes [LED] responsive to malfunctions or undesirable behaviour of LEDs; responsive to LED life; Protective circuits
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60Q—ARRANGEMENT OF SIGNALLING OR LIGHTING DEVICES, THE MOUNTING OR SUPPORTING THEREOF OR CIRCUITS THEREFOR, FOR VEHICLES IN GENERAL
    • B60Q11/00—Arrangement of monitoring devices for devices provided for in groups B60Q1/00 - B60Q9/00
    • B60Q11/005—Arrangement of monitoring devices for devices provided for in groups B60Q1/00 - B60Q9/00 for lighting devices, e.g. indicating if lamps are burning or not
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/023—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements for transmission of signals between vehicle parts or subsystems
    • B60R16/0238—Electrical distribution centers
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
    • G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
    • G01R31/005—Testing of electric installations on transport means
    • G01R31/006—Testing of electric installations on transport means on road vehicles, e.g. automobiles or trucks
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02G—INSTALLATION OF ELECTRIC CABLES OR LINES, OR OF COMBINED OPTICAL AND ELECTRIC CABLES OR LINES
    • H02G3/00—Installations of electric cables or lines or protective tubing therefor in or on buildings, equivalent structures or vehicles
    • H02G3/02—Details
    • H02G3/08—Distribution boxes; Connection or junction boxes
    • H02G3/088—Dustproof, splashproof, drip-proof, waterproof, or flameproof casings or inlets
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S19/00—Satellite radio beacon positioning systems; Determining position, velocity or attitude using signals transmitted by such systems
    • G01S19/38—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system
    • G01S19/39—Determining a navigation solution using signals transmitted by a satellite radio beacon positioning system the satellite radio beacon positioning system transmitting time-stamped messages, e.g. GPS [Global Positioning System], GLONASS [Global Orbiting Navigation Satellite System] or GALILEO
    • G01S19/42—Determining position
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S2205/00—Position-fixing by co-ordinating two or more direction or position line determinations; Position-fixing by co-ordinating two or more distance determinations
    • G01S2205/001—Transmission of position information to remote stations
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01S—RADIO DIRECTION-FINDING; RADIO NAVIGATION; DETERMINING DISTANCE OR VELOCITY BY USE OF RADIO WAVES; LOCATING OR PRESENCE-DETECTING BY USE OF THE REFLECTION OR RERADIATION OF RADIO WAVES; ANALOGOUS ARRANGEMENTS USING OTHER WAVES
    • G01S5/00—Position-fixing by co-ordinating two or more direction or position line determinations; Position-fixing by co-ordinating two or more distance determinations
    • G01S5/0009—Transmission of position information to remote stations
    • G01S5/0018—Transmission from mobile station to base station
    • G01S5/0027—Transmission from mobile station to base station of actual mobile position, i.e. position determined on mobile
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04W—WIRELESS COMMUNICATION NETWORKS
    • H04W4/00—Services specially adapted for wireless communication networks; Facilities therefor
    • H04W4/30—Services specially adapted for particular environments, situations or purposes
    • H04W4/40—Services specially adapted for particular environments, situations or purposes for vehicles, e.g. vehicle-to-pedestrians [V2P]
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04W—WIRELESS COMMUNICATION NETWORKS
    • H04W4/00—Services specially adapted for wireless communication networks; Facilities therefor
    • H04W4/80—Services using short range communication, e.g. near-field communication [NFC], radio-frequency identification [RFID] or low energy communication
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04W—WIRELESS COMMUNICATION NETWORKS
    • H04W84/00—Network topologies
    • H04W84/02—Hierarchically pre-organised networks, e.g. paging networks, cellular networks, WLAN [Wireless Local Area Network] or WLL [Wireless Local Loop]
    • H04W84/10—Small scale networks; Flat hierarchical networks
    • H04W84/12—WLAN [Wireless Local Area Networks]
    • H—ELECTRICITY
    • H04—ELECTRIC COMMUNICATION TECHNIQUE
    • H04W—WIRELESS COMMUNICATION NETWORKS
    • H04W88/00—Devices specially adapted for wireless communication networks, e.g. terminals, base stations or access point devices
    • H04W88/02—Terminal devices

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Lighting Device Outwards From Vehicle And Optical Signal (AREA)

Abstract

: A trailer junction box for sue with a variety of vehicles having a housing encapsulating an internal circuit board 5 providing routing circuits and protection elements. The housing supports external connections to enable input connection from a vehicle control unit connector to the output connectors of a cable harness. The circuit board within the housing provides preconfigured routing circuits 10 between the external connectors, and one or more resettable protection elements each configured to provide protection for one or more external connections. 3/5 en a) U-

Description

3/5
en a)
U- VEHICLE JUNCTION BOX
Technical field
The field of the invention is electrical junction boxes for vehicles including automotive vehicles and marine vessels, for distributing electrical power and control connections from a main controller to components such as lights and accessories. An example of an application of the invention is a junction box for electrical connections between a truck prime mover and trailer.
Background
Traditional junction boxes for distributing electrical power leak water, dust and debris because they require access for installation and replacement of fuses.
These junction boxes also require electrical knowhow for installation, this can lead to errors during installation and cause electrical quality issues. For example, an installer must manually configure connections, based on a wiring diagram or plan. Also, typically needing to solder each individual connection. This can be prone to errors and can also be time consuming.
Further identification and correction of faults typically requires reopening of the junction box and rewiring connections. This requires specialist knowledge or the wiring diagram or a technician who may need to trace connections to reconstruct a wiring diagram. This process can be prone to human error.
There is a need for improved junction boxes.
Summary of the invention
According to one aspect there is provided a trailer junction box comprising: a sealable housing; a set of a plurality of external connectors, disposed on the housing, at least one first connector being configured to mate with a cooperating control unit connector, and at least one second connector each second connector being configured to mate with a cooperating connector from a cable harness; a circuit board providing preconfigured routing circuits between the external connectors, and one or more resettable protection elements each configured to provide protection for at least one external connection; wherein the housing is configured to be hermetically sealed to fully encapsulate the circuit board.
In an embodiment the protection elements include one or more of resettable fuses and current control circuits.
The trailer junction box can further comprise a controller configured to monitor the routing circuits and perform diagnostics functions.
In some embodiments the controller includes a redundancy module configured to monitor smart lamps to activate lighting redundancy measures to maintain compliance when a signal lamp function fails. The routing circuits can be configured to provide redundancy, and wherein the controller includes a redundancy module configured to identify fault conditions in routing circuits and re-rout connections via redundancy circuits in response to identification of fault conditions.
Some embodiments of the trailer junction box further comprise a communication module in data communication with the controller and configured to provide a data connection external to the junction box. In some embodiments the communication module provides a wireless data connection.
Some embodiments of the trailer junction box further comprise a GPS module in data communication with the controller.
In an embodiment the controller is configured to send notification of electrical or signal faults along with other diagnostic data to vehicle or vessels body control unit or other fleet management systems using wired or wireless communication.
Brief description of the drawings
Figure 1 is a block diagram providing an illustrative example of how an embodiment of a junction box provides an interface between a body control system and a cable harness for trailer lights.
Figure 2 is a block diagram showing functional components of an embodiment of a junction box according to the present invention.
Figure 3 is a drawing of an example of an embodiment of a junction box in accordance with an embodiment of the present invention.
Figure 4 is a diagram illustrating an example of internal junction box routing connections.
Figure 5 is an illustrative block diagram representative of examples of embodiments of the present invention.
Detailed Description
Described herein is a trailer junction box comprising a housing that encapsulates an internal circuit board providing routing circuits and protection elements. The housing supports external connections to enable input connection from a vehicle control unit connector to the output connectors of a cable harness. The circuit board within the housing and the circuit provided thereon is for routing of power and control signals between input and output connections.
Junction boxes as described can be configured for a variety of vehicles, including automotive vehicles and marine vessels.
The circuit board provides preconfigured routing circuits between the external connectors, and one or more resettable protection elements each configured to provide protection for one or more external connections.
The preferred embodiment of a trailer junction box is a sealed, durable system that provides protection for the power and control systems of the vehicle. The protection elements can also provide protection to reduce signal interference that may be caused by fault conditions.
The junction box is designed to provide a connection from a main control system to a set of components, such as lights, sensors and other accessories to provide power and control signalling. The diagram of Figure 1 illustrates an example of a junction box 100 for a truck trailer providing enabling connection between a body control system 110. The body control system includes the vehicle's lighting management system which controls the signal lights of the vehicle. This is the input for the junction box. In embodiments where the junction box also connects sensors, the body control system may also receive sensor input signals via the junction box.
The Junction box 100, provides multiple connections for the cabling connecting trailer lights and accessories. In this diagram the cable harness for the trailer lights includes: cables connecting side marker lights 120 on both right and left sides; cables connecting multi-function light assemblies 130, including stop lights, tail lights, reversing lights and indicators; and cables connecting number plate lights 140. Other accessories which may also be connected to the cable harness include sensors, cameras, auditory indicators etc. The cables of the cable harness can also provide power to the lights and accessories, the power supply being connected via the body control unit. Control signals (for example in response to activation of left or right indicators) are generated by the body control system. These signals are relayed to the lights and accessories via the junction box connection. Signals, such as sensor or camera signals can also be fed back to the body control unit via the cable harness. It should be appreciated that different trailers (or other equipment) may carry different arrangements of lights and accessories and have associated differences in cable harness and junction requirements. For example, one truck cab or prime mover, and hence the vehicle control system including the body control unit, may be connected to different trailers having different accessories and cable harness configurations. Further, for multi trailer vehicles, for example B-double trucks or road trains, multiple trailers may also be controlled from the same body control unit.
Aspects of the present disclosure relate to the physical configuration of the junction box to facilitate connection to the cable harness, aspects of the functionality of the junction box.
A block diagram of an embodiment of the junction box is shown in Figure 2, and Figure 3 shows an example of the external connectors and arrangement of these on the housing.
The junction box 100 comprises a housing 310 which supports a set of a plurality of external connectors 320, 330, disposed on the housing 310. At least one connector 320 is configured to mate with a cooperating control unit connector. Other external connectors 330 are configured to mate with cooperating connectors from a cable harness. Sealed inside the housing is a circuit board providing preconfigured routing circuits between the external connectors 320, 330, and one or more resettable protection elements each configured to provide protection for at least one external connection. The housing can be hermetically sealed to fully encapsulate the circuit board.
The external connectors can be configured to cooperate with standard connectors commonly used for cable harnesses. For example, each connector may include a plurality of pins extending outwardly from the housing with surrounding guarding wall sections or socket, shaped to receive a standard lighting cable connector. The guard walls or sockets may be configured to help guide connection and provide some protection against accidental disconnection. The guard walls or sockets can also be shaped to restrict the type of connector that may be connected, to reduce the likelihood of users plugging in incorrect connectors - and hence incorrect lighting elements.
Embodiments of this trailer junction box allow for rapid installation. The lamps are connected by external plugs. Each type of lamp has a different plug connection for ease of installation. Different plug connections can also avoid incorrect connections. The standard connectors and preconfigured routing enables quick, simple and accurate "plug and play" type connection.
The protection elements include one or more of resettable fuses and/or current control circuits. Each routing between an input connection and an output connection can be, or operate as, an independent circuit and each of these circuits can include at least one protection element. In the event of a fault, typically occurring external to the junction box, for example faulty lights or short circuit in the cable harness, the protection elements can provide isolation or current control, which is resettable without the need to open the junction box once the fault has been rectified.
The junction box design facilitates a hermetically sealed box with electrical protection of multiple electrical circuits terminated at a single point. Embodiments can also include functionality (circuits and components) providing potential to detect, diagnose, notify of a fault and/or activate redundancy systems. For example, the junction box can be integrated with ISO 13207-1 standard HCS (Hella Compatibility system) for body control detection of a faulty signal light.
The construction of embodiments of the junction box is robust designed for the harsh operating environments where it will be susceptible to water, dust and UV damage. The trailer box housing is designed of tough plastic or other corrosion resistant housing which is hermitically sealed using welds or glue or other sealing methods to protect the electrical components contained.
Some embodiments use internal self-resetting fuses for the protection elements, to provide electrical protection for both output electronics circuits and the input vehicle control system and do not require internal access which risks leak paths. An alternate embodiment includes current limiting circuits for the protection elements, again enabling restoration of functionality without requiring the junction box to be opened after fault recovery. This feature of resettable protection elements enables the junction box to provide protection for external control circuits, lighting elements and other accessories while being fully sealed. This ability to fully seal the junction box reduces the risk of internal faults, for example due to ingress or water or grime. This can have advantages in improving reliability and functional life of the junction box.
Embodiments can also include an internal junction box controller configured to monitor the routing circuits and perform diagnostics functions. For example, an internal controller may be configured to detect the external connection configuration, monitor for any fault conditions, and where available control utilisation of redundancy circuits.
The junction box provides electrical protection for the vehicle control systems and connects signal lamps and other electronic devices at a single point for easy cable harness fault diagnostics. As illustrated in the block diagram of Figure 2, in this embodiment the internal circuit board supports circuitry and components to implement a diagnostic module 220, a lamp identification module 230, a redundancy control system 240, communication system 250 and GPS module 255.
The diagnostic module 220 is configured to monitor operation and diagnoses faults. The diagnostic module 220 can from part of an automatic diagnostic system which is also configured to notify the driver or fleet manager of status and fault data via the communication sub system 250. The diagnostics system may also include a data store for storing of diagnostic data 260 for example, to log faults and associated data.
The data store may also be utilised by the diagnostics module 220 for storing monitored operational data to enable potential fault identification or warnings. Fault identification is based on identifying change in monitored operation indicating impending fault conditions. Notification of potential or impending faults can be output as signals from the junction box to enable the driver or fleet manager. The driver or fleet manager can then conduct appropriate preventative maintenance on an ad hoc basis or integrated with regular maintenance schedules. This may have an advantage of reduction in down time due to fault corrections. It should be appreciated that some types of faults with trailer lights (for example indicator, brake or tail light failure) can significantly compromise road safety and may even cause a vehicle to be deemed unroadworthy until the fault is corrected. Emergency maintenance can be costly due to downtime and associated loss of productivity or missed deadlines, and personnel costs for emergency repair. The ability to identify impending faults and perform preventative maintenance can be significant in reducing operating cost.
The lamp identification system 230 can recognize the lamp plugged into the junction box and can output the relevant power and signal functions. The lamp type identification module 230 measures electrical characteristics to recognise the lamp type. For example, distinguishing between a smart lamp 270, bulb lamp 272 and LED lamp 275. Where applicable, for example for smart lamps, the lamp type identification module can also be configured to read the electronic identity of the lamp to recognise the lamp type. The lamp type identification may be used to look up lamp functionality or this may be read from the lamp, similarly to the electronic identity. The lamp identification module can adapt signal outputs in accordance with the requirements for different type of lamps or enable/disable functions or signal types based on the lamp types.
The redundancy control system 240 can be configured to analyse data from the automatic diagnostics 220 to determine what function is faulty. The redundancy system 240 can then potentially control operation to compensate for the fault or mitigate the impact caused, for example, controlling smart lamps 270 to provide additional lighting and service functions to temporary compensate for a failed function. In embodiments where the routing circuits are configured to provide redundancy, the redundancy module can be configured to identify fault conditions and re-rout connections appropriately.
The communication module can be incorporated into the controller or as a separate external module via an output connector in data communication with the junction box. The communication subsystem can also be configured to use wireless communication. The communication subsystem is configured to send notifications to a data capture system when an electrical fault occurs. For example, the controller is configured to send notification of electrical or signal faults along with other diagnostic data to vehicle body control unit. Some embodiments may also capture this data for later download or sending to a fleet management system (using wired or wireless) communication. For example, to input to maintenance scheduling and/or adjusting schedules.
For example, the communication subsystem may provide a bus connecting an external data port, or one or more data pins of the first external connector, to which the body control system connector is connected. The communication subsystem can be configured for multiple communication protocols for wired and wireless communication. Some embodiments are configured for wireless communication only, for example Wi-Fi, Bluetooth or cellular data protocols may be used. A data capture system, also configured for wireless communication with the communication subsystem of the junction box, can be associated with the body control system for acquiring diagnostic and other data (such as GPS and status) from the junction box controller.
The GPS module provides a GPS location of the junction box, and hence the trailer, which can be sent via Communication sub system. This information is useful for the fleet managers to find which trailer has an issue and the nearest service station to repair the issue. It should be appreciated that as trailers can be used interchangeably between trucks and more than one trailer may be towed by one truck, the ability to use GPS to isolate faults in a specific trailer avoids the need for maintenance personnel to test each trailer to identify which one has the fault. The ability to identify the individual faulty trailer or vehicle has advantages in improving efficiency of maintenance or swapping out of the faulty unit. Further, the diagnostics reporting the nature of the fault can also have advantages for management of maintenance and fleet planning, for example to allow a fleet manager to predict the required down time for repair and adjust scheduling accordingly.
This junction box is advantageous over existing devices as it reduces installation effort and the need for skilled technicians by facilitating plug in installation. Traditional trailer boxes require electrical knowhow for installation as they typically have terminal connections or require soldering to connect external equipment together. This requires skilled installers, leads to errors during installation and increases installation time. This trailer box invention allows for rapid installation, the lamps are connected by external plugs. Each type of lamp has a different plug connection for easy installation.
An example of an embodiment of the junction box will now be described in more detail with reference to the block diagram of figure 2 and Figure 4 illustrating an example of internal junction box routing connections.
Such embodiments enable protecting vehicle on board electronic systems from cable harness and electronics failures, such as lighting, using automatic resettable fuses or current limiting components on each input circuit contained in a hermetically sealed enclosure.
Figure 4 shows a first external connector 410 and its pin connections. This first connection 410 is shaped to connect with a lead from a vehicle controller, for example a body control unit (not shown). A plurality of second connectors 420a-n which can also be of a plurality of standard connector types for connecting trailer lighting components, this group of connections often being referred to a trailer harness.
Tracks on a printed circuit board provide connections being the first external connector 410 (the input) and the plurality of second external connectors 420a-n. Included in the routing circuits are protected using resettable fuses. The automatic resettable fuses 440 are reset by external systems such as the body control unit of a vehicle or vessel.
The junction box can be used to protect cable harness and electrical hardware such as lighting, from vehicle and marine vessel electrical failure using automatic resettable fuses or current limiting components on each input circuit. In this embodiment protection is provided by triggering the fuse in response to detecting over current, short circuit, open circuit or loss of data communication in the cable harness.
The fuses may be automatically resetting, for example being configured to trip due to excess heat (for example as typically experienced due to high current) and biased to return once cooled. In this example if the fault has not been resolved by the time the fuse has cooled to resent, then the fault will continue to occur, and the fuses be tripped again to provide continuing protection. Other types of fuses may be reset by a junction box controller or the body control system controller. The junction box in configured such that he resettable fuses allow independent isolation of connected electrical systems at a single diagnostic location.
In an embodiment of this invention the junction box has integrated HCS (Hella Compatibility Solution). The Hella Compatibility Solution is a subsystem which provides a signal to the body control unit that emulates a light bulb function in LED lamps to provide bulb compatible failure detection for LED lights. Hella HCS lamps, electronic control and flasher units are designed to ISO 13207-1 to provide compatibility with commercial vehicle indicator failure systems. (Patent: DE102006018308A1 and DE10107578A1)
The junction box is designed to connect to standard connectors, to enable easy installation. Embodiments may include a lamp identification feature to allow the junction box to recognise the type of lamps connected and to route appropriate signal and power to enable the correct function accordingly. This eliminates the risk of incorrect connections. In this embodiment the trailer box measures electrical characteristics or the electronic identity of the lamp to recognise the lamp and determine lamp functionality. This maybe done using a digital communication with a smart lamp where the lamp facilitates network "handshaking".
The junction box is configured with a diagnostics module for automatically diagnosing electrical faults within a cable harness or lighting on vehicle.
An embodiment can further comprise a communication system which sends notification of electrical or signal faults along with other diagnostic data to vehicle body control unit or other fleet management systems using wired or wireless communication. In this embodiment the redundancy system communicates with smart lamps to activate lighting redundancy measures to maintain compliance when a signal lamp function fails.
The lamp identification function can identify connected lamps and route signals and power appropriately to activate all signal functions of a lamp at each lamp plug connection.
Measurement data from the automatic diagnostic system can be stored in Junction box memory, for example solid state memory could be used. Solid state memory is highly suitable being robust, and compact in size, required to be suitable to application in a junction box. Further, such solid-state memory devices are commercially cost effective.
The data can be accessed via communication system for diagnostic requirements.
In an embodiment this trailer junction box has an automatic diagnostic subsystem. The automatic diagnostics monitors voltage, current and impedance of input & output connections as well as communicating with smart lamps to verify if there is an issue with a connected electrical system. The automatic diagnostics system may have a subsystem to capture any issues or irregular measurements for use diagnosing system electrical faults. In this case data can be accessed using the data capture system that may be part of the vehicle/vessel for operators or externally through a wireless or wired network for fleet managers.
In this embodiment the junction box may have a redundancy control system and communication subsystem. The redundancy control system reviews data from the automatic diagnostics to locate which output circuit function is faulty. It can then potentially control lamps to compensate for a failed electrical or lighting function. The communication subsystem uses wired or wireless communication such as Bluetooth, mobile SMS and satellite to send notifications to an external data capture system when an electrical fault occurs. In this case it may send details from the auto diagnostics system, GPS location to a driver or fleet manager. This data can also be requested via data capture system.
In an embodiment the diagnostic module may include a microprocessor, RISC (reduced instruction set computer) processor, FPGA (field programmable gate array) or PLC (programmable logic controller), programmed with logic to monitor operating conditions, and identify fault conditions. For example, fault conditions may be identified by voltage, current or temperature operating conditions outside pre-set thresholds or threshold ranges, operating at give set values indicative of fault conditions (i.e. open or closed circuits), or values outside target operating conditions. In some embodiments the diagnostics module may be configured to affect operation of peripheral circuitry, such as actuation of switches or resettable protection circuits, in response to some fault conditions.
The diagnostics module can be programmed with one or more actions to take in response to each identified fault condition. In an embodiment this may involve a lookup table indexed using out of range or exceeding threshold values for monitored operating conditions indicative of faults, whereby the diagnostic module can identify a fault condition. A lookup table may also be utilised for a fault to lookup programmed response actions, which may include any one or more actions for rectification, mitigation, notification and fault data logging. In an alternative embodiment the diagnostic module may be programmed to run a monitoring subroutine and call one or more fault recording and action subroutines in response to detecting fault conditions. Actions may also be triggered in response to detecting ceasing of a fault condition to restore the circuit to normal operating mode (i.e. resetting a protection device), for example temperature returning to a normal operating range, detecting replacement of a faulty light etc.
The possible actions may vary depending on the embodiment and functionality included in the junction box system. In a basic embodiment fault data may simply be logged, whereas in a system having a redundancy module or smart lamps actions may utilise the functionality of these components to mitigate faults. For example, in response to an identified fault condition the diagnostic module may be configured to actuate a switch to a redundancy circuit, or cause a smart lamp to operate to compensate for another faulty light. In another example, fault data may be logged without action being taken, for example identifying that a light (for example, a tail light) is faulty and logging data regarding the fault without altering system configuration or operation, where no mitigating action may be taken as replacement of the faulty light is the only option to resolve the fault. In this circumstance the diagnostics module may be configured provide fault notifications to the vehicle body control unit.
The diagnostics module may be configured to store data regarding each fault condition, and log data regarding the fault for transfer to the body control unit with the fault notification or for later download. Taking action in response to a fault condition may be optional for some or all fault conditions in some embodiments.
Using this arrangement of features as described embodiments can provide a hermetically sealed, rugged trailer junction box designed for on and off-road transport and marine vessels. This junction box can be mounted to a trailer or vessel and is designed to prevent ingress of water and debris for the safety and durability of the electrical components contained. The junction box facilitates plug and play electrical connections using sealed connector terminations for rapid installation of signal lights, reverse alarms and other electrical systems on trailers or vessels. The junction box provides electrical protection for the vehicle and vessel control systems and connects signal lamps and other electronic devices at a single point for easy cable harness fault diagnostics. The junction box can be integrated with ISO 13207-1 standard HCS (Hella Compatibility system) and can facilitate automatic diagnostics to notify a driver or fleet manager or activate system redundancy measures if an electrical fault occurs.
It is necessary for the junction box to be rugged and sealed against the elements. The external connectors can be leak proof sets of connectors. An electrical connection is required from the external connectors to the circuit board to enable signal routing. Examples of different methods of connection that may be used to provide the electric connection between the external connectors and circuit board are illustrated in Figure 5. In one example pins of the external connector 520 may be connected directly to the circuit board 510, in this embodiment solid physical connection of the pins to the circuit board 510 and the housing 550 support the circuit board within the housing. The direct connection of the pins to the circuit board also provides an electrical connection to the routing circuits (not shown) and protection elements 560. In an alternative example, pins from the external connector 540 may be connected to an intermediary component 545 (such as a resettable fuse or component of a current limiting circuit, processor etc.) and be connected to the routing defined by the circuit 510 board through one or more intermediary components 545. In another example wires 535 may be used to connect the external connectors 530 to the internal components 560 or into the circuit on the circuit board 510. The choice of connection type may be based on robustness requirements for the junction box. More than one type of connection may also be utilised, depending on the nature of the connection and circuit components.
An advantage of embodiments of the described junction box is that due to the preconfigured circuit board, no detailed knowledge of the connection mapping is required, and likelihood of connection errors reduced. This allows a "plug and play" type efficient installation. Circuits may also be configured to accommodate different types of cable harness without requiring reconfiguring. Embodiments may also be automatically adaptable to trailer accessory component functionality (i.e. smart lights), based on diagnostics identifying functional components attached via the cable harness, without requiring operator intervention.
A further advantage is inclusion of internal resettable protection elements. In addition, on board intelligent monitoring and diagnostics can be configured to automatically provide fault identification data to the driver and/or fleet manager.
It will be understood to persons skilled in the art of the invention that many modifications may be made without departing from the spirit and scope of the invention.
In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.
It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.
Definitions: • Fuse array - Circuit protection system with self resetting fuses. • Automatic diagnostic - System which diagnoses faults and uses this data to notify driver or fleet manager via sub systems. • Lamp identification - System can recognize which lamp is plugged into the junction box and output the relevant functions.
• Redundancy control system - Reviews data from the automatic diagnostics to determine what function is faulty. It can then potentially control smart lamps to provide additional lighting and service functions to temporary compensate for the failed function. • Communication Sub System - This function uses wireless communication to send notifications to data capture system when an electrical fault occurs. • GPS - Provides GPS location which can be sent via Communication sub system. This information is useful for the fleet managers to find which trailer or vessel has an issue and the nearest service station to repair the issue. • Smart lamp - Lamp which can communicate to provide additional lighting and service functions. • Bulb Lamp - Standard bulb lamp • LED lamp - Standard LED lamp • Data capture System - Device which communicates with the junction box to monitor faults and location. • Diagnostic data - Electrical fault, functions affected, GPS location and vehicle or vessel data sent to data capture system.

Claims (9)

1. A trailer junction box comprising: a sealable housing; a set of a plurality of external connectors, disposed on the housing, at least one first connector being configured to mate with a cooperating control unit connector, and at least one second connector each second connector being configured to mate with a cooperating connector from a cable harness; a circuit board providing preconfigured routing circuits between the external connectors, and one or more resettable protection elements each configured to provide protection for at least one external connection; wherein the housing is configured to be hermetically sealed to fully encapsulate the circuit board.
2. A trailer junction box as claimed in claim 1 wherein the protection elements include one or more of resettable fuses and current control circuits.
3. A trailer junction box as claimed in claim 2 further comprising a controller configured to monitor the routing circuits and perform diagnostics functions.
4. A trailer junction box as claimed in claim 3 wherein the controller includes a redundancy module configured to monitor smart lamps to activate lighting redundancy measures to maintain compliance when a signal lamp function fails.
5. A trailer junction box as claimed in claim 4 wherein the routing circuits are configured to provide redundancy, and wherein the controller includes a redundancy module configured to identify fault conditions in routing circuits and re-rout connections via redundancy circuits in response to identification of fault conditions.
6. A trailer junction box as claimed in claim 4 or 5 further comprising a communication module in data communication with the controller and configured to provide a data connection external to the junction box.
7. A trailer junction box as claimed in claim 6 wherein the communication module provides a wireless data connection.
8. A trailer junction box as claimed in claim 7 further comprising a GPS module in data communication with the controller.
9. A trailer junction box as claimed in any one of claims 6 to 8 wherein the controller is configured to send notification of electrical or signal faults along with other diagnostic data to vehicle or vessels body control unit or other fleet management systems using wired or wireless communication.
Side marker Side marker Side marker Side marker Side marker
Stop/Tail/Indicator/ Reverse lamp
130 Trailer 110 Junction Box
Number plate lights 100 1/5
140
Side marker Side marker Side marker Side marker Side marker
125
Figure 1
270 210 220 230 240
110 272 2/5
250 275 Diagnostics Data
260
280 255
Figure 2
330 310 320 3/5
Figure 3
440
420a
420b 4/5
420c 420n
430 Figure 4
520 530 540 560 560 560 535 545
510 5/5
Circuit Board
550
Figure 5
AU2020200985A 2019-02-11 2020-02-11 Vehicle junction box Pending AU2020200985A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2019900434 2019-02-11
AU2019900434A AU2019900434A0 (en) 2019-02-11 Vehicle junction box

Publications (1)

Publication Number Publication Date
AU2020200985A1 true AU2020200985A1 (en) 2020-08-27

Family

ID=72146366

Family Applications (1)

Application Number Title Priority Date Filing Date
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Country Status (1)

Country Link
AU (1) AU2020200985A1 (en)

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