CN117638765A - Junction box with parallel switch fault detection - Google Patents
Junction box with parallel switch fault detection Download PDFInfo
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- CN117638765A CN117638765A CN202311079033.5A CN202311079033A CN117638765A CN 117638765 A CN117638765 A CN 117638765A CN 202311079033 A CN202311079033 A CN 202311079033A CN 117638765 A CN117638765 A CN 117638765A
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- 238000005259 measurement Methods 0.000 description 8
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Abstract
The application relates to a junction box with parallel switch fault detection. The junction box includes parallel-connected switches including at least a first switch and a second switch. The first current sensor senses a current through the first switch. The second current sensor senses a current through the second switch. The controller is in communication with the first current sensor and the second current sensor. The controller modifies operation of the junction box in response to detecting a failure of at least one of the switches. The controller detects a failure of one of the first switch and the second switch when the current through the first switch is unbalanced with the current through the second switch.
Description
Cross Reference to Related Applications
The present application claims the benefit of U.S. application Ser. No. 18/450,579, filed 8/16 of 2023, and U.S. provisional application Ser. No. 63/400,959, filed 25 of 2022, the disclosures of U.S. application Ser. No. 18/450,579 and U.S. provisional application Ser. No. 63/400,959 are incorporated herein by reference in their entireties.
Technical Field
The present disclosure relates to power distribution units such as in the form of junction boxes.
Brief Description of Drawings
FIG. 1 illustrates a junction box according to an embodiment of the present disclosure;
FIG. 2A shows a schematic diagram of a junction box according to the prior art; and
fig. 2B shows a schematic diagram of a junction box according to an embodiment of the present disclosure.
Detailed Description
Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present disclosure.
In vehicles, junction boxes are used to distribute electrical power between a power source and one or more loads. For example, junction boxes are the primary hubs in the electrical systems of vehicles, controlling and providing electrical power to various electrical features, such as power windows, power door locks, (interior and exterior) lighting, meters, and audio systems.
Some junction boxes include power switches (power switches) for controllably distributing power. The power switches of the solid state junction box are formed of one or more silicon switches (e.g., MOSFETs, IGBTs, etc.).
Referring now to fig. 1, a junction box 10 is shown in accordance with an embodiment of the present disclosure. Junction box 10 includes a plurality of power switches 14, 16, and 18 that provide distribution of electrical power to a plurality of outputs (i.e., loads) 24, 26, and 28. Processor 30 (e.g., a controller of junction box 10) controls the opening and closing of power switches 14, 16, and 18 based on, for example, commands and/or sensor signals received from inputs 36, 38, 40, and 42.
When the power switch is closed, current flows from the power source to the load through the power switch connected between the power source and the load. In contrast, when the power switch is open, no current flows from the power source to the load through the power switch.
Junction box 10 includes any number of power switches 14, 16, and 18 and features for controlling the transfer of electrical power to loads 24, 26, and 28. Likewise, junction box 10 includes any number of features and configurations for manipulating or otherwise reconfiguring electrical signals in communication therewith.
Junction box 10 operates in any number of environments and supports any number of operations. Junction box 10, which may be referred to as a Power Distribution Unit (PDU), is of a type commonly found in automobiles and other vehicles, wherein a plurality of power distribution lines and connectors are connected to the junction box output to receive electrical power from one or more power sources (e.g., one or more batteries) (not shown) connected to junction box 10. For example, various vehicle control features communicate with inputs 36, 38, 40, and 42 to request the distribution of electrical power to outputs 24, 26, and 28, such that processor 30 receives the input request and performs any number of operations to distribute the requested electrical power to the associated loads 24, 26, and 28, i.e., by closing power switches 14, 16, and 18 associated with the loads. That is, power switch 14 is closed to distribute power to load 24, power switch 16 is closed to distribute power to load 26, and power switch 18 is closed to distribute power to load 28.
Of course, the present disclosure contemplates any number of configurations and features of junction box 10 and is not intended to be limited to the foregoing. The present disclosure contemplates the use of the terminal box 10 in any number of locations, environments, and applications and is not intended to be limited to the foregoing.
The power switches 14, 16, and 18 include any number of configurations and features to support the transfer of electrical power to the loads 24, 26, and 28.
In this embodiment, the power switches 14, 16, and 18 include sensors 46, 48, and 50, a processor (not shown), logic (not shown), or other features that support their operation. These features may be packaged within an integrated circuit and mounted on a printed circuit board, for example, to provide an integrated circuit with dual in-line package (DIP).
The power switches 14, 16, and 18 may be characterized as a relay-less and fuse-less device in that they provide the functionality associated with relays and fuses. That is, the power switches 14, 16, and 18 are opened and closed to control the distribution of electrical power to the output (i.e., provide a relay function), and the power switches are opened to prevent the distribution of electrical power to the output (i.e., provide a fuse function) during a fault condition.
The power switches 14, 16, and 18 are solid state devices having one or more silicon switches (e.g., MOSFETs, IGBTs, etc.). The power switches 14, 16 and 18 may be referred to as smart devices in that they may be controlled by control signals sent from the processor 30, or they may be controlled based on other logical entities in communication therewith.
The sensors 46, 48, and 50 monitor any number of operating conditions associated with the power switches 14, 16, and 18, such as current flow and voltage, and switch temperature levels. In particular, as described herein, the sensors 46, 48, and 50 provide current sensing of the electrical power current output to the loads 24, 26, and 28 through the power switches 14, 16, and 18.
Processor 30 communicates with power switches 14, 16 and 18 and with sensors 46, 48 and 50 via a plurality of communication lines. The power switches 14, 16, and 18 and the sensors 46, 48, and 50 communicate with the processor 30 via a common communication bus (not shown) or other multiple access communication medium.
Processor 30 includes logic 54 for controlling its operation and the operation of power switches 14, 16 and 18. Logic 54 specifies any number of operating and control applications. Logic 54 includes features for controlling the opening and closing of power switches 14, 16, and 18 to control the distribution of electrical power to loads 24, 26, and 28. In this embodiment, the power switches 14, 16, and 18 include registers or other features that provide hardwired logic or other features to support or back up operations associated with opening and closing the power switches 14, 16, and 18, such as providing fault protection and switch opening in the event of a fault with the processor 30 or logic 54 (i.e., to prevent the load from experiencing an over-current or over-voltage condition).
Junction box 10 includes a communication port 58 in communication with processor 30. The external device may program the processor 30 using the communication port 58 and receive information from the processor 30. The present disclosure contemplates processor 30 including logic 54 in conjunction with sensors 46, 48, and 50 to diagnose fault conditions in power switches 14, 16, and 18 such that the fault conditions are communicated to a computer or other individual via communication port 58, for example, to facilitate vehicle repair and troubleshooting.
The opening of the power switches 14, 16 and 18 is controlled by a processor 30 to meter the amount of current flowing therethrough to the outputs 24, 26 and 28. In this embodiment, processor 30 controls the voltage levels and/or other operating parameters of power switches 14, 16, and 18 to control the opening of the power switches.
Processor 30 controls the opening and closing of power switches 14, 16 and 18 to provide reusable fuse operations. This is advantageous during a fault condition because the power switches 14, 16 and 18 are opened during the fault condition to prevent damage and then closed by the processor 30 after the error is corrected.
In this embodiment, the processor 30 includes logic 54 for: the operating conditions accompanying the fault condition are monitored to provide feedback that can be used to diagnose the error condition. For example, processor 30 assigns diagnostic codes based on various fault conditions. Processor 30 then outputs the diagnostic code for external analysis via communication port 58.
The diagnostic code includes any number of parameters and is associated with any number of error detection triggers (error detection trigger). For example, the diagnostic code is associated with a current related condition, such as an open circuit condition (no current flow), a high current error (high current errors) (i.e., different codes for different current levels), a short to ground, a short to battery, etc.
According to an embodiment of the present disclosure, one or more of the power switches 14, 16, and 18 is comprised of a set of power switches (e.g., MOSFETs, IGBTs, etc.) connected in parallel. Thus, a junction box according to an embodiment of the present disclosure includes at least one power switch, and each of the at least one power switch includes a set of power switches connected in parallel. For example, in one embodiment, the junction box includes a first power switch (e.g., power switch 14) and a second power switch (e.g., power switch 16), the first power switch including a first set of power switches connected in parallel, and the second power switch including a second set of power switches connected in parallel.
Referring now to fig. 2A and with continued reference to fig. 1, a schematic diagram of a junction box 60 according to the prior art is shown. Junction box 60 includes power switch 14, in this example, power switch 14 is comprised of a set of power switches 64a, 64b, 64c, and 64d (i.e., junction box 60 includes first power switch S1, second power switch S2, third power switch S3, and fourth power switch S4). The power switches 64a, 64b, 64c, and 64d are connected in parallel as shown in fig. 2A.
Further, power switches 64a, 64b, 64c, and 64d are connected in parallel between an input power source 68 (i.e., a battery) and an output 70 to one or more power loads. In this regard, the power switches 64a, 64b, 64c, and 64d are part of respective branches between the battery 68 and the output 70. For example, the first power switch 64a is part of a first branch between the power supply 68 and the output 70, the second power switch 64b is part of a second branch between the power supply 68 and the output 70, and so on.
The controller 30 of the junction box 60 (labeled "MCU" in FIG. 2A, as well as a "microcontroller") is associated with a gate driver 66 to control the operation of the power switches 64a, 64b, 64c and 64 d. For example, when power switches 64a, 64b, 64c and 64d are normalIn operation, controller 30 controls power switches 64a, 64b, 64c, and 64d to close to cause current to flow from battery 68 to output 70 via each branch. In particular, in this example of four parallel-connected power switches, the current flowing from the battery 68 to the output 70 via each of the four branches is I, according to kirchhoff's law of current L /4. That is, the current I L 4 flow through each of the four power switches 64a, 64b, 64c and 64d and their respective branches to the output 70. Thus, in this case where each of the four power switches 64a, 64b, 64c and 64d is closed, the total current output from the power switch 14 to the load 70 is I L (i.e., I L /4+I L /4+I L /4+I L /4＝I L )。
Junction box 60 also includes a common current sensor 72 (e.g., an amplifier with shunt resistor). The common current sensor 72 is provided by the sensor 46 associated with the power switch 14. The common current sensor 72 senses the total current output from the power switch 14 to the load 70. In particular, the currents output by the power switches 64a, 64b, 64c, and 64d are combined together to form a total current, and the common current sensor 72 senses the total current. For example, when the total current output from the power switch 14 to the load 70 is I L When, for example, each of the four power switches 64a, 64b, 64c and 64d is closed, the common current sensor 72 senses a total current of I L 。
In operation, when a given one of the power switches 64a, 64b, 64c, and 64d fails to close as commanded by the controller 30 (but remains open so that the branch associated with the open power switch is an open circuit and no current can flow along that branch from the battery 68 to the output 70), the total current I L And split among the remaining power switches. For example, when power switch 64d fails to close (as shown in FIG. 2A), the current output through each of the remaining closed power switches 64a, 64b, and 64c follows the kirchhoff current law from I L Increase/4 to I L /3. In this way, even the power switch 64dFailure, the total current output from the power switch 14 to the load 70 remains I L (i.e., I L /3+I L /3+I L /3＝I L )。
Notably, even if the power switch 64d fails and remains open, the common current sensor 72 senses the same total current output I L . Therefore, the failure of the power switch 64d cannot be detected by the common current sensor 72. In summary, when one power switch (e.g., power switch 64 d) fails, current I L Apportioned among the remaining switches (e.g., power switches 64a, 64b, and 64 c) and no difference in current is measured by common current sensor 72.
Referring now to fig. 2B and with continued reference to fig. 1 and 2A, a junction box 70 is shown in accordance with an embodiment of the present disclosure. Junction box 70 differs from junction box 60 in that junction box 70 includes a split current sensor (split current sensor) 74, while junction box 60 includes a common current sensor 72.
The split current sensor 74 is provided by the sensor 46 associated with the power switch 14. The split current sensor 74 includes a first current sensor 76a and a second current sensor 76b (each formed by a respective amplifier with a shunt resistor). The first current sensor 76a senses the current output through the power switches 64a and 64 b. The second current sensor 76b senses the current output through the power switches 64c and 64 d. (in contrast, the common current sensor 72 of the junction box 60 senses the current output through all of the power switches 64a, 64b, 64c, and 64 d.)
Downstream of the split current sensor 74, at the output 70, the currents output by the power switches 64a and 64b are combined with the currents output by the power switches 64c and 64d to form a total current.
When the power switches 64a, 64b, 64c and 64d each operate normally to close and each power switch outputs a current I L At/4, the first current sensor 76a measures the total output current I of the power switches 64a and 64b L 2 (i.e. I) L /4+I L /4＝I L /2), and a second current sensor 76b measures the total output current I of the power switches 64c and 64d L 2 (i.e. I) L /4+I L /4＝I L /2)。
When a power switch such as power switch 64d fails and remains open (as shown in FIG. 2B) and the current output of each of power switches 64a, 64B, and 64c is controlled from I as described above L Increase/4 to I L At/3, the current measurements of the first current sensor 76a and the second current sensor 76b change. Specifically, the first current sensor 76a measures the total output current 2I of the power switches 64a and 64b L 3 (i.e. I) L /3+I L /3＝2I L 3), and the second current sensor 76b measures the total output current I to the power switches 64c and 64d L 3 (i.e. I) L /3+0＝I L 3 because the output current of power switch 64d is zero).
Thus, when a power switch, such as power switch 64d, fails and remains open, since the first current sensor 76a and the second current sensor 76b have different (i.e., unbalanced) current measurements (in this example, 2I L /3≠I L 3) and thus the fact that one of the power switches 64a, 64b, 64c and 64d fails can be detected by the split type current sensor 74. Conversely, when all of the power switches 64a, 64b, 64c, and 64d are operating in order (in the upper order) and are closed, the first current sensor 76a and the second current sensor 76b will have the same (i.e., balanced) current measurement (in particular, in this example, I L /2＝I L /2)。
In addition, in the event that the power switch 64d fails and remains open, because the second current sensor 76b has a current measurement value (2I in this example) that is greater than that of the first current sensor 76a L 3) smaller current measurement (I in this example L 3) and thus the fact that one of the power switches 64c and 64d fails can be detected by the split current sensor 74.
In turn, the controller 30 has the option of detecting which of the power switches 64c and 64d is disabled. For example, in response to detecting the above example imbalance condition, the controller 30 alternately commands the third power switch 64c and the fourth power switch 64d to open. At the fourth power switch 64d has been lostIn the active and open condition, the total output current of the power switches 64c and 64d detected by the second current sensor 76b will be zero when the third power switch 64c is commanded to open, and the total output current of the power switches 64c and 64d detected by the second current sensor 76b will be I when the fourth power switch 64d is commanded to open L /3. From a comparison of these current measurements, the controller 30 readily recognizes that the fourth power switch 64d is disabled.
In summary, when one power switch (e.g., power switch 64 d) fails, current I L Is split among the remaining power switches (e.g., power switches 64a, 64b, and 64 c), and split current sensor 72 detects a current imbalance between the two sets of power switches (i.e., first set of power switches 64a and 64b, and second set of power switches 64c and 64 d). The current imbalance indicates that one of the power switches in the two groups fails.
The controller 30 performs a responsive action in response to detecting that the power switch has failed. For example, the controller 30 modifies operation of the junction box 70, such as by shutting down or reducing operation of the junction box (i.e., electrical output) (e.g., by controlling the on and off duty cycles of one or more power switches) until the failed power switch has been remedied. Further, in an embodiment, the controller 30 generates an alert to notify the failed power switch.
As described, a junction box according to the present disclosure may employ split current sensing of a set of parallel power switches to detect current imbalances, thereby detecting single power switch faults. For example, in power switches (e.g., 12V and 70A or higher) designed as a set of parallel silicon switches (MOSFETs, IGBTs, etc.), the total current sense is split into at least two. The unexpected unbalance in the sensed currents then indicates that one of the power switches has failed (e.g., opened). With a minimum component addition (e.g., additional amplifier/shunt resistor arrangements), a failure of one component of a set of parallel connected power switches (for three or more power switches) can be detected.
A split current sensing arrangement according to the present disclosure may improve the use of a single current measurement or the use of one current measurement per power switch.
Other benefits of a split current sensing arrangement according to the present disclosure may include: single fixed open fault (stuck-open fault) detection required for high ASIL architecture (power to ADAS (advanced driver assistance system), etc.); a cost effective solution to sense each branch (two current sensors instead of four); and other possible layouts (every 5, 6, &..once. Parallel drivers, always detect imbalance, or increase the number of split sensing stages).
The use of split current sensing arrangements according to the present disclosure may be done with any power switch that uses a set of silicon power switches in parallel (without current sensing).
Clause 1: in one embodiment, the present disclosure provides a junction box comprising: a plurality of parallel connected switches including at least a first switch and a second switch; a first current sensor that senses a current through the first switch; a second current sensor that senses a current through the second switch; and a controller in communication with the first current sensor and the second current sensor, wherein the controller detects a failure of one of the first switch and the second switch when the current through the first switch is unbalanced with the current through the second switch.
Clause 2: in another embodiment, the present disclosure provides the junction box of clause 1, wherein the controller detects the first switch failure when the current through the first switch is less than the current through the second switch.
Clause 3: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the controller detects that the first switch and the second switch are operating in sequence when the current through the first switch is balanced with the current through the second switch.
Clause 4: in another embodiment, the present disclosure provides the junction box of any one of the preceding clauses, wherein the plurality of parallel-connected switches further comprises a third switch and a fourth switch, the first current sensor senses current through the first switch and the third switch, the second current sensor senses current through the second switch and the fourth switch, and the controller detects that one of the first switch and the third switch or one of the second switch and the fourth switch fails when current through the first switch and the third switch is unbalanced with current through the second switch and the fourth switch.
Clause 5: in another embodiment, the present disclosure provides the junction box of clause 4, wherein the controller detects that one of the first switch and the third switch fails when the current through the first switch and the third switch is less than the current through the second switch and the fourth switch.
Clause 6: in another embodiment, the present disclosure provides the junction box of clause 5, wherein the controller detects that the first switch fails when the current through the first switch and the third switch is greater when the first switch is controlled by the controller to open than when the third switch is controlled by the controller to open.
Clause 7: in another embodiment, the present disclosure provides the junction box of clause 4, wherein the controller detects that the first switch, the second switch, the third switch, and the fourth switch are operating in sequence when the current through the first switch and the third switch is balanced with the current through the second switch and the fourth switch.
Clause 8: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the plurality of parallel-connected switches includes a first set of switches including the first switch and a second set of switches including the second switch, the first set of switches and the second set of switches include the same number of switches, the first current sensor senses current through the first set of switches, the second current sensor senses current through the second set of switches, and the controller detects that one of the first set of switches or one of the second set of switches fails when current through the first set of switches is unbalanced with current through the second set of switches.
Clause 9: in another embodiment, the present disclosure provides the junction box of clause 8, wherein the controller detects that one of the first set of switches fails when the current through the first set of switches is less than the current through the second set of switches.
Clause 10: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the plurality of parallel-connected switches includes a first set of switches including the first switch, a second set of switches including the second switch, and at least one or more sets of switches, each of the first set of switches, the second set of switches, and the at least one or more sets of switches including the same number of switches, the first current sensor senses current through the first set of switches, the second current sensor senses current through the second set of switches, at least one or more current sensors sense current through the at least one or more sets of switches, respectively, and the controller detects failure of at least one of the first set of switches, the second set of switches, or one or more sets of switches when current through the first set of switches, current through the second set of switches, and current through the at least one or more sets of switches are unbalanced.
Clause 11: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the controller modifies operation of the junction box by modifying operation of one or more of the switches in response to detecting at least one failure of the switches.
Clause 12: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the controller generates a warning notification in response to detecting at least one failure in the switch.
Clause 13: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein the plurality of parallel-connected switches are connected in parallel between the battery and the load.
Clause 14: in another embodiment, the present disclosure provides a junction box according to any one of the preceding clauses, wherein each of the current sensors includes an amplifier and a shunt resistor.
Clause 15: in another embodiment, the present disclosure provides a non-transitory computer-readable storage medium comprising stored computer-executable instructions that cause a controller to: (i) Sensing, with a first current sensor, a current through a first switch of a plurality of parallel connected switches, the plurality of parallel connected switches including at least the first switch and a second switch; (ii) Sensing a current through the second switch with a second current sensor; (iii) In response to detecting a failure of at least one of the switches, modifying operation of one or more of the switches; and (iv) detecting a failure of one of the first switch and the second switch when the current through the first switch is unbalanced with the current through the second switch.
Clause 16: in another embodiment, the present disclosure provides the non-transitory computer-readable storage medium of clause 15, further comprising stored computer-executable instructions that cause the controller to: a failure of the first switch is detected when the current through the first switch is less than the current through the second switch.
Clause 17: in another embodiment, the present disclosure provides a method comprising: sensing, by a first current sensor, a current through a first switch of a plurality of parallel connected switches, the plurality of parallel connected switches including at least the first switch and a second switch; sensing, by a second current sensor, a current through the second switch; modifying, by a controller in communication with the first current sensor and the second current sensor, operation of one or more of the switches in response to detecting at least one of the switches to fail; and detecting, by the controller, a failure of one of the first switch and the second switch due to an imbalance in current through the first switch and current through the second switch.
Clause 18: in another embodiment, the present disclosure provides the method of clause 17, further comprising: a failure of the first switch is detected by the controller when the current through the first switch is less than the current through the second switch.
Clause 19: in another embodiment, the present disclosure provides a method according to any one of the preceding clauses, further comprising: sensing, by the first current sensor, current through a first set of switches including the first switch, the first set of switches belonging to the plurality of switches connected in parallel; sensing, by the second current sensor, current through a second set of switches including the second switch, the second set of switches belonging to the plurality of switches connected in parallel, the first set of switches and the second set of switches including the same number of switches; and detecting, by the controller, a failure of one of the first set of switches or one of the second set of switches when the current through the first set of switches is unbalanced with the current through the second set of switches.
Clause 20: in another embodiment, the present disclosure provides a method according to any one of the preceding clauses, further comprising: sensing, by the first current sensor, current through the first and third switches of the plurality of parallel connected switches, the plurality of parallel connected switches further including the third and fourth switches; sensing, by the second current sensor, current through the second switch and the fourth switch; and detecting, by the controller, a failure of one of the first switch and the third switch or one of the second switch and the fourth switch when the current through the first switch and the third switch is unbalanced with the current through the second switch and the fourth switch.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the disclosure. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. Additionally, features of various implementing embodiments may be combined to form further embodiments of the disclosure.
Claims (20)
1. A junction box, comprising:
a plurality of switches connected in parallel, including at least a first switch and a second switch;
a first current sensor that senses a current through the first switch;
a second current sensor that senses a current through the second switch; and
a controller in communication with the first current sensor and the second current sensor, the controller modifying operation of the junction box in response to detecting a failure of at least one of the switches, and detecting a failure of one of the first switch and the second switch when current through the first switch is unbalanced with current through the second switch.
2. The junction box of claim 1, wherein:
the controller detects a failure of the first switch when the current through the first switch is less than the current through the second switch.
3. The junction box of claim 1, wherein:
the controller detects that the first switch and the second switch are operating in sequence when the current through the first switch balances the current through the second switch.
4. The junction box of claim 1, wherein:
the plurality of switches connected in parallel further comprises a third switch and a fourth switch;
the first current sensor senses current through the first switch and the third switch;
the second current sensor senses current through the second switch and the fourth switch; and
the controller detects a failure of one of the first switch and the third switch or one of the second switch and the fourth switch when the current through the first switch and the third switch is unbalanced with the current through the second switch and the fourth switch.
5. The junction box of claim 4, wherein:
the controller detects a failure of one of the first switch and the third switch when the current through the first switch and the third switch is less than the current through the second switch and the fourth switch.
6. The junction box of claim 5, wherein:
the controller detects that the first switch fails when a current through the first switch and the third switch is greater when the first switch is controlled to be open by the controller than when the third switch is controlled to be open by the controller.
7. The junction box of claim 4, wherein:
the controller detects that the first switch, the second switch, the third switch, and the fourth switch are operating in sequence when the current through the first switch and the third switch is balanced with the current through the second switch and the fourth switch.
8. The junction box of claim 1, wherein:
the plurality of parallel connected switches includes a first set of switches including the first switch and a second set of switches including the second switch, the first set of switches and the second set of switches including the same number of switches;
the first current sensor senses current through the first set of switches;
the second current sensor senses current through the second set of switches; and
the controller detects a failure of one of the first set of switches or one of the second set of switches when the current through the first set of switches is unbalanced with the current through the second set of switches.
9. The junction box of claim 8, wherein:
the controller detects a failure of one of the first set of switches when the current through the first set of switches is less than the current through the second set of switches.
10. The junction box of claim 1, wherein:
the plurality of parallel connected switches includes a first set of switches including the first switch, a second set of switches including the second switch, and at least one or more sets of switches, each of the first, second, and at least one or more sets of switches including the same number of switches;
the first current sensor senses current through the first set of switches;
the second current sensor senses current through the second set of switches;
at least one or more current sensors respectively sense current through the at least one or more sets of switches; and
the controller detects a failure of one of the first set of switches, one of the second set of switches, or one of the at least one or more sets of switches when the current through the first set of switches, the current through the second set of switches, and the current through the at least one or more sets of switches are unbalanced.
11. The junction box of claim 1, wherein:
the controller modifies operation of the junction box by modifying operation of one or more of the switches in response to detecting at least one failure of the switches.
12. The junction box of claim 1, wherein:
the controller generates a warning notification in response to detecting at least one failure of the switches.
13. The junction box of claim 1, wherein:
the plurality of parallel-connected switches are connected in parallel between the battery and the load.
14. The junction box of claim 1, wherein:
each of the current sensors includes an amplifier and a shunt resistor.
15. A non-transitory computer-readable storage medium comprising stored computer-executable instructions that cause a controller to:
sensing, with a first current sensor, a current through a first switch of a plurality of parallel connected switches, the plurality of parallel connected switches including at least the first switch and a second switch;
sensing a current through the second switch with a second current sensor;
in response to detecting a failure of at least one of the switches, modifying operation of one or more of the switches; and
a failure of one of the first switch and the second switch is detected when the current through the first switch is unbalanced with the current through the second switch.
16. The non-transitory computer-readable storage medium of claim 15, further comprising stored computer-executable instructions that cause the controller to: a failure of the first switch is detected when the current through the first switch is less than the current through the second switch.
17. A method, comprising:
sensing, by a first current sensor, a current through a first switch of a plurality of parallel connected switches, the plurality of parallel connected switches including at least the first switch and a second switch;
sensing, by a second current sensor, a current through the second switch;
modifying, by a controller in communication with the first current sensor and the second current sensor, operation of one or more of the switches in response to detecting at least one of the switches to fail; and
by the controller, failure of one of the first switch and the second switch is detected due to an imbalance in current through the first switch and current through the second switch.
18. The method of claim 17, further comprising:
a failure of the first switch is detected by the controller when the current through the first switch is less than the current through the second switch.
19. The method of claim 17, further comprising:
sensing, by the first current sensor, current through a first set of switches including the first switch, the first set of switches belonging to the plurality of switches connected in parallel;
sensing, by the second current sensor, current through a second set of switches including the second switch, the second set of switches belonging to the plurality of switches connected in parallel, the first set of switches and the second set of switches including the same number of switches; and
a failure of one of the first set of switches or one of the second set of switches is detected by the controller when the current through the first set of switches is unbalanced with the current through the second set of switches.
20. The method of claim 17, further comprising:
sensing, by the first current sensor, current through the first and third switches of the plurality of parallel connected switches, the plurality of parallel connected switches further including the third and fourth switches;
sensing, by the second current sensor, current through the second switch and the fourth switch; and
a failure of one of the first switch and the third switch or one of the second switch and the fourth switch is detected by the controller when the current through the first switch and the third switch is unbalanced with the current through the second switch and the fourth switch.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US63/400,959 | 2022-08-25 | ||
| US18/450,579 US20240072639A1 (en) | 2022-08-25 | 2023-08-16 | Junction Box Having Parallel Switch Failure Detection |
| US18/450,579 | 2023-08-16 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117638765A true CN117638765A (en) | 2024-03-01 |
Family
ID=90025919
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311079033.5A Pending CN117638765A (en) | 2022-08-25 | 2023-08-25 | Junction box with parallel switch fault detection |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117638765A (en) |
-
2023
- 2023-08-25 CN CN202311079033.5A patent/CN117638765A/en active Pending
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