CN1268926A - Power distribution control system - Google Patents

Abstract

A system for controlling the distribution of electrical power in land and marine vehicles is fully multiplexed so that all components, whether switchboards or distribution centers, are connected together by a common bus and share all communications information. The actuation of a switch on one switchboard can be indicated on all other switchboards containing the same switch function. Power output problems are indicated on all switchboard locations associated with that output. Switches on any switchboard can actuate multiple outputs of multiple distribution centers.

Description

Power distribution control system

The present invention generally relates to power distribution and control of equipment used in land and sea vehicles, and more particularly to an improved device for power control and power distribution of such equipment.

The basic wiring methods for power distribution in vehicles are still the same today as they were 75 years ago. Typically, all electrical equipment is fed from a single power distribution point through a bulky and cumbersome wiring harness. The disadvantages of this conventional power distribution method include (but are not limited to) the following aspects:

Using this approach makes implementation difficult and expensive for original equipment manufacturers (OEMs), if not prohibiting configuration changes and allowing design flexibility;

Since all electrical circuits must be routed "home" to the central distribution point, the installation process will be very time-consuming and complicated;

Since short circuits or improper wiring circuits may appear anywhere in the wiring harness, it will be difficult to identify and eliminate faults;

Since the wiring harness is often installed behind the cabinet or other structures, the maintenance space is very limited, so the maintenance process will be very time-consuming;

There is no feedback to the user (other than a blown fuse or a tripped circuit breaker) to indicate that the circuit is working properly or to indicate an electrical fault in the system;

There is no enabling circuit to limit the circuit from being energized unless certain conditions are first met;

Because the switch control has multiple contacts, it is difficult to know the state of the circuit at all contacts of the switch control, and even if it is possible, it will be very expensive and complicated to install.

The power distribution control system designed by the invention is used to control the power distribution in land and sea vehicles. The invented system incorporates a number of unique design features heretofore unavailable in power distribution methods. A typical implementation of this design involves power distribution in a large commercial vehicle with an integrated auxiliary lighting system using 12V DC and a hydraulic control system. The system is capable of direct current (DC) and alternating current (AC) power distribution.

The power distribution control system adopts the multiplexing method. Whether it is a switchboard or a power distribution center (PDC), all components are connected together by a common bus and share all communication content. For example, the actuated state of a switch on one switchboard is indicated (by lighting or sounding) on all other switchboards containing the same switch function. Likewise, electrical output failures (eg, shorted circuit, blown circuit breaker, stuck relay, etc.) are indicated at all switchboard locations associated with that output. A switch on any panel can energize multiple outputs from multiple PDCs.

Additional design features include: multiple distribution centers; multiple switchboards; multiple enabling circuits; RF interface; 50% to 90% reduction in installation time; corrosion/water resistance; characteristics (such as twisted pair, optical fiber, existing grid); and can be specially configured for the field environment.

Typical embodiments of the present invention are for use in power control systems in 12 and 24 volt vehicles. Operator control of each output is via one or more remote keypads with output status feedback. Radio (wireless) keyboards with (or without) feedback can also be used.

The system may include (but is not limited to) the following components: up to four electrical distribution controllers; up to two hydraulic controllers; up to four wired keypads; up to two a wireless keyboard; an RF receiver (for supporting wireless keyboards); and a chassis signal interface.

Each component communicates with each other in the network via twisted pair wires, fiber optics or the existing electrical grid. Every button on every keyboard in use can be assigned to any output. All outputs can be programmed to be momentary or continuous. These parameters can be preprogrammed prior to operation using non-volatile data memory if in-circuit reprogramming is possible. Any combination of keys on any keyboard can be used. Separate designs are available for 12V and 24V systems, and for 110/220V systems.

The inventive system can also provide for automatic configuration of switchboards or PDCs. The system will detect if a part has been swapped and can automatically configure that part into a "map" of the fixture it replaces. Field service or retrofit is reduced to simply exchanging parts and re-energizing the system.

It is also very convenient to expand the system. The most basic configuration of this system is a switchboard and a PDC. As needs grow and expansion is required, simply plug in additional power strips or PDCs.

Figure 1 is a schematic diagram of a conventional wiring system for a typical prior art vehicle employing conventional wiring techniques with wiring harnesses leading "home" from fixed equipment and switchboards to distribution center points;

Figure 2 is a schematic diagram of a first embodiment of the invention using multiple switchboards and two power distribution centers (PDCs) for electrical control and hydraulic control respectively;

Figure 3 is a schematic diagram of a second embodiment of network-wide power distribution using multiple switchboards and utilizing 4 Power Distribution Centers (PDCs), 3 for electrical control and one for hydraulic control;

Fig. 4 shows the schematic diagram of the input and output of the 6-circuit module power distribution center (PDC) of the present invention;

Figure 5 is a schematic diagram of a typical 6 to 12 position keyboard used in the present invention; and

Figure 6 is a schematic diagram of the inputs and outputs of a typical logic control unit used in a "star" network control system of the present invention.

Figure 1 is a schematic diagram of a conventional wiring system for a typical prior art vehicle such as a trailer using conventional wiring techniques for wiring harnesses leading "home" from fixed equipment and switchboards to distribution center points. The vehicle 10 includes a marker light 16, a backup light 18, a toolbox light 20, a driver's side light 22, a passenger's side light 24, a left turn light 26, a right turn light 28, a brake light and 30, signal light 32, flasher 34, raise (Work Up) 36 and lower (Work Down) 3 switchboards 12 that are connected to each other. The hydraulic distribution center 40 is connected to the hydraulic controller 42 by a wiring harness 44 . In this prior art arrangement, there are a total of 23 cables between the cab and the vehicle body, 10 cables between the bracket and the toolbox, and 17 cables between each toolbox , there are a total of 58 cables in the toolbox on the right.

Figure 2 is a schematic diagram of a first embodiment of the invention using multiple switchboards and two power distribution centers (PDCs) for electrical control and hydraulic control respectively. Wherein, vehicle 10 comprises and is connected with power distribution center 50 by network cable 48 in order to control marker light 16, reversing light 18, tool box light 20, driver's side light 22, passenger's side light 24, left turn light 26 in the form of network. , right turn light 28 , brake light 30 , signal light 32 , flasher 34 , 3 switchboards 46 for raising 36 and lowering 38 . The hydraulic distribution center 52 is connected to a hydraulic controller 54 by a wiring harness 56 . In the device invented, the number of cables between and inside each part of the vehicle is significantly reduced; there are only 6 cables between the cab and the body, and there are still That's 10 cables, and between each toolbox there are only 8 cables, for a total of 32 cables in the toolbox on the right.

This first embodiment can be specially designed as an 18 channel DC power controller for use in 12 and 24 volt vehicles capable of driving inductive loads up to 20Amp or resistive loads up to 30Amp at 12 volts. Each output uses plug-in relays and fuses or resettable circuit breakers.

1. Input

Power Input: One 3/8" terminal on the battery bus bar, and one #10-32 ground terminal. The power input should be able to withstand reverse battery polarity and 80 volt surges without damage.

Data I/O to Network: 4 wire RJ-11 connectors carrying differential serial data, DC power and common data. Data input/output should not be damaged due to missing/shorting of data cables.

Network data: The enable signal on the chassis control interface (relayed by the network) can be used as the enable signal for all outputs. Each output can be programmed to satisfy one, two or all three enable signals. The chassis interface controller typically sends 5 signals to 5 output channels dedicated to the first power distribution center. However, these output channels can also be designed for other purposes.

2. Output

Power Outputs: 18 Normally Open (N.O.) outputs each with #10-32 binding posts. If there is enough space, each binding post can be provided with a 1/4" quick connector for a normally closed (N.C.) output, and a yellow LED. Green LEDs indicate the status of each output. A red LED indicates the status of the open fuse/circuit breaker with the relay closed. Each output can be designed with momentary ON or latching ON function. Each output can be programmed to remain OFF unless one, two or all three enable conditions are met. Each output uses plug-in relays and plug-in Style fuses/circuit breakers.

3. Indicators

18 green LEDs indicate status of each N.O. output; 18 red LEDs indicate status of open fuse/circuit breaker with relay closed; 18 yellow LEDs indicate energy status when N.C. relay contacts are closed; one green LED Indicates control power.

4. Working voltage range

11.0 volts to 15.0 volts for normal operation, lossless shutdown on brownout (22 to 30 volts for 24 volt systems). Components shall be able to withstand 80 volt surges to all batteries and load terminal equipment without damage.

5. EMI compatibility

The system components should operate reliably in radio frequency fields typical of vehicles equipped with 100 watt radio transmitters in the frequency range 1 to 900 MHz.

6. Data communication

Data communications should be monitored to detect and eliminate erroneous messages. Once the communication is lost, the output should go to OFF state and the indicator should show the fault condition.

7. Boot and crash security

Under no circumstances should the processor be able to boot. A watch-dog timer should be able to detect any foreseeable crash trends and reset the processor non-destructively. Upon power up, each processor tests whether the data in its memory is consistent with its previously stored data, and if not, requires multiple responses.

8. Physics

The printed circuit board is double sided fiberglass with 3 oz copper, plated through holes, red solder mask and legend. It is also preferred to have a conformal coating covering at least part of the logic circuitry. Its size may be approximately 10 inches by 14 inches. It is installed in a cabinet made of polycarbonate or steel. The operating temperature range is preferably from -40 to 85 degrees Celsius (-40 to 185 degrees Fahrenheit).

"Plug and Play" connectors can be added as an option in networked systems. Connect the internal wiring harness in the PDC to the external wiring harness using Packard connectors or similar waterproof connectors. Therefore, whether it is in the outdoor field or in the process of manufacturing, installation or changeover is simplified to a simple and efficient process, thereby greatly reducing the time required for it.

Figure 3 is a schematic diagram of a second embodiment of network-wide power distribution using multiple switchboards and utilizing 4 Power Distribution Centers (PDCs), 3 for electrical control and one for hydraulic control. Wherein, vehicle 10 comprises and is connected on the power distribution center 64 by network cable 62 in order to control sign light 16 in network form, reversing light 18, toolbox light 20, driver's side light 22, passenger's side light 24, left turn light 26 , right turn light 28 , brake light 30 , signal light 32 , flasher 34 , 4 switchboards 60 for raising 36 and lowering 38 . Hydraulic distribution center 66 is connected to hydraulic controller 68 by wiring harness 70 . In the second embodiment of the invention, the number of cables between and within each part of the vehicle is further significantly reduced; now there is only 1 cable between the cab and the There are only two cables between the tool boxes, and only three cables between each tool box, for a total of 32 cables in the right tool box.

This second embodiment can be specially designed as a 6 or 10 channel DC power controller for use in 12 and 24 volt vehicles capable of driving an inductive load of up to 20Amp or a resistive load of 30Amp at 12 volts. Each output uses plug-in relays and fuses.

1. Input

Power Input: One #10-32 terminal post on the battery bus bar, and one #10-32 ground terminal post. The power input should be able to withstand reverse battery polarity and 80 volt surges without damage.

Data I/O to Network: A 4-conductor connector that carries differential serial data, DC power, and common data. Data I/O shall be able to withstand data cable miss/short without damage.

Network Data: The enable signal on the PDC (and other signals relayed by the network) is used as the enable signal for all outputs. Each output can be designed to meet any combination of enable signals. Each output can be assigned to one or more keyboard buttons.

Enable Signal: 12 (24) volt DC signal up to 16 (4 inverting, 12 non-inverting) to 16 1/4 inch connectors. Green LEDs indicate the status of each enable signal. Pull-up/pull-down resistors can also be used if necessary.

2. Output

Switching Power Outputs: 6 to 10 Normally Open (N.O.) outputs each with #10-32 binding posts, if sufficient space is available. Green LEDs indicate the status of each output. A flashing green LED indicates the status of the open fuse/circuit breaker with the relay closed. Each output has an overload slide switch. Each output can be designed to have momentary ON or latch ON function. Each output can be programmed to remain OFF unless any logical AND combination of enable signals (from this or any other PDC's enable input) is true. Each output uses plug-in relays and plug-in fuses/circuit breakers.

Alarm output: The alarm output will provide a flashing DC signal corresponding to the PTO signal. This output will be ratio-limited to provide 100mA to an external siren, solid state tone generator or relay. The PTO signal comes from this or another enable input on the PDC as specified at manufacture.

3. Indicators

6 to 10 green LEDs indicate the status of each N.O. output; 1 green LED indicates the control power; 1 red LED indicates the status of the network connection; up to 16 green LEDs indicate the status of the enable signal.

4. Working voltage range

6.0 volts to 15.0 volts for normal operation, lossless shutdown on brownout (12 to 30 volts for 24 volt systems).

5. EMI compatibility

System components should operate reliably in radio frequency fields typical in vehicles equipped with 100 watt radio transmitters in the frequency range 1 MHz to 900 MHz.

6. Data communication

Data communications should be monitored to detect and eliminate erroneous messages. Once the communication is lost, the output should go to OFF state and the indicator should show the fault condition.

7. Boot and crash security

Under no circumstances should the processor be able to boot. The watchdog timer should detect any foreseeable crash and reset the processor gracefully. Upon power up, each processor tests whether the data in its memory is consistent with its previously stored data, and if not requires multiple responses.

8. Physics

The printed circuit board is double sided fiberglass with 3 oz copper, plated through holes, red solder mask and legend. Preferably there is also a layer of conformal coating covering at least part of the logic circuitry. Its size may be approximately 8 inches by 8 inches. It is installed in a cabinet made of polycarbonate or steel. The operating temperature range is from -40 to 85 degrees Celsius (-40 to 185 degrees Fahrenheit).

FIG. 4 is a schematic diagram of the inputs and outputs of a 6-circuit module power distribution center (PDC) 80 of the present invention. PDC 80 may include a power supply 82, an RS-485 transceiver 84 through which a communication line 86 is routed, and a microprocessor 88 such as an AT89C2051 (ATMEL). Microprocessor 88 includes, processes and controls general purpose inputs 90, status indicators 92, relays 94 (e.g. for power outputs, signal lights, flashing, raising, lowering and auxiliary equipment), feedback 96, in a manner conventional in the art. and output status 98. This PDC can be used independently or as part of a multi-PDC system. Output cables can be routed directly or connected to the printed circuit board in the PDC using waterproof connectors and internal wiring.

Figure 5 is a schematic diagram of a typical 6 to 12 position keyboard of the present invention. The keyboard 100 may include a power supply 102, an RS-485 transceiver 104 through which the communication line 86 is routed, and a microprocessor 108 such as an AT89C2051 (ATMEL). The microprocessor 108 includes, processes and controls a plurality of switches 110 and a plurality of status indicators 112 . In a typical trailer setup, switch 110 may be assigned to power output, signal light 1, signal light 2, turn strobe light, high light, low light, controller, tool light, driver side light, passenger side light, auxiliary Device 1 and Auxiliary Device 2. In a typical marine installation, switches 110 may be assigned to anchor lights, bow lights, bilge pumps, stern lights, masthead lights, capstans, sump pumps, headlights, electrical equipment, refrigeration equipment, waste disposal Pumps and water pumps.

Figure 6 is a schematic diagram of the inputs and outputs of a typical logic control unit 120 used in a "star" network control system of the present invention located at the central point of the system. Logic control unit 120 may include a power supply 122 having keyboard wiring 124 and power distribution center wiring 126 through which RS-485 transceiver 128 directs all keyboard data 130 and power distribution center data 132, and a microcontroller such as an AT89C2051 (ATMEL) Processor 134. Microprocessor 134 also includes, processes, and controls data from transceiver 128, keypad status 135, and PDC and its associated status 136 in a manner conventional in the art. Logic control unit 120 may additionally include an additional RS-485 transceiver 128a for future expansion.

Although the present invention has been described above in conjunction with its preferred embodiments, it will be obvious to those skilled in the art that various modifications and variations can be made without departing from the spirit and scope of the present invention. Accordingly, the scope of the invention is to be limited only by the appended claims and equivalents.

Claims (4)

1. power distribution control system that is used for the vehicle comprises:

A plurality of switch boards that link to each other with microprocessor and be exclusively used in a kind of a plurality of switches of switching function respectively that comprise respectively, described switch board be configured in these vehicle around, described switch board is linked to each other with additional microprocessor at least one center of distribution by common bus; And

A plurality ofly link to each other with described at least one center of distribution encouraging and currentless electrical equipment by described switch by cable, the state that is energized of certain switch in one of them switch board can be at all other comprise on the switch board of this same switch function and be expressed out.

2. power distribution control system as claimed in claim 1 is characterized in that described a plurality of switch board comprises the positioning indicator that is used in reference to the electric power output problem that is shown on all switch boards relevant with this switching function in addition.

3. power distribution control system as claimed in claim 1 is characterised in that wherein described switch board links to each other with described at least one center of distribution by cable.

4. power distribution control system as claimed in claim 1 is characterized in that described switch board links to each other with described at least one center of distribution by radio communication.

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