U.S. patent application number 15/395249 was filed with the patent office on 2018-07-05 for controlling an electric brake of a utility vehicle which has a lithium battery management system.
The applicant listed for this patent is Textron Innovations Inc.. Invention is credited to Robert Charles Bradley, Arthur James Harvey, John Ledden, Norman R. Padgett, Patrick Dwaine Warden.
Application Number | 20180186355 15/395249 |
Document ID | / |
Family ID | 60915343 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180186355 |
Kind Code |
A1 |
Harvey; Arthur James ; et
al. |
July 5, 2018 |
CONTROLLING AN ELECTRIC BRAKE OF A UTILITY VEHICLE WHICH HAS A
LITHIUM BATTERY MANAGEMENT SYSTEM
Abstract
A motion control system controls movement of a utility vehicle.
The motion control system includes an electric brake that (i)
provides mechanical resistance which inhibits a motor of the
utility vehicle from turning when the electric brake is unpowered
and (ii) removes the mechanical resistance to allow the motor of
the utility vehicle to turn when power is provided to the electric
brake. The motion control system further includes a lithium BMS
having a contactor that closes to provide electrical access to a
lithium battery and opens to remove electrical access to the
lithium battery. The motion control system further includes control
circuitry coupled with the electric brake and the lithium BMS. The
control circuitry directs the lithium BMS to maintain closure of
the contactor to provide power from the lithium battery to the
electric brake in response to receipt of a tow signal.
Inventors: |
Harvey; Arthur James; (Beech
Island, SC) ; Padgett; Norman R.; (Evans, GA)
; Ledden; John; (Augusta, GA) ; Bradley; Robert
Charles; (Augusta, GA) ; Warden; Patrick Dwaine;
(Grovetown, GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Textron Innovations Inc. |
Providence |
RI |
US |
|
|
Family ID: |
60915343 |
Appl. No.: |
15/395249 |
Filed: |
December 30, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B60T 13/748 20130101;
Y02T 90/14 20130101; B60L 2240/30 20130101; Y02T 10/64 20130101;
B60L 2240/80 20130101; B60T 7/045 20130101; B60T 17/22 20130101;
B60L 58/10 20190201; F16D 2121/22 20130101; Y02T 10/70 20130101;
B60T 2270/89 20130101; B60L 2250/26 20130101; B60Y 2200/23
20130101; B60L 7/10 20130101; B60L 2200/22 20130101; B60L 2240/42
20130101; B60Y 2400/112 20130101; Y02T 10/7072 20130101; B60T 1/062
20130101; B60L 53/14 20190201; B60L 7/22 20130101 |
International
Class: |
B60T 13/74 20060101
B60T013/74; B60T 7/04 20060101 B60T007/04; B60L 11/18 20060101
B60L011/18; B60L 7/10 20060101 B60L007/10 |
Claims
1. A motion control system that controls movement of a utility
vehicle, the motion control system comprising: an electric brake
configured to (i) provide mechanical resistance which inhibits a
motor of the utility vehicle from turning when the electric brake
is unpowered and (ii) remove the mechanical resistance to allow the
motor of the utility vehicle to turn when power is provided to the
electric brake; a lithium battery management system (BMS) having a
contactor configured to close to provide electrical access to a
lithium battery and open to remove electrical access to the lithium
battery; and control circuitry coupled with the electric brake and
the lithium BMS, the control circuitry being configured to direct
the lithium BMS to maintain closure of the contactor to provide
power from the lithium battery to the electric brake in response to
receipt of a tow signal.
2. A motion control system as in claim 1 wherein the control
circuitry is constructed and arranged to: while receiving the tow
signal, (i) sense whether the utility vehicle is in motion and (ii)
direct the lithium BMS to open the contactor after a predefined
amount of time elapses without sensing motion of the utility
vehicle.
3. A motion control system as in claim 2 wherein the control
circuitry includes: a motion sensor, a timer constructed and
arranged to expire upon reaching the predefined amount of time, and
control logic coupled with the motion sensor and the timer; and
wherein, while the control logic receives the tow signal, the
control logic is configured to: reset the timer upon sensing motion
of the utility vehicle via the motion sensor, output a first
control signal to the lithium BMS while the timer has not expired,
and output a second control signal to the lithium BMS in response
to expiration of the timer, the second control signal being
different from the first control signal.
4. A motion control system as in claim 3 wherein the first control
signal is configured to direct the lithium BMS to maintain closure
of the contactor; and wherein the second control signal is
configured to direct the lithium BMS to open the contactor.
5. A motion control system as in claim 4 wherein the lithium BMS
and the control circuitry are configured to electronically
communicate through a controller area network (CAN) bus; wherein
the control circuitry is constructed and arranged to send, as the
first control signal a first CAN message to the lithium BMS; and
wherein the control circuitry is constructed and arranged to send,
as the second control signal a second CAN message to the lithium
BMS, the second CAN message being different from the first CAN
message.
6. A motion control system as in claim 5 wherein the control
circuitry is configured to periodically send the first CAN message
to the lithium BMS while the control circuitry receives the tow
signal and the utility vehicle is in motion.
7. A motion control system as in claim 5 wherein a tow switch of
the utility vehicle is configured to output the tow signal to the
control circuitry when the tow switch is set to a first position,
and outputs a run signal in place of the tow signal to the control
circuitry when the tow switch is set to a second position that is
different from the first position.
8. A motion control system as in claim 7 wherein the control
circuitry is configured to send a third CAN message to the lithium
BMS when the tow switch is set to the second position, the third
CAN message being different from the first and second CAN
messages.
9. A motion control system as in claim 7 wherein the control
circuitry is configured to: (i) direct the motor to turn in
response to actuation of an accelerator pedal of the utility
vehicle while the tow switch is set to the second position, and
(ii) not direct the motor to turn in response to actuation of the
accelerator pedal of the utility vehicle while the tow switch is
set to the first position.
10. A motion control system as in claim 1 wherein the lithium BMS
is constructed and arranged to automatically open the contactor in
response to detection of a current amount of charge in the lithium
battery falling to a predefined minimum charge threshold.
11. A motion control system as in claim 10 wherein the lithium BMS
is configured to automatically open the contactor when the current
amount of charge in the lithium battery has fallen below the
predefined minimum charge threshold even when the control circuitry
directs the lithium BMS to maintain closure of the contactor.
12. A motion control system as in claim 10 wherein the lithium BMS
is configured to maintain closure of the contactor while the
current amount of charge in the lithium battery is above the
predefined minimum charge threshold and while the control circuitry
is disconnected from the lithium BMS and replaced with a bypass
connection.
13. A motion control system as in claim 1 wherein the lithium BMS
is configured to open the contactor while an external power source
provides power to the electric brake to remove the mechanical
resistance allowing the motor of the utility vehicle to turn.
14. A utility vehicle, comprising: a utility vehicle body; a
lithium battery supported by the utility vehicle body; a motor
supported by the utility vehicle body; and a motion control system
configured to control movement of a utility vehicle, the motion
control system including: an electric brake configured to (i)
provide mechanical resistance which inhibits the motor from turning
when the electric brake is unpowered and (ii) remove the mechanical
resistance to allow the motor to turn when power is provided to the
electric brake, a lithium battery management system (BMS) having a
contactor configured to close to provide electrical access to the
lithium battery and open to remove electrical access to the lithium
battery, and control circuitry coupled with the electric brake and
the lithium BMS, the control circuitry being configured to direct
the lithium BMS to maintain closure of the contactor to provide
power from the lithium battery to the electric brake in response to
receipt of a tow signal.
15. A utility vehicle as in claim 14, further comprising: a tow
switch configured to provide the tow signal, wherein the control
circuitry is constructed and arranged to: while receiving the tow
signal from the tow switch, (i) sense whether the utility vehicle
is in motion and (ii) direct the lithium BMS to open the contactor
in response to a predefined amount of time elapsing without sensing
motion of the utility vehicle.
16. A utility vehicle as in claim 15 wherein the lithium BMS is
constructed and arranged to automatically open the contactor in
response to detection of a current amount of charge in the lithium
battery falling to a predefined minimum charge threshold.
17. A utility vehicle as in claim 16 wherein the lithium BMS is
configured to maintain closure of the contactor while the current
amount of charge in the lithium battery is above the predefined
minimum charge threshold and while the control circuitry is
disconnected from the lithium BMS and replaced with a bypass
connection.
18. A utility vehicle as in claim 16 wherein the lithium BMS is
configured to open the contactor while an external power source
provides power to the electric brake to remove the mechanical
resistance allowing the motor of the utility vehicle to turn.
19. In a utility vehicle, a method of controlling lithium battery
access, the method comprising: signaling a lithium battery
management system (BMS) to provide an electric brake with
electrical access to a lithium battery of the utility vehicle in
response to a tow signal from a tow switch of the utility vehicle,
the electric brake being configured to (i) provide mechanical
resistance which inhibits a motor of the utility vehicle from
turning when the electric brake is unpowered and (ii) remove the
mechanical resistance to allow the motor of the utility vehicle to
turn when power is provided to the electric brake; signaling the
lithium BMS to continue providing electrical access to the lithium
battery of the utility vehicle while sensing motion of the utility
vehicle; and signaling the lithium BMS to discontinue providing
electrical access to the lithium battery when no motion of the
utility vehicle has been sensed for a predefined amount of time.
Description
BACKGROUND
[0001] Some conventional electric vehicles are equipped with
electromagnetic parking brakes that normally remain in braked
positions to prevent the electric vehicles from rolling
inadvertently. When power is provided to the electromagnetic
parking brakes (e.g., in response to human operators pressing on
accelerator pedals), the electromagnetic parking brakes release
thereby allowing electric motors of the electric vehicles to move
the electric vehicles.
[0002] A particular conventional electric vehicle includes a
parking brake release lever that electrically connects a lead acid
battery of the electric vehicle to an electromagnetic parking brake
of the electric vehicle. When a human operator moves the parking
brake release lever from the "braked" position to the "released"
position, such operation results in delivery of power from the lead
acid battery to the electromagnetic parking brake. The
electromagnetic parking brake disengages in response to power from
the lead acid battery thus enabling the electric vehicle to roll
freely, e.g., allowing the electric vehicle to be towed without
being impeded by the electromagnetic parking brake.
SUMMARY
[0003] It should be understood that there are deficiencies to the
above-described conventional approach to electrically connecting a
lead acid battery of an electric vehicle to an electromagnetic
parking brake of the electric vehicle to release the
electromagnetic parking brake. In particular, the above-described
conventional approach is unsuitable for an electric vehicle that
uses power from a lithium battery. Along these lines, suppose that
a human operator simply replaces the lead acid battery of the
electric vehicle with a lithium battery and then moves the parking
brake release lever from the "braked" position to the "released"
position to release the electromagnetic parking brake using power
from the lithium battery. If the human operator forgets to move the
lever from the "released" position back to the "braked" position,
the lithium battery will remain electrically connected to the
electromagnetic parking brake and continue to discharge.
Unfortunately, once a lithium battery has become over-discharged,
subsequent recharging may make the lithium battery unstable.
[0004] Improved techniques are directed to electronically
controlling a lithium battery management system (BMS) of a utility
vehicle in response to a tow signal (or condition). Such a tow
signal may be provided when a user switches a brake release switch
from a "normal" position to a "brake release" position and motion
of the utility vehicle is routinely sensed. In particular, in
response to such a tow signal, control circuitry in accordance with
some embodiments may direct the lithium BMS to close its contactor
thus providing power from a lithium battery to an electric brake of
the utility vehicle. With power available from the lithium battery,
the control circuitry releases (or disengages) the electric brake
thus enabling the utility vehicle to move without resistance from
the electric brake (e.g., to be towed). If the control circuitry of
some such embodiments does not detect vehicle motion for a
predefined amount of time, the control circuitry may direct the
lithium BMS to open its contactor thus terminating power from the
lithium battery to the electric brake causing the electric brake to
re-engage. With the contactor now open, there is no further
discharging of the lithium battery. As a result, such operation
robustly and reliably prevents the lithium battery from becoming
over-discharged thus safeguarding the lithium battery against
becoming unstable.
[0005] One embodiment is directed to a motion control system that
controls movement of a utility vehicle. The motion control system
includes an electric brake configured to (i) provide mechanical
resistance which inhibits a motor of the utility vehicle from
turning when the electric brake is unpowered and (ii) remove the
mechanical resistance to allow the motor of the utility vehicle to
turn when power is provided to the electric brake. The motion
control system further includes a lithium battery management system
(BMS) having a contactor configured to close to provide electrical
access to a lithium battery and open to remove electrical access to
the lithium battery. The motion control system further includes
control circuitry coupled with the electric brake and the lithium
BMS. The control circuitry is configured to direct the lithium BMS
to maintain closure of the contactor to provide power from the
lithium battery to the electric brake in response to receipt of a
tow signal.
[0006] In some arrangements, the control circuitry is constructed
and arranged to: while receiving the tow signal, (i) sense whether
the utility vehicle is in motion and (ii) direct the lithium BMS to
open the contactor after a predefined amount of time elapses
without sensing motion of the utility vehicle.
[0007] In some arrangements, the control circuitry includes a
motion sensor, a timer constructed and arranged to expire upon
reaching the predefined amount of time, and control logic coupled
with the motion sensor and the timer. While the control logic
receives the tow signal, the control logic is configured to reset
the timer upon sensing motion of the utility vehicle via the motion
sensor, output a first control signal to the lithium BMS while the
timer has not expired, and output a second control signal to the
lithium BMS when the timer has expired, the second control signal
being different from the first control signal.
[0008] Another embodiment is directed to a utility vehicle which
includes a utility vehicle body, a lithium battery supported by the
utility vehicle body, a motor supported by the utility vehicle
body, and a motion control system configured to control movement of
a utility vehicle. The motion control system includes: [0009] (A)
an electric brake configured to (i) provide mechanical resistance
which inhibits the motor from turning when the electric brake is
unpowered and (ii) remove the mechanical resistance to allow the
motor to turn when power is provided to the electric brake, [0010]
(B) a lithium battery management system (BMS) having a contactor
configured to close to provide electrical access to the lithium
battery and open to remove electrical access to the lithium
battery, and [0011] (C) control circuitry coupled with the electric
brake and the lithium BMS, the control circuitry being configured
to direct the lithium BMS to maintain closure of the contactor to
provide power from the lithium battery to the electric brake in
response to receipt of a tow signal.
[0012] Yet another embodiment is directed to a method of
controlling lithium battery access which is performed in a utility
vehicle. The method includes: [0013] (A) signaling a lithium
battery management system (BMS) to provide an electric brake with
electrical access to a lithium battery of the utility vehicle in
response to a tow signal from a tow switch of the utility vehicle,
the electric brake being configured to (i) provide mechanical
resistance which inhibits a motor of the utility vehicle from
turning when the electric brake is unpowered and (ii) remove the
mechanical resistance to allow the motor of the utility vehicle to
turn when power is provided to the electric brake; [0014] (B)
signaling the lithium BMS to continue providing electrical access
to the lithium battery of the utility vehicle while sensing motion
of the utility vehicle; and [0015] (C) signaling the lithium BMS to
discontinue providing electrical access to the lithium battery when
no motion of the utility vehicle has been sensed for a predefined
amount of time.
[0016] Other embodiments are directed to higher and lower level
systems, assemblies, apparatus, processing circuits, etc. Some
embodiments are directed to various processes, electronic
components and circuitry which are involved in controlling an
electric brake of a utility vehicle which has a lithium BMS.
[0017] This Summary is provided merely for purposes of summarizing
some example embodiments so as to provide a basic understanding of
some aspects of the disclosure. Accordingly, it will be appreciated
that the above described example embodiments are merely examples
and should not be construed to narrow the scope or spirit of the
disclosure in any way. Other embodiments, aspects, and advantages
will become apparent from the following detailed description taken
in conjunction with the accompanying drawings which illustrate, by
way of example, the principles of the described embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The foregoing and other objects, features and advantages
will be apparent from the following description of particular
embodiments of the present disclosure, as illustrated in the
accompanying drawings in which like reference characters refer to
the same parts throughout the different views. The drawings are not
necessarily to scale, emphasis instead being placed upon
illustrating the principles of various embodiments of the present
disclosure.
[0019] FIG. 1 is a perspective view of an example utility vehicle
which controls electrical access to a lithium battery.
[0020] FIG. 2 is a block diagram of particular systems and
components of the utility vehicle of FIG. 1 in accordance with some
example embodiments.
[0021] FIG. 3 is a block diagram of additional details of the
utility vehicle of FIG. 1 in accordance with some example
embodiments.
[0022] FIG. 4 is a block diagram of particular details of a wakeup
circuit of a battery management system of the utility vehicle of
FIG. 1 in accordance with some example embodiments.
[0023] FIG. 5 is a block diagram of particular user controls that
provide input to the wakeup circuit of FIG. 4 in accordance with
some example embodiments.
[0024] FIG. 6 is a block diagram of particular charging circuitry
of the utility vehicle of FIG. 1 in accordance with some example
embodiments.
[0025] FIG. 7 is a flowchart of a procedure which is performed by
the battery management system of the utility vehicle of FIG. 1 in
accordance with some example embodiments.
[0026] FIG. 8 is a block diagram of particular components of the
utility vehicle during a first towing situation in accordance with
some example embodiments.
[0027] FIG. 9 is a flowchart of a procedure which is performed by
particular components of the utility vehicle during the first
towing situation in accordance with some example embodiments.
[0028] FIG. 10 is a block diagram of particular components of the
utility vehicle during a second towing situation in accordance with
some example embodiments.
[0029] FIG. 11 is a block diagram of particular components of the
utility vehicle during a third towing situation in accordance with
some example embodiments.
DETAILED DESCRIPTION
Overview
[0030] An improved technique is directed to electronically
controlling a lithium battery management system (BMS) of a utility
vehicle in response to a tow signal or condition. Such a tow signal
may be provided when a user switches a brake release switch from a
"normal" position to a "brake release" position and motion of the
utility vehicle is routinely sensed. In particular, in response to
such a tow signal, control circuitry in accordance with some
embodiments directs the lithium BMS to close its contactor thus
providing power from a lithium battery to an electric brake of the
utility vehicle. With power available from the lithium battery, the
control circuitry releases (or disengages) the electric brake thus
enabling the utility vehicle to move without resistance from the
electric brake (e.g., to be towed). If the control circuitry of
some such embodiments does not detect vehicle motion for a
predefined amount of time, the control circuitry directs the
lithium BMS to open its contactor thus terminating power from the
lithium battery to the electric brake causing the electric brake to
re-engage. With the contactor now open, there is no further
discharging of the lithium battery. Accordingly, such operation
robustly and reliably prevents the lithium battery from becoming
over-discharged thus safeguarding the lithium battery against
becoming unstable.
[0031] The various individual features of the particular
arrangements, configurations, and embodiments disclosed herein can
be combined in any desired manner that makes technological sense.
Additionally, such features are hereby combined in this manner to
form all possible combinations, variants and permutations except to
the extent that such combinations, variants and/or permutations
have been expressly excluded or are impractical. Support for such
combinations, variants and permutations is considered to exist in
this document.
[0032] FIG. 1 shows an example utility vehicle 20 which controls
electrical access to a lithium battery. The utility vehicle 20
includes a utility vehicle body 22 (e.g., a chassis, a frame,
etc.), a set of tires (or wheels) 24, and a motion control system
26. It should be understood that the utility vehicle 20 has the
form factor of a golf car by way of example only and that other
form factors are suitable for use as well such as those of personal
transport vehicles, food and beverage vehicles, hospitality
vehicles, all-terrain vehicles (ATVs), utility task vehicles
(UTVs), motorcycles, scooters, vehicles for specialized
applications, as well as other lightweight vehicles and utility
vehicles.
[0033] The motion control system 26 controls vehicle movement such
as drive provided by the set of tires 24, speed control, braking,
and so on thus enabling the utility vehicle 20 to perform useful
work. The motion control system 26 of the illustrated embodiments
includes, among other things, a motor system 30, a lithium battery
system 32, and additional components 34 such as a set of user
controls 36 (e.g., a brake release switch, a foot pedal, a keyed
switch, etc.) and cabling 38. As will be explained in further
detail below, the utility vehicle 20 runs on power from a lithium
battery and is equipped with a sleep/wakeup feature that
automatically disconnects the lithium battery in response to
certain timeout conditions thus preventing the lithium battery from
further discharging. Further details will now be provided with
reference to FIGS. 2 and 3.
[0034] FIGS. 2 and 3 show particular details of the motion control
system 26 of the utility vehicle 20 (FIG. 1) of some example
embodiments. FIG. 2 shows certain general components of the motion
control system 26 of some embodiments and how these components are
related. FIG. 3 shows particular lower level details of the motion
control system 26 in accordance with some embodiments.
[0035] As shown in FIG. 2, the motor system 30 includes a motor
controller 40, an electric motor 42 which is linked to the set of
tires 24 (FIG. 1), and an electric brake 44 coupled with the
electric motor 42. The motor controller 40 of some embodiments
controls delivery of stored electric power from the lithium battery
system 32 to the electric motor 42 which ultimately turns at least
some of the tires 24 to move the utility vehicle 20. Additionally,
the motor controller 40 of some embodiments controls delivery of
regenerative power from the electric motor 42 to recharge the
lithium battery system 32 (e.g., during braking, while the utility
vehicle 20 coasts downhill without any pedal depression, etc.).
[0036] The electric brake 44 is constructed and arranged to provide
mechanical resistance which inhibits turning of the electric motor
42 when the electric brake 44 is unpowered, and remove the
mechanical resistance to release the electric motor 42 thus
allowing the electric motor 42 to turn when the electric brake 44
receives power. Accordingly, in some embodiments, when the utility
vehicle 20 sits idle (i.e., the utility vehicle 20 is awake but a
user is not pressing on the accelerator pedal, the utility vehicle
20 is turned off, etc.), the electric brake 44 remains engaged and
the utility vehicle 20 sits in a parked state.
[0037] The lithium battery system 32 includes a battery management
system (BMS) 50 and a lithium battery 52. The BMS 50 controls
electrical access to the lithium battery 52. Additionally, as will
be explained in further detail shortly, the BMS 50 of some
embodiments responds to various events such as sleep events (e.g.,
timeouts) to prevent excessive discharging of the lithium battery
52 thus safeguarding the lithium battery 52 from becoming over
discharged. In some embodiments, the BMS 50 responds to other
events as well such as wakeup events (e.g., actuation of the user
controls 36), charging situations, fault conditions, and so on to
properly and safely control charging and discharging of the lithium
battery 52.
[0038] It should be understood that a variety of form factors are
suitable for the lithium battery 52. For example, the lithium
battery 52 may include multiple lithium battery cells, a single
battery pack, combinations thereof, and so on.
[0039] The additional components 34 may, for example, include the
set of user controls 36 (e.g., pedals, switches, etc.), the cabling
38, a charging receptacle 60, and perhaps other electrical
components 62 (e.g., lights, a global positioning system (GPS),
specialized equipment, etc.). In some arrangements, the cabling 38
includes a communications bus, such as, for example, a controller
area network (CAN) bus through which the motor system 30 and the
lithium battery system 32 exchange communications 70 such as
electronic CAN messages in accordance with the CAN protocol.
[0040] As shown in FIG. 3, in accordance with some example
embodiments, the battery management system (BMS) 50 of the lithium
battery system 32 includes a power delivery interface 100, a
lithium battery interface 102, a wakeup circuit 104, a contactor
106, and a charge regulation circuit 108. These components may
reside together as a single assembly or unit (e.g., within the same
enclosure) or in a distributed manner among different locations on
the utility vehicle body 22 (also see FIG. 1).
[0041] The power delivery interface 100 couples with the motor
system 30. Similarly, the lithium battery interface 102 couples
with the lithium battery 52. The wakeup circuit 104 controls
closing and opening of the contactor 106 to electrically connect
the motor system 30 to the lithium battery 52 and disconnect the
motor system 30 from the lithium battery 52, respectively. During
such operation, the charge regulation circuit 108 controls signal
conditioning during discharging and charging of the lithium battery
52.
[0042] As further shown in FIG. 3, the contactor 106 includes a set
of target contacts 120 that couple with the power delivery
interface 100, a set of source contacts 122 that couple with the
lithium battery interface 102, and an electromagnetic actuator 124.
Although FIG. 3 shows the contactor 106 controlling two signal
paths between the motor system 30 and the lithium battery 52 by way
of example (i.e., there are two source contacts 122 and two target
contacts 120), other arrangements include different numbers of
contacts and signal paths (e.g., one, three, four, etc.) depending
on the particular application/electrical needs/etc. (e.g., DC power
signals at different voltages, AC power signals in different
phases, ground, etc.).
[0043] The wakeup circuit 104 includes control logic 130 and a
timer 132 which operate to manage access to the lithium battery 52.
As will be explained in further detail shortly, such operation may
be based on a variety of inputs 134 from the motor system 30, from
the user controls 36 (directly or indirectly), and so on. Along
these lines, in response to a wakeup event (e.g., a user turning on
the BMS 50), the wakeup circuit 104 outputs an actuator signal 136
that actuates the electromagnetic actuator 124 in a first direction
140 from a first position to a second position that connects
respective source contacts 122 to corresponding target contacts 120
to electrically connect the motor system 30 to the lithium battery
52. Along these lines, the electromagnetic actuator 124 may be
provisioned with a solenoid or coil that closes the contactor 106
in response to the actuator signal 136.
[0044] Additionally, in response to a sleep event (e.g.,
encountering a predefined time period of non-use while the BMS 50
is awake), the wakeup circuit 104 terminates output of the actuator
signal 136 which releases the electromagnetic actuator 124. In
particular, the electromagnetic actuator 124 is spring biased in a
second direction 142 which is opposite the first direction 140.
Accordingly, termination of the actuator signal 136 enables the
electromagnetic actuator 124 to return back from the second
position to the first position thus automatically separating the
source contacts 122 from the target contacts 120 when the wakeup
circuit 104 terminates output of the actuation signal 136 thus
disconnecting the motor system 30 from the lithium battery 52. As a
result, there are no parasitic loads placed on the lithium battery
52 that could otherwise further discharge the lithium battery 52 to
an over-depleted state.
[0045] In other embodiments, the wakeup circuit 104 does not need
to constantly maintain the actuator signal 136. Instead, the wakeup
circuit 104 controls engagement and disengagement of the contactor
106 using discrete engagement and disengagement signals. With such
use of a dedicated release signal, maintenance of a signal and
termination for release is not required.
Wakeup/Sleep
[0046] FIGS. 4 through 5 provide particular details of how the
battery management system (BMS) 50 responds to wakeup and sleep
events in accordance with some embodiments. FIG. 4 shows example
details of wakeup circuitry 200 which is suitable for the wakeup
circuit 104 (also see FIG. 3) in accordance with some embodiments.
FIG. 5 shows particular user controls 36 that couple with the
inputs 134 and control operation of the wakeup circuit 104 (FIG. 3)
in accordance with some embodiments.
[0047] As shown in FIG. 4, the wakeup circuitry 200 controls access
to the lithium battery 52 (FIG. 3) in response to various events,
situations, faults, etc. As shown in FIG. 4, the wakeup circuitry
200 includes, in an example embodiment, a communications interface
202, memory 204, processing circuitry 206, and additional circuitry
208. Such components form the control logic 130 and the timer 132
of the wakeup circuit 104 (FIG. 3).
[0048] The communications interface 202 is constructed and arranged
to connect the wakeup circuitry 200 to one or more communications
media such as a controller area network (CAN) bus (also see the
cabling 38 in FIG. 1). Such communications may include different
media such as copper-based (e.g., USB, RJ45, etc.), fiber optic
communications, wireless communications (i.e., WiFi, cellular,
Bluetooth, etc.), infrared, combinations thereof, and so on.
[0049] The memory 204 stores a variety of memory constructs 220
including an operating system 222, specialized battery management
code 224, configuration data 226 (e.g., identification data,
predefined timeout settings, charging settings, version data, model
data, etc.), and other software constructs, code and data 228
(e.g., activity/event logs, utilities, tools, etc.). Although the
memory 204 is illustrated as a single block in FIG. 4, the memory
204 is intended to represent both volatile and non-volatile storage
(e.g., random access memory, flash memory, etc.), and may, in some
embodiments, include a plurality of discrete physical memory
units.
[0050] The processing circuitry 206 is configured to run in
accordance with instructions of the various memory constructs 220
stored in the memory 204. In particular, the processing circuitry
206 runs the operating system 222 to manage various computerized
resources (e.g., processor cycles, memory allocation, etc.).
Additionally, the processing circuitry 206 runs the specialized
battery management code 224 to electronically control access to the
lithium battery 52 (FIGS. 2 and 3). The processing circuitry 66 may
be implemented in a variety of ways including via one or more
processors (or cores) running specialized software, application
specific ICs (ASICs), field programmable gate arrays (FPGAs) and
associated programs, microcontrollers, discrete components, analog
circuits, other hardware circuitry, combinations thereof, and so
on. In the context of one or more processors executing software, a
computer program product 240 is capable of delivering all or
portions of the software to the wakeup circuitry 200 (e.g., also
see the memory constructs 220 in FIG. 4). The computer program
product 240 has a non-transitory (or non-volatile) computer
readable medium which stores a set of instructions which controls
one or more operations of the wakeup circuitry 200. Examples of
suitable computer readable storage media include tangible articles
of manufacture and other apparatus which store instructions in a
non-volatile manner such as flash memory, a magnetic storage medium
(e.g., various disk memories such as a hard drive, floppy disk, or
other magnetic storage medium), tape memory, optical disk (e.g.,
CD-ROM, DVD, Blu-Ray, or the like), and the like. It will be
appreciated that various combinations of such computer readable
storage media may be used to provide the computer readable medium
of the computer program product 240 in some embodiments.
[0051] The additional circuitry 208 represents other circuitry of
the wakeup circuitry 200. Such circuitry may include hardware
counters, signal drivers, connectors, sensors, and so on. In some
arrangements, where the utility vehicle is specialized equipment
(e.g., a food and beverage vehicle, an ATV, etc.) the additional
circuitry 208 may represent other components such as an electronic
thermostat, lighting control, and so on.
[0052] With reference to FIG. 5 and in accordance with some
embodiments, the user controls 36 includes a keyed switch 270, and
an accelerator (or throttle) pedal 280, and a park brake release
switch 290 which are electrically connected in parallel to the BMS
50 (also see FIG. 2). Such user controls 36 may communicate with
the BMS 50 via the inputs 134 (FIG. 3). In some embodiments, other
user controls 36 may communicate with the BMS 50 as well such as a
brake pedal, a forward/reverse switch, and so on.
[0053] It should be understood the control logic 130 and the timer
132 of the wakeup circuit 104 (FIG. 3), which in some embodiments
are formed by the wakeup circuitry 200 (FIG. 4), operate to monitor
user activity of the utility vehicle 20 as well as transition the
BMS 50 from a sleeping state to an awake state and vice versa.
Further details of such operation will now be provided.
[0054] During operation, the wakeup circuit 104 monitors operation
of the user controls 36 to determine whether to electrically
connect the lithium battery 52 to the motor system 30 or
electrically disconnect the lithium battery 52 from the motor
system 30. For example, suppose that a human operator (or user)
wishes to operate the utility vehicle 20 after an extended period
of non-use such as a 24-hour period. In such a situation, the
utility vehicle 20 is initially in a sleep (or unawake) mode or
state in which the wakeup circuit 104 (FIG. 3) is completely
unpowered and the contactor 106 is open (i.e., where there is no
circuit formed between the lithium battery 52 and the motor system
30). Accordingly, there are no electrical loads on the lithium
battery 52 that could otherwise drain charge from the lithium
battery 52.
[0055] Now, suppose that the user turns the keyed switch 270 (FIG.
5) from an OFF position to an ON position. In such a situation and
in accordance with some embodiments, the wakeup circuit 104 of the
BMS 50 turns on and responds by outputting the actuation signal 136
to close the contactor 106 (FIG. 3). As a result of such a wakeup
event, the contactor 106 connects the source contacts 122 to the
target contacts 120 thus connecting the lithium battery 52 to the
motor system 30 and waking the motor system 30.
[0056] At this time and in accordance with some embodiments, both
the BMS 50 and the motor system 30 perform various self-tests. For
example, the BMS 50 checks the amount of charge remaining in the
lithium battery 52 and, if the amount of charge is below a
predefined minimum charge threshold, the BMS 50 terminates (e.g.,
immediately terminates) the actuation signal 136 to electrically
disconnect the lithium battery 52 from the motor system 30. Such
operation prevents the lithium battery 52 from becoming
over-discharged. It should be understood that, while the BMS 50
remains awake, the BMS 50 continues to monitor charge remaining in
the lithium battery 52 and terminates the actuation signal 136 to
disconnect the lithium battery 52 from the motor system 30 if the
remaining charge reaches (or falls below) the predefined minimum
charge threshold to safeguard the battery against becoming
over-discharged. In particular, there is still safety margin
between the predefined minimum charge threshold and an
over-discharged level.
[0057] In some embodiments, after passing their respective
self-tests, the BMS 50 and the motor system 30 communicate with
each other (e.g., exchange communications 70 such as CAN messages)
to verify configuration information (e.g., model numbers, versions,
status, etc.). In some arrangements, the motor system 30 may be one
of multiple models and the wakeup circuit 104 operates using
different configuration settings depending on the particular model
identified via communications with the motor system 30.
[0058] Also, at this time, the control logic 130 of the wakeup
circuit 104 starts the timer 132 (FIG. 3) which counts or tracks
time until the timer 132 reaches a predefined idle time threshold
(i.e., a maximum idle time limit). In accordance with some
embodiments, example values that are suitable for use for the
predefined idle time threshold include time amounts within the time
range of 2 hours to 6 hours (e.g., 3 hours, 4 hours, 5 hours,
etc.). If the timer 132 counts from an initial time value to the
predefined idle time threshold (a sleep event), the timer 132
outputs a sleep event signal to the control logic 130 of the wakeup
circuit 104 which directs the control logic 130 to terminate output
of the actuation signal 136 thus disconnecting the lithium battery
52 from the motor system 30. Such operation prevents the lithium
battery 52 from unnecessarily succumbing to parasitic loads from
the motor system 30, from the contactor 106 (i.e., the coil
maintaining the contactor 106 in the closed position), and perhaps
from elsewhere in the utility vehicle 20.
[0059] However, after BMS 50 has woken up, suppose that the user
actuates the accelerator pedal 280 (e.g., moves the pedal 280 from
its non-depressed position) before the timer 132 reaches the
predefined idle time threshold. In response to this sensed user
activity, the control logic 130 restarts the timer 132 to the
initial time value. The timer 132 is prevented from reaching the
predefined idle time threshold and expiring. It should be
understood that moving the accelerator pedal 280 may further signal
the motor system 30 to operate the motor 42 (e.g., rotate the motor
42 in a particular direction and at a particular speed based on
other factors).
[0060] However, if the user leaves the utility vehicle 20
unattended and the timer 132 expires by reaching the predefined
idle time threshold, the timer 132 expires (a sleep event) and
sends a sleep event signal to the control logic 130. In response to
the sleep event signal, the control logic 130 terminates output of
the actuation signal 136 thus opening the contactor 106 to
disconnect the lithium battery 52 from the motor system 30 (FIG. 3)
and protecting the lithium battery 52 against further
discharge.
[0061] In accordance with some embodiments, if the BMS 50 has
fallen asleep, the user is able to wake the BMS 50 by moving the
keyed switch 270 to the ON position (another wakeup event).
Likewise, in accordance with some embodiments, if the BMS 50 has
fallen asleep and the keyed switch 270 is in the ON position, the
user is able to wake the BMS 50 by actuating the pedal 280 (yet
another wakeup event).
[0062] In some embodiments, while the BMS 50 is awake and the park
brake release switch 290 is in a "normal" configuration and the
keyed switch 270 is in the ON position, the control circuitry 250
of the motor system 30 only provides power to release (or
disengage) the electric brake 44 when the user presses the pedal
280. Otherwise, if the keyed switch 270 is in the OFF position, the
control circuitry 250 does not output power to the electric brake
44 and the electric brake 44 remains engaged. That is, the electric
brake 44 continues to inhibit movement of the motor 42 (FIG. 3) so
that the set of tires 24 of the utility vehicle 20 do not move
freely and the utility vehicle 20 remains parked.
[0063] In some embodiments, the park brake release switch 290 is
formed by an actual physical switching device that a user can move
to different positions. In other embodiments, the park brake
release switch 290 is formed by a set of jumpers (e.g., connectors,
cables, etc.) that are switchable or arrangeable into different
connecting configurations (e.g., a normal configuration, a tow
configuration, etc.).
[0064] As will be discussed in further detail later below and in
accordance with some embodiments, the motor controller 40 (FIGS. 2
and 3) may be controlled by a separate tow switch to enable the
utility vehicle 20 to be towed. Here, in accordance with some
embodiments, the motor controller 40 (i) senses vehicle motion,
(ii) routinely outputs special communications 70 (e.g., CAN
messages) to the BMS 50 to keep the BMS 50 awake in response to the
sensed vehicle motion, and (iii) conveys power to the electric
brake 44 to disengage the electric brake 44 and allow the utility
vehicle 20 to roll freely. Additionally, in some embodiments, the
motor controller 40 starts (or restarts) an internal timer whenever
the motor controller 40 senses motion of the utility vehicle 20. If
the timer reaches a predefined idle time limit due to the absence
of sensed motion for a predefined amount of time, the motor
controller 40 directs the BMS 50 to go to sleep resulting in no
further drain on the lithium battery 52. In this situation, the
contactor 106 opens and electric brake 44 no longer receives power
thus providing mechanical resistance to the motor 42 which holds
the utility vehicle 20 in place.
Charging
[0065] FIG. 6 shows particular details of the charging circuitry
300 which charges the lithium battery 52 of the utility vehicle 20
(also see FIG. 1), in accordance with some example embodiments. In
accordance with the embodiments illustrated in FIG. 6, the charging
circuitry 300 includes a first plug 302, a charger (or adaptor)
304, and a second plug 306. The first plug 302 is constructed and
arranged to connect the charger 304 to an external power source 310
such as an AC outlet. The second plug 306 is constructed and
arranged to connect the charger 304 to the charging receptacle 60
of the utility vehicle 20 (also see FIG. 2). The charger 304 is
constructed and arranged to convert and condition a power signal
from the external power source 310 for use by the utility vehicle
20.
[0066] As further shown in FIG. 6, the charging receptacle 60
electrically couples with the motor controller 40 and the battery
management system (BMS) 50. Accordingly, when the receptacle 60
receives power from the charging circuitry 300, the receptacle 60
provides power to the motor controller 40 and BMS 50. In some
embodiments, this initial power from the charging circuitry 300
wakes up the BMS 50 and the motor controller 40 (FIG. 3). In some
embodiments, the receptacle 60 also provides an interlock signal
320 to the motor controller 40 which has also woken up. In response
to the interlock signal 320, the motor controller 40 outputs a
communication 330 (e.g., a CAN message) that informs the BMS 50
that the charging circuitry 300 is plugged in to the receptacle 60
and the BMS 50 then closes the contactor 106. With the contactor
106 now closed, the BMS 50 conveys a charging signal 340 from the
charging circuitry 300 to the lithium battery 52. In some
arrangements, the charge regulation circuit 108 (FIG. 3) conditions
the charging signal 340 to properly charge the lithium battery
52.
[0067] While the lithium battery 52 charges in response to receipt
of the charge signal 340 and in accordance with some embodiments,
the BMS 50 monitors the lithium battery 52 to prevent overcharging.
In particular, in response to sensing that the lithium battery 52
has charged to a predefined maximum charge threshold (or level),
the BMS 50 deactivates the charge regulation circuit 108, e.g.,
sets the duty cycle of pulse width modulation (PWM) circuitry back
to 0%, where other pulse widths determine different charging rates.
In some arrangements, the BMS 50 then immediately goes to sleep. In
other arrangements, the BMS imposes a timeout (e.g., 30 minutes)
and goes to sleep if the timeout period expires without further
user activity.
Additional Details
[0068] FIG. 7 is a flowchart of a procedure 360 which is performed
by the battery management system (BMS) 50 of the utility vehicle 20
to control access to the lithium battery 52 in accordance with some
example embodiments.
[0069] At 362, the BMS 50 mechanically disconnects a lithium
battery interface from a power delivery interface in response to a
sleep event. The lithium battery interface couples with a lithium
battery supported by the utility vehicle, and the power delivery
interface couples with a set of loads of the utility vehicle. For
example, a timer of the wakeup circuit may expire after a period of
non-use thus indicating that the BMS 50 may disconnect the lithium
battery 52 without interfering with a user of the utility vehicle
20. Such disconnection prevents parasitic loads from further
draining the lithium battery 52.
[0070] At 364, after the lithium battery interface is mechanically
disconnected from the power delivery interface, the BMS 50
mechanically reconnects the lithium battery interface to the power
delivery interface in response to a wakeup event. For example, in
accordance with some embodiments and in response to certain
conditions, the user may press an accelerator pedal or cycle a
keyed switch to wakeup the BMS 50.
[0071] At 366, after the lithium battery interface is mechanically
reconnected to the power delivery interface, the BMS 50 maintains
connection between the lithium battery interface and the power
delivery interface to convey power from the lithium battery 52 to
the set of loads of the utility vehicle through the lithium battery
interface and the power delivery interface. In particular, the BMS
50 may start a timer to measure a period of non-use and maintain
lithium battery access as long as the timer does not expire and as
long as the lithium battery does not discharge below a predefined
safe level.
[0072] As described above, improved techniques are directed to
controlling electrical access to lithium batteries 52 on utility
vehicles 20. Such techniques provide the ability to automatically
disconnect the lithium batteries 52 from loads in response to
timeout or sleep events. Such operation prevents the lithium
batteries 52 from discharging even due to parasitic loads while the
utility vehicles 20 are idle. Accordingly, the lithium batteries 52
will not discharge to unnecessarily low levels (e.g., safeguard
levels). As a result, such operation robustly and reliably prevents
the lithium batteries 52 from being recharged after being
over-discharged and thus safeguards the lithium batteries 52
against becoming unstable.
Disengaging the Electric Brake and Towing
[0073] FIGS. 8 through 11 show various techniques for releasing the
electric brake 44 (e.g., to tow the utility vehicle 20). FIG. 8
shows one brake release technique which involves communication
between the motor controller 40 and the BMS 50 in accordance with
some embodiments. FIG. 9 shows a procedure which is performed by
the motor controller 40 when releasing the electric brake 44 in
accordance with some embodiments. FIG. 10 shows another brake
release technique which involves wiring the BMS 50 without
involving the motor controller 40 in accordance with some
embodiments. FIG. 11 shows yet another brake release technique
which involves wiring the electric brake 44 without involving the
BMS 50 in accordance with some embodiments.
[0074] As shown in FIG. 8, the motor controller 40 includes control
circuitry 250 and a timer 252. Additionally, the motor controller
40 couples with various components of the utility vehicle 20 via
pathways 400 (also see the cables 38 in FIG. 1). In some
embodiments, such components include a tow switch 402 (e.g., a
dedicated run/tow switch under a hinged seat of the utility vehicle
20, a park brake release set of jumpers, etc.), a motion sensor
404, the lithium battery system 32, and the electric brake 44. In
some embodiments, the motor controller 40 connects with the lithium
battery system 32 via a pathway 410 (e.g., a CAN bus) and a power
bus 412. Additionally, in some embodiments, the motor controller 40
connects with the electric brake 44 via an electric brake path
414.
[0075] During operation, suppose that the user wishes to release
the electric brake 44 in order to tow the utility vehicle 20. To
this end and in accordance with some embodiments, the user switches
the tow switch 402 from a "non-tow mode" position to a "tow mode"
position. Such activity provides a tow signal 420 to the control
circuitry 250 of the motor controller 40 which, in turn, starts the
timer 252 and energizes the electric brake 44 by providing a power
signal 422 from lithium battery system 32 to the electric brake 44
thus enabling the electric motor 42 (FIG. 3) to turn and the
utility vehicle 20 to roll.
[0076] Additionally, in some embodiments, the control circuitry 250
of the motor controller 40 sends a communication 70 (e.g., a
particular CAN message) to the lithium battery system 32 directing
the BMS 50 to stay awake because the utility vehicle 20 is now in
tow mode, and the BMS 50 responds by maintaining closure of the
contactor 106 (e.g., by continuing to output the actuation signal
136). Accordingly, the lithium battery system 32 continues to
provide access to the power signal 422 on the power bus 412, and
the motor controller 40 is able to deliver that power signal 422 to
the electric brake 44 through the electric brake path 414 to
disengage the electric brake 44.
[0077] In some embodiments, the control circuitry 250 operates the
timer 252 to measure the time that elapses without sensing vehicle
motion. That is, each time the control circuitry 250 receives a
motion signal 424 from the motion sensor 404 (FIG. 8), the control
circuitry 250 resets the timer 252 as well as sends a communication
70 to the lithium battery system 32 directing the BMS 50 to
continue to keep the contactor 106 closed (i.e., directing the BMS
50 to stay awake).
[0078] However, in some embodiments, if the timer 252 ultimately
expires (e.g., counts to a predefined time limit) due to lack of
sensed vehicle motion, the control circuitry 250 determines that a
timeout event has occurred and sends a different communication 70
(e.g., a different CAN message) to the lithium battery system 32
directing the BMS 50 to go to sleep. In response to this
communication 70, the BMS 50 terminates output of the actuation
signal 136 (FIG. 3) thus enabling the contactor 106 to spring back
to its original open position. Accordingly, in some embodiments,
the lithium battery system 32 terminates output of the power signal
422 and goes to sleep thus preventing further discharging of the
lithium battery 52. As a result, the motor controller 40 goes to
sleep and the electric brake 44 re-engages with the motor 42 thus
preventing the utility vehicle 20 from moving.
[0079] In accordance with some embodiments, an example suitable
amount of time for the predefined time out limit is an amount of
time within the range of 15 minutes to 60 minutes (e.g., 15
minutes, 30 minutes, 45 minutes, etc.). Accordingly, the lithium
battery 52 is not allowed to excessively drain in the event that
the user forgets to turn the tow switch 402 from the "tow mode"
position back to the "non-tow mode" position.
[0080] FIG. 9 shows a procedure 430 which is performed by the motor
controller 40 to control electrical access to the lithium battery
when towing the utility vehicle 20.
[0081] At 432, the motor controller 40 signals the lithium BMS to
continue to provide electrical access to a lithium battery of the
utility vehicle in response to a tow signal from a tow switch of
the utility vehicle. Accordingly, the motor controller 40 is able
to then energize the electric brake thus releasing the electric
brake. For example, the user may switch the tow switch from the
"non-tow mode" position to the "tow mode" position. In some
arrangements, the motor controller 40 directs the BMS to stay awake
via communications 70 on a communications pathway 410.
[0082] As mentioned earlier, the electric brake (i) provides
mechanical resistance which inhibits a motor of the utility vehicle
from turning when the electric brake is unpowered and (ii) removes
the mechanical resistance to allow the motor of the utility vehicle
to turn when power is provided to the electric brake. Accordingly,
the electric brake disengages in response to the user actuating the
tow switch to the "tow mode" position and the user is able to then
tow the utility vehicle 20.
[0083] At 434, the motor controller 40 signals the lithium BMS to
continue providing electrical access to the lithium battery of the
utility vehicle 20 while sensing motion of the utility vehicle 20.
Here, in accordance with some embodiments, the motor controller 40
may routinely communicate with the BMS via the communications path
410. As long as the motor controller 40 continues to sense motion
of the utility vehicle 20 before timing out (e.g., by operating the
internal timer 252), the motor controller 40 continues to direct
the BMS to keep the contactor of the BMS closed.
[0084] At 436, the motor controller 40 signals the lithium BMS to
discontinue providing electrical access to the lithium battery when
no motion of the utility vehicle has been sensed for a predefined
amount of time. Here, in accordance with some embodiments, the
motor controller 40 times out due to the lack of sensing motion
from a motion sensor. Accordingly, in accordance with some
embodiments, the motor controller 40 sends a different
communication to the BMS that directs the BMS to allow the
contactor to open and go to sleep. As a result, the lithium battery
is safely disconnected thus preventing further discharge.
[0085] As shown in FIG. 10 and as an alternative to the user
switching the tow switch 402 from the "normal" position to the
"brake release" position in order to tow the utility vehicle 20,
the user may wire the lithium battery system 32 to the electric
brake 44 without involving the motor controller 40 in accordance
with some embodiments. Along these lines, the user rearranges
certain wiring so that the lithium battery 52 provides the power
signal 412 to the electric brake 44 to disengage the electric brake
44 from the motor 42 to enable the utility vehicle 20 to roll
freely. In some arrangements, such pathway reconfiguring is
represented and embodied by the park brake release switch 290 in
FIG. 5.
[0086] Here, wiring paths 440, 442 are provided to direct the BMS
50 to close the contactor 106 and thus provide electrical access to
the lithium battery 52. In some embodiments, such wiring may
involve addition or modification of particular jumpers, connectors,
and/or wires that normally provide parts of the regular signal
pathways 400 (e.g., compare FIG. 10 to FIG. 8). However, in this
alternative configuration, the lithium battery system 32 outputs
the power signal 422 to the electric brake 44 by passing the motor
controller 40, e.g., by tapping into the lithium battery system 32
itself to obtain a control signal 450 that feeds back to the
lithium battery system 32 to direct the BMS 50 to close the
contactor 106.
[0087] It should be understood that, in some embodiments, the
control logic 130 within the lithium battery system 32 (FIG. 3)
continues to protect the lithium battery 52 against being
over-discharged. In some embodiments, the control logic 130
activates its own timer 132 and the timer 132 may timeout after a
predefined amount of time if not reset (also see FIG. 3).
[0088] As shown in FIG. 11 and as yet another alternative, the user
may couple an external power source 460 with the electric brake 44
in accordance with some embodiments thus enabling the user to
release the electric brake 44 without involving the BMS 50. Along
these lines, the user attaches the electric brake 44 to the
external power source 460 via a wiring harness or umbilical cord
462. With the wiring harness 462 properly in place, the external
power source 460 outputs an external power signal 464 to the
electric brake 44 which disengages the electric brake 44 in
accordance with some embodiments thus enabling the electric motor
42 (FIG. 3) to turn. With the electric brake 44 energized via
external power, the user is now able to move the utility vehicle
20.
[0089] It should be understood that since the lithium battery
system 32 and the motor controller 40 are not involved in this
third alternative, both the lithium battery system 32 and the motor
controller 40 may remain asleep. Thus, there is no risk of
over-discharging the lithium battery 52.
Further Details
[0090] As described above, improved techniques are directed to
electronically controlling a lithium BMS 50 of a utility vehicle 20
in response to a tow signal (i.e., switching of the tow switch
402). In some embodiments, when control circuitry 250 of the
utility vehicle 20 receives the tow signal, the control circuitry
250 directs the lithium BMS 50 to maintain closure of its contactor
106 and provides power from a lithium battery 52 to an electric
brake 44 of the utility vehicle 20. In response, the electric brake
44 releases (or disengages) thus enabling the utility vehicle 20 to
move without mechanical resistance from the electric brake 44
(e.g., to be towed). In some embodiments, if the control circuitry
250 does not detect vehicle motion for a predefined amount of time,
the control circuitry 250 directs the lithium BMS 50 to open its
contactor 106 thus terminating power from the lithium battery 52 to
the electric brake 44 causing the electric brake 44 to re-engage.
With the contactor 106 now open, there is no further discharging of
the lithium battery 52. As a result, such operation robustly and
reliably prevents the lithium battery 52 from becoming
over-discharged thus safeguarding the lithium battery 52 against
becoming unstable.
[0091] While various embodiments of the present disclosure have
been particularly shown and described, it will be understood by
those skilled in the art that various changes in form and details
may be made therein without departing from the spirit and scope of
the present disclosure as defined by the appended claims.
[0092] In accordance with some arrangements and as disclosed above,
it should be understood that the BMS 50 has the ability to
disconnect the lithium battery 52 from loads if unsafe conditions
are sensed. The disconnect mechanism is the contactor 106 which
consumes energy when engaged. To conserve energy, the BMS 50
disconnects the lithium battery 52 after some timeout period. A
wakeup signal is required to reconnect the lithium battery 52 for
charging and normal use. That is, the lithium vehicle control
system wakeups the BMS 50 to use the utility vehicle 20. Such a
wakeup is accomplished without additional operator input.
[0093] In some embodiments, the BMS 50 and motor controller 40
routinely communicate (e.g., over the CAN bus). Accordingly, the
BMS 50 understands the current status of the motor controller 40
and vice versa. Additionally, as mentioned earlier, the BMS 50
monitors the status of a variety of switch inputs, e.g., a
maintenance switch, a keyed switch, a pedal switch, etc.
[0094] During operation, the BMS 50 disconnects itself from all
electrical loads on the utility vehicle 20 by opening its contactor
106. Events that cause the BMS 50 to close its contactor 106 may be
referred to as wakeup events, or simply wakeups. The BMS 50 of some
embodiments includes multiple inputs for wakeup signals. Along
these lines, users may expect the utility vehicle 20 to go when the
key is on and the pedal is pressed--whether the utility vehicle 20
has sat for a long time or not. Accordingly, the maintenance
switch, the keyed switch, and the throttle pedal switch are all
capable of waking up the BMS 50 of some embodiments.
[0095] In some embodiments, the BMS 50 may be woken by closing the
keyed switch 270. In a particular embodiment, after four hours of
inactivity, the BMS 50 goes back to sleep. It can be re-awoken by
cycling the keyed switch 270, or pressing the throttle pedal 280. A
"towing" mode is entered by closing the tow switch 402. This
maintains power to the electric brake 44 (release) until the motor
controller 40 senses a predefined amount of time of inactivity
(e.g., 30 minutes). That is, the motor controller 40 signals the
BMS 50 that tow mode is active, and later may assert another signal
when tow mode times out. In some embodiments, status bits within
the communication 70 sent from the motor controller 40 to the BMS
50 inform the BMS 50 whether the utility vehicle 20 is in tow mode
and whether the timer has timed out. The BMS 50 stay awakes while
tow mode is active, and goes to sleep shortly after it times out.
This prevents the BMS 50 from opening the contactor 106, thus
releasing the electric brake 44 while the utility vehicle 20 is
being towed.
[0096] In some arrangements, there are two pairs of brake release
connectors that can be swapped to power (release) the electric
brake 44 directly from the lithium battery 52. This allows towing
of the utility vehicle 20 when the motor controller 40 is not
functional. The BMS 50 goes back to sleep after a brake release
timeout period, or after the brake release connectors are returned
to their normal operating positions.
[0097] In some embodiments, the same BMS 50 may support operation
of different types of motor controllers 40. To this end, the motor
controller 40 of some embodiments sends a message (e.g., a CAN
message) to the BMS 50 that includes controller type. Upon receipt,
the BMS 50 of some embodiments stores the controller type in
non-volatile memory. The BMS 50 uses the controller type to
determine timeout values, and responses to wakeup signals. The
first time the BMS 50 is connected to a different type motor
controller 40, the BMS 50 may not wakeup exactly as desired. To
minimize the differences between wakeup protocols, wakeup signals
may be re-assigned. For example, the BMS' first wakeup signal may
be connected to the keyed switch on for a first controller type,
and the maintenance switch on a second controller type. Similarly,
the second wakeup signal may be connected to the throttle pedal for
the first controller type and the keyed switch for the second
controller type. Furthermore, the third wakeup signal may be
connected to the park brake release connectors for the first
controller type and the throttle pedal switch for the second
controller type. These input assignments minimize the logic
differences between wakeup. The most common wakeup methods of
turning on the first controller type key switch and the second
controller type maintenance switch will work properly regardless of
the vehicle type memorized by the BMS 50. As long as this wakeup
happens once, the BMS 50 will continue to wakeup and sleep properly
until it is transferred to another utility vehicle 20 that uses the
other controller type.
[0098] When the charger is plugged into the utility vehicle 20,
charging initiates regardless of whether the BMS 50 is asleep or
awake. If the BMS 50 is awake, plugging in the charger asserts a
charger interlock signal from the charge receptacle to the motor
controller 40. The motor controller 40 may be configured to send a
signal to the BMS 50 informing the BMS 50 that the charger is
plugged in. For example, in some embodiments, the motor controller
40 may inform the BMS 50 that the charger is plugged in via a
status bit in a message, such as a CAN message.
[0099] The BMS 50, in some embodiments, may be configured in
response to the signal from the motor controller 40 to activate a
charging mode. In these embodiments, the BMS 50 then sets a signal
(e.g., a PWM signal) appropriately (when not charging, the BMS 50
sets the PWM signal to a fault mode as a failsafe). Charging can
then take place. The BMS 50 stays awake until charging is complete,
and goes to sleep shortly after charging is complete.
[0100] In some embodiments, if the charger is plugged into a
utility vehicle 20 where the BMS 50 is asleep, then the charger
provides power to the vehicle's electrical system. This wakes up
the BMS 50 and motor controller 40. If the BMS 50 receives a
communication (e.g., a CAN message) from the motor controller 40
with the charging status bit set, then it will close its contactor
106 and set the signal (e.g., the PWM signal) appropriately.
Charging then commences.
[0101] Additionally, it should be understood that the keyed switch
was described above as being used in certain example embodiments.
It will be appreciated that the keyed switch is just one example of
an ignition switch that may be used in various embodiments. For
example, in other example embodiments, the vehicle uses a keyless,
push-button ignition rather than a keyed switch. Such ignition is
enabled when an "electronic key" (e.g., an RF device) on the
passenger's person is within range of a wireless sensor of the
vehicle. Here, an actuation of the switch occurs through presence
of the electronic key in combination with physical actuation of the
button.
[0102] Furthermore, in some embodiments, the BMS 50 utilizes an
inactivity timer that measures inactivity time based on current
(also see the timer 132 in FIG. 3). For example, the inactivity
timer starts timing inactivity when current sensed from the lithium
battery falls below a predefined current threshold (e.g., 3 amps).
As long as the current remains below this predefined current
threshold, the inactivity timer continues to measure time. However,
if the current rises above the predefined current threshold, the
inactivity timer is cleared (or reset) because this rise in current
above the predefined current threshold is considered detected
activity. The inactivity timer then starts counting again when
current falls below the predefined current threshold. If the
inactivity timer ever reaches a timeout value, the inactivity timer
is considered to have expired (i.e., detected an inactivity timeout
event).
[0103] Additionally, it should be understood that a variety of
different types of motion sensing circuits are suitable for use to
sense vehicle motion (also see the motion sensor 404 in FIG. 8).
Examples of suitable motion sensing circuits include current
sensors, global navigation satellite system sensors, and so on. In
some embodiments, a global positioning system (GPS) sensor is used
to determine a change in position of the vehicle. Such
modifications and enhancements are intended to belong to various
embodiments of the disclosure.
* * * * *