| |
| United States Patent
|
7,039,534 |
| Ryno , et al. |
May 2, 2006 |
Charging monitoring systems
Abstract
An electronic system for the continuous monitoring of voltage
charge within the electrical system of a motor vehicle having an
electrical generation source and a secondary electrochemical cell or
battery. The system comprises a programmable in-vehicle monitor
having a flashing LED indicator that alerts the vehicle operator of
the condition of the electrical system. An example of the invention
comprises a plug-in housing for use in a vehicle
accessory-power-socket. Additionally, a method of market
distribution is disclosed.
| Inventors: |
Ryno; Ronald A.
(Gilbert, AZ), Ryno; Shirlee M. (Gilbert, AZ) |
| Appl. No.:
|
10/970,583 |
| Filed: |
October 20, 2004 |
Related U.S. Patent Documents
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Application Number |
Filing Date |
Patent Number |
Issue Date |
|
60517150 |
Nov., 2003 |
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| Current U.S.
Class: |
702/63 ;
320/134; 320/135; 320/136; 320/163; 324/427; 324/430; 702/64 |
| Current
International Class: |
G01R
31/36 (20060101) |
| Field of
Search: |
702/63,64,65,66
324/427,430,433 320/150,164,134,161,136,135,163 |
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Barlow; John
Assistant Examiner: Vo; Hien
Attorney, Agent or Firm:
Stoneman Law Offices,
Ltd. Stoneman; Martin L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to and claims priority from prior
provisional application Ser. No. 60/517,150, filed Nov. 3, 2003,
entitled "CHARGING MONITORING SYSTEM", the contents of which are
incorporated herein by this reference and are not admitted to be
prior art with respect to the present invention by the mention in
this cross-reference section.
Claims
What is claimed is:
1. A monitoring system, relating to monitoring of at least one
electrical system having at least one current-carrying circuit, such
circuit comprising at least one variable operating voltage, such
system comprising: a) continuous-accessor means for continuously
accessing the at least one variable operating voltage of the at
least one current-carrying circuit; b) sampler means, electrically
coupled to said continuous-accessor means, for sampling the at least
one variable operating voltage; c) sample-voltage valuer means,
electrically coupled to said sampler means, for providing at least
one sampled voltage value for the at least one variable operating
voltage; d) benchmark memory storage means for storing a plurality
of programmable benchmark voltage values for the at least one
variable operating voltage; e) sampled-voltage-value storage means,
electrically coupled to said sampler means, for storing the at least
one sampled voltage value; f) logic-processor means, electrically
coupled to said benchmark memory storage means and said
sampled-voltage-value storage means, for logically processing the at
least one sampled voltage value, wherein said logic-processor means
comprises i) sampled-voltage indicator means for providing at least
one indication of the at least one sampled voltage value, ii)
comparator means for comparing the at least one indication of the at
least one sampled voltage value with at least one of the plurality
of programmable benchmark voltage values, and iii) output signal
generator means for generating at least one output signal from said
comparator means; and g) user-sensable signalling device controller
means, electrically coupled with said output signal generator means,
for controlling at least one user-sensable signalling device.
2. A monitoring system, relating to vehicle-user monitoring of at
least one vehicular electrical charging system having at least one
current-carrying circuit, such circuit comprising at least one
operating voltage and at least one rechargeable energy storage
battery, such system comprising: a) at least one continuous-accessor
adapted to continuously access the at least one operating voltage of
the at least one current-carrying circuit; b) at least one sampler,
electrically coupled to said at least one continuous-accessor,
adapted to sample the at least one operating voltage; c) at least
one sample-voltage valuer, electrically coupled to said at least one
sampler, structured and arranged to provide at least one sampled
voltage value for the at least one operating voltage; d) at least
one benchmark memory storage to store a plurality of programmable
benchmark voltage values for the at least one operating voltage; e)
at least one sampled-voltage-value storage, electrically coupled to
said at least one sampler, to store the at least one sampled voltage
value; f) at least one logic-processor, electrically coupled to said
at least one benchmark memory storage and said at least one
sampled-voltage-value storage, for logically processing the at least
one sampled voltage value, wherein said at least one logic-processor
comprises i) at least one sampled-voltage indicator structured and
arranged to provide at least one indication of the at least one
sampled voltage value, ii) at least one comparator to compare the at
least one indication of the at least one sampled voltage value with
at least one of the plurality of programmable benchmark voltage
values, and iii) at least one output signal generator to generate at
least one output signal from said at least one comparator; and g) at
least one user-sensable signaling-device controller, electrically
coupled with said at least one output signal generator, structured
and arranged to control at least one user-sensable signalling
device.
3. The monitoring system according to claim 2 further comprising at
least one user-sensable signalling device, coupled to said at least
one output signal generator, structured and arranged to provide at
least one user-sensable signal.
4. The monitoring system according to claim 3 wherein said at least
one user-sensable signalling device is adapted to provide at least
four unique user-sensable signals.
5. The monitoring system according to claim 3 wherein said at least
one user-sensable signalling device comprises a single illumination
source.
6. The monitoring system according to claim 2 wherein said at least
one logic-processor is programmable.
7. The monitoring system according to claim 2 wherein said at least
one logic-processor comprises electrically erasable, programmable
read-only memory.
8. The monitoring system according to claim 2 wherein said at least
one sample-voltage valuer comprises at least one analog-to-digital
converter structured and arranged to convert the at least one
operating voltage from at least one analog signal to at least one
digital value.
9. The monitoring system according to claim 2 wherein said at least
one continuous-accessor is adapted to sample the at least one
operating voltage of exactly one of the at least one
current-carrying circuits.
10. The monitoring system according to claim 2 wherein said at least
one sampler comprises at least one circuit structured and arranged
to electrically process the at least one operating voltage.
11. The monitoring system according to claim 10 further comprising:
a) at least one calibration tester adapted to perform at least one
calibration test to measure actual performance of at least one
monitoring function of said monitoring system; b) wherein said at
least one calibration tester is adapted to produce calibration test
data on performing the at least one calibration test.
12. The monitoring system according to claim 11 further comprising
at least one programmer adapted to program said at least one
logic-processor.
13. The monitoring system according to claim 12 wherein said at
least one programmer comprises at least one control program adapted
to control the logical processing of the at least one sampled
voltage value.
14. The monitoring system according to claim 13 wherein: a) said at
least one control program comprises at least one calibrator adapted
to calibrate the monitoring performance of said monitoring system to
match at least one target monitoring performance; and b) said at
least one calibrator calibrates the operational performance of said
monitoring system by utilizing the at least one set of calibration
test data.
15. The monitoring system according to claim 13 further comprising:
a) at least one circuit-supporting substrate adapted to support said
at least one circuit; b) wherein said at least one
circuit-supporting substrate comprises at least one peripheral edge;
and c) said at least one peripheral edge comprises at least one
electrical edge-coupler adapted to permit at least one removably
engageable electrical coupling between said at least one circuit and
at least one other circuit of at least one other device.
16. The monitoring system according to claim 15 wherein said at
least one other device comprises said at least one calibration
tester.
17. The monitoring system according to claim 15 wherein said at
least one other device comprises said at least one programmer.
18. The monitoring system according to claim 15 wherein said at
least one other device comprises the at least one vehicular
electrical charging system.
19. The monitoring system according to claim 13 wherein said at
least one calibration tester comprises said at least one programmer.
20. The monitoring system according to claim 15 wherein said at
least one edge connector comprises at least one electrically
conductive contact electrically coupled to said at least one
circuit.
21. The monitoring system according to claim 20 wherein said at
least one edge connector comprises: a) at least one electrically
conductive data contact adapted to conduct at least one data signal
to at least one data-using component of said monitoring system; and
b) at least one electrically conductive power contact adapted to
conduct electrical power to said at least one circuit.
22. The monitoring system according to claim 10 wherein said at
least one circuit comprises at least one first filter adapted to
filter radio frequency energy from the at least one operating
voltage.
23. The monitoring system according to claim 22 wherein said at
least one circuit further comprises: a) at least one second filter
adapted to filter out conducted high frequency noise from the at
least one operating voltage; and b) at least one third filter
adapted to filter out conducted low frequency noise from the at
least one operating voltage.
24. The monitoring system according to claim 2 wherein said at least
one continuous-accessor requires only one positive electrical
connection and only one grounded connection to the at least one
current-carrying circuit.
25. The monitoring system according to claim 2 wherein said at least
one continuous-accessor comprises at least one vehicular accessory
power socket adapter to electrically engage at least one vehicular
accessory power socket.
26. The monitoring system according to claim 25 wherein: a) said at
least one vehicular accessory power socket adapter comprises at
least one cylindrical housing; and b) said at least one cylindrical
housing comprises at least one interior cavity portion adapted to
essentially contain said monitoring system.
27. A monitoring system, relating to vehicle-user monitoring of at
least one vehicular electrical charging system having at least one
current-carrying circuit, such circuit comprising at least one
operating voltage, at least one rechargeable energy storage battery
and at least one accessory power socket, such system comprising: a)
at least one continuous-accessor adapted to continuously access the
at least one operating voltage of the at least one current-carrying
circuit by engaging the at least one accessory power socket; b) at
least one sampler, electrically coupled to said at least one
continuous-accessor, adapted to sample the at least one operating
voltage; c) at least one sample-voltage valuer, electrically coupled
to said at least one sampler, structured and arranged to provide at
least one sampled voltage value for the at least one operating
voltage; d) at least one benchmark memory storage to store a
plurality of programmable benchmark voltage values for the at least
one operating voltage; e) at least one sampled-voltage-value
storage, electrically coupled to said at least one sampler, to store
the at least one sampled voltage value; f) at least one
logic-processor, electrically coupled to said at least one benchmark
memory storage and said at least one sampled-voltage-value storage,
for logically processing the at least one sampled voltage value,
wherein said at least one logic-processor comprises i) at least one
sampled-voltage indicator structured and arranged to provide at
least one indication of the at least one sampled voltage value, ii)
at least one comparator to compare the at least one indication of
the at least one sampled voltage value with at least one of the
plurality of programmable benchmark voltage values, and iii) at
least one output signal generator to generate at least one output
signal from said at least one comparator; and iv) at least one
user-sensable signalling device controller, electrically coupled
with said at least one output signal generator, structured and
arranged to control at least one user-sensable signalling device.
28. A kit system, containing at least one monitoring device for
monitoring at least one vehicular electrical charging system, such
kit system comprising: a) at least one continuous-accessor adapted
to continuously access at least one operating voltage of the at
least one current-carrying circuit by engaging the at least one
accessory power socket; b) at least one sampler, electrically
coupled to said at least one continuous-accessor, adapted to sample
the at least one operating voltage; c) at least one sample-voltage
valuer, electrically coupled to said sampler means, structured and
arranged to provide at least one sampled voltage value for the at
least one operating voltage; d) at least one benchmark memory
storage to store a plurality of programmable benchmark voltage
values for the at least one operating voltage; e) at least one
sampled-voltage-value storage, electrically coupled to said at least
one sampling means, to store the at least one sampled voltage value;
f) at least one logic-processor, electrically coupled to said at
least one benchmark memory storage and said at least one
sampled-voltage-value storage, for logically processing the at least
one sampled voltage value, wherein said at least one logic-processor
comprises i) at least one sampled-voltage indicator structured and
arranged to provide at least one indication of the at least one
sampled voltage value, ii) at least one comparator to compare the at
least one indication of the at least one sampled voltage value with
at least one of the plurality of programmable benchmark voltage
values, and iii) at least one output signal generator to generate at
least one output signal from said at least one comparator; and iv)
at least one user-sensable signalling device controller,
electrically coupled with said at least one output signal generator,
structured and arranged to control at least one LED; g) at least one
LED socket having at least one retaining ring; h) at least one ring
connector; i) at least one butt connector; j) at least one cable
tie; k) at least one installation and operating instruction; and l)
at least one consumer package.
29. A kit system, containing at least one monitoring device for
monitoring at least one vehicular electrical charging system, such
kit system comprising: a) at least one monitoring device comprising;
i) at least one continuous-accessor adapted to continuously access
at least one operating voltage of said at least one vehicular
electrical charging system by engaging at least one vehicular
accessory power socket, ii) at least one sampler, electrically
coupled to said at least one continuous-accessor, structured and
arranged to sample the at least one operating voltage, iii) at least
one sampled voltage-value generator, electrically coupled to said at
least one sampler, to provide at least one sampled voltage value for
the at least one operating voltage, iv) at least one benchmark
memory device to store a plurality of programmable benchmark voltage
values for the at least one operating voltage, v) at least one
storage memory, electrically coupled to said at least one sampler,
to store the at least one sampled voltage value, and vi) at least
one logic-processor, electrically coupled to said at least one
benchmark memory device and said at least one storage memory,
structured and arranged to logically process the at least one
sampled voltage value, wherein said at least one logic-processor
comprises, (a) at least one sampled voltage indicator adapted to
provide at least one indication of sampled voltage value, (b) at
least one comparator to compare the at least one indication of
sampled voltage value with at least one of the plurality of
programmable benchmark voltage values, (c) at least one output
signal device adapted to provide at least one output signal from
said at least one comparator, and vii) at least one visual signal
device controller, electrically coupled with said at least one
output signal device, structured and arranged to control at least
one visual signal device; b) at least one installation and operating
instruction; and c) at least one consumer package.
30. A method for providing vehicle-specific voltage monitoring
systems for each of a plurality of differing motor vehicles each
having at least one electrical charging system, such method
comprising the steps of: a) identifying at least one plurality of
such differing motor vehicles; b) assembling vehicle-specific
benchmark voltage data for each one of such plurality of differing
motor vehicles; c) providing at least one programmable device,
adapted to in-vehicle use, structured and arranged to i) sample
voltage from such electrical charging system and ii) compare such
sampled voltage to the vehicle-specific benchmark voltage data; d)
providing vehicle-specific software, using the vehicle-specific
benchmark voltage data, such vehicle-specific software being
downloadable to provide at least one program to such at least one
in-vehicle programmable device; and e) providing to vehicle
aftermarkets such vehicle-specific voltage monitoring systems.
Description
BACKGROUND
This invention relates to providing a system for improved monitoring
of a vehicle electrical system. More specifically, this invention
relates to the continuous monitoring of voltage charge within the
electrical system of a motor vehicle having an electrical generation
source and a secondary, typically electrochemical, cell or battery.
The lead-acid storage battery has proven to be an efficient and
reliable electrochemical energy source since its commercial
introduction about 125 years ago. In addition to being a highly
efficient energy source, lead-acid storage batteries are also
relatively inexpensive to produce and therefore lend themselves to a
broad range of applications.
Motorized vehicles are one common example of a commercial use for
lead-acid storage batteries. Typically, electrical systems found
within motorized vehicles comprise an alternator, secondary storage
battery, circuit controlling devices (such as an ignition switch)
and a variety of current-drawing electrical loads. During normal
operation, the battery is used to start the vehicle's engine,
thereinafter the engine drives an alternator that charges the
secondary storage battery while the engine is operating. To charge
the battery, the alternator must produce an output voltage higher
than that of the open-circuit voltage of the battery. This
"elevated" voltage condition causes current to flow into the
battery, thereby charging it. It is well known that the performances
of motor-driven alternators vary greatly. This is especially true of
compact alternator units employed in, for example, production of
motorcycles. Depending on the output of the alternator, the combined
loads of the various electrical devices, and the condition of the
battery, the voltage within the electrical system may fluctuate
between conditions of severe voltage overcharge and severe voltage
undercharge. Both overcharge and undercharge conditions are
potentially damaging to electrical system components, to the point
of rendering the host vehicle inoperable. Often, the motor vehicle
operator is unaware of a pending failure until the vehicle fails to
start on attempting to start the engine.
Existing systems to meter the voltage status of vehicular electrical
systems have been either inexpensive and acutely inaccurate or
relatively accurate but exceedingly expensive and complex to
implement. Often an indication of impending failure is marked by
very small fluctuations in electrical system voltage. These small
fluctuations in voltage are presently undetectable by inexpensive
charge warning indicators. Therefore, a need exists within the motor
vehicle industry for an inexpensive but highly accurate predictive
device to monitor the voltage condition of a vehicular electrical
system.
OBJECTS AND FEATURES OF THE INVENTION
A primary object and feature of the present invention is to provide
a system for improved monitoring of a vehicle electrical system
overcoming the above-stated problems.
It is a further object and feature of the present invention to
provide such a system to monitor a vehicle's charging system voltage
when the vehicle's charging system is in operation.
It is another object and feature of the present invention to provide
such a system to monitor a vehicle's secondary storage battery
voltage when the vehicle charging system is not in operation.
It is a further object and feature of the present invention to
provide such a system that is programmable to match a specific
vehicle application.
It is yet a further object and feature of the present invention to
provide such a system to monitor a vehicle's charging system voltage
by engaging the vehicle's accessory power plug.
It is an additional object and feature of the present invention to
provide such a system that is supplied as an OEM product or consumer
aftermarket kit.
It is a further object and feature of the present invention to
provide such a system that utilizes surface mounted electronic
components to produce systems having a small format circuit board.
It is an additional object and feature of the present invention to
provide such a system that utilizes a plug-in-type edge connector to
permit testing and programming of the system at any time after
system manufacture.
It is a further object and feature of the present invention to
provide such a system and method, permitting electronic component
calibration to provide improved monitoring accuracy.
It is a further object and feature of the present invention to
provide such a system that permits precise calibration of system
components.
A further primary object and feature of the present invention is to
provide such a system that is efficient, inexpensive, and handy.
Other objects and features of this invention will become apparent
with reference to the following descriptions.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment hereof, this invention
provides a monitoring system, for vehicle-user monitoring at least
one vehicular electrical charging system having at least one
current-carrying circuit, such circuit comprising at least one
operating voltage and at least one rechargeable energy storage
battery, such system comprising: continuous-accessor means for
continuously accessing the at least one operating voltage of the at
least one current-carrying circuit; sampler means, electrically
coupled to such continuous-accessor means, for sampling the at least
one operating voltage; sample-voltage valuer means, electrically
coupled to such sampler means, for providing at least one sampled
voltage value for the at least one operating voltage; benchmark
memory storage means for storing a plurality of programmable
benchmark voltage values for the at least one operating voltage;
sampled-voltage-value storage means, electrically coupled to such
sampler means, for storing the at least one sampled voltage value;
logic-processor means, electrically coupled to such benchmark memory
storage means and such sampled-voltage-value storage means, for
logically processing the at least one sampled voltage value, wherein
such logic-processor means comprises sampled-voltage indicator means
for providing at least one indication of the at least one sampled
voltage value, comparator means for comparing the at least one
indication of the at least one sampled voltage value with at least
one of the plurality of programmable benchmark voltage values, and
output signal generator means for generating at least one output
signal from such comparator means; and user-sensable signalling
device controller means, electrically coupled with such output
signal generator means, for controlling at least one user-sensable
signalling device.
In accordance with another preferred embodiment hereof, this
invention provides a monitoring system, for vehicle-user monitoring
at least one vehicular electrical charging system having at least
one current-carrying circuit, such circuit comprising at least one
operating voltage and at least one rechargeable energy storage
battery, such system comprising: at least one continuous-accessor
adapted to continuously access the at least one operating voltage of
the at least one current-carrying circuit; at least one sampler,
electrically coupled to such at least one continuous-accessor,
adapted to sample the at least one operating voltage; at least one
sample-voltage valuer, electrically coupled to such at least one
sampler, structured and arranged to provide at least one sampled
voltage value for the at least one operating voltage; at least one
benchmark memory storage to store a plurality of programmable
benchmark voltage values for the at least one operating voltage; at
least one sampled-voltage-value storage, electrically coupled to
such at least one sampling means, to store the at least one sampled
voltage value; at least one logic-processor, electrically coupled to
such at least one benchmark memory storage and such at least one
sampled-voltage-value storage, for logically processing the at least
one sampled voltage value, wherein such at least one logic-processor
comprises at least one sampled-voltage indicator structured and
arranged to provide at least one indication of the at least one
sampled voltage value, at least one comparator to compare the at
least one indication of the at least one sampled voltage value with
at least one of the plurality of programmable benchmark voltage
values, and at least one output signal generator to generate at
least one output signal from such at least one comparator; and at
least one user-sensable signalling device controller, electrically
coupled with such at least one output signal generator, structured
and arranged to control at least one user-sensable signalling
device. Moreover, it provides such a monitoring system further
comprising at least one user-sensable-signalling device, coupled to
such at least one output signal generator, structured and arranged
to provide at least one user-sensable signal.
Additionally, it provides such a monitoring system wherein such at
least one user-sensable-signalling device is adapted to provide at
least four unique user-sensable signals. Also, it provides such a
monitoring system wherein such at least one user-sensable signalling
device comprises a single illumination source. In addition, it
provides such a monitoring system wherein such at least one
logic-processor is programmable. And, it provides such a monitoring
system wherein such at least one logic-processor comprises
electrically erasable programmable read-only memory.
Further, it provides such a monitoring system wherein such at least
one sample voltage-valuer comprises at least one analog-to-digital
converter structured and arranged to convert the at least one
operating voltage from at least one analog signal to at least one
digital value. Even further, it provides such a monitoring system
wherein such at least one continuous-accessor is adapted to sample
the at least one operating voltage from not more than one of the at
least one current-carrying circuits. Moreover, it provides such a
monitoring system wherein such at least one sampler comprises at
least one circuit structured and arranged to electrically process
the at least one operating voltage.
Additionally, it provides such a monitoring system further
comprising: at least one calibration tester adapted to perform at
least one calibration test to measure actual performance of at least
one monitoring function of such monitoring system; wherein such at
least one calibration tester is adapted to produce calibration test
data on performing the at least one calibration test. Also, it
provides such a monitoring system further comprising at least one
programmer adapted to program such at least one logic-processor.
In addition, it provides such a monitoring system wherein such at
least one programmer comprises at least one control program adapted
to control the logical processing of the at least one sample voltage
value. And, it provides such a monitoring system wherein: such at
least one control program comprises at least one calibrator adapted
to calibrate the monitoring performance of such monitoring system to
match at least one target monitoring performance; and such at least
one calibrator calibrates the operational performance of such
monitoring system by utilizing the at least one set of calibration
test data.
Further, it provides such a monitoring system further comprising: at
least one circuit-supporting substrate adapted to support such at
least one circuit; wherein such at least one circuit-supporting
substrate comprises at least one peripheral edge; and such at least
one peripheral edge comprises at least one electrical edge-coupler
adapted to permit at least one removably engageable electrical
coupling between such at least one circuit and at least one other
circuit of at least one other device. Even further, it provides such
a monitoring system wherein such at least one other device comprises
such at least one calibration tester.
Moreover, it provides such a monitoring system wherein such at least
one other device comprises such at least one programmer.
Additionally, it provides such a monitoring system wherein such at
least one other device comprises the at least one vehicular
electrical charging system. Also, it provides such a monitoring
system wherein such at least one calibration tester comprises such
at least one programmer. In addition, it provides such a monitoring
system wherein such at least one edge connector comprises at least
one electrically conductive contact electrically coupled to such at
least one circuit. And, it provides such a monitoring system wherein
such at least one edge connector comprises: at least one
electrically conductive data contact adapted to conduct at least one
data signal to at least one data using component of such monitoring
system; and at least one electrically conductive power contact
adapted to conduct electrical power to such at least one circuit.
Further, it provides such a monitoring system wherein such at least
one circuit comprises at least one first filter adapted to filter
radio frequency energy from the at least one operating voltage. Even
further, it provides such a monitoring system wherein such at least
one circuit further comprises: at least one second filter adapted to
filter out conducted high frequency noise from the at least one
operating voltage; and at least one third filter adapted to filter
out conducted low frequency noise from the at least one operating
voltage.
Even further, it provides such a monitoring system wherein such at
least one continuous-accessor comprises: one positive electrical
connection to the at least one current-carrying circuit; and one
grounded connection. Even further, it provides such a monitoring
system wherein such at least one continuous-accessor comprises at
least one vehicular accessory power socket adapter to electrically
engage at least one vehicular accessory power socket. Even further,
it provides such a monitoring system wherein: such at least one
vehicular accessory power socket adapter comprises at least one
cylindrical housing; and such at least one cylindrical housing
comprises at least one interior cavity portion adapted to
essentially contain such monitoring system.
In accordance with another preferred embodiment hereof, this
invention provides a monitoring system, for vehicle-user monitoring
at least one vehicular electrical charging system having at least
one current-carrying circuit, such circuit comprising at least one
operating voltage, at least one rechargeable energy storage battery
and at least one accessory power socket, such system comprising: at
least one continuous-accessor adapted to continuously access the at
least one operating voltage of the at least one current-carrying
circuit by engaging the at least one accessory power socket; at
least one sampler, electrically coupled to such at least one
continuous-accessor, adapted to sample the at least one operating
voltage; at least one sample-voltage valuer, electrically coupled to
such sampler means, structured and arranged to provide at least one
sampled voltage value for the at least one operating voltage; at
least one benchmark memory storage to store a plurality of
programmable benchmark voltage values for the at least one operating
voltage; at least one sampled-voltage-value storage, electrically
coupled to such at least one sampling means, to store the at least
one sampled voltage value; at least one logic-processor,
electrically coupled to such at least one benchmark memory storage
and such at least one sampled-voltage-value storage, for logically
processing the at least one sampled voltage value, wherein such at
least one logic-processor comprises at least one sampled-voltage
indicator structured and arranged to provide at least one indication
of the at least one sampled voltage value, at least one comparator
to compare the at least one indication of the at least one sampled
voltage value with at least one of the plurality of programmable
benchmark voltage values, and at least one output signal generator
to generate at least one output signal from such at least one
comparator; and at least one user-sensable signalling device
controller, electrically coupled with such at least one output
signal generator, structured and arranged to control at least one
user-sensable signalling device.
In accordance with another preferred embodiment hereof, this
invention provides a kit system, containing at least one monitoring
device for monitoring at least one vehicular electrical charging
system, such kit system comprising: at least one continuous-accessor
adapted to continuously access at least one operating voltage of the
at least one current-carrying circuit by engaging the at least one
accessory power socket; at least one sampler, electrically coupled
to such at least one continuous-accessor, adapted to sample the at
least one operating voltage; at least one sample-voltage valuer,
electrically coupled to such sampler means, structured and arranged
to provide at least one sampled voltage value for the at least one
operating voltage; at least one benchmark memory storage to store a
plurality of programmable benchmark voltage values for the at least
one operating voltage; at least one sampled-voltage-value storage,
electrically coupled to such at least one sampling means, to store
the at least one sampled voltage value; at least one
logic-processor, electrically coupled to such at least one benchmark
memory storage and such at least one sampled-voltage-value storage,
for logically processing the at least one sampled voltage value,
wherein such at least one logic-processor comprises at least one
sampled-voltage indicator structured and arranged to provide at
least one indication of the at least one sampled voltage value, at
least one comparator to compare the at least one indication of the
at least one sampled voltage value with at least one of the
plurality of programmable benchmark voltage values, and at least one
output signal generator to generate at least one output signal from
such at least one comparator; and at least one user-sensable
signalling device controller, electrically coupled with such at
least one output signal generator, structured and arranged to
control at least one LED; at least one LED socket having at least
one retaining ring; at least one ring connector; at least one butt
connector; at least one cable tie; at least one installation and
operating instruction; and at least one consumer package.
In accordance with another preferred embodiment hereof, this
invention provides a kit system, containing at least one monitoring
device for monitoring at least one vehicular electrical charging
system, such kit system comprising: at least one monitoring device
comprising; at least one continuous-accessor adapted to continuously
access at least one operating voltage of such at least one vehicular
electrical charging system by engaging at least one vehicular
accessory power socket, at least one sampler, electrically coupled
to such at least one continuous-accessor, structured and arranged to
sample the at least one operating voltage, at least one sampled
voltage-value generator, electrically coupled to such at least one
sampler, to provide at least one sampled voltage value for the at
least one operating voltage, at least one benchmark memory device to
store a plurality of programmable benchmark voltage values for the
at least one operating voltage, at least one storage memory,
electrically coupled to such at least one sampler, to store the at
least one sampled voltage value, and at least one logic-processor,
electrically coupled to such at least one benchmark memory device
and such at least one storage memory, structured and arranged to
logically process the at least one sampled voltage value, wherein
such at least one logic-processor comprises, at least one sampled
voltage indicator adapted to provide at least one indication of
sampled voltage value, at least one comparator to compare the at
least one indication of sampled voltage value with at least one of
the plurality of programmable benchmark voltage values, at least one
output signal device adapted to provide at least one output signal
from such at least one comparator, and at least one visual signal
device controller, electrically coupled with such at least one
output signal device, structured and arranged to control at least
one visual signal device; at least one installation and operating
instruction; and at least one consumer package.
In accordance with another preferred embodiment hereof, this
invention provides a method relating to improving the accuracy of a
vehicular voltage monitoring system comprising the steps of:
ascertaining at least one baseline operational characteristic of
such vehicular voltage monitoring system by operational testing of
such voltage monitoring system; selecting at least one target
operational characteristic of such vehicular voltage monitoring
system; and adjusting such at least one baseline operational
characteristic of such vehicular voltage monitoring system to match
such at least one target operational characteristic; wherein such
adjusting at least includes altering at least one software component
of such vehicular voltage monitoring system.
In accordance with another preferred embodiment hereof, this
invention provides a method for providing vehicle-specific voltage
monitoring systems for each of a plurality of differing motor
vehicles each having at least one electrical charging system, such
method comprising the steps of: identifying at least one plurality
of such differing motor vehicles; assembling vehicle-specific
benchmark voltage data for each one of such plurality of differing
motor vehicles; providing at least one in-vehicle programmable
device structured and arranged to sample voltage from such
electrical charging system and compare such sampled voltage to the
vehicle-specific benchmark voltage data; providing vehicle-specific
software, using the vehicle-specific benchmark voltage data, such
vehicle-specific software being downloadable to provide at least one
program to such at least one in-vehicle programmable device; and
providing to vehicle aftermarkets such vehicle-specific voltage
monitoring systems.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows, in simplified block diagram form, a typical host
vehicle utilizing a monitoring system according to a preferred
embodiment of the present invention.
FIG. 2 graphically shows the operation of a visual indicator in
response to detected voltage conditions within the host vehicle
electrical system according to the preferred embodiment of FIG. 1.
FIG. 3 shows a perspective view of the monitoring system according
to a preferred embodiment of FIG. 1.
FIG. 4 shows a perspective view of the monitoring system of FIG. 3
with the outer protective jacket removed to permit review of the
circuit board.
FIG. 5 shows a schematic circuit diagram illustrating the preferred
arrangements of electronic components comprising the monitoring
system according to the preferred embodiment of FIG. 3.
FIG. 6 shows a simplified diagram generally illustrating the
preferred steps in programming a micro-controller chip for use
within the preferred embodiments of the monitoring system.
FIG. 7 shows a simplified flow diagram generally illustrating the
preferred sequence of programmed steps of the monitoring system
control software according to a preferred embodiment of the present
invention.
FIG. 8 shows a view of the upper surface of the monitoring system
illustrating the preferred configuration of the circuit board and
the general steps in assembling the system according to the
preferred embodiment of FIG. 4.
FIG. 9 shows a view of the lower surface of the monitoring system
illustrating the preferred configuration of the circuit board
according to the preferred embodiment of FIG. 4.
FIG. 10a shows a schematic diagram of the monitoring system
comprising surface mounted components, according to an alternate
preferred embodiment of the present invention.
FIG. 10b shows a top view of a surface mount board used to assemble
the monitoring system of FIG. 10a.
FIG. 10c shows a bottom view of the surface mount board of FIG. 10b.
FIG. 11 shows a perspective view illustrating a plug-in monitoring
system comprising a vehicular accessory plug-style housing according
to an alternate preferred embodiment of the present invention.
FIG. 12 shows a perspective view illustrating a consumer kit for the
commercial distribution of the monitoring system according to
another preferred embodiment of the present invention.
FIG. 13 shows a diagram illustrating edge an edge connector of the
monitoring system, coupled to a test/programming fixture, in
preparation of component testing and programming of the monitoring
system, according to a preferred embodiment of the present
invention.
FIG. 14a shows a first portion of a schematic diagram illustrating
the circuit arrangements of the test/programming fixture according
to a preferred embodiment of the present invention.
FIG. 14b shows a second portion of a schematic diagram illustrating
the circuit arrangements of the test/programming fixture according
to FIG. 14a.
FIG. 15 shows a diagrammatic overview of the preferred procedures
employed when calibrating/programming the monitoring system
according to preferred methods of the present invention.
FIG. 16 shows a diagram illustrating the preferred procedures
employed when calibrating/programming the monitoring system
utilizing a personal computer according to preferred methods of the
present invention.
FIG. 17 shows a diagram illustrating the steps by which the
operation of the monitoring system is tested according to a
preferred method of the present invention.
FIG. 18 shows a simplified diagram illustrating a supplier's overall
business method for designing, manufacturing and selling a
vehicle-specific voltage monitoring system.
DETAILED DESCRIPTION OF THE BEST MODES AND PREFERRED EMBODIMENTS OF
THE INVENTION
Referring now to the drawings, FIG. 1 illustrates, in block diagram
form, typical host vehicle 102 utilizing monitoring system 100 to
continuously monitor the operational status of electrical system
106. For the purposes of best following the teachings of the present
disclosure, it is assumed that electrical system 106 resides within
a motorized host vehicle, such as, for example, a motorcycle, car,
or boat, and that the nominal operating voltage of electrical system
106 is twelve (12) volts DC.
In the diagrammatic example of FIG. 1, electrical system 106
typically comprises secondary storage battery 108, alternator 104,
ignition control device 109 and electrical load 110, as shown.
Electrical load 110 typically comprises such diverse current-drawing
devices as a starter motor, headlights, gauges, fans and similar
electrical equipment. During normal operation, alternator 104
charges battery 108 when the engine of host vehicle 102 is
operating. To charge battery 108, alternator 104 produces a voltage
higher than that of the open-circuit voltage of battery 108. This
"elevated" voltage condition causes current to flow into battery
108, thereby charging it. Since battery 108 and alternator 104 are
interconnected with the remainder of electrical system 106, the
charging voltage (or lack thereof) is impressed on the entire
electrical system 106, as shown. Monitoring system 100 preferably
effectively utilizes this continuity of ignition circuit pathways to
permit a simple and straightforward integration of monitoring system
100 within electrical system 106, as will be further described
below.
Preferably, monitoring system 100 operates by initially sampling the
voltage within electrical system 106, at any convenient point having
power when the ignition circuit is on and alternator 104 is
operating. Additionally, monitoring system 100 is preferably adapted
to monitor the status of battery 108 if the ignition switch
(ignition circuit) is on (closed) and alternator 104 of host vehicle
102 is not operating.
The preferred integration of monitoring system 100 into electrical
system 106 requires two physical points of electrical connection
comprising positive lead 112 and negative lead 114, as shown (at
least embodying herein continuous-accessor means for continuously
accessing the at least one operating voltage of the at least one
current-carrying circuit and further herein embodying wherein such
continuous-accessor means is adapted to sample the at least one
operating voltage from not more than one of the at least one
current-carrying circuits). Positive lead 112 of monitoring system
100 is preferably connected to any readily accessible circuit point
within electrical system 106 (that has power when the ignition
circuit is on), as shown. Negative lead 114 of monitoring system 100
is preferably connected to vehicle ground 116, as shown. It should
be noted that monitoring system 100 is preferably designed to draw
such small amounts of electrical current (approximately 18 milliamps
when monitoring system 100 is operating) that monitoring system 100
can be connected to virtually any powered circuit point within host
vehicle 102, as shown.
Preferably, positive lead 112 and negative lead 114 are electrically
coupled to circuitry (at least embodying herein wherein such sampler
means comprises circuit means for electrically processing the at
least one operating voltage and further embodying herein sampler
means, electrically coupled to such continuous-accessor means, for
sampling the at least one operating voltage), internal to monitoring
system 100, that preferably samples and processes the voltage within
electrical system 106. Preferably, monitoring system 100 comprises
visual indicator 118 (at least embodying herein user-sensable-signalling
means, coupled to such output signal generator means, for providing
at least one user-sensable signal and further embodying herein,
wherein such user-sensable signalling means comprises a single
illumination source), most preferably light emitting diode (LED)
120, to alert a user of the status of electrical system 106, as
shown.
In preferred operation, monitoring system 100 indicates the status
of electrical system 106 by generating visually distinct flash
patterns at LED 120, each flash pattern corresponding to a specific
voltage condition within electrical system 106. In the preferred
embodiment of FIG. 1, monitoring system 100 preferably generates
four distinct flash patterns as described in connection with FIG. 2
below (at least embodying herein wherein such user-sensable
signalling means is adapted to provide at least four unique user-sensable
signals).
In reference to FIG. 2 and with continued reference to FIG. 1, FIG.
2 graphically illustrates the preferred operation of monitoring
system 100 and visual indicator 118 in response to the detected
voltage within electrical system 106. Preferably, LED 120 is
controlled by an internal micro-controller programmed to illuminate
LED 120 at a predetermined patterned rate based on the voltage
sample taken from electrical system 106. FIG. 2 summarizes preferred
programmed flash rates at LED 120 and corresponding sampled voltage
ranges for a single representative application (such as a
motorcycle). It should be noted that the monitoring system is
preferably highly customizable to a wide range of unique
applications and that the example voltage values noted within FIG. 2
are representative of only one of many possible application based
presets.
Preferably, LED 120 illuminates to produce a rapid series of easily
discernable flashes under LED fast flash condition 124. Preferably,
LED fast flash condition 124 indicates that electrical system 106 is
overcharging. Assume, for example, that under LED fast flash
condition 124, monitoring system 100 has detected a charging output
of 15 volts (nominal) or higher within electrical system 106. The
operator of host vehicle 102 may, based on this indication, reliably
predict that an excessive voltage condition exists that could damage
battery 108 within a short time.
Preferably, LED 120 in not illuminated during LED off condition 126.
Preferably, Under LED off condition 126, monitoring system 100 has
detected that the output of electrical system 106 is sufficient to
keep battery 106 charged. Preferably, LED off condition 126
indicates to the operator that electrical system 106 is functioning
within normal parameters.
Preferably, LED 120 illuminates in a slow repetition of easily
discernable flashes during LED slow flash condition 128. Preferably,
monitoring system 100 produces LED slow flash condition 128 on
detecting that battery 108 is not being charged completely. Under
this condition, monitoring system 100 has, for example, detected a
voltage between 12.25 V and 11.75 V (nominal). Preferably, by
observing LED slow flash condition 128, the operator of host vehicle
102 is alerted that electrical system 106 in not keeping up with
electrical load 110. This condition generally indicates that too
many current drawing electrical accessories are being operated at
once. In addition, this indication alerts the operator that host
vehicle 102 could contain a defective regulator or alternator 104.
Furthermore, on observing this indication, the operator will
reliably predict that, although battery 108 is not being completely
charged, battery 108 will generally restart the vehicle if the
condition has not persisted for an extended period.
Preferably, LED 120 is continuously illuminated during LED "on
steady" condition 130. Preferably, LED "on steady" condition 130
indicates that monitoring system 100 has detected that battery 108
is being severely undercharged. Under this condition, the voltage
sampled, for example, by monitoring system 100 has dropped below
11.75 V (nominal). A vehicle operator observing LED "on steady"
condition 130 is alerted that battery 108 is being rapidly
discharged and that battery 108 may not start the vehicle again.
Monitoring system 100 is also preferably adapted to provide an
indication of battery status when the engine and alternator 104 of
host vehicle 102 are not operating. In this mode, monitoring system
100 preferably indicates the status of battery 108. If battery 108
is fully charged, LED 120 will typically be off when the ignition
circuit is on (closed). After a short period, LED 120 may enter LED
slow flash condition 128 due to internal electrical drain on battery
108 imposed by operating components or shorts within electrical
system 106. LED slow flash condition 128 preferably indicates that
the voltage of battery 108 has dropped to 12.25 or below. If the LED
stays on without flashing that preferably indicates that battery
voltage is less than 11.75 volts indicating battery 108 may require
charging in order to start host vehicle 102.
FIG. 3 is a perspective view of monitoring system 100 according to a
preferred embodiment of the present invention. Preferably,
monitoring system 100 comprises circuit board 134, positive lead
112, negative lead 114, LED anode wire 138, LED cathode wire 140,
LED 120 and protective jacket 136, as shown. Preferably, the
component structure of monitoring system 100 is readily adaptable to
dual in-line package (DIP), shrink dual in-line package (SDIP), and
similar through-hole forms, as shown. The physical dimensions of
circuit board 134 are preferably compact to facilitate the
installation of monitoring system 100 within a wide range of vehicle
applications, both OEM and after-market. Preferably, circuit board
134 comprises an outer dimension of no more than about 3/4 inch by
13/4 inch, as shown. Preferably, positive lead 112, negative lead
114, LED anode wire 138 and LED cathode wire 140 each comprise a
single 22 gauge (AWG 22) stranded (7/30) conductor having a maximum
voltage capacity of 300 volts. Preferably, protective jacket 136
comprises heat shrink tubing and is applied over circuit board 134
to form a protective sleeve over the circuit assemblies, as shown.
Preferably, protective jacket 136 comprises a premium grade PVC. A
preferred example heat shrink tubing suitable for use as protective
jacket 136 is model FIT-221 produced by Alpha Wire Company of
Elizabeth, N.J., U.S.A. (www.alphawire.com).
FIG. 4 is a perspective view of monitoring system 100 with
protective jacket 136 removed to permit review of the general
assemblies of circuit board 134 according to the preferred
embodiment of FIG. 3. Preferably, circuit board 134 is composed of
FR4 glass epoxy having a preferred thickness of about 0.062'', and a
base copper weight of about 1/2 oz per square inch. Preferably,
circuit board 134 comprises two layers of copper circuit traces, one
on upper surface 142, and one on lower surface 144, as shown.
Preferably, all holes and vias within circuit board 134 are
through-plated. Preferably, to assist in the assembly and quality
control of monitoring system 100, upper surface 142 of circuit board
134 is preferably screen-printed with component designation indicia
146, as shown. Additionally, screen-printed indicia 148, comprising
such secondary information as off-board connections, part numbers,
company name and similar labeling are preferably applied to circuit
board 134, as shown. Preferably, the above-described screen-printing
is applied in a contrasting color, most preferably white.
Preferably, upper surface 142 and lower surface 144 are coated with
a green solder mask 150 that matches the color of circuit board 134,
as shown. Solder mask 150 preferably covers all surfaces of circuit
board 134 excepting locations where solder is to be applied. This
preferred application of solder mask 150 increases production
quality control by preventing solder splash that can cause short
circuits. In addition, the applicant has determined that use of
solder mask 150 increases the in-service reliability of monitoring
system 100 by reducing environmental deterioration of the copper
portions of circuit board 134 over time.
Preferably, positive lead 112, negative lead 114, LED anode wire 138
and LED cathode wire 140 each comprise UL Style 1007 wire having a
temperature range of -20 degrees C. to +105 degrees C. Preferably,
positive lead 112 is red in color. Preferably, negative lead 114 is
black. LED anode wire 138 is preferably white, and LED cathode wire
140 is preferably green.
Preferably, LED 120 comprises a T-5 mm case style, as shown.
Preferably, LED 120 is a "SUPER RED" producing light in the 660 nm
range. Preferably, LED 120 has an effective viewing angle of about
30 degrees. The epoxy lens finish of LED 120 is preferably "WATER
CLEAR". A preferred example LED suitable for use as LED 120 is part
SSL-LX5093SCR/X produced by Lumex Corporation of Palatine, Ill.,
U.S.A. (www.lumex.com).
In reference to FIG. 5, with continued reference to FIG. 1 through
FIG. 4, FIG. 5 is a schematic circuit diagram illustrating the
preferred arrangements of electronic componentry comprising
monitoring system 100, according to the preferred embodiment of FIG.
3.
Preferably, positive lead 112 on circuit board 134 is electrically
coupled to electrical system 106 of host vehicle 102 (as shown in
the block diagram of FIG. 1). On circuit board 134, sampled voltage
from positive lead 112 is passed to RF choke 152 (noted as L1), as
shown.
A number of vehicle applications (for example, some Harley Davidson
motorcycles) produce levels of RF energy sufficient to cause erratic
operation of monitoring system 100. Preferably, RF Choke 152 (at
least embodying herein at least one first filter adapted to filter
radio frequency energy from the at least one operating voltage) is
utilized to condition the incoming current to prevent radio
frequency energy produced by host vehicle 102 from entering
monitoring system 100, thereby reducing erratic operation related to
RF energy. RF choke 152 preferably comprises a 1-millihenry
miniature epoxy conformal-coated radio frequency choke. Preferably,
choke 152 has a Q of about 50 at 0.79 MHz and a preferred resonant
frequency of about 1.6 MHz. RF choke 152 preferably comprises an
average DC resistance of about 10 ohms and a maximum current
capacity of about 130 mA. A preferred example choke suitable for use
as RF choke 152 is the 434-23 series produced by Mouser Electronics
of Mansfield, Tex., U.S.A. (www.mouser.com).
Preferably, following RF choke 152 are two filter capacitors.
Preferably, first capacitor 154 (C1) is a 0.1 uF ceramic multilayer
capacitor rated at 50 volts and is a temperature coefficient type
Y5V, as shown. First capacitor 154 preferably functions to filter
the high frequency electrical noise on input circuit 151.
Second capacitor 156 (C2) is the second filter capacitor on input
circuit 151, as shown. Preferably, second capacitor 156 is a 220-uF
aluminum electrolytic capacitor with a 50 volt working range.
Preferably, second capacitor 156 has a rated temperature range of
about -25 degrees C. to +85 degrees C. Second capacitor 156
preferably functions to filter the low frequency electrical noise
from input circuit 151. It should be noted that, in most cases, a
10-microfarad capacitor is acceptable as an input filter capacitor;
however, because monitoring system 100 typically operates in a harsh
electrical environment (for example, within a motor vehicle), it is
often necessary to increase the capacity of the capacitor to 220
microfarads to properly filter the sampled voltage. Preferred
example capacitors suitable for use as first capacitor 154 and
second capacitor 156 are the Mono-Kap series capacitors produced by
Vishay Intertechnology, Inc. of Malvern, Pa., U.S.A. and Aluminum
Electrolytic Capacitors Series M type A produced by Panasonic U.S.A.
(www.panasonic.com).
After being filtered, the samples voltage is applied to five-volt
voltage-regulator 158 (S1), as shown. Preferably, voltage-regulator
158 is a three terminal, fixed voltage, integrated circuit, as
shown. Preferably, voltage-regulator 158 has an operating
temperature range of 0 degrees C. to +70 degrees C. and can deliver
100 mA of output current. Preferably, voltage-regulator 158 has an
output voltage tolerance of about plus or minus 3%. Preferred
example voltage-regulators suitable for use as voltage-regulator 158
are the LM140L/LM340L series regulators produced by National
Semiconductor Corporation of Santa Clara, Calif., U.S.A.
(www.national.com). Preferably, voltage-regulator 158 provides the
proper operating voltage to micro-controller 160 (U1), and precision
voltage-reference 162 (D1), as shown.
Preferably, circuit board 134 is arranged such that all power,
ground, and signal leads are very short, to limit electrical noise
and spurious emissions. It should be noted that the preferred layout
of circuit board 134 preferably locates micro-controller 160 very
close to voltage-regulator 158, thereby permitting the use a single
0.1 microfarad bypass third capacitor 164 (C3), as shown.
Preferably, third capacitor 164 is identical to first capacitor 154
and is preferably adapted to bypass unwanted electrical noise to
ground. Upon reading the teachings of this specification, those with
ordinary skill in the art will now understand that, under
appropriate circumstances, considering such issues as specific
vehicle application and availability of materials, other less
compact circuit board layouts (thereby requiring two bypass
capacitors, one for the voltage-regulator, and one for the
micro-controller), etc., may suffice.
Preferably, micro-controller 160 comprises an on-board
analog-to-digital ("A/D") converter, as shown. Preferably,
micro-controller 160 comprises an 8-pin flash-based 8-bit CMOS
microcontroller model PIC12F629/675 as produced by Microchip
Technology Inc. of Chandler, Ariz., U.S.A. In order to operate, A/D
converter 166 (at least embodying herein sample-voltage valuer
means, electrically coupled to such sampler means, for providing at
least one sampled voltage value for the at least one operating
voltage) requires at least one voltage reference source. This
voltage-reference is the preferred comparison point from which all
of the A/D conversions are made. Further discussion on the operation
of A/D converter 166 will be presented in connection with FIG. 6.
Two sources of voltage-reference are available to micro-controller
160. The first voltage-reference source is internal, typically
comprising the voltage supplied to micro-controller 160. Within
alternate embodiments, this reference voltage may be supplied by
voltage-regulator 158. The second and preferred voltage reference
source is an externally developed voltage-reference, as described
below.
Upon reading the teachings of this specification, those with
ordinary skill in the art will now understand that, under
appropriate circumstances, considering such issues as availability
of highly accurate voltage regulators, etc., other component
arrangements, such as the use of an internal voltage reference
arrangement to supply the A/D converter, etc., may suffice.
Preferably, all resistors used within monitoring system 100 comprise
1/4 watt, 1% tolerance metal film resistors, as shown. Fifth
resistor 170 (R5) preferably comprises a 2000-ohm resistor, as
shown. Preferably, fifth resistor 170 is electrically coupled to
voltage-regulator 158 to provide current for the operation of
precision voltage reference 162, as shown. Preferred example
resistors suitable for use in the present embodiment the MFR series
metal film resistors produced by Yageo Corporation of Plano Tex.,
U.S.A. (www.yageo.com).
Preferably, precision voltage reference 162 is a precision
micropower shunt voltage-reference. A preferred example precision
voltage reference voltage-regulator suitable for use as precision
voltage reference 162 is the model LM4040 precision voltage
reference produced by National Semiconductor Corporation of Santa
Clara, Calif., U.S.A. (www.national.com).
Preferably, precision voltage reference 162 produces an output of
about 4.096 volts at the junction of precision voltage reference 162
and fifth resistor 170, as shown. Selecting a preferred standard
voltage reference of 4.096 volts permits the use of the regulated
5-volts as the supply to precision voltage reference 162, as shown.
Using precision voltage reference 162 as the preferred external
reference, the overall tolerance of the monitoring system 100 is
approximately 0.04 volts (four hundredths of a volt).
In reading the teachings of the following disclosure, it is helpful
to recall that there are essentially two conditional states within a
digital processor. These two states are preferably identified by
several names: logical high and logical low; true and false; yes and
no; +5 volts and 0 volts. In general, the functioning of digital
devices requires all programming and data to be reduced to this
binary format.
Preferably, fourth resister 172 (R4) is a 10,000-ohm resistor, as
shown. Fourth resister 172 preferably provides a logical high of
about +5 volts to an unused general-purpose input/output pin 174
(GP2) and external micro-controller reset pin 176 (MCLR) located on
micro-controller 160, as shown. The preferred action of forcing an
input pin into a logical low (zero volts) or logical high (+5 volt)
condition ensures stable operation of micro-controller 160. The
preferred forcing of MCLR 176 to a logical high condition prevents
micro-controller 160 from resetting due to random electrical noise.
Preferably, the voltage applied to the input of A/D converter 166
must not exceed the reference voltage that is developed from
precision voltage reference 162 (4.096 volts). Given that the
voltage to be sampled from electrical system 106 of host vehicle 102
can vary from a low of 8 or 9 volts to well over 15 volts, it is
necessary to scale the sampled voltage to a level that is compatible
with micro-controller 160. Preferably, second resistor 178 (R2) and
third resistor 180 (R3) are functionally arranged to scale the
sampled voltage to a useable level, as shown. Preferably, second
resistor 178 is electrically coupled to the battery positive input
signal after it has been filtered by first capacitor 154 and second
capacitor 156, as shown. Preferably, second resistor 178 is a
4020-ohm resistor with a 1% tolerance. Preferably, third resistor
180 is a 1000-ohm resistor also with a 1% tolerance. Together,
second resistor 178 and third resistor 180 forms a voltage divider
that scales the vehicle voltage down by a factor of approximately
five. Preferably, the scaled voltage (herein after referred to as
VREF) taken from the junction of second resistor 178 and third
resistor 180 is applied to the A/D input pin 182 (AN3) located on
micro-controller 160, as shown.
FIG. 6 generally illustrates the steps of programming
micro-controller 160 for use within monitoring system 100.
Preferably, micro-controller 160 comprises an eight-pin,
flash-based, 8-bit CMOS micro-controller in a PDIP package.
Preferably, micro-controller 160 comprises an 8-pin flash-based
8-bit CMOS microcontroller model PIC12F629/675 as produced by
Microchip Technology Inc. of Chandler, Ariz., U.S.A. Preferably, use
of a flash based micro-controller permits micro-controller 160 to be
reprogrammed repeatedly instead of only once as with a non-flash
unit (those skilled in the art will understand the term "Flash" to
mean that the memory portion of the device is of an EEPROM type).
This preferred feature allows for custom reprogramming of
micro-controller 160 as may be required for specific vehicle
applications. Preferably, micro-controller 160 contains an internal
four MHz oscillator that permits micro-controller 160 to process
program instructions at the speed of 4 MHz without the need for an
external oscillator. In addition, micro-controller 160 preferably
comprises A/D converter 166 as previously described in FIG. 5.
Preferably, micro-controller has six input/output pins, as shown.
Preferably, micro-controller 160 is capable of directly supplying
electrical current to operate LED 120, as illustrated in FIG. 5.
Programming micro-controller 160 to function as desired requires
several steps. Preferably, first step 184 comprises coding software
control program 190, as shown. Second step 186 preferably comprises
compiling and testing control program 190. Third step 188 preferably
comprises transferring the compiled version of control program 190
into micro-controller 160, as shown.
The preferred computer language used to develop control program 190
is a subset of the C language called PICC that is designed
specifically for the Microchip.RTM. series of micro-controllers.
Versions of the PICC software are available for a number of computer
platforms including Microsoft Windows.RTM. based PCs. After control
program 190 is written, it is preferably compiled with the PICC
compiler, as shown. Preferably, the compiler converts control
program 190, written in the PICC language, to the binary code that
operates the micro-controller.
Once control program 190 is compiled into a binary file, it is
preferably transferred to Device Programmer 192 (also known as a
PROM burner or Prom Programmer). Preferably, PROM programmer 192
comprises a unit comparable in specification to a Microchip Pro Mate
II Device Programmer with an AC124001 programmer socket installed.
To write the compiled version of control program 190 to the chip,
microcontroller 160 is mounted in PROM programmer 192 and a command
is given for PROM programmer 192 to write the file to the chip.
Preferably, PROM programmer 192 erases any previous program that may
already be in micro-controller 160 and then writes the new file to
the chip. Preferably, PROM programmer 192 then verifies that the
program was successfully written to micro-controller 160. On
completion of the write procedure, micro-controller is ready for use
within monitoring system 100.
In reference to FIG. 7, with continued reference to the circuit
diagram of FIG. 5, FIG. 7 is a simplified flow diagram illustrating
the preferred sequence of programmed steps coded within control
program 190, according to a preferred embodiment of the present
invention. Preferably, control program 190 is written in such a way
as to instruct micro-controller 160 to compare a sampled A/D output,
temporarily held by micro-controller 160, (at least embodying herein
sampled-voltage-value storage means, electrically coupled to such
sampler means, for storing the at least one sampled voltage value)
against predetermined voltage values stored in memory (at least
embodying herein benchmark memory storage means for storing a
plurality of programmable benchmark voltage values for the at least
one operating voltage) and to flash LED 120 in a defined pattern
based on the determined value of the sampled input voltage.
Preferably, the first step executed within control program 190 is
variable definition step 200 that defines all global variables
subsequently used by control program 190, as shown. Port
initialization step 202 preferably initializes the ports and
peripherals of micro-controller 160, as shown. The ports are the
input and output connections on micro-controller 160. These ports
can be used to either send or receive binary information as
determined by the software. The peripherals are on-chip hardware
functions built into micro-controller 160 (e.g., A/D converter 166).
Within the present preferred embodiment, I/O (input/output) ports 1,
2, 3, and 4 are preferably set as inputs. Preferably, ports 0, 5,
and 6 of micro-controller 160 are set as outputs. Preferably, next,
A/D converter 166 is configured via two program commands in A/D
configuration step 204, as shown.
The preferred procedure to turn on LED 120 is generally described in
the following steps. Five volts is applied to first resistor 194
(R1) (see FIG. 5), which preferably comprises a 255-ohm 1% tolerance
1/4-watt resistor, as shown. Preferably, the opposite end of first
resistor 194 is connected to the anode of LED 120, as shown. The
cathode of the LED 120 is preferably connected to output port 196
(GP5) (see FIG. 5) on micro-controller 160, as shown. To turn LED
120 on, a logical low is preferably written to output port 196. This
essentially connects output port 196 to ground thereby completing
the circuit from first resistor 194 through LED 120 through output
port 196 to ground. To turn the LED 120 off, a logical high is
preferably written to output port 196. This action opens the circuit
ground and LED 120 is turned off.
On completion of A/D configuration step 204, LED 120 is flashed in a
short sequence by start-up flash sequence step 206, as shown (the
applicant preferably chose to flash the word "hi" in Morse code).
Start-up flash sequence step 206 is designed to alert the user to
the fact that the unit is on and operating properly.
Preferably, the analog voltage applied to the input of A/D converter
166 is converted to a digital representation by A/D converter 166.
A/D converter 166 on micro-controller 160 preferably comprises a
10-bit A/D converter. Recalling from the previous discussion that in
a binary representation, there are two states, 0 or 1. Consequently,
each data bit can have 2 possible combinations (0 or 1). Ten bits
together have two to the tenth power possible combinations (or 1024
in decimal).
The scaled vehicle voltage applied to the input of A/D converter 166
preferably comprises a maximum of 4 volts. The input maximum voltage
(4) divided by the number of possible A/D combinations (1024)
results in approximately 0.003876 volts per step. That number
multiplied by the scale factor (5) provides the actual vehicle volts
per step (in the present example, the ratio is about 0.01938 volts
per step). It is therefore understood that the digital count
approximately equals the vehicle volts divided by 0.01938 (for
example, 12 volts divided by 0.01938 equals 619.2). In actual use,
the 10-bit number is preferably converted to an 8-bit number. The
resulting value for the present example is therefore 154 (i.e., the
range and reading are 1/4.sup.th as large in 8-bit as in 10-bit).
Preferably converting to an 8-bit number permits the use of 8 bit
arithmetic that processes faster on micro-controller 160 than the
equivalent 10 bit numbers.
On completion of flash sequence step 206, control program 190
immediately enters an endless loop, comprising the main body of the
program. Preferably, on execution of voltage sample step 208, a
command is sent to A/D converter 166 to sample the voltage on the
A/D input pin, as shown. Preferably, next, A/D converter 166
converts the sample voltage to an equivalent binary value in A/D
conversion step 211, as shown (at least embodying herein
sampled-voltage indicator means for providing at least one
indication of the at least one sampled voltage value). Preferably,
in voltage comparison step 209 (at least embodying herein comparator
means for comparing the at least one indication of the at least one
sampled voltage value with at least one of the plurality of
programmable benchmark voltage values), the binary A/D result is
compared to a stored group of preset binary voltage values (numbers)
that define the benchmark points for determining when monitoring
system 100 should enter a specific LED flash condition and LED
control subroutine(s) 207 (at least embodying herein user-sensable
signalling device controller means, electrically coupled with such
output signaller means, for controlling at least one user-sensable
signalling device).
For example, if the result of voltage comparison step 209 is above
the preset over charge value (i.e. the LED fast flash condition 124
of FIG. 2), control program 190 preferably initiates fast flash
subroutine 210, as shown. Preferably, fast flash subroutine 210
first writes a command to the LED control port that turns LED 120 on
(at least embodying herein output signal generator means for
generating at least one output signal from such comparator means).
The program then preferably enters a delay loop that maintains LED
120 on for a short period. Preferably, when the delay loop finishes,
a command is written to the LED control port to turn the LED 120
off. Another delay loop is preferably entered to ensure that the LED
will remain off for an appropriate period.
Preferably, if the A/D result is between the preset normal range
values, LED off subroutine 212 is initiated, causing a command to be
written to the LED control port to turn the LED off, as shown.
If the A/D result is between the preset partial under charge values
(i.e. the LED slow flash condition 128 of FIG. 2), control program
190 preferably initiates slow flash subroutine 214, as shown.
Preferably, slow flash subroutine 214 comprises subroutine code
similar to fast flash subroutine 210; however, the delay loops
within slow flash subroutine 214 preferably comprise different
timing so that LED 120 will flash slowly.
If the A/D result is below the preset severe under charge values,
LED steady on subroutine 216 is preferably initiated and a command
is written to the LED control port to turn LED 120 on. After these
four actions have completed, the main loop preferably repeats, as
shown. Subsequently, a new A/D conversion is commanded and the
comparisons preferably repeated. Preferably, the program continues
to loop until power is removed from micro-controller 160 (at least
embodying herein logic-processor means).
FIG. 8 shows a top view of upper surface 142 of monitoring system
100 illustrating the preferred configuration of the commercial
embodiment of circuit board 134 according to the preferred
embodiment of FIG. 4. FIG. 9 is a view of lower surface 144 of
monitoring system 100 illustrating the preferred configuration of
the circuit board according to the preferred embodiment of FIG. 8.
Assembly of monitoring system 100 preferably begins with preparation
of positive lead 112, negative lead 114, LED anode wire 138, and LED
cathode wire 140. Preferably, one each of a red wire (positive lead
112), black wire (negative lead 114), green wire (LED cathode wire
140), and white wire (LED anode wire 138) is cut to a length of
about 9''. Preferably, the wire insulation is stripped, preferably
about 1/4 inch from each wire end, as shown. Preferably, using
well-known means, the stripped wire ends are tinned with low residue
flux solder that adheres to the IPC ANSI/J-STD-006-A standard
(preferably used throughout the assembly). Preferably, one end of
LED cathode wire 140 is soldered to the cathode terminal of LED 120
at a distance of about 1/4 inch from LED 120, as shown. Preferably,
LED anode wire 138 is similarly soldered to the anode lead of LED
120, as shown. Preferably, the leads to LED 120 protruding beyond
the solder joint are cut and removed, using means well known to
those skilled in the art. Preferably, heat shrink tubing 220 (
3/32'' diameter by 1/2 '' long) is placed over the solder
connections and heated at a temperature of approximately 120 degrees
C. Preferably, heat shrink tubing 220 comprises a shrink ratio of 2
to 1, operating temperature of 55 degrees to 135 degrees C., tensile
strength of about 1500 psi, longitudinal shrinkage of -5% and
dielectric strength of 500 V/mil. Additionally heat shrink tubing
220 preferably passes UL Standard 224 and CSA Standard 198.
The next step in assembly of monitoring system 100 comprises
assembling the various components of circuit board 134. Most
components are preferably placed on upper surface 142 (component
side) of circuit board 134, as shown. Preferably, component leads
are formed to extend through mounting hole(s) 132 of circuit board
134, as shown.
It is noted that the circuit trace on lower surface 144 (solder
layer) between positive lead 112 (J4) and second capacitor 156 is
discontinuous (as a result of the preferred RF filter addition), as
shown. Preferably, RF choke 152 is placed on lower surface 144 of
circuit board 134 with leads extending up through holes for positive
lead 112 (J4) and first capacitor 154, as shown. Preferably, RF
choke 152 is soldered when positive lead 112 (J4) and first
capacitor 154 is soldered. Preferably, the resistors are then placed
on circuit board 134 in their respective positions, as shown.
Preferably, the resistor leads are soldered on lower surface 144
(solder layer) of circuit board 134, as shown. Excess lead lengths
are preferably cut off using well-known means. Preferably, fifth
resistor 170 is placed on lower surface 144 with one lead placed
through the hole for third capacitor 164, closest to pin 1 of
micro-controller 160. Preferably, the second lead of fifth resistor
170 is formed at a right angle and is connected to pin 6 of
micro-controller 160, as shown. Preferably, the third pin (no
connect) of precision voltage reference 162 is removed, as shown.
Preferably, precision voltage reference 162 is placed on lower
surface 144 of circuit board 134, as shown. Preferably, the anode
lead of precision voltage reference 162 is inserted through the
other hole for third capacitor 164, as shown. Preferably, the
cathode lead of precision voltage reference 162 is formed around the
lead of fifth resistor 170 that connects to pin 6 of
micro-controller 160, as shown. Excess lead lengths are preferably
cut off, as shown.
Preferably, micro-controller 160 (U1) is now placed on circuit board
134, as shown. Preferably, each of the eight pins of
micro-controller 160 is soldered to circuit board 134, as shown.
Preferably, first capacitor 154 and third capacitor 164 are then
placed on circuit board 134 and soldered. Next, voltage regulator
158 is inserted and soldered, as shown. After voltage regulator 158
is in place, second capacitor 156 is placed and soldered. Lastly,
the red, black, green and white wires are inserted through their
respective holes on the board. Preferably, positive lead 112 is
soldered to jumper J4, negative lead 114 to jumper J5, LED cathode
wire 140 to jumper J2, LED anode wire 138 to jumper J3, as shown.
Preferably, all wire leads are soldered on lower surface 144 of
circuit board 134, as shown. Throughout the assembly process, excess
lead lengths of the wires and components are preferably removed.
The next preferred step is to apply acrylic lacquer conformal
coating 230 to circuit board 134. Acrylic lacquer conformal coating
230 protects the assembly from moisture and static electricity.
Preferably, conformal coating 230 comprises 419B-340G aerosol
produced by MG Chemicals. (www.mgchemicals.com). In addition,
acrylic lacquer conformal coating 230 provides a preferred chemical
and abrasion resistance. Preferably, three coats of acrylic lacquer
conformal coating 230 are applied to circuit board 134 to obtain
optimal protection. Preferably, the coating on circuit board 134 is
permitted to cure for about 24 hours. The final preferred assembly
step is to place a segment of 11/2'' diameter by 13/4'' long
heat-shrink tubing over the assembled circuit board 134. Heat-shrink
tubing 232 forms a preferred protective sleeve over the assembled
circuit board 134 (as illustrated in FIG. 3). Preferably,
heat-shrink tubing 232 is essentially identical in specification to
heat-shrink tubing 220 described above. Preferably, circuit board
mounting hole 234 is left exposed, as shown.
FIG. 10a shows a schematic diagram of monitoring system 100,
comprising surface mounted components, according to an alternate
preferred embodiment of the present invention. FIG. 10b shows a top
view of surface mount board 350 used to assemble the monitoring
system 100 of FIG. 10a. FIG. 10c shows a bottom view of surface
mount board 350 of FIG. 10b. Preferably, as illustrated in FIG. 10a,
FIG. 10b, and FIG. 10c monitoring system 100 is adaptable to utilize
alternate preferred component packaging including; Surface-Mount
Technology (SMT), Surface Mount Device (Philips SMD), or Surface
Mount Component (SMC) packaging, as shown. Although functionally
identical, SMCs are much smaller than through-hole type components
and therefore permit the development circuit boards having a smaller
size than an equivalent through-hole design. By utilizing surface
mounted components, the production of a monitoring device embodiment
comprising a relatively compact board size is possible, as shown.
Preferably, the component relationships of surface mount board 350
are essentially identical to those described for the through-hole
component embodiment of FIG. 5.
The following table provides a listing of equivalent surface mounted
components used in the fabrication of surface mount board 350:
TABLE-US-00001 Part Part No. Description Manufacturer C1 (154)
PCC1828TR-ND 0.1 UF CERAMIC PANASONIC C3 (164) R4 (172)
311-10.0KFTR-ND 10K 1% 1/8 W YAGEO R6 R1 (194) 311-255FTR-ND 255 1%
1/4 W YAGEO R3 (180) 311-1.00KFTR-ND 1.0K 1% 1/8 W YAGEO R7 R5 (170)
311-2.00KFTR-ND 2.0K 1% 1/8 W YAGEO R2 (178) 311-4.02KFTR-ND 4.02K
1% 1/8 W YAGEO U1 (160) PIC12F675-I/SN-ND MICROCONTROLLER MICROCHIP
TECH. C2 (156) 647-UWT1V221MN1RGS 220 UF 25 V NICHICON S1 (158)
296-11118-2-ND UA78L05 TEXAS INSTRUMENTS L1 (152) 445-1198-1-ND 1 MH
130 MA CHOKE TDK D1 (162) LM4040CIM3-4.1-ND 4.1 V PRECISION NATIONAL
REFERENCE SEMICONDUCTOR
In addition, surface mount board 350 (at least embodying herein at
least one circuit-supporting substrate) preferably comprises
edge-connector 352 located along a peripheral edge (at least
embodying herein wherein such at least one circuit-supporting
substrate comprises at least one peripheral edge; and such at least
one peripheral edge comprises at least one electrical edge-coupler).
The preferred arrangement of edge connector 352 is best illustrated
in FIG. 10a and FIG. 10b. Preferably, edge connector 352 permits
monitoring system 100 to be plugged into a test/programming fixture
for programming (or repeated reprogramming). Preferably, edge
connector 352 comprises six conductive contacts 345 located on upper
surface 346 and six conductive contacts located on lower surface
347, as shown. Preferably, conductive contacts 345 are electrically
coupled, as shown, to the various electronic components of surface
mount board 350 (at least embodying herein wherein such at least one
edge connector comprises at least one electrically conductive
contact electrically coupled to such at least one circuit). The
preferred use of edge connector 352 permits monitoring system 100 to
be programmed (or reprogrammed) to customer specifications without
component replacement. Preferably, the use of edge-connector 352
permits a single board design to monitor the electrical systems of a
wide range of vehicle applications, each having unique monitoring
requirements. Further, the preferred use of edge-connector 352
permits all components (including microcontroller) to be
pre-assembled on board at time of manufacture, thereby greatly
reducing the cost of production. Edge connector 352 (at least
embodying herein at least one removably engageable electrical
coupling between such at least one circuit and at least one other
circuit of at least one other device) is preferably adapted to
provide direct programming access to micro-controller 160, as shown.
Customization of the operating parameters of monitoring system 100
is therefore possible at any time after component assembly. In
addition, each unit can be reprogrammed innumerable times. In some
preferred vehicle applications, edge connector 352 can be utilized
to couple monitoring system 100 to the vehicle electrical system to
be monitored (at least embodying herein at least one removably
engageable electrical coupling between such at least one circuit and
at least one other circuit of at least one other device, wherein
such at least one other device comprises the at least one vehicular
electrical charging system)
FIG. 11 shows a perspective view illustrating plug-in monitoring
system 101, comprising a vehicular accessory plug-style housing,
according to an alternate preferred embodiment of the present
invention. Preferably, plug-in monitoring system 101 (at least
embodying herein wherein such at least one continuous-accessor
comprises at least one vehicular accessory power socket adapter to
electrically engage at least one vehicular accessory power socket)
comprises an essentially cylindrical housing 252 designed to contain
circuit board 134 and engage within a standard accessory power
socket 240 of host vehicle 102, as shown. A typical accessory power
socket 240 (illustrated using dashed lines) consists of a hollow,
cylindrically-shaped, grounded contact 242 and a positive supply
contact 244, as shown. Preferably, socket-engaging portion 246 of
cylindrical housing 252 is adapted such that, when engaged within
accessory power socket 240, negative ground terminal(s) 248 contacts
and forms an electrical connection with grounded contact 242, as
shown. Similarly, positive terminal 250 contacts and forms an
electrical connection with positive supply contact 244, as shown.
Negative ground terminal(s) 248 are preferably constructed from a
resilient spring steel to assist in maintaining an electrical
connection with grounded contact 242, as well as to firmly retain
socket-engaging portion 246, by friction, within accessory power
socket 240, as shown. Plug-in monitoring system 101 has a preferred
overall length of about 4'', as shown. Preferably, Plug-in
monitoring system 101 has a maximum outer diameter designed to allow
for smooth insertion and frictional retention within accessory power
socket 240 (a standard 12-volt vehicular accessory power socket
typically has an interior diameter of about 3/4). Upon reading this
specification it will be understood by those of skill in the art
that, under appropriate circumstances, such as international power
socket standards, other applications, etc., other shapes and
diameters, such as 1/2-inch, 10-millimeter, rectangular, etc., may
suffice. LED 120 is preferably located to be clearly visible to the
operator of the vehicle while Plug-in monitoring system 101 is
engaged within accessory power socket 240, as shown.
FIG. 12 shows a perspective view illustrating a preferred consumer
kit 260 for the commercial distribution of monitoring system 100,
according to another preferred embodiment of the present invention.
Preferably, the following table lists the items that are preferably
included in consumer kit 260:
TABLE-US-00002 Quantity Description 1 each Monitoring system 100 1
each LED socket 262a with retaining ring 262b 2 each Ring connector
264 (preferably, 16 22ga #6 with vinyl insulating sleeve) 2 each
Butt connector 266 (preferably, 16 22ga with vinyl insulating
sleeve) 2 each Standard 4'' black plastic zip cable tie 268 1 each
Installation and operating instructions 270
Preferably, consumer kit 260 is assembled by placing the above
listed items in consumer packaging, preferably comprising a
4''.times.6'' reclosable 2-mil poly bag 272, and printed closure
card 274, as shown. Preferably, closure card 274 comprises suitable
product identifying indicia 276, as shown. Upon reading the
teachings of this specification, those with ordinary skill in the
art will now understand that, under appropriate circumstances,
considering such issues as commercial demand, sales trends, and
diversification of product lines, other monitoring system kits,
etc., other monitoring system kits, such as a kit containing a
plug-in monitor-type system, instructions and packaging, etc., may
suffice.
FIG. 13 shows a diagram illustrating edge connector 352 of
monitoring system 100, coupled to test/programming fixture 354, in
preparation of component testing and programming of surface mount
board 350, according to a preferred embodiment of the present
invention. The preferred use of edge connector 352 takes beneficial
advantage of the data storage feature built into microcontroller
160. Preferably, microcontroller 160 comprises at least one integral
EEPROM cell. Typically, information (data) written to this cell
remains resident even after power is removed from the unit.
Preferably, monitoring system 100 is adapted to access and utilize
this information during operation.
Because of component manufacturing tolerances, most electronic
components comprise inherent variations in operational performance.
For example, a 10,000-ohm resistor with a 1% tolerance (the closest
tolerance generally available) can have an actual value of 9900 to
10100 ohms. With a critical circuit, requiring a 10,000-ohm
resistor, this tolerance can be excessive. Because most circuits
comprise multiple components, the sum of each component tolerance
can, together, result in an actual performance varying widely from
the designers target performance.
Preferably, monitoring system 100 overcomes these inaccuracies
through the use of a novel component calibration method using
test/programming fixture 354 (at least embodying herein at least one
calibration tester adapted to perform at least one calibration test
to measure actual performance of at least one monitoring function of
such monitoring system, and at least embodying herein at least one
programmer adapted to program such at least one logic-processor).
Preferably, monitoring system 100 utilizes calibration hardware and
software to test the actual performance of the components of the
circuit board. Preferably, the calibration program tests the
operating parameters of the particular circuit board components and
writes calibration data to the EEPROM cell of micro-controller 160
(at least embodying herein wherein such at least one calibration
tester is adapted to produce calibration test data on performing the
at least one calibration test). Preferably, this information remains
with monitoring system 100 indefinitely unless erased. Preferably, a
standard operating program is then loaded into micro-controller 160.
The operating program then accesses the calibration data stored in
the EEPROM cell and uses it to correct accuracy discrepancies caused
by manufacturing/component tolerances. Preferred calibration methods
of the present invention are described in greater detail in FIG. 15.
Preferably, test/programming fixture 354 comprises both hardware and
software components, as shown. Preferably, hardware components of
test/programming fixture 354 include; fixture circuit board 356,
programming device 358 and personal computer (hereinafter referred
to as PC 360), as shown. Software components of test/programming
fixture 354 preferably include at least one program, preferably
operating on PC 360.
FIG. 14a shows a first portion of a schematic diagram illustrating
the circuit arrangements of test/programming fixture 354 according
to FIG. 13. FIG. 14b shows a second portion of a schematic diagram
illustrating the circuit arrangements of test/programming fixture
354 according to FIG. 14a. Referring to FIG. 13, FIG. 14a and FIG.
14b, preferably, test/programming fixture 354 receives 24 VDC from
modular power supply 362 preferably located externally of fixture
circuit board 356 (of test/programming fixture 354), as shown.
Preferably, 24 VDC power from modular power supply 362 feeds
regulated 5 VDC supply 364 and variable voltage supply 366 located
on fixture circuit board 356. Preferably, the voltage generated by 5
VDC supply 364 is used to power the various integrated circuits on
fixture circuit board 356, as shown. Preferably, variable voltage
supply 366 is used during the calibration and testing procedures.
Preferably, variable voltage supply 366 comprises a plurality of
digital potentiometers 368, as shown. Preferably, variable voltage
supply 366 comprises 22 digital potentiometers identified on FIG.
14a as U5 through U25, as shown. Preferably, U5 and U6 comprise
10,000-ohm digital potentiometers electrically coupled in parallel,
as shown. Preferably, U5 and U6, when coupled, comprise a combined
value essentially approximating a single 5,000-ohm potentiometer.
Preferably, U5 and U6 set the coarse voltage level. Preferably, U4
and U7 through U25 comprise 1,000-ohm digital potentiometers.
Preferably, U4 and U7 through U25 are electrically coupled in
parallel, as shown. Preferably, the electrically coupled parallel
combination of U4 and U7 through U25 approximates a single 50-ohm
potentiometer. The coupled arrangement of U4 and U7 through U25
preferably set the fine voltage level.
Preferably, relays K1 through K7 (as best illustrated in FIG. 14b)
perform signal switching on fixture circuit board 356 as described
below.
Preferably, test/programming fixture 354 comprises an embedded
fixture microcontroller 396 (U26), as best shown in FIG. 14b.
Preferably fixture microcontroller 396 comprises a 40-pin, 4 MHz, 8
kB, standard-flash Microcontroller with A/D converter, preferably
model PIC16F877-04/P-ND as produced by Microchip Technology Inc. of
Chandler, Ariz., U.S.A. Preferably, the circuiting of fixture
microcontroller 396 is adapted to control the digital potentiometers
and relays of test/programming fixture 354, as shown. Preferably,
fixture microcontroller 396 communicates with PC 360 by means of
serial port 370 connected to jumper J1, as shown. Preferably,
transceiver device U2 functions as an RS-232 communication
interface, supporting serial communication operations between
test/programming fixture 354 and PC 360, as shown.
Preferred components used in the fabrication of fixture circuit
board 356 of test/programming fixture 354 are summarized in the
following table:
TABLE-US-00003 Qty References Value Stock No. Source 27 C1, C2, C3,
C4, C5, C6, C16, 0.1 UF 50 V BC1127CT-ND BC Components C17, C18,
C19, C20, C21, Digi-Key C22, C23, C24, C25, C26, C27, C28, C29, C30,
C31, C32, C33, C34, C35, C36 4 C10, C11, C12, C13 0.47 UF 50 V
493-1098-ND Nichicon/ Digi-Key 1 R8 1.0K 1% 1.00KXBK-ND Digi-Key 1
C7 1.0 UF 50 V P5174-ND Panasonic/ Digi-Key 1 R2 1.21K 1.21KXBK-ND
Digi-Key 8 R3, R9, R10, R11, R13, R14, 10K 10.0KXBK-ND Digi-Key R15,
R16 2 C8, C9 10 UF 50 V P5178-ND Panasonic 1 U26 (fixture 16F877
PIC16F877- Microchip/ microcontroller 396) 04/P-ND Digi-Key 1 D1
1N4007 1N4007DICT-ND Diodes Inc. 7 D2, D3, D4, D5, D6, D7, D8 1N4148
1N4148DICT-ND Diodes Inc. 4 J2, J3, J7, J8 2 Pin A1921-ND Digi-Key 1
R6 2.0K 1% 2.00KXBK-ND Digi-Key 1 R7 2.1K 1% 2.10KXBK-ND Digi-Key 2
C14, C15 22 PF 50 V BC1005CT-ND BC Components 1 R1 243 243XBK-ND
Digi-Key 1 R12 255 255XBK-ND Digi-Key 2 Q1, Q2 2N2222A P2N2222AOS-ND
Digi-Key 1 Y1 4.9152 MHZ CTX050-ND CTS/Digi-Key 2 R4, R5 499 1%
499XBK-ND Digi-Key 1 D9 5.0 VREF LM4040AIZ- National 5.0-ND
Semiconductor/ Digi-Key 1 U3 7805 LM7805CT-ND Fairchild
Semiconductor 1 J4 CONN05 A19471-ND Digi-Key 2 J5, J6 CONN09
A19473-ND Digi-Key 1 U1 LM317 LM317AT-ND National Semiconductor/
Digi-Key 1 U2 MAX202 MAX202CPE-ND Maxim/ Digi-Key 1 D10 Red LED
160-1127-ND Digi-Key 7 K1, K2, K3, K4, K5, K6, K7 SPDT 306-1018-ND
Coto Technology/ Digi-Key 1 J1 To DB9 A19470-ND Digi-Key 20 U4, U7,
U8, U9, U10, U11, X9C102P 1K X9C102P-ND Xicor/ U12, U13, U14, U15,
U16, Digi-Key U17, U18, U19, U20, U21, U22, U23, U24, U25 2 U5, U6
X9C103P 10K X9C103P-ND Xicor/ Digi-Key
FIG. 15 shows a diagrammatic overview of the preferred procedures
employed when programming/calibrating monitoring system 100
according to preferred methods of the present invention. Preferably,
calibration program 372 is loaded into monitoring system 100 as
shown in step 375. Preferably, a known voltage is then applied to
the voltage sensing connection of monitoring system 100 as indicated
in step 377. Preferably, monitoring system 100 reads the applied
voltage and converts it to a digital representation as indicated in
step 379. Preferably, calibration program 372, while running on
monitoring system 100, stores the digital representation of the
known voltage value (hereinafter referred to as calibration data
374) to the EEPROM cell on micro-controller 160 as indicated in step
381. Preferably, steps 377 through 381 are repeated two additional
times (one for each remaining voltage level/cut-point that will
preferably trigger a specified LED flash pattern), as indicated in
step 383.
On completion of step 383, calibration program 100 is erased from
monitoring system 100 leaving calibration data 372 intact within the
EEPROM cell as indicated in step 385. Preferably, the on-board
monitoring program (hereinafter referred to as monitoring program
386) is then loaded into micro-controller 160, as indicated in step
387. Preferably, monitoring program 387 uses calibration data 374
stored within the EEPROM cell on micro-controller 160 as the
calibrated voltage and cut-point references.
In subsequent preferred step 388, monitoring system 100 (containing
monitoring program 386) is again tested to confirm that the system
is functioning within target operational criteria established for
the device. Preferably, test/programming fixture 354 is adapted to
test monitoring system 100 by measuring the performance of
monitoring system 100 under various simulated vehicle voltage
conditions. Preferably, test/programming fixture 354 adjusts the
voltage levels sampled by monitoring system 100 in preset amounts
above and below each of the target voltage conditions. Based on the
responses of monitoring system 100, a pass/fail message is sent to
PC 360 as indicated in step 391.
Referring now to FIG. 13, FIG. 14a, and FIG. 14b, with continued
reference to FIG. 15, the following description provides, in greater
detail, the preferred setup and operation of test/programming
fixture 354. Preferably, card edge connector 390 is electrically
coupled to jumper J5, as shown. Preferably, card edge connector 390
is adapted to accept edge connector 352 of monitoring system 100,
for programming and/or testing (as best illustrated in FIG. 13).
Preferably, jumper J1 is coupled to serial port 370 that is
connected to PC 360 running the Fixture Control Program (hereinafter
referred to as FCP 392), as shown. Preferably, jumper J6 is
connected to programming device 358, preferably a commercially
available unit such as a Pro Mate II Device Programmer available
from Microchip Technology Inc. of Chandler, Ariz., USA. Preferably,
programming device 358 performs the actual programming of
micro-controller 160.
Preferably, prior to programming micro-controller 160, monitoring
voltage levels and cutoff points are selected corresponding to the
vehicle electrical system to be monitored. Preferably, as a default,
FCP 392 is adapted to utilize a standard set of operating parameters
for the programming of monitoring system 100. If other application
specific cut-points or voltage levels are required, FCP 392
preferably comprises a software user interface to permit the input
of non-standard operating parameters using PC 360.
FIG. 16 shows a diagram illustrating the preferred procedures
employed when programming monitoring system 100 utilizing PC 360.
Referring to FIG. 16 with continued reference to the schematic
diagrams of FIG. 14a and FIG. 14b, preferably, a user selects
"Program Device" from user interface menu 394 displayed on PC 360,
as indicated in step 393. Preferably, FCP 392 sends the default (or
modified) voltage levels and/or cut-points to fixture
microcontroller 396 (U26). Preferably, fixture microcontroller 396
receives the data and stores it in temporary memory, as indicated in
step 395. Preferably, fixture microcontroller 396 then sets the
variable voltage regulator to the appropriate level by means of
digital signals sent to the digital potentiometers as indicated in
step 397.
Preferably, on completion of step 397, fixture microcontroller 396
selectively switches relays K1 through K7 to "programming mode" as
indicated in step 399.
In programming mode step 401, the operatin |