PROGRAMMABLE CONTROLLER FOR A VEHICLE

Abstract

A programmable controller stores operational data for a number of embedded functions in multiple vehicles from one or more known manufacturers and is programmable to operation in a selected vehicle among the multiple vehicles.

Description

FIELD OF INVENTION

This invention relates to control modules for managing conditions of a vehicle. In one aspect, the invention relates to controlling the conditions in the passenger cabin of a vehicle using a heating, ventilation, and air conditioning (HVAC) system. Most particularly, the invention relates to a universal replacement controller that is configured as a replacement for a defective controller in a variety of vehicles.

BACKGROUND

The ambient conditions in a vehicle are subject to many variables from without and within the vehicle. External conditions, like sun, wind, rain, snow, and frost, influence passenger comfort. Internal conditions, like the number and size of passengers, preferences for heating and cooling, compartment size can influence passenger comfort. Addressing these ambient conditions is especially difficult when the Original Equipment Manufacture's (OEM) controller becomes defective or inoperative. While OEM replacement controllers may be available, they tend to be expensive and they can be difficult to find in the marketplace for older vehicles. It is sometimes possible to find used controller on the secondary market, such as at salvage yards; however, the second-hand market can be risky and there are seldom guarantees as to their performance.

Moreover, suppliers and retailers have to provide a wide variety of replacement controllers for the OEM variety of different vehicles. Different OEM controllers will typically have variations such as different printed circuit board assembly (PCBA) arrangements and optional components such as rear window defrosters. This variation results in the need for multiple product SKUs with the associated increase in handling, storage, and manufacturing costs.

As a result of these conditions, the marketplace desires a reliable, less expensive option to the OEM replacement controllers. The present invention answers that marketplace need with a replacement controller that is easily programmed according to the specific vehicle application.

SUMMARY

A method and apparatus for replacing an OEM controller is disclosed. A single controller has a number of embedded applications and the selected application within the controller can be called to service through the programming feature of the replacement controller.

In one aspect, the present disclosure is directed to a method for matching a programmable replacement controller to a vehicle, including the steps of identifying a vehicle by make, model and year; selecting a programmable controller that has embedded control data compatible with the identified vehicle's existing control data and established programming procedures; identifying the location of the embedded data that is compatible with the identified vehicle's existing control data; accessing the identified location of the embedded data; and, following the established programming procedures.

In another aspect, the present disclosure is directed to a programmable replacement controller comprising embedded control data, programming controls for accessing, a connector half, and programming controls that activate. The embedded control data is compatible with existing OEM control data for a plurality of vehicle groups stored in a memory. The programming controls for accessing are for accessing the embedded control data compatible with existing OEM control data and extracting embedded control data compatible with a selected vehicle group among the plurality of vehicle groups.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of the various features, pin arrangements, parameters associated with a typical OEM controller;

FIGS. 2 through 7 are expanded schematic illustrations of the wiring harnesses that would be associated with the OEM controller of the type illustrated FIG. 1,

FIG. 8A is a perspective view of a 24-pin connector half for a control module connectable to the half of FIG. 1;

FIG. 8B is a front elevation view of the connector of FIG. 8A;

FIG. 9 illustrates an exemplary dual slide controller face panel;

FIG. 10 is an exploded view of an exemplary digital controller face panel, replacement control module, and circuit boards;

FIG. 11 illustrates circuit boards in accordance with another embodiment of the invention;

FIG. 12 is a schematic illustration of the various features, pin arrangements, parameters associated with the controller incorporating the circuit boards of FIG. 11; and

FIG. 13 is a flow diagram illustrating operation of the controller incorporating the circuit boards of FIG. 11.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference to FIG. 1, it can be seen that an exemplary OEM climate control system 100 has a number of designated locations for certain components within the vehicle's OEM wiring harness and those designations terminate on specific pins of the connector half 102. In the exemplary climate control system 100 connector half 102 comprises twenty-four pin locations marked A1-A12 and B1-B12 with HVAC components connected to the pin locations. As illustrated in FIG. 1, a Recirculation Actuator has input from A1. A Defrost Actuator has input from B3 and outputs to A4. A Coolant Bypass Valve has input from A9. An HVAC Enable Control has input from A10. Input to Controller Blower Motor outputs to A11. An NC Pressure Sensor Signal outputs to A12. An A/C Compressor Status Signal outputs to B12. A Mode Actuator has input from B4 and outputs to A5. A Right Air Temp Actuator has input from B1 and outputs to A2. A Left Air Temp Actuator has input from B2 and outputs to A3.

The replacement controller 10 has a compatible twenty-four pin connector half 12, shown in FIGS. 8A, 8B, and 10 that is a direct plug connection to the existing elements of the OEM system 100. As discussed further below, the replacement controller 10 is configurable by vehicle to have the controller pins functionally compatible with a plurality of OEM climate control systems.

FIGS. 2 through 7 illustrate more detailed representative schematics for the elements of the OEM system 100. In particular, FIGS. 2-7 show the electrical schematic diagram for the climate control system of a 2007 Buick Rainier. One of skill in the art would appreciate that different vehicles have variations in the electrical schematics of their HVAC systems that are nonetheless applicable to a suitable replacement controller 10 as disclosed in the present invention.

FIG. 9 shows the face panel of a replacement controller 10A according to the present invention with a plurality of control elements 20-32 that are used to accomplish configuration and activation in the manner discussed further below and for user operations after the activation programming is completed. Some features, such as rear defrost, are optional on vehicles. In order to provide a single replacement controller 10A applicable to vehicles with or without this feature, the controller can be provided with a variable feature slot that is covered by a removable plate or weakened portion of the cover plate that may be removed without damaging the cover plate. When removed, this variable feature provides a connection point for a functional button 32 that will enable the additional feature.

Because the pin allocations for all target vehicles are not identical and all models may not have all pins operational or active, the replacement unit 10 has a first PCBA 70 (FIG. 10) including a memory module 72 that is preloaded with assignment instructions software for a number of vehicles. Since all models or model years from the same OEM may not have identical features, it is necessary for the software in the memory to recognize the target vehicle, the features in that vehicle and the associated pins so that the correct information from the memory can upload or activate for the target vehicle. It is also important to identify the pin assignments correctly because other features are controlled by the vehicle's on-board computers and the replacement unit 10 must not interfere with the normal operation of any other vehicle features.

The exploded view in FIG. 10 shows a faceplate 14 with digital control elements 40-56 that are used to accomplish configuration and activation as discussed below. The replacement controller 10 also includes a back plate 11 including the connector half 12, a first PCBA or board 70, and a second PCBA or board 90 with control components 92, 94 and an LCD system 98. However, the boards 70, 90 in this exploded view have the same functionality as the earlier faceplate configuration.

The first and second PCBA 70, 90 house the electronic components of the replacement controller 10. The memory 72 stores identifying information for a plurality of vehicles, and may also store configuration and calibration software instructions for a plurality of vehicles. A processor 74 communicates with and controls other components on the first and second PCBA 70, 90, and the processor may contain embedded applications for configuration and calibration of the replacement controller 10. Other electronic components may include network components s (including wireless communication components), power components, integrated circuits for implementing any of the above, and the like.

The process of installing the replacement controller 10 begins with identifying the target vehicle in a look-up table and then following the programming steps for the vehicle as shown in a procedure such as the example below. These instructions are applicable to the exemplary digital climate controller 10B shown in FIG. 10 having operative user inputs 40-56 that are typically used for regular operation of the climate controller 10 when fully installed. The particular buttons and displays described below are exemplary, but other button(s) and displays are contemplated to conform to other OEM components and procedures.

Exemplary Configuration Selection Instructions

• • STEP 1: Start the vehicle (the engine must be running).
  • STEP 2: Enter configuration mode: Press and hold the “Power” 48 and “Front Defrost” 54 buttons until the LCD Screen 58 displays the default configuration number (e.g., “04”).
  • STEP 3: Find the Configuration # for a given vehicle from a reference table such as Table 1.
  • STEP 4: Select vehicle: Select your vehicle's Configuration Number by pressing the “Fan Up” or “Fan Down” buttons 44. The first digit on the display 58 will change to a “5” (indicating the configuration needs to be set).
  • STEP 5: Set configuration: Once the desired configuration is displayed, press and release the “recirculation” button 50. The first digit will change back to a “0” (indicates the configuration has been set).
  • STEP 6: Confirm: Press and release the “auto” button 46 to confirm. The LCD Screen 58 returns to normal operating display information.
  • STEP 7: Internal calibration: Wait while the system performs a calibration sequence indicated by the recirculation 50 and front defrost 54 button lamps being illuminated. This sequence may take up to, e.g., one minute. Configuration is complete when one or both of these button lamps 50, 54 turn off.

In a representative air delivery system, there are multiple factors with multiple internal variables that must be addressed to provide a replacement unit that will operate in the same manner as the end user has experienced with the OEM unit.

A replacement controller 10 of the present invention will have a plurality of configurations available in memory which are selectable by a user and then executed by a process similar to that above. The replacement controller may have, for example, two to ten such configurations, and each configuration may be applicable to multiple vehicle models and model years.

An exemplary replacement controller 10 with configurations corresponding to different models and years of vehicles is illustrated in Table 1 below.

Config-
urations Vehicle Applications
01       2003-2004 Cadillac Escalade; 2003-2004 Chevrolet Avalanche,
         Silverado, Suburban, and Tahoe; and 2003-2004 GMC Sierra
         and Yukon.
02       2007 Chevrolet Silverado; 2007 GMC Sierra; 2005-2006
         Cadillac Escalade; 2005-2006 Chevrolet Avalanche, Silverado,
         Suburban, and Tahoe; 2005-2006 GMC Sierra and Yukon.
03       2003-2007 Hummer H2.
04       2004 Buick Rainier, 2003-2004 Chevrolet Trailblazer,
         2003-2004 GMC Envoy, and 2003-2004 Oldsmobile Bravada.
05       2005-2006 Buick Rainier, 2005-2006 Chevrolet Trailblazer, and
         2005-2006 GMC Envoy.
06       2002 Chevrolet Trailblazer, 2002 GMC Envoy, and 2002
         Oldsmobile Bravada.
07       2007 Buick Rainier and 2007-2009 Chevrolet Trailblazer.

The replacement controller 10 illustrated in Table 1 provides a single replacement device that can replace several OEM controllers. OEM vehicles of a given configuration (e.g., the 2007 Buick Rainier and 2007-2009 Chevrolet Trailblazer) may be considered a “vehicle group” where multiple OEM vehicle types correspond to a single replacement configuration. Thus, a “vehicle group” may be a single model in multiple years like Configuration 03 above or multiple models in a single year like Configuration 06 above.

A second exemplary configuration selection procedure is based on holding one or more selected programming elements for a selected time to scroll through the available configurations. A default configuration can be made available based on vehicle popularity and service data and, if the vehicle corresponds to the default configuration, the selection procedure may not be necessary. A second configuration can be selected by: pressing and holding both the Recirculation button 50 and an AC button 52 for five to ten seconds. A corresponding third configuration selection procedure includes: press and hold Recirculation button 50 and the AC button 52 for ten to fifteen seconds. A corresponding procedure for returning to the first (default configuration) includes: press and hold the Recirculation button 50 and the AC button 52 for sixteen to twenty seconds. This configuration selection procedure may have a vehicle state prerequisite such as ignition being off and blower being not in off mode.

FIG. 10 shows multiple views of an exemplary digital programmable replacement climate controller 10B. The face of the unit 10B, shown of the left in FIG. 10, has a number of user inputs 40-56 that enable a user to select a feature and personalize that feature, such as fan speed, temperature, air conditioning, inside/outside air, etc. to the user's preferences. As described above, when the replacement controller 10B is being installed, the user inputs serve as programming controls. Once the vehicle identification is entered, the inputs 40-56 shift to programming and, after the programming is completed they shift back to user inputs. The connector 12 for the replacement climate controller 10 is shown in the center 11 of FIG. 10. The circuit boards 70, 90 with the memory 72, processor 74, and associated components to achieve compatibility are shown on the right side of FIG. 10.

The physical characteristics (e.g., size, shape, proportion) of the replacement controller 10 and its constituent parts may be designed to fit within various vehicle dashboards. Although the faceplate 14 is illustrated as substantially planar, it may instead be convexly curved to conform to a particular dashboard shape. Likewise, the faceplate 14 may be an oval, trapezoid, or any other shape suitable to replace an OEM controller and fit an OEM dashboard. The length, width, and depth of the faceplate 14, back plate 11, and first and second PCBA 70, 90 may likely be modified as dictated by the spatial constraints of the OEM dashboard. In this manner, the replacement unit 10 will provide a suitable fit and finish for the vehicle and will maintain the aesthetic quality of the vehicle interior.

Moreover, one of ordinary skill in the art would recognize that any suitable hardware may be employed for the embodiments described above, particularly the first and second PCBAs 70, 90. Data, including vehicle identifying information, embedded configurations, and stored instructions, may be stored in the memory 72 of the first PCBA, in a memory on the second PCBA 90, or in additional storage hardware, permanently or temporarily. Furthermore, the instructions described herein may be implemented in a computer program, software, or firmware incorporated in a computer-readable medium for execution by a computer or processor. Examples of computer-readable media include electronic signals (transmitted over wired or wireless connections) and non-transitory computer-readable storage media. Examples of non-transitory computer-readable storage media include, but are not limited to, a read only memory (ROM), a random-access memory (RAM), a register, cache memory, semiconductor memory devices, magnetic media, such as internal hard disks and removable disks, magneto-optical media, and optical media such as CD-ROM disks, and digital versatile disks (DVDs). As such, a computer-readable medium, computer, processor, and/or non-transitory computer-readable storage media may be incorporated in any of the components described above, or in additional hardware.

In another embodiment, the invention makes use of the on-board diagnostics protocol (OBD II) available in all vehicles after 1995. The OBD II protocol generally has a standard connector configuration with two parallel rows of pins, 1-8 and 9-16 with a select communication network associated therewith. Vehicle manufacturers are free to select from among various standard communication formats for communication along the network with the vehicle electronics. As an example, General Motors vehicles typically use SAE J1850 VPW (Variable Pulse Width Modulation) for communications, while ISO15765-4 (CAN) is used in the vast majority of cars.

In the current example, the controller connects to the J1850 format communication network and is used to communicate between climate controller and the body control module (BCM) and other vehicle electronics. The vehicle identification number (VIN) is retrievable through the J1850 format communication network and provides useful detailed information about the vehicle's features, such as an air conditioner, a rear defroster, and other features.

Since vehicle specific data is available for virtually all vehicles, the features data for the intended range of vehicles is stored in memory, such as memory 72 of the first PCBA in FIG. 10. By accessing the VIN through the OBD II's communication network, it is possible to know the specific list of features associated with a given vehicle. The programmable replacement controller in this embodiment will automatically undergo the configuration procedure after it is connected to the vehicle and secures the VIN. The VIN will then determine the information to be retrieved from memory 72. The automatic configuration for the target vehicle will begin when the module detects that there is a battery connection and the vehicle ignition is on. The following is an example of the programming procedure.

• • 1. Confirm that the vehicle ignition is in the off position and the vehicle is off.
  • 2. Connect to the replacement controller to the connector half in the vehicle, accessing the OBD II communication network.
  • 3. Start the vehicle and leave it running until the configuration is completed.
  • 4. With the vehicle running, all of the buttons or lights on the replacement module will illuminate to indicate that the vehicle is being identified in the memory.
  • 5. When the vehicle data from memory has been programmed in the module, the illuminated buttons or lights turn off to indicate the programming configuration is completed and the controller is ready for use.

Referring to FIGS. 11-13, another embodiment of the invention will be described. This embodiment of the invention makes possible the use of the OBD II communication network as in the previous embodiment, but further provides a user with a direct, convenient way to identify the vehicle configuration to facilitate programming. As in the previous embodiments, the controller of the present embodiment includes one or more PCBAs 70′, 90. In the present embodiment, a DIP switch 80, or the like manual or digital switch, is connected to the PCBA 70′. An illustrative DIP switch 80 is the DS01C-254-L-04BE switch available from CUI Devices of Lake Oswego, OR. The disclosure is not limited to this particular switch, nor is it limited to manual DIP switches, but can include additional switches configured to facilitate user input.

The DIP switch 80 may be secured directly to the PCBA 70′ or may be connected via a programming connector as illustrated in the schematic of FIG. 12. While the DIP switch 80 shown positioned on the PCBA 70′, it may be alternatively positioned, for example, on the PCBA 90. The DIP switch 80 is positioned such that it is easily accessible to a user prior to installation of the controller. As will be described in more detail hereinafter, the DIP switch 80 allows the user to set a preferred configuration for the controller, which configuration may indicate a desire for auto-configuring or may indicate a specific vehicle group configuration. In the illustrated embodiment, the DIP switch 80 has four poles, each with an associated number 1-4. The user can set each pole in either an “ON” or “OFF” position (in FIG. 11, each of the poles is set to the OFF position). With this arrangement, the user can set the DIP switch to one of eight different configurations, for example, configurations 1-7 illustrated in Table 1, and an eighth “Auto-Config” configuration. While eight configurations are described herein, the disclosure is not limited to such and a switch with a lesser or larger amount of configurations may be utilized, for example, an eight-pole DIP switch. Additionally, the Auto-Config configuration may not be identified to the end user, but instead may be held reserved for a customer service line to help configure the controller in the event the user has difficulty programming the controller.

When the controller determines that the DIP switch is set to the Auto-Config configuration, the OBD II communication network is used to communicate between the controller and the body control module (BCM) and other vehicle electronics, as in the previous embodiment. The vehicle identification number (VIN) is retrievable through the OBD II communication network and provides useful detailed information about the vehicle's features, such as an air conditioner, a rear defroster, and other features.

Since vehicle specific data is available for virtually all vehicles, the features data for the intended range of vehicles is stored in memory, such as memory 72 of the first PCBA 70′. By accessing the VIN through the OBD II communication network, it is possible to know the specific list of features associated with a given vehicle. The programmable replacement controller in this embodiment will automatically undergo the configuration procedure after it is connected to the vehicle and secures the VIN. The VIN will then determine the information to be retrieved from memory 72. In the event that the Auto-Config does not work, the user can then change the DIP switch 80 to indicate a specific configuration number.

Alternatively, if the user sets the DIP switch 80 to a configuration number associated with one of the corresponding vehicle groups, the controller will then retrieve the information of the pre-selected vehicle group from the memory 72 and the controller will be programmed in a manner described above. To assist the user in determining the proper DIP switch setting, the user may be provided with information as shown in Table 2 below, for example, via a package insert and/or a webpage or the like. In cases where the Auto-Config configuration is reserved, the 00 configuration would not be included in the Table.

Config-	Vehicle Applications	DIP Switch
urations		Setting
00	Auto-Config	DSW 1 off,
		all other on
01	2003-2004 Cadillac Escalade; 2003-2004	DSW 2 off,
	Chevrolet Avalanche, Silverado,	all other on
	Suburban, and Tahoe; and 2003-2004
	GMC Sierra and Yukon.
02	2007 Chevrolet Silverado; 2007 GMC	DSW 3 off,
	Sierra; 2005-2006 Cadillac Escalade;	all other on
	2005-2006 Chevrolet Avalanche,
	Silverado, Suburban, and Tahoe; 2005-
	2006 GMC Sierra and Yukon.
03	2003-2007 Hummer H2.	DSW 2, 3 off,
		all other on
04	2004 Buick Rainier, 2003-2004 Chevrolet	DSW 4 off,
	Trailblazer, 2003-2004 GMC Envoy, and	all other on
	2003-2004 Oldsmobile Bravada.
05	2005-2006 Buick Rainier, 2005-2006	DSW 2, 4 off,
	Chevrolet Trailblazer, and 2005-2006	all other on
	GMC Envoy.
06	2002 Chevrolet Trailblazer, 2002 GMC	DSW 3, 4 off,
	Envoy, and 2002 Oldsmobile Bravada.	all other on
07	2007 Buick Rainier and 2007-2009	DSW 2, 3, 4 off,
	Chevrolet Trailblazer.	all other on

With reference to FIG. 13, the following is an example of the programming procedure utilized in conjunction with the controller of the present embodiment.

STEP 1, the user sets the DIP Switch 80 to the desired configuration, based on Table 2, prior to installation of the controller.

STEP 2, the controller enters into the Configuration Mode when the ignition is on after a loss of battery power.

STEP 3, the controller determines the configuration setting of the DIP Switch 80.

STEP 4, the controller determines if the Auto-config configuration setting is selected.

STEP 5, if the answer in STEP 4 is no, the controller will retrieve the information from memory 72 associated with the vehicle group connected with the selected configuration and will do actuator calibration and begin normal functions.

STEP 6, if the answer in STEP 4 is yes, the controller will use the OBD II's communication network to retrieve the VIN, and then, using the VIN's 5th (Model) and 10th (Year) digits on the VIN Module, determine the configuration number. Once the configuration number is determined, the controller will move to STEP 5 and complete the calibration.

While the various embodiments of the controller have been described herein with reference to a climate control module, the disclosure is not limited to such. The systems and methods described herein may be utilized with other vehicle modules, for example, powertrain control modules, transmission control modules, brake control modules, suspension control modules, power distribution modules, airbag control modules, vehicle control modules, passenger door modules, battery management systems, sunroof modules, rain sensor modules, heated seat modules, and the like.

Claims

1. A method for matching a replacement controller to control data in a control system from an original equipment manufacturer, the method comprising: identifying original equipment manufacturer control data in a selected vehicle;providing a replacement controller having embedded control data including data that is compatible with the identified original equipment manufacturer control data in the selected vehicle;identifying data within the embedded control data of the replacement controller that is compatible with control data in the selected vehicle;selecting the identified data within the embedded control data of the replacement controller based on user input received from a configuration switch; and,programming the replacement controller with the selected data.

2. The method of claim 1, wherein identifying control data in a selected vehicle includes identifying the selected vehicle by make, model and year.

3. The method of claim 1, wherein the configuration switch is configured such that the user may input a configuration selection from a group consisting of at least two different vehicle configurations.

4. The method of claim 3, wherein the configuration switch is a DIP switch which facilitates the input of at least two configuration selections.

5. The method of claim 3, wherein the configuration switch includes at least a third configuration selection which facilitates automatic configuration.

6. The method of claim 5, wherein the automatic configuration includes retrieving the relative vehicle configuration through an on-board communication network of the selected vehicle.

7. The method of claim 6, wherein the on-board communication network retrieves the VIN of the connected vehicle and the VIN is utilized to determine the relative vehicle configuration.

8. A replacement controller for a selected vehicle comprising: a memory that stores selectable control data that is compatible with a plurality of vehicles from one or more known manufacturers, including control data for the selected vehicle;a configuration switch configured to receive a user input indicative of a configuration of the selected vehicle;a first set of programming controls for selecting data from the memory that is compatible with the configuration of the selected vehicle within the plurality of vehicles; and,a second set of programming controls for applying the selected data from the memory and rendering the replacement controller operative in the selected vehicle.

9. The replacement controller of claim 8, wherein the selectable control data includes climate control data.

10. The replacement controller of claim 8, further comprising a faceplate with the first set and the second set of programming controls, and a back plate with a connector half configured to operatively connect with a connector half associated with an existing wiring harness in the selected vehicle.

11. The replacement controller of claim 8, wherein the replacement controller is contained within a housing and has a connector half with a plurality of pins positioned to mate with selected pins among a plurality of pins that connect with an existing wire harness in the selected vehicle.

12. The replacement controller of claim 8, wherein the configuration switch is configured such that the user may input a configuration selection from a group consisting of at least two different vehicle configurations.

13. The replacement controller of claim 12, wherein the configuration switch is a DIP switch which facilitates the input of at least two configuration selections.

14. The replacement controller of claim 12, wherein the configuration switch includes at least a third configuration selection which facilitates automatic configuration.

15. The replacement controller of claim 14, wherein the automatic configuration includes retrieving the selected vehicle configuration through an on-board communication network of the selected vehicle.

16. The replacement controller of claim 15, wherein the on-board communication network retrieves the VIN of the selected vehicle and the VIN is utilized to determine the selected vehicle configuration.