Patent Grant
7893809
The subject matter herein relates generally to service disconnect assemblies, and more particularly, to service disconnect assemblies for electronic modules.
High voltage electronic modules are used as power supplies, such as battery packs for automotive applications. The electronic modules typically include a fuse system with a service disconnect assembly for removing the fuse. The service disconnect assembly removes the fuse from the electronic module to protect an operator or technician when servicing or repairing the electronic module. The service disconnect assembly includes a fuse holder that holds the fuse. As the service disconnect assembly is mated to the electronic module, the fuse is loaded into a fuse chamber of the electronic module.
Electronic modules having fuse systems are not without disadvantages. For instance, the service disconnect assemblies are typically mated with the electronic module by loading the service disconnect module in a loading direction and then latching the service disconnect module to the electronic module using a latch. The service disconnect assemblies are removed from the electronic module in an opposite direction and may be inadvertently removed from the fuse chamber, such as when the latch is not properly latched or unintentionally unlatched. To overcome the problem of inadvertent removal, at least some known service disconnect assemblies include multi-step latching, such as by incorporating sliding of the service disconnect assembly in a sliding direction after the fuse is loaded into the fuse chamber.
A need remains for a service disconnect assembly that allows a technician or operator to safely couple a fuse to an electronic module. A need remains for a service disconnect assembly that avoids unintentional removal from the electronic module. A need remains for a service disconnect assembly that allows a technician or operator to safely uncouple the fuse from the electronic module.
In one embodiment, a service disconnect assembly is provided for an electronic module and includes a fuse carrier having a holder configured to hold a fuse for the electronic module, where the fuse carrier has an attachment finger extending from the holder. The attachment finger has a peg. The service disconnect assembly also includes a service disconnect cover having a hood forming a channel, with the hood having a window exposing a portion of the channel. The attachment finger is received in the channel to couple the fuse carrier to the service disconnect cover. The service disconnect cover is slidable with respect to the fuse carrier between an initial position and a final position, wherein the hood moves with respect to the attachment finger as the service disconnect cover is moved between the initial and final positions. The peg is aligned with the window in the final position. A handle is rotatably coupled to the service disconnect cover and the handle has a catch aligned with the window. The handle is movable to a locked position wherein the catch blocks the peg to prevent relative movement between the service disconnect cover and the fuse carrier.
Optionally, at least a portion of the handle may be received in the channel through the window when the handle is in the locked position. The peg may extend from the attachment finger and include a first end and a second end with the catch engaging the second end to prevent movement of the service disconnect cover in a direction from the final position to the initial position. The catch may engage the first end to prevent movement of the service disconnect cover to the final position when the handle is in the locked position. The service disconnect cover may be movable in a linear sliding direction relative to the fuse carrier, with the catch being aligned with the peg in the sliding direction when the catch is in the locked position. Optionally, the channel may extend longitudinal between opposed first and second ends, with the attachment finger positioned proximate to the second end when the service disconnect cover is in the initial position, and the attachment finger being positioned proximate to the first end when the service disconnect cover is in the final position.
In another embodiment, a service disconnect assembly for an electronic module is provided including a fuse carrier having a holder configured to hold a fuse for the electronic module, with the fuse carrier being receivable in a fuse chamber of the electronic module to electrically connect the fuse with the electronic module. The fuse carrier has alignment fingers each having a tip and a catch surface extending from the alignment fingers and positioned a distance from the respective tip. The tips of the alignment fingers being configured to engage ramp surfaces in the fuse chamber to flex the tips from a blocking position to a clearance position, with the alignment fingers engaging the ramp surfaces as the fuse carrier is loaded into the fuse chamber. The service disconnect assembly also includes a service disconnect cover having an end wall with the fuse carrier being coupled to the service disconnect cover. The service disconnect cover is slidable with respect to the fuse carrier between an initial position and a final position, wherein the catch surfaces of the alignment fingers catch the end wall to block movement of the service disconnect cover from the initial position to the final position when the tips are in the blocking position, and wherein the end wall is configured to clear the catch surfaces with the tips are in the clearance position.
In a further embodiment, a service disconnect assembly for an electronic module is provided including a module cover having a fuse chamber defined by chamber walls that has an opening providing access to the fuse chamber. The module cover includes a locking feature extending into the fuse chamber from a respective chamber wall with the locking feature including a ramp facing away from the opening and forming a detention area. The service disconnect assembly includes a fuse carrier having a holder configured to hold a fuse for the electronic module and the fuse carrier is received in the fuse chamber to electrically connect the fuse with the electronic module. The service disconnect assembly also includes a service disconnect cover having a mounting block where the fuse carrier is coupled to the mounting block. The mounting block includes a locking finger extending from the mounting block. The service disconnect cover is positioned adjacent the module cover such that the locking finger engages the locking feature. The service disconnect cover is movable with respect to the module cover between an initial position and a final position, wherein the locking finger slides along the ramp surface toward the detention area as the service disconnect cover is moved from the initial position to the final position. The locking finger is captured in the detention area by the ramp when the service disconnect cover is in the final position.
The electronic module 100 includes a plurality of terminals 104. The electronic module 100 also includes a fuse system 106 for protecting the electronic module 100 and/or for protecting service personnel during repair and/or maintenance. The fuse system 106 has a fuse 108 that is configured to be electrically connected to at least one of the terminals 104. The service disconnect assembly 110 is utilized for loading and unloading the fuse 108. For example, when the service disconnect assembly 100 is properly mated and/or locked in position with respect to the electronic module 100, the fuse 108 is connected to the terminals 104 to complete a circuit. The service disconnect assembly 110 removes the fuse 108 from the electronic module 100 to protect an operator or technician when servicing or repairing the electronic module 100.
The electronic module 100 includes a module cover 112 proximate the terminals 104. The module cover 112 includes a fuse chamber 114 that receives the fuse 108. The fuse 108 is electrically connected to at least one of the terminals 104 when the fuse 108 is loaded into the fuse chamber 114. In an exemplary embodiment, the module cover 112 also includes a high voltage interlock 116. The service disconnect assembly 110 includes a corresponding high voltage interlock 118 that connects to the high voltage interlock 116 of the module cover 112 to complete an interlock circuit. For example, when the service disconnect assembly 110 is properly mated and/or locked in position with respect to the module cover 112, the high voltage interlocks 116, 118 are connected to one another to complete the interlock circuit.
During assembly, the service disconnect assembly 110 is mated with the module cover 112 in a loading direction, shown in
In an exemplary embodiment, the service disconnect assembly 110 includes at least one position assurance feature as a safety feature. For example, the service disconnect assembly 110 may include features to ensure that the fuse 108 is properly positioned with respect to the fuse chamber 114. Additionally, or alternatively, the service disconnect assembly 110 may include features to ensure that the service disconnect assembly 110 is properly positioned with respect to the fuse 108. Additionally, or alternatively, the service disconnect assembly 110 may include features to ensure that the service disconnect assembly 110 is locked or otherwise secured in position with respect to the fuse 108 and/or the module cover 112.
In an exemplary embodiment, the module cover 112 includes an interlock chamber 130 exposing the high voltage interlock 116. The interlock chamber 130 is configured to receive the high voltage interlock 118 of the service disconnect assembly 110 during assembly.
The service disconnect assembly 110 includes a fuse carrier 132 having a holder 134 configured to hold the fuse 108. The service disconnect assembly 110 also includes a service disconnect cover 136 and a handle 138 coupled to the service disconnect cover 136. The fuse carrier 132 is coupled to the service disconnect cover 136 prior to being coupled to the module cover 112 as a unit. In an exemplary embodiment, the service disconnect cover 136 is movable with respect to the fuse carrier 132 after the unit is coupled to the module cover 112 to provide multi-step latching. For example, the service disconnect cover 136 may be slidable along the module cover 112 while the fuse 108 is held in place within the fuse chamber 114.
The fuse carrier 132 includes the holder 134 and a plurality of attachment fingers 140 extending from the holder 134. In an exemplary embodiment, the holder 134 has a generally rectangular cross-section that defines a space for the fuse 108. The fuse 108 is loaded into the space defined by the holder 134 and held therein by latches 142. The holder 134 may have any shape depending on the shape of the fuse 108. The holder 134 has alignment ribs 144 extending therefrom that are received in the alignment channels 128 in the module cover 112 to align the fuse carrier 132 with the fuse chamber 114. Optionally, the alignment ribs 144 may be positioned to provide polarization or keying to properly orient the fuse carrier 132 within the fuse chamber 114. For example, in an exemplary embodiment, one side of the fuse carrier 132 includes a single alignment rib 144 and the other side of the fuse carrier 132 includes two alignment ribs 136.
The attachment fingers 140 extend from the holder 134. In an exemplary embodiment, the attachment fingers 140 are latches having a latching surface 146 generally facing the holder 134 when assembled. The latching surfaces 146 engage a portion of the service disconnect cover 136 to secure the attachment fingers 140 to the service disconnect cover 136. The attachment fingers 140 may be slidably coupled to the service disconnect cover 136 such that the service disconnect cover 136 is capable of moving with respect to the attachment fingers 140 while the attachment fingers 140 are coupled to the service disconnect cover 136. In an exemplary embodiment, the attachment fingers 140 are deflectable toward one another, such as during mating with the service disconnect cover 136. At least one of the attachment fingers 140 includes a peg 148. As will be described in further detail below, the peg 148 may be used as a position assurance feature to ensure that the fuse carrier 132 is properly positioned with respect to the service disconnect cover 136.
In an exemplary embodiment, the fuse carrier 132 includes a plurality of alignment fingers 150 extending from a rear 152 of the holder 134 and/or the attachment fingers 140. As described in further detail below, the alignment fingers 150 may be used as a position assurance feature to ensure that the fuse carrier 132 is properly positioned within the fuse chamber 114. The alignment fingers 150 include beams 154 that extend to tips 156. The alignment fingers 150 also include rear facing catch surfaces 158 that extend outward, generally perpendicularly from the beams 154. In the illustrated embodiment, the catch surfaces 158 extend outward away from one another. Alternatively, the catch surfaces 158 may extend inward toward one another in alternative embodiments. In the illustrated embodiment, the catch surfaces 158 are axially aligned with one another along the beams 154, however the catch surfaces 158 need not be aligned in other embodiments. The catch surfaces 158 face generally rearward toward the tips 156 and away from the holder 134. The catch surfaces 158 are positioned a distance 160 from the tips 156 such that the tips 156 extend rearward beyond the catch surfaces 158.
In an exemplary embodiment, a bottom 162 of each tip 156 is angled inward. The tips 156 are configured to engage ramp surfaces 164 of the module cover 112. The ramp surfaces 164 are provided at a rear of the fuse chamber 114. As described in further detail below, the alignment fingers 150 are deflected by the ramp surfaces 164 from a blocking position to a clearance position during loading of the fuse 108 into the fuse chamber 114. In the illustrated embodiment, the alignment fingers 150 are deflected inward by the ramp surfaces 164, however the alignment fingers 150 may be deflected outward in alternative embodiments. The alignment fingers 150 are initially and normally splayed outward with respect to one another from the fixed ends of the beams 154 to the tips 156. When the alignment fingers 150 engage the ramp surfaces 164, the alignment fingers 150 are flexed inward toward one another, such as to a position in which the beams 154 are generally parallel to one another. When the alignment fingers 150 are deflected and moved, the catch surfaces 158 are similarly deflected and moved from a blocking position to a clearance position.
The service disconnect cover 136 includes an exterior surface 170 and an interior surface 172. The exterior surface 170 is exposed to the surrounding or external environment when the service disconnect assembly 110 is coupled to the module cover 112. The interior surface 172 generally faces the module cover 112 when the service disconnect cover 136 is coupled to the module cover 112. The service disconnect cover 136 has a hood 174 that forms an internal channel 176 (shown in
The handle 138 is coupled to the exterior surface 170 of the service disconnect cover 136. Optionally, the handle 138 may be coupled to the opposite ends of the hood 174. In the illustrated embodiment, the handle 138 includes slots 186 that receive pins 188 extending from the service disconnect cover 136. The pins 188 are secured in the slots 186, such as by a snap-fit. The handle 138 is rotatably coupled to the service disconnect cover 136, such as by rotating about the pins 188. In an exemplary embodiment the handle 138 is rotatable between a locked position and an unlocked position. The handle 138 may be coupled to the service disconnect cover 136 by alternative means in alternative embodiments.
In an exemplary embodiment, the high voltage interlock 118 extends from the interior surface 172 of the service disconnect cover 136. The high voltage interlock 118 may be positioned proximate one of the sides 182.
When the fuse carrier 132 is loaded into the mounting block 190, the attachment fingers 140 extend into the hollow interior of the mounting block 190 and at least partially into the channel 176. In the initially loaded position, the attachment fingers 140 are positioned proximate to the first or forward end 193 of the channel 176. When the fuse carrier is moved (e.g. slid or transferred forwardly) with respect to the fuse carrier 132, the attachment fingers 140 are positioned proximate to the second or rear end 195 of the channel 176.
When the fuse carrier 132 is loaded into the mounting block 190, the alignment fingers 150 extend through the opening 200 to the outside of the mounting block 190. As such, at least a portion of the alignment fingers 150 are positioned inside the mounting block 190 and at least a portion of the alignment fingers 150 are positioned outside the mounting block 190. When the fuse carrier 132 is initially loaded into the mounting block 190, the catch surfaces 158 of the alignment fingers 150 engage an interior 204 of the mounting block 190 and the tips 156 engage the edges 202. In the initial position, the alignment fingers 150 are in a blocking position and block movement (e.g. sliding) of the service disconnect cover 136 with respect to the fuse carrier 132. However, when the alignment fingers 150 are moved to the clearance position, such as when the fuse carrier 132 is loaded into the fuse chamber 114 (shown in
The service disconnect cover 136 includes a plurality of locking fingers 206. The locking fingers 206 may be used as a position assurance feature to ensure that the service disconnect cover 136 is coupled to the module cover 112. The locking fingers 206 extend outward from the side walls 196 and/or 198. In an exemplary embodiment, the locking fingers 206 include curved top surfaces 208 and are generally elongated from top to bottom. In an exemplary embodiment, the side walls 196 and/or 198 include a slot 210 adjacent the locking finger 206. The slots 210 provide flexibility and allow the locking fingers 206 to deflect in a direction along the longitudinal axis of the locking finger 206. The locking fingers 206 may be deflected in a flexing direction that is generally perpendicular to the direction of movement of the service disconnect cover 136 as the service disconnect cover 136 is moved from the initial position to the final position. In the illustrated embodiment, two locking fingers 206 are shown on the side wall 198. Any number of locking fingers 206 may be provided. The side wall 196 may include the same number of locking fingers 206, a different number of locking fingers 206, and may even have no locking fingers 206. Optionally, the locking fingers 206 may be sized and/or shaped differently. The locking fingers 206 may be provided at different vertical positions with respect to the interior surface 172 of the service disconnect cover 136. In an exemplary embodiment, the top surfaces 208 of the locking fingers 206 are vertically aligned with one another.
With reference back to
As illustrated in
In an exemplary embodiment, the ramp 220 includes first and second ramp surfaces 228, 230 meeting at a peak 232. Optionally, the peak 232 may be curved. The first ramp surface 228 is generally forward facing and the second ramp surface 230 is generally rearward facing. The locking finger 206 rides along the ramp surfaces 228, 230 as the service disconnect cover 136 is moved between the initial and final positions. The locking finger 206 initially engages the ramp surface 230 as the service disconnect cover 136 is moved from the initial position to the final position. The locking finger 206 initially engages the ramp surface 228 as the service disconnect cover 136 is moved from the final position to the initial position. Optionally, the top surface 208 of the locking finger 206 engages the ramp 220 as the service disconnect cover 136 is slid between the initial and final positions. The locking finger 206 moves along the ramp 220 in a first or forward direction as the service disconnect cover 136 is moved from the initial position to the final position. The locking finger 206 moves along the ramp 220 in a second or rearward direction as the service disconnect cover 136 is moved from the final position to the initial position. In an exemplary embodiment, the locking feature 126 and the locking finger 206 define a bi-stable lock to ensure that the service disconnect cover 136 is in either the initial position or the final position. The locking feature 126 and the locking finger 206 do not allow the service disconnect cover 136 to rest in a position other than the initial position or the final position, such as along the ramp 220, with the ramp surfaces 228, 230 forcing the locking finger 206 in one direction or the other direction. The ramp surfaces 228, 230 force the locking finger 206 along the respective ramp surface 228, 230 away from the peak 232 in the absence of a force or active movement by an operator in the direction of either the initial position or the final position.
The attachment fingers 140 extend into the mounting block 190 such that the ends of the attachment fingers 140 are received in the channel 176 of the hood 174. Optionally, the channel 176 may extend at least partially into the mounting block 190. In an exemplary embodiment, the latching surfaces 146 of the attachment fingers 140 engage a shoulder 240 of the channel 176 that defines a catch surface. The fuse carrier 132 is vertically held in position with respect to the service disconnect cover 136 by the attachment fingers 140. As described above, the service disconnect cover 136 is slidable with respect to the fuse carrier 132, and the shoulder 240 is configured to slide horizontally relative to the attachment fingers 140 while maintaining the vertical position of the fuse carrier 132 with respect to the service disconnect cover 136.
In an exemplary embodiment, the service disconnect cover 136 includes a window 242 in the hood 174. The window 242 exposes a portion of the channel 176. In the illustrated embodiment, the window 242 is located proximate to a rear end 244 of the hood 174. The window 242 is located along a side 246 and a top 248 of the hood 174. In the illustrated position, the attachment fingers 140 are positioned forward of the window 242 such that the attachment fingers 140 are not aligned with the window 242 and the attachment fingers 140 are not exposed by the window 242. In alternative embodiments, in the initial position, at least a portion of the attachment fingers 140 may be aligned and/or exposed by the window 242.
The handle 138 is rotatably coupled to the service disconnect cover 136 and is movable between an unlocked position, such as the position illustrated in
In use, the service disconnect cover 136 is moved in a sliding direction, shown by the arrow B in
In an exemplary embodiment, the catch 250 receives the peg 148 when the handle 138 is in the locked position. For example, at least a portion of the peg 148 extends into the cavity formed by the catch 250. The finger engagement surface 252 of the catch 250 is configured to engage the first end 254 of the peg 148 to resist movement of the handle 138, and thus the service disconnect cover 136, with respect to the fuse carrier 132. As such, with the catch 250 aligned with the peg 148, the peg 148 blocks movement of the service disconnect cover 136 from the final position back to the initial position.
An exemplary assembly operation will be described below with reference to
As illustrated in
A service disconnect assembly 110 is thus provided that allows a technician or operator to safely couple and uncouple the fuse 108 from the electronic module 100. The service disconnect assembly 110 includes a plurality of position assurance features that avoid unintentional removal of the fuse and/or interlock from the electronic module 100. The position assurance features allow for multi-step latching that employs separate and discrete, conscious movements by the operator to fully mate the service disconnect assembly 110 with the electronic module 100. For example, the service disconnect assembly 110 is loaded into the module cover 112 in a primary loading direction and then slid in a different direction to a locked position. The locking features 126 and locking fingers 206 define a position assurance feature that ensures that the service disconnect assembly 110 is locked or otherwise secured in position with respect to the module cover 112. The alignment fingers 150 and the ramp surfaces 164 define a position assurance feature that ensures that the fuse 108 is fully loaded into the fuse chamber 114 before the service disconnect cover 136 is able to move to the final position. The peg 148 of the attachment finger 140 and the catch 150 of the handle 138 cooperate to define a position assurance feature that ensures that the service disconnect cover 136 is locked or otherwise secured in position with respect to the fuse carrier 132.
It is to be understood that the above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (and/or aspects thereof), may be used in combination with each other. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely exemplary embodiments. Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the appended claims, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects. Further, the limitations of the following claims are not written in means—plus-function format and are not intended to be interpreted based on 35 U.S.C. §112, sixth paragraph, unless and until such claim limitations expressly use the phrase “means for” followed by a statement of function void of further structure.
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