Solid state switch with over-temperature and over-current protection

Information

  • Patent Application
  • 20070194009
  • Publication Number
    20070194009
  • Date Filed
    December 08, 2006
    19 years ago
  • Date Published
    August 23, 2007
    18 years ago
Abstract
An intake air heating system for an internal combustion engine includes an electric heater that heats the intake air, a control circuit that switches a voltage to the electric heater based on a control signal and an over-temperature signal, a temperature sensor that generates a temperature signal based on a temperature of the control circuit, and a temperature sensing circuit that generates the over-temperature signal based on the temperature signal and a predetermined temperature.
Description

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:



FIG. 1 is a functional block diagram of an intake-air heater system;



FIG. 2 is a schematic drawing of a power module of the circuit of FIG. 1;



FIG. 3 is a schematic of a first embodiment of a gate driver module of the system of FIG. 1;



FIG. 4 is a schematic of a second embodiment of a gate driver module of the system of FIG. 1;



FIG. 5 is a plan view of a protective housing and thermal mass for the power module of FIG. 2;



FIG. 6 is a plan view of the protective housing and thermal mass of FIG. 5 that includes the gate driver module of FIG. 4;



FIG. 7 is a timing chart showing an example of heater power as a function of time;



FIG. 8 is a schematic of a circuit for independently controlling rise and fall times of transistors in the power module;



FIG. 9 is a schematic of a circuit for gating a control signal of the gate driver module;



FIG. 10 is a schematic of a temperature sensing module;



FIG. 11 is a schematic of a watchdog timer module;



FIG. 12 is a schematic of a current-sense module;



FIG. 13 is a schematic of a fault latch module; and



FIG. 14 is a schematic of a contactor module.


Claims
  • 1. An intake air heating system for an internal combustion engine, comprising: an electric heater that heats the intake air;a control circuit that switches a voltage to the electric heater based on a control signal and an over-temperature signal;a temperature sensor that generates a temperature signal based on a temperature of the control circuit; anda temperature sensing circuit that generates the over-temperature signal based on the temperature signal and a predetermined temperature.
  • 2. The intake air heating system of claim 1 wherein the temperature sensor is a thermistor.
  • 3. The intake air heating system of claim 1 wherein the predetermined temperature is represented by a voltage that is generated by a voltage divider.
  • 4. The intake air heating system of claim 1 wherein the control circuit includes at least one transistor that switches current through the electric heater and wherein the temperature sensor monitors a temperature of the at least one transistor.
  • 5. The intake air heating system of claim 1 further comprising a solenoid that selectively interrupts current to the electric heater.
  • 6. The intake air heating system of claim 5 wherein the solenoid is a spring-loaded pilot duty solenoid.
  • 7. An intake air heating system for an internal combustion engine, comprising: an electric heater that heats the intake air;a control circuit that switches a voltage to the electric heater based on a control signal and a watchdog timer signal; anda watchdog timer that generates the watchdog timer signal based on a predetermined time and a duration that the control signal commands the electric heater to be on.
  • 8. The intake air heating system of claim 7 wherein the control signal is a pulse-width modulated (PWM) control signal.
  • 9. The intake air heating system of claim 8 wherein the predetermined time is greater than a period of the PWM control signal.
  • 10. The intake air heating system of claim 7 wherein the predetermined time is represented by a voltage that is generated by a voltage divider.
  • 11. The intake air heating system of claim 7 wherein the watchdog timer includes a timer that is reset by the control signal and that generates a time signal.
  • 12. The intake air heating system of claim 11 wherein the time signal represents the duration that the control signal commands the electric heater to be on.
  • 13. The intake air heating system of claim 11 wherein the timer is a resistor-capacitor (RC) circuit.
  • 14. An intake air heating system for an internal combustion engine, comprising: an electric heater that heats the intake air;a control circuit that switches a voltage to the electric heater based on a control signal and an overload signal;a load sensing circuit that compares an electrical load of the electric heater to a predetermined load and that generates the overload signal based on the comparison.
  • 15. The intake air heating system of claim 14 wherein the load sensing circuit determines the electrical load based on a voltage of the electric heater.
  • 16. The intake air heating system of claim 15 wherein the predetermined load is represented by a voltage that is generated by a voltage divider.
  • 17. The intake air heating system of claim 16 wherein the voltage divider is powered by the voltage that is switched to the electric heater.
  • 18. An intake air heating system for an internal combustion engine, comprising: an electric heater that heats the intake air;a control circuit that generates a gate drive signal;a transistor that switches a voltage to the electric heater based on the gate drive signal; anda rise and fall time control circuit that communicates the gate drive signal to the transistor and that determines a rise time and a fall time of the transistor.
  • 19. The intake air heating system of claim 18 wherein the rise and fall time control circuit includes first and second resistances that determine the rise and fall times.
  • 20. A method of heating intake air for an internal combustion engine, comprising: switching power to an electric heater based on a control signal and an over-temperature signal;generating a temperature signal based on a temperature of a device that performs the switching function; andgenerating the over-temperature signal based on the temperature signal and a predetermined temperature.
  • 21. The method of claim 20 wherein generating the temperature signal includes varying a resistance based on the temperature of the device.
  • 22. The method of claim 20 wherein the predetermined temperature is represented by a second voltage.
  • 23. The method of claim 20 wherein the device is a transistor.
  • 24. The method of claim 20 further comprising selectively interrupting current to the electric heater based on the control signal.
  • 25. The method of claim 24 further comprising providing a spring-loaded pilot duty solenoid that selectively interrupts the current to the electric heater.
  • 26. A method of heating intake air for an internal combustion engine, comprising: switching power to an electric heater based on a control signal and a watchdog timer signal; andgenerating the watchdog timer signal based on a predetermined time and a duration that the control signal commands the electric heater to be on.
  • 27. The method of claim 26 wherein the control signal is a pulse-width modulated (PWM) control signal.
  • 28. The method of claim 27 wherein the predetermined time is greater than a period of the PWM control signal.
  • 29. The method of claim 26 wherein the predetermined time is represented by a voltage magnitude.
  • 30. The method of claim 26 further comprising resetting the watchdog timer signal based on the control signal.
  • 31. The method of claim 30 wherein the control signal indicates a length of time for the electric heater to be on.
  • 32. A method of heating intake air for an internal combustion engine, comprising: switching power to an electric heater based on a control signal and an overload signal;comparing an electrical load of the electric heater to a predetermined load; andgenerating the overload signal based on the comparing step.
  • 33. The method of claim 32 wherein the electrical load is based on a voltage across the electric heater.
  • 34. The method of claim 33 wherein the predetermined load is represented by a voltage magnitude.
  • 35. The method of claim 34 wherein the voltage divider is powered by the power that is switched to the electric heater.
  • 36. A method of heating intake air for an internal combustion engine, comprising: generating a gate signal for a transistor;conducting the gate signal through a first impedance when the gate signal is turning the transistor on;conducting the gate signal through a second impedance when the gate signal is turning the transistor off; andusing the transistor to switch power to an electric heater, wherein a rise time and a fall time of the transistor are based on the first and second impedances, respectively.
  • 37. The method of claim 36 further comprising providing first and second resistances to implement the first and second impedances.
Provisional Applications (1)
Number Date Country
60774893 Feb 2006 US
Continuation in Parts (1)
Number Date Country
Parent 11486884 Jul 2006 US
Child 11636692 US