Safety device for power circuit and fuse box

1. Field of the Invention

The invention relates to a safety device for a power circuit and a fuse box effectively adapted for the safety device. The power circuit supplies power to loads on two related systems. The loads include, for example, an actuator and an electrical control unit (referred to as ECU) for controlling the actuator.

2. Description of Relevant Art

A conventional energization system for a 14 V-system automotive includes a junction box. The box includes a branched power circuit. The system includes ECUs. The system includes loads for producing physical output, such as an actuator. The power circuit supplies a current to the ECUs and actuators through common fuses. The system allows a voltage from a power supply to be directly inputted to the ECUs. Respective ECUs include corresponding series regulator inside them, which converts to a low-voltage of, for example, 5V for actuating an internal circuit.

With recent advances in development, an automotive is equipped with a motor generator with efficient fuel cost, and can drive at a high-voltage of 42 V. Voltage conversion of a high-voltage of 42 V, using a series regulator, causes excessive loss. A proposal is that all ECUs house more efficient switching converters. The proposal, however, would result in remarkably high prices.

Another proposal is that a junction box includes a DC/DC converter within it. The converter collectively converts the voltage of a 42 V power supply into a lower voltage of 12 V to be distributed to respective ECUs. One system includes a power circuit for a high-voltage, which applies a voltage of 42 V to an actuator. Another system includes a power circuit for low-voltage, which applies a voltage of 12 V to an ECU. Respective power circuits have corresponding fuses for high and low voltage in them to protect the circuits.

As the ECU controls the actuator, the two systems are closely related to each other. If an abnormality occurs on one system when a current is being supplied to loads on the two systems, the supply of current to the other system is necessarily stopped.

In the 14 V system, a current is supplied to both of the actuator and ECU through fuses. For example, in response to an abnormality in the actuator, fusion of a fuse automatically stops the supply of a current to an ECU. In response to an abnormality in the ECU, fusion of a fuse automatically stops the supply of current to the actuator. These produce no specific problems.

Another proposal is that energization system is separated into systems for the actuator and the ECU respectively. A current is supplied to each of the actuator and the ECU through corresponding fuses for high and low voltage. The fusion of one fuse in the system due to an abnormality allows the other fuse to be left effectively, and to continuously supply a current to the other load.

When a fuse fuses if an abnormality exists on, for example, the actuator, the supply of a current to the ECU for controlling it should stop. After the fusion of one fuse, a voltage is continuously applied to the remaining load. The application can cause an abnormality on the remaining system, such as a rapid short-circuit or a rare-short. Systems separated from a power circuit produce new problems.

The invention is directed to a safety device for a power circuit, and a fuse box effectively adapted for the safety device. Where a current is applied to two related loads of two systems, the fusion of the fuse on one system caused by the fusion of the fuse on other system ensures the safety of entire circuit.

A first aspect of the invention is directed to a safety device for a power circuit. The device includes a first power circuit including a first load and a first fuse element for receiving a first voltage power from a power supply to supply the first voltage power to the first load through the first fuse element. The device includes a second power circuit including a second load and a second fuse element for receiving a second voltage power from a converter, which converts the first voltage power into the second voltage power, to supply the second voltage power to the second load through the second fuse element. The device includes a fusion system for fusing the other of the first and second fuse elements when an arbitrary one of the first and second fuse elements fuses.

Preferably, the fusion system includes a circuit for applying overcurrent to the other fuse element to be fused when said arbitrary fuse element fuses.

Preferably, the fusion system includes a heating element for heating the other fuse element to be fused at a fusion temperature when said arbitrary fuse element fuses.

Preferably, the first power circuit includes a first power terminal connected to the power supply. The first power circuit includes a second load terminal connected to the first load. The second power circuit includes a second power terminal connected to the power supply. The second power circuit includes a second load terminal connected to the second load. The first fuse element includes a first fusible member extending from the first power terminal. The second fuse element includes a second fusible member extending from the second power terminal. The fusion system includes a first conductive member extending from the first load terminal, and conductively contacting with the first fusible member. The fusion system includes a second conductive member extending from the second load terminal, and conductively contacting with the second fusible member. The fusion system includes a displacing system for displacing a corresponding conductive member to contact with the other fusible member, the other conductive member or the other load terminal, when said arbitrary fusible member fuses.

Preferably, the second load includes a controller for controlling the first load.

Preferably, the second power circuit supplies a current to the controller, serving as a power circuit for low-voltage. The first power circuit supplies a current to the first load, serving as a power circuit for high-voltage.

Preferably, the first fuse element includes a first fusible member arranged side by side with a first circuit member of the first power circuit. The second fuse element includes a second fusible member arranged side with by side a second circuit member of the second power circuit. The fusion system includes a first conductive member having a tendency to deform to contact with the second circuit member. The first conductive member is separated away from the second circuit member, and is retained against the first fusible member. The fusion system includes a second conductive member having a tendency to deform to contact with the first circuit member. The second conductive member is separated away from the first circuit member, and is retained against the second fusible member.

Preferably, the fusion system includes a first shunt circuit between the first fuse element and the first load for grounding the first power circuit. The fusion system includes a control circuit responsive to identical electric potentials of both terminals of the second fuse element to open the first shunt circuit.

Preferably, the control circuit is responsive to an electric potential difference between both terminals of the second fuse element to close the first shunt circuit.

Preferably, the fusion system includes a second shunt circuit between the second fuse element and the second load for grounding the second power circuit. The fusion system includes a control circuit responsive to identical electric potentials of both terminals of the first fuse element to open the second shunt circuit.

Preferably, the control circuit is responsive to an electric potential difference between both terminals of the second fuse element to close the first shunt circuit.

A second aspect of the invention is directed to a fuse box adapted for power circuits. The fuse box includes a first power terminal configured to connect a power supply via a first power circuit. The fuse box includes a first load terminal configured to connect a load of the first power circuit. The fuse box includes a second power terminal configured to connect the power supply via a second power circuit. The fuse box includes a second load terminal configured to connect a load of the second power circuit. The fuse box includes a first fusible member extending from the first power terminal. The fuse box includes a second fusible member extending from the second power terminal. The fuse box includes a first conductive element extending from the second load terminal, and conductively contacting with the first fusible member. The fuse box includes a second conductive member extending from the second load terminal, and conductively contacting with the second fusible member. The fuse box includes a displacing system for displacing a corresponding one of the first and second conductive members to contact with the other fusible member, the other conductive member or the other load terminal, when an arbitrary one of the first and second fusible members fuses.

Preferably, said corresponding conductive member has resilience.

Preferably, the displacing system includes a resilient member biasing said corresponding conductive member against said arbitrary fusible member.

According to the safety device, when one of the first and second fuse elements fuses, the other fuse element is forced to fuse, thus stopping current to the other load. Thus, if an abnormality occurs on one of the first and second loads in association with each other, continuous supply of a current to the other load would produce inconvenience. The device securely prevents this inconvenience and ensures safety.

For example, one of two loads is an actuator and the other load is a control unit for controlling the actuator. If an abnormality on the actuator causes a fuse to be fused, this device prevents continuous application of current to the control unit. Similarly, if an abnormality on the controller causes the other fuse to be fused, the device prevents continuous application of current to the actuator.

For example, a combination of logical circuit ensures the safety of the power circuits.

For example, a combination of the heating element and the circuit for energizing the heating element ensures the safety of the power circuits.

According to the device, an abnormality on the first load causes the application of overcurrent to the first power circuit to fuse the first fusible member. The fusion disengages the retention of the first fuse element in a normal position. The first conductive member is displaced toward the second fusible member, the second conductive member, and the second load terminal for conductive contact.

Thus, the second fusible member is joined with the first load, as well as with the second load. The joint allows the instant application of overcurrent more than normal to the second fusible member. The overcurrent fuses the second conductive member, which simultaneously stops the energization of both loads, thus ensuring safety.

If an abnormality occurs on the second load, the fusion of the second conductive member allows the fusion of the first conductive member in a reversed motion. Similarly, this simultaneously stops the energization of both loads, thus ensuring safety.

If the controller has an abnormality when the second fuse element for energizing the controller fuses, the energization of the first load to be controlled by the controller stops. On the other hand, if the first load has an abnormality when the first fuse element for energizing the first load fuses, the energization of the controller stops. This ensures safety of the entire energization system.

If one of the first and second fuse elements of the first and second power circuits fuses due to an abnormality, the other fuse element is securely fused. The fusion prevents an unforeseen situation, such as the generation of overcurrent or a rare short-circuit.

According to the fuse box, when the application of overcurrent to the first power circuit allows the fusion of the first fusible member, the fusion disengages the retention of the first conductive member at a normal position. The first conductive member is displaced toward the second fusible member, the second conductive member or the second load terminal for conductive contact. Thus, overcurrent more than normal is instantly applied to the second fusible member. The overcurrent fuses the second conductive member, stopping the energization of the load, and thus ensuring safety. When the application of overcurrent to the second power circuit allows the fusion of the second fusible member, in a reversed motion, the fusion of the first fusible member stops the energization of the load, ensuring safety.

One of the first and second fusible members is fused, and the corresponding conductive member in conductively contact with said one fuse element conductively contact with the other fuse element by its own resilience. Thus, compared to using another spring separated from a conductive member, this reduces the number of components and simplifies the structure.

FIG. 1 is a circuit diagram illustrating an energization system in an entire constitution, which includes the safety device according to the first embodiment;

FIG. 2 is a circuit diagram illustrating an energization system in an entire constitution, which includes the safety device according to the second embodiment;

FIG. 3 is a perspective external view of the fuse box, which is adapted for the system of FIG. 8;

FIG. 4 is a sectional view of the fuse box in FIG. 3;

FIGS. 5A and 5B are illustrative views of the behavior when a 14 V fusible conductive member (corresponding to a fuse) is fused first; FIG. 5A illustrates a step of fusing a 14V fusible electrical conductive member; FIG. 5B illustrates a step of fusing a 42 V fusible electrical conductive member due to the displacement of the 14 V fusible conductive member successively after the fusion of the 14 V fusible conductive member;

FIGS. 6A and 6B are illustrative views of the behavior when a 42 V fusible conductive member (corresponding to a fuse) is fused first; FIG. 6A illustrates a step of fusing a 42V fusible conductive member; FIG. 6B illustrates a step of fusing a 14 V fusible electrical conductive member due to the displacement of the 42 V fusible conductive member successively after the fusion of the 42 V fusible conductive member;

FIG. 7 is a sectional view of the fuse box according to another embodiment; and

FIG. 8 is a circuit diagram, which includes systems of 42 V and 12 V separated each other according to the third embodiment.

The embodiments of the invention will hereby be described with reference to the drawings.

First Embodiment

The energization system includes 42 V power supply 9 . The system includes a logic circuit (forced-fusion circuit) 20 for forced-fusion. Power supply 9 supplies a voltage of 42 V to a junction box 1 . Box 1 supplies a voltage of 42 V to actuator 4 , and a voltage of 12 V to ECU 3 , respectively. Actuator 4 produces a physical output.

Relative to the system in FIG. 1, box 1 includes high-voltage power circuit 2 A (second power circuit), which applies a voltage of 42V to actuator (second load) 4 . Box 1 includes low-voltage power circuit 2 B, which applies a voltage of 12 V to ECU (first load) 3 for the control of actuator 4 . Box 1 includes fuse 5 A (second fuse) for high-voltage on circuit 2 A. Box 1 includes fuse (first fuse) 5 B for low-voltage on circuit 2 B. Box 1 includes DC/DC converter 8 , which collectively converts a high voltage of 42 V into a low voltage of 12 V to be supplied to circuit 2 B. Box 1 houses converter 8 , fuses 5 A, 5 B, and circuit 20 .

Logical circuit 20 includes two parallel comparators 21 A, 21 B. Circuit 20 includes OR circuit 22 , with the respective input terminals connected to corresponding comparators 21 A, 21 B. Circuit 20 includes two transistors 23 A, 23 B, with the respective input terminals connected in parallel to the output terminal of OR circuit 20 . When one fuse 5 A (or 5 B) is fused, overcurrent is forced to flow through the other fuse 5 B (or 5 A). The overcurrent fuses the other fuse 5 B (or 5 A).

Each of comparators 21 A, 21 B monitors the voltage between the both terminals of each of high and low-voltage fuses 5 A, 5 B. Normally, without the fusion of fuse 5 A or 5 B, little potential difference between the both terminals of fuse 5 A or 5 B occurs. If the fusion of one fuse 5 A (or 5 B) produces potential difference for some reason, comparator 21 A (or 21 B) has inverted output to be outputted as a High signal. The fusion of one fuse 5 A (or 5 B) allows OR circuit 22 to actuate transistor 23 A (or 23 B). The non-fused fuse 5 B (or 5 A) has the terminal connected to the load, which is short circuited to the ground. The short circuit allows overcurrent to flow through fuse 5 B (or 5 A). The over current forces the other fuse 5 B (or 5 A) to be fused.

The operation of the system is described.

Comparator 21 B detects the voltage between both terminals of fuse 5 B through which ECU 3 is energized. For example, an abnormality in the system of ECU 3 causes fuse 5 B to be fused. The potential difference between both terminals of fuse 5 B allows comparator 21 B to output a High signal. The signal allows OR circuit 22 to output a drive signal to transistors 23 A and 23 B. Transistor 23 A short circuits the other fuse 5 A to the ground, with the terminal connected to the load. The short-circuit allows overcurrent to flow through fuse 5 A, which forces it ( 5 A) to be fused. The fusion stops the energization of actuator 4 .

On the other hand, comparator 21 A detects the voltage between both terminals of fuse 5 A through which actuator 4 is energized. For example, an abnormality in the system of actuator 4 causes fuse 5 A to be fused. The potential difference between both terminals of fuse 5 A allows comparator 21 A to output a High signal. The signal allows OR circuit 22 to output a drive signal to transistors 23 A and 23 B. Transistor 23 B short circuits the other fuse 5 B to ground, with the terminal connected to the load, to the ground. The short-circuit allows overcurrent to flow through fuse 5 B, which forces it ( 5 B) to be fused. The fusion stops the energization of ECU 3 .

When one of fuses 5 A, 5 B for high and low-voltages is fused, the other one is forced to fuse. The fusion prevents an unforeseen situation, such as the abnormal running of actuator 4 , additional production of an overcurrent, or a rare short, thus ensuring a safe entire system. In particular, the supplement of logical circuit 20 ensures safety and simplifies the constitution.

Second Embodiment

A modification is added to a part of the system according to the first embodiment to constitute the system as shown in FIG. 2 . The system includes heater (for example, electrically heated wire) 30 for heating fuses 5 A, 5 B to a fusion temperature. The system includes logical circuit 35 for energizing heater 30 . The heater 30 heats one fuse 5 B (or 5 A) to a fusion temperature, when the other fuse 5 A (or 5 B) is fused. Heater 30 primarily corresponds to a forced-fusion means.

The circuit (a part of two comparators 21 A, 21 B and OR circuit 22 ) for the detection of fusion on one fuse 5 A (or 5 B) is identical to the one of the first embodiment. The difference is that when an output signal of comparator 21 turns into High, OR circuit 22 drives transistor 33 . The direct application of a power supply voltage of 42 V to heater 30 produces heat.

The operation of the system is described.

In the system, comparator 21 B detects the voltage between both terminals of fuse 5 B. For example, an abnormality in the system of actuator 4 causes fuse 5 B to be fused. The potential difference between the terminals of fuse 5 B allows comparator 21 B to output a High signal. Transistor 33 allows a voltage of 42 V to be applied to heater 30 . The heat produced by heater 30 forces the other fuse 5 A to be fused. The fusion stops the energization of actuator 4 .

On the other hand, comparator 21 A detects the voltage between both terminals of fuse 5 A. For example, an abnormality in the system of actuator 4 causes fuse 5 A to be fused. The potential difference between the terminals of fuse 5 B allows comparator 21 A to output a High signal. OR circuit 22 outputs a drive signal to transistor 33 . Transistor 33 allows a voltage of 42 V to be applied to heater 30 . The heat produced by heater 30 forces the other fuse 5 B to be fused. The fusion stops the energization of ECU 3 .

The embodiment obtains the identical benefit to the first embodiment.

Third Embodiment

The first and second embodiments each recite the system with the safety device, in which an electric work allows for the forced-fusion of the remaining fuse. The third embodiment recites the system with the safety device, in which a mechanical work fuses the remaining fuse.

The arrangement of fuse box 50 on the system of FIG. 8 constitutes a safety device.

In FIGS. 3 and 4, fuse box 50 includes a casing 51 for safety protection, which is common to high (42 V) and low (14 V) voltage power circuits 2 A and 2 B. Box 50 includes 42 V power supply terminal (second power terminal) 52 A, and 42 V load terminal (second load terminal) 53 A, in casing 51 . Terminal 52 A is connected to the power supply 9 of high-voltage power circuit (second power circuit) 2 A. Terminal 53 A is connected to the load 4 of circuit 2 A. Box 50 includes 14 V power supply terminal (first power terminal) 52 B in casing 51 and 14 V load terminal (first load terminal) 53 B. Terminal 52 B connects to power supply 8 of circuit 2 B. Terminal 53 B connects to load 3 of circuit 2 B. Box 50 includes 42 V fusible conductive member (second fusible conductive member) 54 A and 12 V fusible conductive member (first fusible conductive member) 54 B, which extend from terminals 52 A, 52 B toward terminals 53 A, 53 B, respectively. Box 50 includes 42 V non-fusible conductive member (second non-fusible conductive member) 55 A and 14V non-fusible conductive member (first non-fusible conductive member) 55 B, which extend from terminals 53 A, 53 B toward terminals 52 A, 52 B, respectively. Conductive members 55 A, 55 B are retained at a normal position, contacting and conducting with the ends of conductive members 54 A, 54 B, respectively. Conductive members 55 A, 55 B disengage from retention at the normal position due to the fusion of conductive members 54 A, 54 B in conductive contact with them.

Conductive members 54 A, 54 B, 55 A, 55 B include leaf springs with resilient ends, respectively. Inside conductive member 54 A has a resilient force, which tends to deform outwardly as is shown by the arrow A 2 . Outside conductive member 55 A has a resilient force, which tends to deform inwardly as shown by the arrow A 1 . The balance between the resilient forces allows conductive members 54 A, 55 A to be retained at a normal position as is shown in FIG. 4, before the fusion of conductive member 54 A.

Inside conductive member 54 B has a resilient force, which tends to deform it outwardly as shown by the arrow B 2 . Outside conductive member 55 B has a resilient force, which tends to deform it inwardly as shown by the arrow B 1 . The balance between the resilient forces allows conductive members 54 B, 55 B to be retained at a normal position as shown in FIG. 4, before the fusion of conductive member 54 B.

The contact and electrical conduction between conductive members 54 A or 54 B and conductive member 55 A or 55 B constitute a 42 V or 14V line. Conductive members 54 A and 54 B correspond to high and low-voltage fuses 5 A and 5 B of FIG. 8, respectively.

Conductive member 54 A or 54 B and conductive member 55 A or 55 B have ends, which are curled opposite to each other. The curl 55 A or 55 B, in FIGS. 5A, 5 B, 6 A and 6 B, serve to retain stable contact with conductive member 54 B or 54 A due to the fusion of conductive members 54 A or 54 B. The contact portion between conductive members 54 A and 55 A or 54 B and 55 B join to improve reliable solderless electrical conduction.

Casing 51 includes rib 56 in it, which prevents careless contact between members of 42V and 14V at a normal position. Box 50 requires strict distinction between positive pole (connected to the power supply) and negative poles (connected to the load), and between voltages of 42 V and 14 V. The outer side of casing 51 has projection 61 and recess 62 , which prevent error in the mounting direction. In FIG. 4, casing 51 includes the top face provided with indications 63 , which represent poles (positive, negative) and voltage (42V, 14V).

Next, the operation is described.

Normally, in FIG. 4, a current of 42 V flows in turn through terminal 52 A, conductive member 54 A, 55 A, and terminal 53 A, which constitute a 42 V line. A current of 14 V flows in turn through terminal 52 B, conductive member, 54 B, 55 B, and terminal 53 B, which constitute a 14V line. The arrows L 1 , L 2 , L 3 and L 4 indicate the flow of current.

When an abnormality occurs in the load system of 14 V line, the operation proceeds, as shown in FIGS. 5A and 5B. When an abnormality occurs in the load system of 42 V line, the operation proceeds, as shown in FIGS. 6A and 6B.

Production of some abnormality on a load connected to 14 V line causes overcurrent more than normal to flow through the line. Heat, produced by conductive members 54 B, 55 B, fuses conductive member 54 B at fusion portion P 1 in FIG. 5 A.

The contact of conductive member 55 B with conductive member 54 B retains conductive member 55 B at a normal position. The fusion of conductive member 54 B loses the mate to conductive member 55 B under balanced force. Conductive member 55 B displaces in a direction B 1 (refer to FIG. 4) due to its own resilient force, as shown in FIG. 5B, thus contacting a portion connected to the load in an energization portion of 42V. The contact portion may be the end of conductive member 54 A, or, in principle, any portion of conductive member 55 A or terminal 53 A. In FIG. 5A, contact with the end of conductive member 54 A is established. The contact allows current to flow from the power supply of the 42 V line to the load of 14 V line under abnormality again. Overcurrent more than normal one flows through the 42 V line. The overcurrent fuses the conductive member 54 A. The fusion stops the energization of both loads, thus ensuring safety.

While, if some abnormality occurs on a load connected to 14 V line, overcurrent more than normal flows through the 14 V line. Heat is produced by conductive members 54 A, 55 A to fuse conductive member 54 A at fused portion P 3 , as shown in FIG. 6 A.

The contact of conductive member 55 A with conductive member 54 A allows conductive member 55 A to be retained at a normal position. The fusion of conductive member 54 A loses the mate to conductive member 55 A under balanced force. Conductive member 55 A displaces due to its own resilient force in a direction A 1 (refer to FIG. 4 ), as shown in FIG. 6 B. Conductive member 55 A contacts with an energization portion of 14V (fusible conductive member 54 B in the embodiment). The contact allows current to flow from the power supply of the 14 V line to the load of 42 V line again. Overcurrent more than normal flows through the 42 V line. The overcurrent fuses the conductive member 54 B. The fusion stops the energization of both loads, thus ensuring safety.

In box 50 , conductive members 54 A, 55 B of leaf spring correspond to forced-fusion means, which forces the remaining conductive members (corresponding to a fuse) 54 A, 54 B to be fused. If either of conductive member 54 B or 54 A of 14 V or 42 V line is fused first, members, connected to the power supply on the 14 V or 42 V lines have no contact with each other in the step of fusing the remaining one.

Box 50 includes conductive members 55 A, 55 of a leaf spring. When one conductive member 54 A or 54 B fuses, it contacts with the remaining conductive member 54 B or 54 A. The structure of conductive members 55 A, 55 B themselves of leaf spring decreases the number of components, thus simplifying the structure. Identically to this, another spring 59 A, 59 B may be provided to bias against conductive member 55 A or 55 B in a direction A 1 or B 1 as shown in FIG. 7 .

The embodiment serves a high voltage as 42 V and a low voltage as 12 V or 14 V. A value of voltage is arbitrarily established.

The entire contents of Japanese Patent Applications P2001-289523 (filed on Sep. 21, 2001) are incorporated herein by reference.

Although the invention has been described above by reference to certain embodiments of the invention, the invention is not limited to the embodiments described above. Modifications and variations of the embodiments described above will occur to those skilled in the art, in light of the above teachings. The scope of the invention is defined with reference to the following claims.