Description:FIELD OF INVENTION
[0001] The present invention is generally related to an electrical device for use with an electric vehicle, and more particularly to an electrical device and method for minimizing unnecessary draining of an auxiliary battery in an electric vehicle during transportation and periods of non-use.
BACKGROUND OF INVENTION
[0002] As electric vehicles continue to grow in popularity, original equipment manufacturers (OEMs) are intensively focusing on improving their motors, batteries (power-producing devices), and other critical controllers essential for vehicle operation. Typically, electric vehicles feature a Vehicle Control Unit (VCU) within the controller network, which is consistently powered by a 12V auxiliary battery. With the increasing complexity of electric vehicles, which now function as software-driven systems, a malfunction in the VCU software can prevent the vehicle from starting. A common remedy for this issue is to power reset the VCU, thereby clearing fault conditions as the software reinitializes following the reset. This practice is widespread across various electronic devices that utilize controllers or processors, such as mobile phones.
[0003] In normal conditions, the 12V auxiliary battery continuously powers the MVCU, even when the vehicle is off, drawing a small amount of current. Over prolonged periods of non-usage, this current draw can drain the entire auxiliary battery. A fully drained auxiliary battery poses a significant inconvenience, making it difficult to start the vehicle.
[0004] Additionally, the VCU is constantly powered by the 12V auxiliary battery, with wire harness lengths for VCU power connections ranging from 0.5 meters to 3 meters. These wire harnesses are vulnerable to damage from external agents, such as rodent bites, which can cause short circuits between the 12V supply and ground, potentially leading to fire hazards.
[0005] To address these issues, fuses are typically employed as protective measures. However, these fuses are usually concealed and made inaccessible to the average user. As a safety precaution, OEMs often remove these fuses from the power line after completing the Pre-Dispatch Inspection at the manufacturing plant, before shipping the vehicle to the dealership. This process involves removing and refitting several body panels at both the manufacturing plant and the dealership, negatively impacting the vehicle's fit and finish and increasing process time at both locations.
[0006] Moreover, a reset and kill switch, if provided without adequate protection, risks being inadvertently activated or obstructed by external materials.
[0007] To resolve these issues and enhance customer experience, the present invention provides an electrical device equipped with a reset switch. This device enables users to reset the VCU without the need for tools, effectively addressing VCU-related faults and ensuring vehicle reliability.
[0008] Thus, in view of the above, there is a long-felt need in the industry to address the aforementioned deficiencies and inadequacies.

SUMMARY OF THE INVENTION
[0009] An electrical device and method for minimizing unnecessary draining of an auxiliary battery in an electric vehicle during transportation and periods of non-use are provided substantially, as shown in and/or described in connection with at least one of the figures.
[0010] An aspect of the present disclosure relates to an electrical device for minimizing the draining of an auxiliary battery in an electric vehicle. The electrical device includes a reset switch; a fuse; a Master Vehicle Control Unit (MVCU), and a protection cover. The reset switch is integrated within a harness using a sealed connector. The reset switch is connected in series with the MVCU through the fuse. The protection cover is configured to encase the reset switch to prevent unintended operation. In an aspect, the protection cover is made from a durable material that is resistant to environmental factors, thereby ensuring the reset switch remains securely protected during transportation and handling.
[0011] In an aspect, the reset switch is implemented as an on-off reset switch with a rating of 250V and 6A, in series with the permanent supply of the auxiliary battery.
[0012] In an aspect, the fuse is a 5A fuse.
[0013] In an aspect, the sealed connector is a 90 series two-pole sealed connector.
[0014] In an aspect, the reset switch is connected in series with a permanent 12V supply of the MVCU through the fuse.
[0015] Another aspect of the present invention relates to a method for extending the lifespan of an auxiliary battery of an electric vehicle and enhancing the efficiency of its energy management system. The method includes a step of integrating a reset switch within a harness using a sealed connector. The method includes a step of incorporating the reset switch in series with a permanent 12V supply of a Master Vehicle Control Unit (MVCU) through a fuse. The method includes a step of covering the reset switch with a protection cover to prevent unintended activation.
[0016] In an aspect, the reset switch is configured to cut the supply to the MVCU during transportation to avoid the auto wake-up of the vehicle.
[0017] In an aspect, the reset switch is implemented as an On-Off type reset switch with a rating of 250V and 6A.
[0018] In an aspect, the sealed connector is a 90 series two-pole sealed connector.
[0019] In an aspect, the sealed connector is configured to provide a waterproof and dustproof connection for the reset switch within the harness.
[0020] Accordingly, one advantage of the present invention is that the reset switch (reset cum kill switch) enhances the user experience by providing easy access to power reset the MVCU.
[0021] Accordingly, one advantage of the present invention is that it provides a secure predefined area that is away from any accidental operation and easy to access to the customer.
[0022] These features and advantages of the present disclosure may be appreciated by reviewing the following description of the present disclosure, along with the accompanying figures wherein reference numerals refer to like parts.

BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The accompanying drawings illustrate the embodiment of devices, systems, methods, and other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent an example of the boundaries. In some examples, one element may be designed as multiple elements, or multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another and vice versa. Furthermore, the elements may not be drawn to scale.
[0024] Various embodiments will hereinafter be described in accordance with the appended drawings, which are provided to illustrate, not limit, the scope, wherein similar designations denote similar elements, and in which:
[0025] FIG. 1 illustrates a circuitry view of an electrical device for minimizing draining of an auxiliary battery, in accordance with at least one embodiment.
[0026] FIG. 2 illustrates an installed view of the electrical device integrated in an electric vehicle, in accordance with at least one embodiment.
[0027] FIG. 3 illustrates a perspective view of a reset switch installed in the electric vehicle, in accordance with at least one embodiment.
[0028] FIG. 4 illustrates a perspective view of a harness using a sealed connector, in accordance with at least one embodiment.
[0029] FIG. 5 illustrates a flowchart of a method for extending the lifespan of an auxiliary battery of an electric vehicle and enhancing the efficiency of its energy management system, in accordance with at least one embodiment.

DETAILED DESCRIPTION OF THE EMBODIMENTS HEREIN
[0030] The present disclosure is best understood with reference to the detailed figures and description set forth herein. Various embodiments have been discussed with reference to the figures. However, those skilled in the art will readily appreciate that the detailed descriptions provided herein with respect to the figures are merely for explanatory purposes, as the methods and systems may extend beyond the described embodiments. For instance, the teachings presented and the needs of a particular application may yield multiple alternative and suitable approaches to implement the functionality of any detail described herein. Therefore, any approach may extend beyond certain implementation choices in the following embodiments.
[0031] References to “one embodiment,” “at least one embodiment,” “an embodiment,” “one example,” “an example,” “for example,” and so on indicate that the embodiment(s) or example(s) may include a particular feature, structure, characteristic, property, element, or limitation but that not every embodiment or example necessarily includes that particular feature, structure, characteristic, property, element, or limitation. Further, repeated use of the phrase “in an embodiment” does not necessarily refer to the same embodiment.
[0032] During the transportation of a vehicle, it is necessary to either remove the auxiliary (aux) battery fuse or disconnect the 12V aux battery. This procedure is crucial to prevent the unintended wake-up of the vehicle, which occurs when the system attempts to charge the aux battery, thereby avoiding unnecessary battery drain and mitigating the risk of fire incidents due to short circuits. Similarly, when a vehicle is stored in an idle condition for an extended period, disconnecting the aux battery is essential to prevent battery drain.
[0033] If the aux battery becomes fully drained, the vehicle will fail to start, as the aux battery provides the necessary starting voltage to wake up the main battery. Moreover, the ability to reset the electrical system after restoring the MVCU permanent supply helps customers and service personnel resolve errors effectively. Once the MVCU supply is cut and then reconnected, the MVCU will reboot and reinitialize, clearing any existing errors in the MVCU.
[0034] Previously, customers, dealership personnel, or service technicians had to remove the front panel to access and remove the aux battery fuse or disconnect the aux battery manually. This process was time-consuming and often compromised the vehicle's fit and finish. However, the introduction of a reset and kill switch with a protective cover has significantly simplified this task for plant workers, service technicians, dealership staff, and customers. The protective cover is designed to prevent accidental activation of the reset switch.
[0035] To implement this solution, a reset switch (On-Off type) with a 250V 6A rating has been integrated into a series with the MVCU aux battery's permanent supply. This switch is designed as a pigtail and serves as a subsidiary component of the main wiring harness. Additionally, the switch's location is both serviceable and user-friendly, ensuring it does not disturb the vehicle's fit and finish or require special tools for access. This design makes the reset switch easily accessible for customers and service personnel.
[0036] This reset and kill switch setup is beneficial for all electric vehicles equipped with a 12V aux battery in their architecture, which provides the initial supply voltage. In other vehicles, the only available solution for this use case is the use of an inaccessible fuse or miniature circuit breaker (MCB).
[0037] The present invention provides a mechanism to reset or power off an electric vehicle. The electrical device resets the Master Vehicle Control Unit (MVCU) in the event of a software fault. Additionally, the present invention protects the auxiliary battery of the electric vehicle from draining under various conditions such as a) When the vehicle is in an off state for extended periods, such as during a long vacation of the customer. B) When the vehicle is unused and stored or stocked at a dealership or manufacturing plant. C) During transportation. Furthermore, the present invention enhances the safety of the electric vehicle by preventing any vehicle components from being powered up during transportation, thereby avoiding accidental short circuits or mishaps.
[0038] FIG. 1 illustrates a circuitry view of an electrical device (100) for minimizing draining of an auxiliary battery (102), in accordance with at least one embodiment. The electrical device (100) includes a reset switch (106); a fuse (108); a Master Vehicle Control Unit (MVCU) (110), and a protection cover (112) (shown in FIG. 2). The reset switch (106) is integrated within a harness (402) (shown in FIG. 4) using a sealed connector (404a and 404b) (shown in FIG. 4). The reset switch (106) is connected in series with the MVCU (110) through the fuse (108). The protection cover (112) is configured to encase the reset switch (106) to prevent unintended operation. In an embodiment, the sealed connector is a 90-series two-pole sealed connector. In an embodiment, the reset switch (106) is connected in series with a permanent 12V supply of the MVCU (110) through the fuse (108). In an embodiment, the fuse (108) is a 5A fuse. In an embodiment, the reset switch (106) acts as a reset cum kill switch. In operation, the current rating of the MVCU is only 1A at 14.2V and the same current passes through the reset cum kill switch.
[0039] In an embodiment, the terms Master Vehicle Control Unit (MVCU) and Vehicle Control Unit (VCU) can be used alternatively. In the present invention, the MVCU is configured to handle multiple functionalities that include but are not limited to TFT cluster control, telematics, and vehicle control.
[0040] FIG. 2 illustrates an installed view of the electrical device (100) integrated in an electric vehicle (104), in accordance with at least one embodiment. In an embodiment, the present invention is not limited to only electric vehicles (104) but can also be implemented in other two-wheeled vehicles. In an embodiment, the protection cover (112) is made from a durable material that is resistant to environmental factors, thereby ensuring the reset switch remains securely protected during transportation and handling. FIG. 2 is explained in conjunction with FIGS. 1 and 3. The reset switch (106) is located in a predefined area (202) in such a way that it is serviceable and user-friendly, ensuring it does not disturb the vehicle's fit and finish or require special tools to access. This design makes access user-friendly for customers.
[0041] FIG. 3 illustrates a perspective view of the reset switch (106) installed in the electric vehicle (104), in accordance with at least one embodiment. FIG. 3 is explained in conjunction with FIG. 2. In an embodiment, the reset switch (106) is implemented as an on-off reset switch with a rating of 250V and 6A, in series with the permanent supply of the auxiliary battery (102). During the experiment, the reset switch (106) never failed due to overrating design considerations. DVP testing was conducted on the reset switch (106) for more than 10,000 cycles at a 2A current rating.
[0042] By providing the reset cum kill switch (106) with the protection cover (112), tasks for plant personnel, service technicians, dealerships, and customers have become significantly easier. The protection cover (112) prevents unintentional contact with the reset switch (106). The reset switch (On-Off type) is implemented with a 250V 6A rating in series with the MVCU auxiliary battery's permanent supply. It is implemented as a pigtail and is a child part of the main wiring harness. The reset switch (106) is useful for all-electric vehicles (EVs) that have a 12V auxiliary battery in their architecture for providing the initial supply voltage.
[0043] In an embodiment, the reset switch (106) is used in place of a fuse, as commonly found in existing electric vehicles. In an additional embodiment, the reset switch (106) serves as a universal switch for three different functions: reset, kill switch, and power cut-off. Furthermore, the reset switch (106) is compact and user-friendly compared to the existing reset fuse.
[0044] FIG. 4 illustrates a perspective view of a harness (402) using a sealed connector (404a and 404b), in accordance with at least one embodiment. The reset switch (106) is integrated within the harness (402) using the sealed connector (404a and 404b). In an embodiment, the sealed connector includes a 90-series two-pole sealed male connector (404a) and a 90-series two-pole sealed female connector (404b). These connectors are designed to provide a robust and reliable connection between the reset switch (106) and the rest of the electrical system within the vehicle. The two-pole configuration facilitates the transmission of electrical signals while maintaining the integrity of the connection. The use of these high-quality sealed connectors (404a and 404b) enhances the durability and longevity of the reset switch (106) installation, ensuring consistent performance even under harsh conditions.
[0045] As used herein, and unless the context dictates otherwise, the term “configured to” or “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “configured to”, “configured with”, “coupled to” and “coupled with” are used synonymously. Within the context of this document terms “configured to”, “coupled to” and “coupled with” are also used euphemistically to mean “communicatively coupled with” over a network, where two or more devices can exchange data with each other over the network, possibly via one or more intermediary device.
[0046] FIG. 5 illustrates a flowchart of a method 500 for extending the lifespan of an auxiliary battery of an electric vehicle and enhancing the efficiency of its energy management system, in accordance with at least one embodiment. The method 500 includes a step 502 of integrating a reset switch within a harness using a sealed connector. The method 500 includes a step 504 of incorporating the reset switch in series with a permanent 12V supply of a Master Vehicle Control Unit (MVCU) through a fuse. The method 500 includes a step 506 of covering the reset switch with a protection cover to prevent unintended activation. In an embodiment, the reset switch is configured to cut the supply to the MVCU during transportation to avoid auto wake-up of the vehicle. In an embodiment, the reset switch is implemented as an On-Off type reset switch with a rating of 250V and 6A. In an embodiment, the sealed connector is a 90-series two-pole sealed connector. In an embodiment, the sealed connector is configured to provide a waterproof and dustproof connection for the reset switch within the harness.
[0047] Thus, the present electric device and method, involving the adaptation and modification of the harness, provide a quick solution to vehicle breakdowns related to MVCU fault states. It extends the lifespan of the auxiliary (aux) battery by preventing excessive drain during long periods of nonuse. The addition of the reset and kill switch eliminates unnecessary rework at the manufacturing plant and dealership, thereby increasing productivity. This process also preserves the vehicle's fit and finish by avoiding the need to reopen the vehicle. Additionally, the reset switch functions as a kill switch, indirectly preventing vehicle theft. Furthermore, it prevents the battery from waking up during transportation, ensuring safety and efficiency.
[0048] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, utilized, or combined with other elements, components, or steps that are not expressly referenced.
[0049] No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
[0050] It will be apparent to those skilled in the art that various modifications and variations can be made to the present invention without departing from the scope of the invention. There is no intention to limit the invention to the specific form or forms enclosed. On the contrary, the intention is to cover all modifications, alternative constructions, and equivalents falling within the scope of the invention, as defined in the appended claims. Thus, it is intended that the present invention cover the modifications and variations of this invention, provided they are within the scope of the appended claims and their equivalents.
, Claims:I/We claim:
1. An electrical device (100) for minimizing draining of an auxiliary battery (102) in an electric vehicle (104), comprising:
a reset switch (106);
a fuse (108);
a Master Vehicle Control Unit (MVCU) (110), wherein the reset switch (106) is integrated within a harness using a sealed connector, wherein the reset switch (106) is connected in series with the MVCU (110) through the fuse (108); and
a protection cover (112) configured to encase the reset switch (106) to prevent unintended operation.

2. The electrical device (100) as claimed in claim 1, wherein the reset switch (106) is implemented as an on-off reset switch with a rating of 250V and 6A, in series with the permanent supply of the auxiliary battery (102).

3. The electrical device (100) as claimed in claim 1, wherein the fuse (108) is a 5A fuse.

4. The electrical device (100) as claimed in claim 1, wherein the sealed connector is a 90 series two-pole sealed connector.

5. The electrical device (100) as claimed in claim 1, wherein the reset switch (106) is connected in series with a permanent 12V supply of the MVCU (110) through the fuse (108).

6. A method for extending the lifespan of an auxiliary battery of an electric vehicle, comprising:
integrating a reset switch within a harness using a sealed connector;
incorporating the reset switch in series with a permanent 12V supply of a Master Vehicle Control Unit (MVCU) through a fuse; and
covering the reset switch with a protection cover to prevent unintended activation.

7. The method as claimed in claim 6, wherein the reset switch is configured to cut the supply to the MVCU during transportation to avoid auto wake-up of the vehicle.

8. The method as claimed in claim 6, wherein the reset switch is implemented as an On-Off type reset switch with a rating of 250V and 6A.

9. The method as claimed in claim 6, wherein the sealed connector is a 90 series two pole sealed connector.

10. The method as claimed in claim 6, wherein the sealed connector is configured to provide a waterproof and dustproof connection for the reset switch within the harness.