Battery-spark and reverse polarity protection method and circuit for safely connecting a trolling motor to a power source
View Patent ↗The protection method and circuit provide a time delay after a first contact with the power source is made until full power is allowed connection to the trolling motor. This time delay is longer than the “bounce” time, or the time a user may “bounce” a contact on and off of a battery terminal, during a typical batter connection. Therefore, this delay prevents sparking at the battery terminal. During the time delay, an initial pre-charge brings the main capacitor's voltage up to the battery voltage in a low stress, no spark process prior to being connected directly across the battery source terminal by relay contacts.
1. A power control circuit for providing battery spark and reverse polarity protection in a trolling motor, the power control circuit comprising:
a power control switch, a first pole of the power control switch electrically coupled to a positive battery cable of the trolling motor, the power control switch in a normally open position;
a charging circuit electrically coupled to a second pole of the power control switch, the charging circuit further coupled to the positive battery cable, wherein when the positive battery cable makes an initial contact with a positive battery terminal, a pair of main capacitors in the charging circuit begin charging; and
a delay circuit electrically coupled to the positive battery cable, wherein the delay circuit closes the power control switch after a predetermined time delay after the initial contact.
2. The power control circuit of claim 1 , wherein the charging circuit pre-charges the pair of main capacitors through a charging diode and a charging resistor.
3. The power control circuit of claim 2 , wherein the charging diode prevents reverse polarity current from reaching the pair of main capacitors.
4. The power control circuit of claim 1 , wherein the charging circuit charges the pair of main capacitors to 90 percent of maximum before the power control switch is closed.
5. The power control circuit of claim 1 , wherein the delay circuit closes the power control switch 300 milliseconds after the initial contact.
6. The power control circuit of claim 1 , wherein the delay circuit further includes a relay coil and a pair of transistors connected in a high-gain, darlington configuration such that the pair of transistors drive the relay coil to close the power control switch when the pair of transistors reach a threshold voltage.
7. The power control circuit of claim 6 , wherein the delay circuit further includes a timing resistor and a timing capacitor, wherein a current through the timing resistor charges the timing capacitor to a bias voltage required to turn on the pair of transistors.
8. The power control circuit of claim 6 , wherein the pair of transistors further drive the relay coil to supply power to a pair of motor relays.
9. The power control circuit of claim 1 , wherein the charging and delay circuits are implemented on a controller board located in a controller head assembly.
10. The power control circuit of claim 1 , further including a tilt switch electronically coupled with the delay and charging circuits, the tilt switch turns off a throttle of the power control circuit when the trolling motor is tilted at a minimum tilt angle from an operating position.
11. The power control circuit of claim 10 , wherein the minimum tilt angle is in a range of forty-five to seventy-five percent.
12. The power control circuit of claim 10 , wherein the tilt switch is physically coupled to a top surface of the controller board.
13. The power central circuit of claim 1 , wherein a time delay from the initial contact to after the bounce time is an integral of CR/(Vb−Vc), wherein C is a fixed capacitance, R is a fixed resistance, Vb is a battery voltage and Vc is a delay capacitor voltage.
14. A method of preventing battery spark when connecting a trolling motor to a battery, the method comprising:
making an initial connection with a battery cable of a trolling motor to a battery terminal;
charging a pair of main capacitors in a charging circuit while a power control switch to the battery terminal is open;
delaying the closing of the power control switch for a predetermined amount of time with a delay circuit, wherein the predetermined amount of time is greater than a bounce time; and
closing the power control switch with the delay circuit at the end of the predetermined time period.
15. The method of claim 14 , wherein the charging circuit charges the pair of main capacitors through a charging diode and a charging resistor.
16. The method of claim 15 , wherein the charging diode prevents reverse polarity current from reaching the pair of main capacitors.
17. The method circuit of claim 14 , wherein the charging circuit charges the pair of main capacitors to 90 percent of maximum before the closing step.
18. The method of claim 14 , wherein the delay circuit effectuates the closing step 300 milliseconds after the initial contact.
19. The method of claim 14 , comprising driving a relay coil and with a pair of transistors in the delay circuit, wherein the pair of transistors are connected in a high-gain, darlington configuration when the pair of transistors reach a threshold voltage.
20. The method of claim 19 , further comprising charging a timing capacitor in the delay circuit to a bias voltage required to turn on the pair of transistors with a current through a timing resistor.
21. The method of claim 19 , further comprising driving the relay coil to supply a pair of motor relays with the pair of transistors.
22. The method of claim 14 , wherein the charging and delay circuits are implemented on a controller board located in a controller head assembly.
23. The method of claim 14 , further comprising coupling a tilt switch electronically with the delay in charging circuits, wherein the tilt switch turns off the throttle of the power control circuit when the trolling motor is tilted at a minimum tilt angle from an operating position.
24. The method of claim 23 , wherein the minimum tilt angle is in a range of forty-five to seventy-five percent.
25. The method of claim 23 , wherein the tilt switch is physically coupled to a top surface of the controller board.
26. The method of claim 14 , wherein a time delay from the initial contact to after the bounce time is an integral of CR/(Vb−Vc) wherein C is a fixed capacitance, R is a fixed resistance, Vb is a battery voltage and Vc is a delay capacitor voltage.
27. A delay circuit for providing a time delay to avoid a bounce time when connecting a pair of trolling motor battery cables to a battery, the delay circuit comprising:
a relay coil, wherein the relay coil controls a position of a power control switch, the power control switch being in a normally open position and electrically coupled between a positive battery cable of the trolling motor and a charging circuit; and
a pair of transistors connected in a high-gain darlington configuration that are turned on when a current through a timing resistor charges a timing capacitor to a bias voltage, wherein the pair of transistors reach a threshold voltage and drive the relay coil to close the power control switch, thus connecting a load to the battery terminals and avoiding the bounce time.