I IIIII IIIIIIII Ill lllll lllll lllll lllll lllll lllll lllll lllll 111111111111111111
`US007222684B2
`
`c12) United States Patent
`Norman et al.
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 7,222,684 B2
`May 29, 2007
`
`(54) SYSTEM, APPARATUS, AND METHOD FOR
`PROVIDING CONTROL OF A TOY VEHICLE
`
`(75)
`
`Inventors: David A. Norman, Greenville, TX
`(US); Robert H. Mimlitch, III,
`Rowlett, TX (US); Richard Torrance,
`Greenville, TX (US)
`
`(73) Assignee: Innovation First, Inc., Greenville, TX
`(US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`(21) Appl. No.: 10/076,795
`
`(22) Filed:
`
`Feb. 12, 2002
`
`(65)
`
`Prior Publication Data
`
`US 2002/0121395 Al
`
`Sep. 5, 2002
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/268,447, filed on Feb.
`12, 2001.
`
`(51)
`
`Int. Cl.
`B60K 1/00
`(2006.01)
`(52) U.S. Cl. ...................... 180/65.1; 446/465; 446/484
`(58) Field of Classification Search ............... 180/65.1,
`180/908, 167,170,174
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`4,334,221 A *
`4,336,858 A *
`4,341,982 A *
`5,056,613 A *
`5,172,665 A *
`5,349,276 A *
`5,453,672 A *
`5,762,532 A *
`5,951,362 A *
`5,994,853 A *
`6,287,167 Bl*
`6,468,127 Bl*
`6,591,178 B2 *
`* cited by examiner
`
`6/1982
`6/1982
`7/1982
`10/1991
`12/1992
`9/1994
`9/1995
`6/1998
`9/1999
`11/1999
`9/2001
`10/2002
`7/2003
`
`Rosenhagen et al ........... 463/6
`Loyzim ...................... 180/179
`Lahti et al. ................... 318/51
`Porter et al. ................ 180/178
`Kuroda .................. 123/339.22
`. ....... 318/268
`Mezzatesta et al.
`Avitan ........................ 318/493
`Ishizuka et al.
`............ 446/457
`Siu ............................ 446/462
`Ribbe .......................... 318/16
`Kondo
`....................... 446/454
`Lee ............................ 446/457
`Krueger et al. ............... 701/83
`
`Primary Examiner----Christopher P. Ellis
`Assistant Examiner-Bridget Avery
`(74) Attorney, Agent, or Firm-Fish & Richardson P.C.
`
`(57)
`
`ABSTRACT
`
`A system, apparatus, and method for providing a soft-start
`for a toy vehicle configured to be operated by a person. The
`method includes receiving a throttle signal operable to
`induce motion via a motor operating as a drive mechanism
`of the toy vehicle. A transition signal may be generated
`based on the throttle signal. The transition signal may be
`applied to effect operation of the motor. The transition signal
`may be a pulse width modulated signal having a duty cycle
`between 20 and 100 percent to provide for an acceleration
`that avoids the problems of conventional control systems.
`The transition signal may be ramped in a linear or non-linear
`fashion. The system may couple the soft-start control circuit
`between a ground terminal of a battery of the toy vehicle and
`motor(s), thereby allowing the soft-start control circuit to
`operate on a low voltage (i.e., not the high voltage of the
`battery).
`
`3,732,751 A *
`
`5/1973 Berman et al ................. 475/2
`
`40 Claims, 13 Drawing Sheets
`
`100
`
`

`

`U.S. Patent
`U.S. Patent
`
`May 29, 2007
`May 29, 2007
`
`Sheet 1 of 13
`Sheet 1 of 13
`
`US 7,222,684 B2
`US 7,222,684 B2
`
`0
`0
`
`0
`
`FIG.1
`
`~
`
`0
`
`

`

`200
`_f 218
`
`215
`
`2220
`
`220
`
`HI/LO
`SWITCH
`
`2250
`
`MOTOR
`
`MOTOR
`
`230b
`
`e •
`
`00
`•
`~
`~
`~
`
`~ = ~
`
`205
`
`BATIERY
`
`227 / I GND
`
`,,..-210
`
`FOOT
`PEDAL
`SWITCH
`
`FWD/REV
`SWITCH
`
`VBAn
`
`217
`
`FWD
`REV
`
`222b
`
`FIG. 2
`(PRIOR ART}
`
`I
`
`I
`
`225b
`
`~
`~
`N
`~\,Ci
`N
`0
`0
`-....J
`
`200
`3000
`r - - - - - - - - - - - - - - - - - - -~ - - - - - - - - - - - -~ - - - - - - - - - - - ,
`:
`205
`210
`215
`222o
`220
`225o
`I
`
`22
`8
`VBAn
`
`FOOT
`PEDAL
`SWITCH
`
`BATIERY
`
`_
`
`GND
`
`+
`
`212
`
`I
`I
`I
`I
`I 227
`I
`VBAn
`L_______________
`I
`315
`
`SOFT-START
`CONTROL
`CIRCUIT
`
`320b
`
`FWD
`
`FWD/REV
`SWITCH
`
`222b
`
`___n_n_n_rf 312
`
`HI/LO
`SWITCH
`
`MOTOR
`
`MOTOR
`
`225b
`
`230b
`
`I
`I
`I
`I
`I
`I
`I
`I
`_____________ ...J
`
`3200
`
`305
`FIG. 3
`
`('D
`('D
`
`rJJ =(cid:173)
`.....
`N
`0 ....
`....
`
`~
`
`d r.,;_
`-....l
`'N
`N
`N
`O'I
`00
`
`~ = N
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 3 of 13
`
`US 7,222,684 B2
`
`300b
`
`,---------,
`I
`I
`I
`I
`I
`I
`I
`I 305
`I
`I
`
`320b
`
`Soft-Start
`Control
`Circuit
`
`311~ _
`
`-5v+
`
`2050
`
`111(
`
`310
`
`-6V+
`1 I I I 1
`
`205b
`
`VBAn
`
`315
`
`212
`
`210
`
`FPS
`
`CIRCUIT BREAKER
`405
`
`I
`I
`I
`I
`I
`I
`I
`_J
`
`3200
`
`222b
`
`2220
`
`FORWARD
`REVERSE
`
`HIGH/LOW
`SWITCH
`
`FORWARD /REVERSE
`SWITCH
`
`220
`
`2250
`
`MOTOR
`
`FIG. 4
`
`

`

`I
`
`Power
`Supply
`Unit
`
`,,I
`
`""'
`.....
`
`-,
`
`315
`
`BATT
`
`BATT
`0
`
`I
`
`\
`
`5
`
`V
`
`2220
`
`FORWARD SHIFT
`REVERSE SHIFT
`
`222b
`
`\
`)
`
`505
`
`...
`...
`
`510
`
`I
`
`Controller
`
`_..,
`-,
`
`..
`...
`... ,,,..
`
`I
`
`Input
`Conditioning
`Unit
`
`520.../
`
`, ,
`Drive Circuit Signal
`Conditioning
`Unit
`
`, ,
`
`525\
`
`Drive Circuit
`
`.. -,
`
`l'---3200
`u
`
`312;mnn
`FIG. 5
`
`SOFT-START
`CONTROL
`CIRCUIT
`
`e •
`
`00
`•
`~
`~
`~
`
`~ = ~
`
`~
`~
`~
`N
`~\,Ci
`N
`0
`0
`-....J
`
`('D
`('D
`
`.i;...
`
`rJJ =(cid:173)
`.....
`0 ....
`....
`
`~
`
`d r.,;_
`
`-....l
`'N
`N
`N
`O'I
`00
`
`~ = N
`
`

`

`,---------
`I CONTROLLER
`510
`~
`I
`_f_ 'ff,
`I
`I
`- - - - - -
`INPUT CONDITIONING -1 I
`I I
`UNIT
`I I
`t5V I
`I I
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`I
`I I
`
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`
`Ql
`
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`
`R2
`
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`
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`
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`
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`
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`
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`
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`
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`
`ITIJ6
`
`525
`_L ______ --,
`liRi CIRCUIT
`I
`Vsott1
`I
`I
`I
`I~
`I
`MOTOR
`I
`rnJl
`
`630/
`
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`
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`
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`I
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`I DRIVE CIRCUIT = I I
`=
`.J:. I
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`-
`I
`JNIT ____ J I
`L---------------~
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`SUPPLY r 515
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`0 ....
`....
`
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`
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`
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`00
`
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`
`t5V
`
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`
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`
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`= 615 I
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`I
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`J 1_1
`I
`I
`I
`L--~---.J
`
`FIG. 6
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 6 of 13
`
`US 7,222,684 B2
`
`(a) V 11=I P=ED=AL=====:=:!(====--7-05-t
`
`V
`
`PEDAL
`
`V I PEDAL
`.
`
`(b)
`
`( c)
`
`V I SHIFT
`.
`
`(d)
`
`V I PEDAL
`.
`
`( e)
`
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`
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`
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`
`(g)
`
`(h)
`
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`
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`
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`
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`
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`
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`
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`
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`
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`Tg T10 T11
`T12
`
`r - - -_
`
`_,_/_740
`
`L_n___J
`T13 T14 T15
`T15
`
`FIG. 7
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 7 of 13
`
`US 7,222,684 B2
`
`--
`
`t--
`
`~
`+
`t--
`
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`
`..........
`
`---u ---
`
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`
`.....J c3 LLJ a..
`
`>
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 8 of 13
`
`US 7,222,684 B2
`
`.......... u
`Cl)
`en
`..___..
`.......
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`
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`
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`
`---0
`
`.............
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 9 of 13
`
`US 7,222,684 B2
`
`........... u
`Cl.)
`en
`....__.
`........
`
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`
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`
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`en
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`+ 1--
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`
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`oo
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`I
`
`I-(cid:173)
`::::,
`a_
`I-(cid:173)
`::::,
`0
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 10 of 13
`
`US 7,222,684 B2
`
`910
`
`915
`
`920
`
`905
`
`START
`
`RECEIVE SIGNAL(S)
`TO INDUCE MOTION OF
`TOY VEHICLE
`
`GENERATE TRANSITION
`SIGNAL RANGING FROM
`A FIRST TO A SECOND
`LEVEL OVER A TIME PERIOD
`
`APPLY TRANSITION
`SIGNAL TO MOTOR
`
`925
`
`END
`
`FIG. 9
`
`

`

`U.S. Patent
`U.S. Patent
`
`May 29, 2007
`May 29, 2007
`
`Sheet 11 of 13
`Sheet 11 0f 13
`
`US 7,222,684 B2
`US 7,222,684 B2
`
`0
`I.{'")
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`C>
`
`EggSE28
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`now
`
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`
`8%
`
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`
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`89
`
`
`

`

`I INPUTS
`,----1-1
`
`,,....-5050
`
`r--
`1
`R3 1 I
`I
`I
`I
`
`525a
`__r:_ ______ l
`
`---
`
`DRIVE CIRCUIT
`
`R11
`
`R12
`
`R5
`
`06
`
`Rl
`
`02
`
`I
`R7 I I
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`CONDITIONING I
`~ L _____________________ _
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`
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`
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`
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`
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`
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`
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`
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`
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`
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`I
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`I
`I
`
`R10
`
`FIG. 11
`
`=
`1105~
`-
`FAILSAFE O[T[CJ CIRCLITR\'
`L---------------
`
`MOTOR 1
`
`MOTOR 2
`
`I REIAY _{_ lOlO
`
`,- -,
`L___±__c-i i;
`I B I -
`I
`L - :::=--' _ _J
`r--r---------
`
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`
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`
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`
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`
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`
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`
`I
`
`e •
`
`00
`•
`~
`~
`~
`
`~ = ~
`
`~
`~
`N
`~\,Ci
`N
`0
`0
`-....J
`
`BATT
`
`-,
`
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`('D
`
`rJJ =(cid:173)
`.....
`....
`N
`0 ....
`....
`
`~
`
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`
`d r.,;_
`-....l
`'N
`N
`N
`O'I
`00
`
`~ = N
`
`

`

`U.S. Patent
`
`May 29, 2007
`
`Sheet 13 of 13
`
`US 7,222,684 B2
`
`1210
`
`12.15
`
`1220
`
`1225
`
`1235
`
`1205
`
`START
`
`RECEIVE ON/OFF
`SIGNAL INDICATIVE
`TO TURN ON/OFF MOTOR
`
`GENERATE SWITCH SIGNAL
`TO APPLY TO MOTOR
`
`MONITOR SWITCH
`SIGNAL
`
`DETERMINE IMPROPER
`OPERATION OF
`SWITCH SIGNAL
`
`NO
`
`YES
`
`DISENGAGE MOTOR
`FROM BATTERY
`
`1240
`
`END
`
`FIG. 12
`
`

`

`US 7,222,684 B2
`
`1
`SYSTEM, APPARATUS, AND METHOD FOR
`PROVIDING CONTROL OF A TOY VEHICLE
`
`CROSS-REFERENCES TO RELATED
`APPLICATIONS
`
`This Application for Patent claims the benefit of priority
`from, and hereby incorporates by reference for any and all
`purposes the entire disclosure of, co-pending U.S. Provi(cid:173)
`sional Application for Patent having Ser. No. 60/268,447,
`filed Feb. 12, 2001.
`
`BACKGROUND OF THE INVENTION
`
`1. Technical Field of the Invention
`The principals of the present invention generally relate to
`toy vehicles that may be ridden by people, and more
`specifically, but not by way of limitation, to a system,
`apparatus, and method for softening the initiation of motion
`of the toy vehicle.
`2. Description of Related Art
`As shown in FIG. 1, toy vehicles 100 for riding on or in
`have become popular for operators 110, such as children.
`The toy vehicles 100 may generally include ride-on and
`ride-in vehicles, including, but not limited to, automobiles,
`trucks, boats, airplanes, scooters, etc. Conventional control
`systems for the toy vehicles 100 have typically been limited
`to applying a direct current (DC) from a DC battery to a
`motor upon pressing or otherwise operating a "gas" pedal or
`other throttle mechanism. This type of control, however,
`basically operates as an on/off switch. In other words, when
`the pedal is pressed, the motor is applied a voltage for full
`power (i.e. maximum angular velocity). One reason for such
`a simplistic design is cost reasons.
`FIG. 2 is an exemplary block diagram of a conventional
`control system 200 for the toy vehicle 100. The conventional
`control system 200 includes a battery 205, foot pedal switch
`210, forward/reverse switch 215 for direction control, hi/lo
`switch 220 for fast and slow speeds, and motors 225a and
`225b. The toy vehicles 100 are typically limited to a battery 40
`205 for a power source rather than using other fuel sources,
`such as gasoline. The battery 205 is coupled to a foot pedal
`switch 210, which operates to provide power from the
`battery 205 to other electrical components of the control
`system 200 via line 212. The battery 205 supplies battery 45
`voltage V BATT· Additionally, the foot pedal switch 210
`operates as a failsafe device that prevents power from
`incidentally or accidentally being applied to the motors 225
`for safety purposes. To operate as a failsafe device, the foot
`pedal switch 210 is a "make or break" switch with a spring 50
`return to OFF as understood in the art. The foot pedal switch
`210 is further coupled to the forward/reverse switch 215 via
`line 217 and generates a throttle signal 218.
`The forward/reverse switch 215 receives battery power
`via line 217, is operable to switch the direction of the motors 55
`225 from forward to reverse so as to operate the toy vehicle
`100 forward or reverse, respectively. The forward/reverse
`switch produces two signals, FWD and REV, which are
`applied to the hi/lo switch 220 via lines 222a and 222b
`(collectively 222). The hi/low switch 220 is further coupled 60
`to the motors 225 and operable to drive the motors 225 in
`parallel or series to provide for high and low speed of the toy
`vehicle 100. Further, the hi/lo switch 220 is coupled to the
`negative terminal 227 of the battery 205, which is electri(cid:173)
`cally coupled to the low side. As understood in the art, each 65
`of the components of the control system 200 receive power
`from the battery, but that power is relatively high for solid
`
`2
`state electronics, thereby making alternative control systems
`difficult and too expensive for the toy industry to consider a
`viable option.
`There exists several problems when utilizing the control
`5 system 200, or any other basic direct drive system for
`controlling toy vehicles 100. These problems may include (i)
`excessive acceleration, (ii) jerk, (iii) safety ( e.g., controlling
`and flipping the vehicle at startup), and (iv) wearing of the
`mechanical components of the drive train for the toy vehicle
`10 100. While each of these problems have existed in the toy
`vehicles 100 for a long period of time, the toy industry and
`makers of toy vehicles 100 are very cost sensitive due to
`consumer pricing demands and production costs. Solutions
`to these problems have been unavailable due in large part to
`15 pricing and technical concerns of toy manufacturers for the
`toy vehicles 100.
`With regard to excessive acceleration (dV/dt) and jerk
`( dA/dt), the acceleration and jerk result in a whiplash effect
`on the operator 110 and passenger(s). In terms of wearing of
`20 the mechanical components, when the toy vehicle 100
`changes direction from forward to reverse and vice versa, a
`complete stop is not required. As all gear drives have a
`certain amount of backlash (i.e., small amounts of gap
`between gear teeth), the gears allow the motor to tum in the
`25 opposite direction without applying force to the output (e.g.,
`wheels) of the drive train until the entire backlash is reduced
`to zero, thereby subjecting the motors 225 and drive train to
`the full load at full speed at each change in direction. In other
`words, since the motor 225 has no significant initial resis-
`30 tance to movement in the opposite direction due to backlash,
`the motor 225 accelerates rapidly until the backlash is
`eliminated. The motor 225 is therefore moving at near full
`speed in the reverse direction while the vehicle is still
`moving in a high speed in the opposite direction. Once the
`35 backlash is eliminated, the input and output to the drive train
`are rotating in the opposite direction and the gears exert
`substantial forces on one another as the drive train suddenly
`reverses direction. These substantial forces tend to wear out
`the motors, gears, and other mechanical components in the
`drive train.
`In terms of safety, toy vehicles 100, such as automobiles
`and scooters, have the ability to flip or turnover due to the
`excessive acceleration of the toy vehicle 100. Additionally,
`because of the high acceleration, the wheels are often unable
`to gain traction on the surface, especially a wet surface. The
`traction problem, too, may result in the toy vehicle 100
`becoming uncontrollable for the operator 110 and passen(cid:173)
`gers, especially children. Additionally, toy manufacturers
`have been developing toy vehicles 100 with more speed and
`power thereby resulting in the exacerbation of the problems
`identified above.
`
`SUMMARY OF THE INVENTION
`
`To overcome the problems and limitations of conven(cid:173)
`tional control systems for toy vehicles, a soft-start control
`circuit may be integrated into the conventional control
`systems. The soft-start control circuit according to the
`principles of the present invention reduces or eliminates the
`above-identified problems, including excessive acceleration,
`jerk, flipping of the vehicle, and wearing of mechanical
`components. By integrating the soft-start control circuit into
`the existing control systems without having to redesign the
`fundamentals of the control systems, the toy makers quickly
`and easily may upgrade the toy vehicles for a cost that
`allows the toy to remain competitive within the consumer
`acceptable price range.
`
`

`

`3
`One embodiment according to the principals of the
`present invention includes a system and method for provid(cid:173)
`ing a soft start for a toy vehicle configured to be operated by
`a person. The method may include receiving a throttle signal
`operable to induce motion via a motor operating as a drive 5
`mechanism for the toy vehicle. A transition signal may be
`generated based on the throttle signal. The transition signal
`may be applied to affect operation of the motor. The tran(cid:173)
`sition signal may be a pulse width modulated signal having
`a duty cycle between 20 and 100 percent to provide for an 10
`acceleration that avoids the problems of conventional con(cid:173)
`trol systems and appears and feels more realistic. The
`transition signal may be ramped in a linear or non-linear
`fashion. The system according to the principles of the
`present invention may couple the soft-start control circuit 15
`between a negative terminal of a battery and motor( s) of the
`toy vehicle, thereby allowing the soft-start control circuit to
`switch a low-side voltage and not the high-side of the
`battery. A second embodiment according to the principals of
`the present invention includes a system and method for 20
`disabling a toy vehicle. According to the principles of the
`present invention, the method includes receiving an on/off
`signal indicative to tum on and off the motor. A switch signal
`is generated to apply to the motor to induce motion of the toy
`vehicle. Operation of the switch signal is monitored. An 25
`improper switch signal may be determined. The motor may
`be disengaged from the battery upon determining an
`improper switch signal.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`Amore complete understanding of the method and appa(cid:173)
`ratus of the present invention may be obtained by reference
`to the following Detailed Description when taken in con(cid:173)
`junction with the accompanying Drawings wherein:
`FIG. 1 is an exemplary toy vehicle being ridden by an
`operator, such as a child;
`FIG. 2 is an exemplary block diagram of a conventional
`control system utilized by the toy vehicle of FIG. 1;
`FIG. 3 is an exemplary block diagram including the
`conventional control system of FIG. 2 having a soft-start
`control circuit that incorporates the principles of the present
`invention integrated therewith;
`FIG. 4 is a more detailed exemplary block diagram of the
`control system for the toy vehicle providing the soft-start 45
`control circuit of FIG. 3;
`FIG. 5 is an exemplary block diagram of the soft-start
`control circuit of FIG. 3;
`FIG. 6 is an exemplary schematic of the soft-start control
`circuit of FIGS. 3-5;
`FIG. 7 provides eight exemplary conditioned input signals
`applied to the soft-start control circuit of FIG. 6;
`FIGS. SA-SC are an exemplary set of graphs that show the
`response of the soft-start control circuit of FIG. 6 to a change
`of input conditions provided by the operator of the toy
`vehicle;
`FIG. 9 is an exemplary flow diagram providing a high
`level operation of the soft-start control circuit of FIGS. 36;
`FIG. 10 is an exemplary block diagram of a control
`system of a toy vehicle of FIG. 1 that does not include a foot
`pedal;
`FIG. 11 is an exemplary schematic of a control circuit
`with failsafe circuitry of FIG. 10; and
`FIG. 12 is an exemplary flow diagram describing the 65
`failsafe operation of the control circuit with failsafe circuitry
`of FIGS. 10 and 11.
`
`US 7,222,684 B2
`
`4
`DETAILED DESCRIPTION OF THE
`PRESENTLY PREFERRED EXEMPLARY
`EMBODIMENTS
`
`The principals of the present invention provide for a
`soft-start control circuit capable of being integrated into a
`conventional control system for toy vehicles. The soft-start
`control circuit is operable to reduce excessive acceleration
`generated by the conventional control systems due to
`switching battery voltage directly to motor(s) of the toy
`vehicles. A soft-start circuit may utilize a processor for
`receiving signals from the conventional control system and
`applying a transition signal such that the motor(s) are not
`excessively accelerated. The transition signal is variable
`such that full power is not substantially instantaneously
`applied to the motor. In other words, the transition signal
`causes the motor to be ramped from no power to full power.
`In one embodiment, the soft-start control circuit is coupled
`between a ground terminal of a battery of the toy vehicle and
`a low-side terminal of the motor(s). The transition signal
`generated by the soft-start control circuit may be a pulse
`width modulation signal having a duty cycle between 20 and
`100 percent, linearly ( e.g., ramp) or non-linearly ( e.g.,
`exponential), at startup, thereby reducing or eliminating
`excessive acceleration. Additionally, the soft-start control
`circuit may include failsafe circuitry to provide the operator
`of the toy vehicle the ability to disable the motors of the
`vehicle for safety purposes.
`FIG. 3 is an exemplary block diagram 300 including the
`30 conventional control system 200 having a soft-start control
`circuit 305 integrated therewith. As shown, the soft-start
`control circuit is coupled between the negative terminal 227
`of the battery 205 and the hi/lo switch 220. The soft-start
`control circuit 305 further receives inputs of the positive
`35 terminal 228 of the battery 205 and forward and reverse
`signals 222a and 222b. The battery voltage V BATT simply
`provides operational power to the soft-start control circuit
`305, and the forward and reverse signals 222 provide an
`indication that the foot pedal switch 210 is engaged and for
`40 indicating when a shift between forward and reverse occurs.
`The soft-start control circuit 305 is operable to apply a
`transition signal 312 on the return path 320a and 320b
`(collectively 315) between the motors 225 and the battery
`205.
`The soft-start control circuit 305 is integrated in the return
`path 320 of the control system 300, however, it should be
`understood that the soft-start control circuit 305 could be
`included in the forward path (i.e., between the positive
`terminal 228 of the battery 205 and the motors 225) to affect
`50 the high-side voltage to the motors 225. However, by
`integrating the soft-start control circuit 305 in the return path
`320, the circuitry is less complicated and less expensive due
`to not having to use field effect transistors as a high-side
`switch. Additionally, the soft-start control circuit 305 may be
`55 disabled via a jumper ( e.g., switch) or altering control
`parameters, either by software or hardware, of the soft-start
`control circuit 305.
`FIG. 4 is a more detailed exemplary block diagram 300b
`of the control system for the toy vehicle 100 providing the
`60 soft-start control circuit 305. The six-volt batteries 205a and
`205b are connected in series so as to provide for a total
`battery voltage V BATT of twelve volts, which is delivered to
`the foot pedal switch 210 and the soft-start control circuit
`305 via line 212. Again, the soft-start control circuit 305
`utilizes the battery voltage V BATT for a power supply, and
`does not switch the battery voltage V BATT· If soft-start
`control circuit 305 were operating in the forward path of the
`
`

`

`US 7,222,684 B2
`
`5
`control system, then the battery voltage V BATT would be
`switched. The foot pedal switch 210 is normally open such
`that when the passenger 110 running the toy vehicle 100
`engages the foot pedal switch 210, a connection is made
`(i.e., the switch is closed) and the battery voltage is applied 5
`to the rest of the control system 300b. A circuit breaker 405
`is utilized to prevent an overcurrent situation and to avoid
`damaging other electrical components or the motors 225.
`The forward/reverse switch 215 is shown as being nor(cid:173)
`mally open. Upon the operator 110 shifting between forward 10
`and reverse, the forward/reverse switch 215 closes and the
`motors 225 are applied a reverse polarity to change driving
`direction of the toy vehicle 100. The forward and reverse
`signals 222a and 222b, are applied to the soft-start control
`circuit 305 for determining that the foot pedal switch 210 is 15
`engaged and for indicating when a shift between forward
`and reverse occurs. The hi/lo switch 220 is operable to allow
`the passenger 110 to shift the speed of the vehicle from low
`to high and vice-versa. Because the hi/lo switch 220 is
`normally open, the toy vehicle 100 is configured to be in low 20
`speed mode by operating the motors in series (i.e., each
`motor operates on six volts as understood in the art). Upon
`a shift from low to high speed, the hi/lo switch 220, which
`is a double-pole double-throw switch, configures the motors
`225 to be operating in parallel, thereby operating both 25
`motors on twelve volts.
`As shown, the soft-start control circuit 305 is coupled to
`the low-side of230a and 230b of the motors 225 to allow the
`soft-start control circuit 305 to apply a transition signal 312
`to the motors 225. The transition signal 312 operates to
`affect the angular velocity of the motors 225 by altering the
`average voltage being applied to or drawn by the motors
`225. In one embodiment, the transition signal 312 is a pulse
`width modulation signal having a duty cycle that ranges
`from about 20 to 100 percent, where the motors 225 deliver 35
`full power when the duty cycle is 100 percent.
`FIG. 5 is an exemplary block diagram 500 ofan embodi(cid:173)
`ment of the soft-start control circuit 305. The soft-start
`control circuit 305 includes an input conditioning unit 505,
`controller 510, power supply unit 515, drive circuit signal
`conditioning unit 520, and drive circuit 525. The power
`supply unit 515 is operable to receive the plus and minus
`(i.e., ground) battery voltage ( + V BATT and -V BATT) and
`generate a five-volt ( +5V) supply for the other components
`of the soft-start control circuit 305. The input conditioning
`unit 505 is operable to receive the forward and reverse
`signals 222a and 222b, which may be analog or digital, and
`condition the signals for input to the controller 510. In an
`alternative embodiment, the soft-start control circuit 305
`simply may be powered-up and begin performing the soft(cid:173)
`start functionality (e.g., acceleration control). The controller
`510 receives the conditioned forward and reverse signals for
`generating and applying the transition signal 312 to the
`return path 320a, which may be ramped and/or delayed
`based on the forward and reverse signals 222a and 222b. The
`controller 510 may utilize a processor that executes software
`to perform the logical decisions and generate the transition
`signal 312 based on an algorithm, for example. The software
`may be stored in ROM or other storage device to be read by
`the processor and executed thereby. The drive circuit signal
`conditioning unit 520 is operable to condition or prepare the
`output of the controller for the drive circuit 525. The drive
`circuit 525 operates to apply the transition signal 312
`generated by the controller 510 to the low-side 230a and
`230b of the motors 225.
`FIG. 6 is an exemplary schematic of an embodiment of
`the soft-start control circuit 305 of FIGS. 3-5. As shown, the
`
`6
`schematic includes the input conditioning unit 505, control(cid:173)
`ler 510, power supply unit 515, drive circuit signal condi(cid:173)
`tioning unit 520, and drive circuit 525. The power supply
`unit 515 develops a five-volt source 605, which may be
`utilized by the input conditioning unit 505, controller 510,
`and drive circuit signal conditioning unit 520. The input
`conditioning unit 505 receives the forward and reverse
`signals 222a and 222b via connectors JS and J7, respec-
`tively. Diodes 610a and 610b are utilized to protect other
`components of the input conditioning unit 505 and prevent
`false triggering of the soft-start control circuit 305. Addi(cid:173)
`tionally, the diodes 61 Oa and 61 Ob provide isolation of the
`forward and reverse signals 222a and 222b as one is high
`(e.g., positive) and the other low (e.g., negative). Alterna(cid:173)
`tively, the two signals could be implemented as separate
`signals input to the processor. The forward and reverse
`signals 222a and 222b are logically OR' d to determine when
`at least one of the signals 222a and 222b is high. Upon
`determining that one of the forward 222a or reverse 222b
`signals is high, the transistor QlO is utilized to generate a
`five-volt input signal to the controller 510.
`The controller 510 includes a processor 615 that executes
`software to develop the transition signal to 312. The pro(cid:173)
`cessor 615 receives the five-volt signal from QlO to indicate
`that either the forward or reverse signal 222a and 222b is
`high. The processor 615 executes the software and outputs
`the appropriate transition signal 312 to the drive circuit
`signal conditioning unit 520 via line 620. The drive circuit
`30 signal conditioning unit 520 performs a level shift of the
`transition signal 312 via transistor QS in preparation for the
`drive circuit.
`The drive circuit 525 includes a bridge circuit 625 formed
`of two transistors Q3 and Q7. The bridge circuit is operable
`to form a push-pull drive to tum field effect transistors
`(FE Ts) Q5 and Q6 on and off. The FE Ts Q5 and Q6, which
`may be part number IRL2203NS ( one producer being Inter(cid:173)
`national Rectifier, El Segundo, Calif. 90245), are used as
`40 high current switches that apply the pulse width modulation
`formed by the processor 615 between the motor 225 and
`negative terminal 227 of the battery 205. The Schottky
`diodes 630 operate as a "fly back" diodes that handle current
`feedback from the motors 225 due to the pulse width
`modulation of the motor 225 to prevent the FETs Q5 and Q6
`from burning up.
`FIG. 7 provides eight exemplary conditioned input signals
`705-740 applied to the controller 510 via controller input
`line 612 based on the foot pedal and shift for changing
`50 direction. The conditioned input signals 705-740 are indica(cid:173)
`tive of either pedal or forward/reverse shift operations of the
`toy vehicle 100. It should be understood that the toy vehicle
`100 could have other functions or mechanisms that are
`utilized by the controller 510 to affect operation of the
`55 motors 225.
`FIG. 7(a) provides conditioned input signal 705 that
`indicates that the toy vehicle 100 is off and that the pedal is
`not depressed, thereby causing the foot pedal switch 210 to
`remain open. FIG. 7(b) provides conditioned input signal
`60 710 that indicates that the pedal is depressed at time Tl,
`thereby causing the foot pedal switch 210 to close. FIG. 7(c)
`provides conditioned input signal 715 that indicates that the
`pedal is released at time T2, thereby causing the foot pedal
`switch 210 to open. FIG. 7(d) provides conditioned input
`65 signal 720 that indicates that a direction shift is initiated via
`a shift stick or other mechanism while the pedal is
`depressed, thereby causing the conditioned signal input to
`
`45
`
`

`

`US 7,222,684 B2
`
`7
`the controller 510 to toggle OFF at time T3 and back ON at
`time T4 so that the processor 615 recognizes that a shift
`occurs.
`FIG. 7(e) provides conditioned input signal 725 that
`indicates that the pedal is momentarily released ( e.g., foot 5
`slips off pedal), thereby causing the conditioned input signal
`725 to toggle at times TS and T6. FIG. 7(j) provides
`conditioned input signal 730 that indicates that the pedal is
`momentarily pressed ( e.g., foot accidentally presses the
`pedal), thereby causing the conditioned input signal 730 to 10
`toggle at times T7 and TS. FIG. 7(g) provides conditioned
`input signal 735 that indicates that the pedal is being pulsed
`by the operator 110 of the toy vehicle 100, thereby causing
`the conditioned input signal 735 to toggle at times T9-T12.
`FIG. 7(h) provides conditioned input signal 740 that indi- 15
`cates that a direction shift is being pulsed by the operator 110
`of the toy vehicle 100,