System and method for controlling cycling of a vehicle contactor

A system for controlling the cycling of a high voltage contactor that is connected to a high voltage bus on a vehicle, the system comprising:

• a battery control module (BCM) configured to generate a first contactor command for the contactor, wherein the contactor is activated in response to the first contactor command;
• a controller having a timer that is initiated when the first contactor command has been generated, wherein the timer is set to expire once a predetermined cycle time has been reached, the controller, prior to the timer expiring, determining whether a second contactor command should be generated subsequent to the generation of the first contactor command based at least in part upon the position of a vehicle ignition switch;
• and
• wherein upon determining that the second contactor command should be generated, the BCM generates the second contactor command upon the expiration of the timer, thereby activating the contactor in response to the second contactor command.

A method of controlling cycling of a high voltage contactor that is configured to couple a high voltage battery to a generator and a motor over a high voltage bus, wherein the contactor, the generator, the motor and the high voltage bus are located on a hybrid electric vehicle (HEV), the method comprising:

• generating a first contactor command in response to placement of a vehicle ignition in an ignition-on position;
• closing the contactor in response to the first contactor command being generated to couple the high voltage battery to the generator and the motor over the high voltage bus;
• initiating a timer when the first contactor command has been generated, wherein the timer is set to expire once a predetermined cycle time has been reached;
• determining, based on the timer, whether a second contactor command should be generated subsequent to the generation of the first contactor command in response to placement of a vehicle ignition in an ignition-off position;
• opening the contactor in response to the second contactor command being generated when the timer has expired to de-couple the high voltage battery from the generator and the motor;
• generating the first contactor command subsequent to the second contactor command in response to a second placement of the vehicle ignition in the ignition-on position;
• closing the contactor in response to the first contactor command being generated subsequent to the second contactor command being generated to couple the high voltage battery to the generator and the motor over the high voltage bus;
• and
• initiating the timer when the first contactor command has been generated subsequent to the second contactor command.