Bimodal emergency energy supply system for emergency unhooking of high-voltage battery

Abstract

The invention discloses a bimodal emergency energy supply system for emergency unhooking of a high-voltage battery, and belongs to the technical field of new energy automobile safety, and the bimodal emergency energy supply system comprises a wired emergency channel which comprises a super capacitor energy storage module and provides instantaneous high-power electric energy for the system; the wireless emergency channel is constructed based on a magnetic resonance coupling principle and provides non-contact electric energy transmission for the system; the intelligent arbitration module is in signal connection with the wired emergency channel and the wireless emergency channel, monitors state parameters of each channel in real time, and preferentially selects the wired emergency channel based on a preset arbitration strategy, selects the wireless emergency channel when the wired emergency channel is unavailable or the performance is insufficient, or fuses electric energy output of the wired emergency channel and the wireless emergency channel; wherein the electric energy output end of the system is connected to the emergency unhooking execution module and is used for outputting electric energy to the emergency unhooking execution module so as to trigger the unhooking action. According to the application, the limitation of a single path is broken through by adopting a bimodal energy supply mode, and emergency physical isolation of a high-voltage loop can be ensured to be realized within the shortest time.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle safety technology, and in particular to a dual-mode emergency power supply system for emergency disconnection of high-voltage batteries. Background Technology

[0002] With the rapid development of new energy vehicles, the safety of power batteries has become a key technological bottleneck restricting the industry's development. Existing power battery mounting structures typically employ rigid connections; if a battery experiences thermal runaway and triggers a fire, the fire can quickly spread to the entire vehicle, causing serious casualties and property damage.

[0003] To address this issue, existing technology provides a quick-release device for power batteries and a vehicle (patent publication number CN118833031A), which achieves physical separation of the battery pack through a mechanical unlocking mechanism. The device includes a bracket mechanism (comprising an upper bracket and a lower bracket), a locking mechanism (including a locking element and a mating element), and an unlocking and disengagement mechanism (a driving element, a driven frame, and an unlocking element). Upon thermal runaway triggering a signal via a mechanical transmission path, the driving element drives the driven frame to slide along a preset direction. The locking state is released by the cooperation of the inclined surface and the unlocking element, causing the upper and lower brackets to separate along a first direction, thereby achieving rapid disengagement of the power battery from the vehicle frame.

[0004] However, the mechanical transmission path of this device relies on the coordinated movement of the driving components (such as motors / hydraulic cylinders), driven frame, and unlocking components. Its response time is limited by the mechanical friction coefficient, structural clearance, and transmission efficiency, making it difficult to meet the industry safety standard of completing detachment within 3-5 minutes in the early stage of thermal runaway. At the same time, under long-term use, the driving components are prone to output torque decay due to lubrication failure. The inclined mating structure between the driven frame and the unlocking components may become stuck due to foreign object intrusion, material fatigue, or high-temperature creep. Under extreme conditions (such as -40℃ low temperature or 150℃ high temperature environment), it may even fail completely, thus leading to the inability to successfully unlock and detach in emergency situations. Summary of the Invention

[0005] The purpose of this invention is to provide a dual-mode emergency power supply system for emergency disconnection of high-voltage batteries, so as to solve the problems of response delay, low reliability of action and easy failure under extreme conditions caused by the reliance on a single energy supply method in the emergency disconnection actuator of the prior art.

[0006] To achieve the above objectives, this application adopts the following technical solution:

[0007] This application discloses a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, which is activated upon receiving an emergency disconnection command. Its features include:

[0008] A wired emergency channel, including a supercapacitor energy storage module, is used to provide instantaneous high-power electrical energy to the system;

[0009] A wireless emergency channel, constructed based on the principle of magnetic resonance coupling, is used to provide contactless power transmission for the system.

[0010] The intelligent arbitration module is connected to the wired emergency channel and the wireless emergency channel to monitor the status parameters of each channel in real time, and selects the wired emergency channel first based on a predetermined arbitration strategy, and selects the wireless emergency channel when it is unavailable or has insufficient performance, or combines the power output of the two.

[0011] The power output terminal of the system is connected to the emergency uncoupling execution module, which provides the power output to the emergency uncoupling execution module to trigger the uncoupling action.

[0012] Preferably, the wired emergency channel also includes:

[0013] The physically isolated power supply network unit is installed in the positive output path of the vehicle-mounted low-voltage power supply system, electrically isolated from the high-voltage network, and includes a controlled disconnecting switch device for conducting the charging circuit from the vehicle-mounted low-voltage power supply system to the supercapacitor energy storage module when the emergency disconnection command is received.

[0014] The self-detection and switching control unit is used to monitor the state of charge, key operating parameters and electrical safety status of the supercapacitor energy storage module in real time, and send a fault signal to the intelligent arbitration module when an abnormality is detected.

[0015] Preferably, the supercapacitor energy storage module adopts a hybrid energy storage structure, including:

[0016] The first-stage energy storage unit, consisting of a double-layer capacitor array, is used to provide instantaneous pulse power in the millisecond range.

[0017] The second-stage energy storage unit, composed of lithium-ion capacitors, is used to provide continuous power output for a certain period of time after the first-stage energy storage unit has discharged.

[0018] Preferably, the wireless emergency channel includes:

[0019] The energy transmitting end includes a high-frequency inverter circuit and a transmitting coil, which is used to convert direct current into a high-frequency alternating magnetic field;

[0020] The energy receiving end includes a receiving coil, a dynamic impedance matching network, and a rectifier circuit, used to receive the high-frequency alternating magnetic field and convert it into DC output.

[0021] The wireless communication and control unit uses load modulation for in-band communication and executes a secure handshake protocol based on encryption algorithms to achieve device authentication and data transmission.

[0022] Preferably, the arbitration strategy of the intelligent arbitration module includes:

[0023] The wired emergency channel is enabled by default.

[0024] When the wired emergency channel is determined to be below a set threshold or to be faulty based on real-time monitoring data, it will automatically switch to the wireless emergency channel.

[0025] When it is determined from real-time monitoring data that the wireless emergency channel has failed to handshake multiple times in a row, a forced switchback to the wired emergency channel is initiated.

[0026] Preferably, the intelligent arbitration module also has a pre-configured three-level emergency protocol for performing the following operations when both the wired and wireless emergency channels are insufficient or unavailable:

[0027] a. Activate the backup supercapacitor bank;

[0028] b. Activate degraded power supply mode to limit output power;

[0029] c. Send the highest level of security alert to the vehicle control system.

[0030] Preferably, the intelligent arbitration module also includes an energy composite output control unit, which adopts an ORing circuit architecture, selectively or simultaneously obtains power from the wired emergency channel and the wireless emergency channel, and performs dynamic current sharing control to synthesize a total output that meets the power requirements.

[0031] Preferably, the emergency unhooking execution module is an electromagnetically driven explosive bolt, which includes a bolt body connecting a high-voltage circuit and a vehicle body, a magnetic material disposed within the bolt body, an electromagnetic coil surrounding the magnetic material, and a detonation device linked to the magnetic material.

[0032] The high current provided by the system generates a strong magnetic field through the electromagnetic coil of the bolt, driving the magnetic material to move, thereby mechanically triggering the detonation device and completing the unhooking.

[0033] Preferably, the system is powered by the vehicle-mounted low-voltage power supply system;

[0034] The vehicle-mounted low-voltage power supply system continuously supplies power to the energy transmitter of the wireless emergency channel under normal and emergency conditions, and charges the supercapacitor energy storage module when the intelligent arbitration module determines that the wired emergency channel is activated.

[0035] An electric vehicle equipped with a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery as described in any of the preceding claims.

[0036] The present invention has the following beneficial effects:

[0037] 1. The system employs two parallel power supply modules: a wired emergency channel and a wireless emergency channel. The wired channel, based on a supercapacitor, can provide high power output in a short time to quickly cut off high-voltage circuits. The wireless channel, based on magnetic resonance coupling, can also respond rapidly and achieve efficient energy transmission. This dual-mode power supply method overcomes the limitations of a single path; even if one channel fails, the other can continue to operate, greatly improving the system's reliability and stability.

[0038] 2. Through the intelligent arbitration module, the priority of wired and wireless emergency channels is dynamically adjusted based on real-time status monitoring, and composite energy output control is realized. This can improve the intelligence level and adaptability of the system, and ensure emergency physical isolation of the high-voltage circuit in the shortest possible time, effectively improving the safety of electric vehicles.

[0039] 3. The supercapacitor energy storage module in the wired emergency channel adopts a hybrid energy storage structure. The front end is a 10F / 48V double-layer capacitor array, providing millisecond-level pulse discharge; the back end is a 100mF / 60V lithium-ion capacitor for continuous power supply. This hybrid energy storage design can provide high power output in a short time while ensuring the system's continuous power supply capability, taking into account both instantaneous power and continuous power supply requirements, thus improving the system's reliability and stability.

[0040] 4. The wireless emergency channel is based on magnetic resonance coupling technology. Through the energy transmitter and receiver, and in conjunction with the wireless control strategy, it achieves efficient energy transmission. The equipped triaxial receiving coil and dynamic matching network can automatically adapt to vehicle assembly tolerances, ensuring efficient energy reception under different installation positions and postures, effectively solving the impact of vehicle assembly errors on energy transmission efficiency. Attached Figure Description

[0041] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0042] Figure 1 This is a schematic diagram of a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, provided in an embodiment of this application.

[0043] Figure 2This is a schematic diagram of the structure of the wired emergency channel provided in the embodiments of this application;

[0044] Figure 3 This is a flowchart of the self-detection unit provided in the embodiments of this application;

[0045] Figure 4 This is a flowchart illustrating the operation of a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, as provided in an embodiment of this application. Detailed Implementation

[0046] To make the technical solution of this application clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. The terms "first," "second," etc., in the claims and specification of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such terms can be used interchangeably where appropriate. This is merely a way of distinguishing objects with the same attributes in the embodiments of this application. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion, so that a process, method, system, product, or apparatus that comprises a series of units is not necessarily limited to those units, but may include other units not explicitly listed or inherent to these processes, methods, products, or apparatuses.

[0047] like Figure 1 As shown, this disclosure provides a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, which is activated upon receiving an emergency disconnection command. The system is characterized by comprising:

[0048] The wired emergency channel includes a supercapacitor energy storage module to provide instantaneous high-power electrical energy to the system;

[0049] The wireless emergency channel, built based on the principle of magnetic resonance coupling, is used to provide contactless power transmission for the system;

[0050] The intelligent arbitration module is connected to the wired emergency channel and the wireless emergency channel to monitor the status parameters of each channel in real time. Based on a predetermined arbitration strategy, it prioritizes the wired emergency channel, selects the wireless emergency channel when the wired channel is unavailable or has insufficient performance, or combines the power output of both.

[0051] The system's power output terminal is connected to the emergency uncoupling execution module, which provides power output to the emergency uncoupling execution module to trigger the uncoupling action.

[0052] This disclosure provides a dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, which activates upon receiving an emergency disconnection command. The command requires the simultaneous fulfillment of three conditions: a) the main battery temperature exceeds 15°C; b) the voltage descent rate reaches 500V / s or higher and lasts for 5ms; c) the CAN bus must receive a 0x3FF safety alarm signal. The 0x3FF alarm falls under the ASIL-D functional safety requirement defined by the ISO 26262 standard—the highest level of safety certification in automotive electronic systems, specifically for critical systems that could directly cause fatal safety accidents. The appearance of this specific alarm signal indicates the detection of abnormal states such as communication interruption or data tampering on the CAN bus, and that such an anomaly has been determined to be an emergency situation that may pose an extreme threat to the safety of the entire vehicle, necessitating immediate disconnection protection measures.

[0053] Through a multi-dimensional cross-verification mechanism based on temperature, voltage, and communication status, the system avoids the risk of false triggering and ensures that emergency power supply is initiated with a millisecond-level response speed in real thermal runaway scenarios, driving the rapid and reliable triggering of the high-voltage battery physical isolation device, thereby achieving immediate protection for the safety of the entire vehicle.

[0054] Specifically, the system employs two parallel energy supply modules: a wired emergency channel and a wireless emergency channel. The wired emergency channel, based on a supercapacitor energy storage module, can provide high power output in a short time, quickly cutting off the high-voltage circuit. The wireless emergency channel, built on the principle of magnetic resonance coupling, can also respond rapidly, achieving contactless and efficient energy transmission. This dual-mode energy supply method overcomes the limitations of a single path; the two channels act as hot backups for each other. Even if one emergency channel fails, the other can continue to operate, greatly improving the system's reliability and stability. For example, in a collision emergency disengagement scenario, the total time from the collision sensor triggering the safety state to driving the explosive bolts to cut off the high-voltage connection is less than 100ms, significantly improving response speed, effectively reducing accident risks, and enhancing the safety of personnel and vehicles.

[0055] The system also includes an intelligent arbitration module, which is the core control unit. Its signals are connected to both the wired and wireless emergency channels, and it monitors parameter changes in both channels in real time. Based on a pre-set arbitration strategy and the acquired real-time channel information, it dynamically adjusts the priorities of the wired and wireless emergency channels, achieving composite energy output control. For example, when the state of charge (SOC) of the wired emergency channel is detected to be below 20%, it switches to the wireless emergency channel promptly to ensure a continuous supply of emergency energy. If the wireless emergency channel fails to connect three times consecutively, the wired emergency channel is forcibly activated, ensuring the system can operate normally under any circumstances. This intelligent arbitration mechanism and composite energy output control not only intelligently select the optimal energy supply path but also ensures emergency physical isolation of the high-voltage circuit in the shortest possible time, effectively improving the safety of electric vehicles.

[0056] The system's energy output is connected to an emergency disconnection execution module, which triggers physical isolation by receiving energy output. Specifically, when the system determines that the main battery is thermally runaway, the intelligent arbitration module controls the dual-mode emergency power supply module to output instantaneous energy to the emergency disconnection execution module, driving it to quickly physically disconnect the high-voltage battery from the load, thereby achieving the emergency disconnection function.

[0057] In some embodiments, such as Figure 2 As shown, the wired emergency access route also includes:

[0058] The physically isolated power supply network unit is located in the positive output path of the vehicle-mounted low-voltage power supply system, electrically isolated from the high-voltage network, and includes a controlled disconnecting switch device for conducting the charging circuit from the vehicle-mounted low-voltage power supply system to the supercapacitor energy storage module when an emergency disconnection command is received.

[0059] The self-detection and switching control unit is used to monitor the state of charge, key operating parameters and electrical safety status of the supercapacitor energy storage module in real time, and send a fault signal to the intelligent arbitration module when an abnormality is detected.

[0060] Specifically, the physically isolated power supply network unit is a sheet metal isolation cavity structure installed in the positive output path of the vehicle's low-voltage power supply system. This sheet metal isolation cavity is integrally molded from high-strength alloy material, possessing excellent mechanical strength and anti-electromagnetic interference performance. An aluminum nitride ceramic substrate is fixedly installed inside, which not only has good insulation properties but also achieves efficient heat dissipation of the electronic components within the cavity through its high thermal conductivity, ensuring stable operation of the unit in complex vehicle environments. Preferably, the isolation distance of this physically isolated cavity is greater than or equal to 800 mm, thereby effectively blocking the coupling path of high-voltage electromagnetic signals. The overall withstand voltage rating of this unit reaches 3000V, capable of withstanding transient overvoltage impacts that may occur in the vehicle's high-voltage system. Therefore, in the event of leakage, short circuit, or other failures of the high-voltage battery, it reliably isolates the electrical connection between the high-voltage circuit and the emergency channel, preventing the risk of functional failure caused by high-voltage interference signals intruding into the emergency channel.

[0061] Meanwhile, this physically isolated power supply network unit also integrates an AND logic power supply switch composed of dual magnetic latching relays. This dual magnetic latching relay employs a dual-coil structure design, and its contact system possesses high current-carrying capacity and low contact resistance. Under normal conditions, it maintains a conducting state through an AND logic control strategy, ensuring the normal power supply circuit of the vehicle's low-voltage power system. In emergency situations such as vehicle collisions or high-voltage system malfunctions, this power supply switch can respond to the cut-off command issued by the vehicle safety controller within microseconds, achieving rapid high-voltage cut-off through the synchronous disconnection of the dual relay contacts, forming a dual safety protection mechanism.

[0062] Through this structural design, the physically isolated power supply network unit can quickly disconnect the high-voltage circuit from the vehicle's low-voltage power system and emergency access when the main battery experiences thermal runaway. This is achieved through the combination of the physical isolation of the sheet metal isolation cavity and the active disconnection function of the dual magnetic latching relay. This fundamentally prevents high-voltage current leakage to the vehicle body and passenger compartment area, thereby comprehensively ensuring the structural safety of the vehicle and the personal safety of passengers in fault conditions.

[0063] This self-detection and switching control unit, as the core control module of the emergency energy system, possesses all-time, multi-dimensional status monitoring and intelligent switching functions, enabling seamless connection between wired and wireless emergency channels. The unit adopts a distributed sensor network architecture, using high-precision acquisition circuits to monitor key operating parameters of the wired emergency channel in real time. These parameters include the supercapacitor's SOC (State of Charge), real-time operating temperature, output voltage, loop contact resistance, and system insulation resistance. Specifically, SOC monitoring interacts with the supercapacitor's built-in Kalman filter estimation system to obtain charge information with an accuracy of ±3%; temperature monitoring uses a high-precision thermocouple sensor with a sampling frequency of 10Hz, covering a temperature measurement range of -40℃ to 85℃ with a resolution of 0.1℃; voltage monitoring is achieved through a differential amplifier circuit, with measurement errors controlled within ±0.5%; and contact resistance and insulation resistance are periodically detected using a dedicated impedance measurement module, with a sampling period that can be set from 1 to 10 seconds according to system requirements, ensuring timely detection of potential risks such as abnormal loop connections or deterioration in insulation performance.

[0064] The self-detection and switching control unit incorporates an intelligent decision-making algorithm that can monitor various parameters of the wired emergency channel in real time, including the supercapacitor's SOC, key operating parameters, and electrical safety status. Key operating parameters include, but are not limited to, temperature and voltage; electrical safety status includes, but is not limited to, contact resistance and insulation resistance. The unit performs real-time analysis and logical judgment based on the acquired data. Figure 3 As shown, when the SOC of the supercapacitor in the wired emergency channel is detected to be lower than a preset threshold (e.g., 20%), the control unit will promptly send a CAN message to the intelligent arbitration module to switch the wired emergency channel to a wireless emergency channel, ensuring a continuous supply of emergency power. The CAN message ID is 0x321, and the digital field contains four fields: channel status, temperature, voltage, and CRC checksum. Specifically, the channel status field occupies one byte and is used to indicate the operating status and system mode of the emergency channel. The most significant bit (Bit 2) is defined as the emergency mode flag; when this bit is 1, it indicates that the system has entered an emergency state. The system is configured to directly trigger the emergency disconnect procedure. The second most significant bit (Bit1) indicates whether the wireless channel is ready (1 indicates ready, 0 indicates not ready), and the least significant bit (Bit0) indicates whether the wired channel is ready (1 indicates ready, 0 indicates not ready). The remaining fields (temperature, voltage, CRC) are used to transmit real-time monitoring data and verification information to ensure the integrity and reliability of message transmission. When the relay contacts of the limited emergency channel are detected to be stuck, the backup relay group is activated. When the line insulation failure is detected, the faulty branch is disconnected. When abnormal voltage fluctuations are detected, the emergency disconnect procedure is directly triggered.

[0065] This self-detection and switching function, through the construction of a multi-layered fault monitoring system and a rapid response switching mechanism, can quickly notify the intelligent arbitration module to activate the wireless backup channel when the wired emergency channel experiences performance degradation or failure, fundamentally avoiding the risk of emergency power supply interruption. Simultaneously, the control unit also has fault recording and alarm functions, storing fault type, occurrence time, and parameter change curves in non-volatile memory and sending alarm information to the vehicle control system via the vehicle bus, providing data support for subsequent maintenance and significantly improving the reliability, safety, and maintainability of the emergency power system.

[0066] In some embodiments, the supercapacitor energy storage module adopts a hybrid energy storage structure, including:

[0067] The first-stage energy storage unit, consisting of a double-layer capacitor array, is used to provide instantaneous pulse power in the millisecond range.

[0068] The second-stage energy storage unit, composed of lithium-ion capacitors, is used to provide continuous power output for a certain period of time after the first-stage energy storage unit has discharged.

[0069] The supercapacitor energy storage module of the wired emergency channel adopts a hybrid energy storage topology, achieving stable power supply in multiple scenarios through the coordinated operation of front-end and back-end capacitor units. The front-end is configured with a 10F / 48V double-layer capacitor array, which consists of multiple high-performance double-layer capacitor cells connected in series and parallel. This array features extremely low equivalent series resistance and rapid charge / discharge response characteristics, capable of releasing instantaneous high-power pulse current within milliseconds. This fully meets the instantaneous high-power demands of the system under emergency cut-off and emergency start-up conditions, ensuring that the emergency disconnection actuator completes its response in the shortest possible time. The back-end is equipped with a 100mF / 60V lithium-ion capacitor unit. This unit combines the technological advantages of traditional capacitors and lithium batteries, possessing high energy density and cycle life. After the front-end pulse discharge is completed, it automatically switches to continuous power supply mode, providing a stable DC power supply to system control circuits, sensors, and other components, ensuring the system maintains normal operation of core functions for a considerable period after the main power supply fails. Simultaneously, the front-end double-layer capacitor array and the back-end lithium-ion capacitor unit are connected via a silicon carbide MOSFET to form a bidirectional DC / DC converter, employing a three-phase interleaved parallel topology.

[0070] To achieve precise energy management, this supercapacitor energy storage module integrates a SOC estimation system based on the Kalman filter algorithm. By collecting capacitor voltage, current, and temperature parameters in real time, a dynamic mathematical model is established to accurately predict the remaining power. Simultaneously, the module incorporates a temperature-compensated equalization control circuit. This circuit employs a distributed sampling architecture to independently monitor the temperature of each individual capacitor cell and ensures an operating temperature range of -40℃ to 85℃ through an equalization adjustment mechanism. This prevents localized overheating or overcharging / over-discharging, ensuring that the supercapacitor can accurately estimate its power and maintain good performance under various environmental conditions.

[0071] This supercapacitor energy storage module operates within a temperature range of -40℃ to 85℃. In low-temperature environments, a preheating circuit ensures capacitor activity, while in high-temperature environments, an overheat protection mechanism is activated. Combined with the efficient heat dissipation structure of the aluminum nitride ceramic substrate, this guarantees stable operation under extreme conditions. This hybrid energy storage design combines the instantaneous high-power output of the front-end double-layer capacitor with the continuous energy supply of the back-end lithium-ion capacitor, significantly improving the system's power supply reliability and dynamic response speed. It effectively resolves the contradiction between instantaneous power demand and continuous power supply capability inherent in traditional energy storage devices.

[0072] In some embodiments, the wireless emergency channel includes:

[0073] The energy transmitting end includes a high-frequency inverter circuit and a transmitting coil, which is used to convert direct current into a high-frequency alternating magnetic field;

[0074] The energy receiving end includes a receiving coil, a dynamic impedance matching network, and a rectifier circuit, which is used to receive high-frequency alternating magnetic fields and convert them into direct current output.

[0075] The wireless communication and control unit uses load modulation for in-band communication and executes a secure handshake protocol based on encryption algorithms to achieve device authentication and data transmission.

[0076] The wireless emergency channel serves as a backup energy transmission path for the system. It consists of an energy transmitter, an energy receiver, and a wireless communication and control unit based on magnetic resonance coupling technology. It can achieve contactless and efficient energy transmission when the wired emergency channel fails.

[0077] The energy transmitter employs a high-frequency inverter module as its core conversion unit. This module, based on a zero-voltage switching (ZVS) topology, uses precise drive signals to control the on / off state of the power switching transistors, effectively reducing switching losses. Its operating frequency is stable within 85kHz ± 5%, and its energy conversion efficiency is ≥92% under rated load conditions, efficiently converting input DC power into high-frequency AC power. The transmitter coil uses a multi-strand Litz wire wound planar spiral structure. By optimizing the number of turns and wire diameter parameters, the coil's quality factor (Q value) is >200, significantly reducing losses caused by high-frequency skin effect and proximity effect. The coil surface is uniformly coated with a polyimide insulation layer with an insulation withstand voltage of 3kV, effectively isolating the electrical connection between the vehicle's metal components and the coil, ensuring interference-free operation in the complex electromagnetic environment of the vehicle and achieving stable energy radiation. This transmitter design, through frequency stability control and coil structure optimization, maintains stable energy output within the vehicle's assembly tolerance range, significantly improving the system's transmission efficiency and operational stability.

[0078] The energy receiver integrates a shielding layer made of nanocrystalline alloy material. This shielding layer, formed through a special lamination process, effectively absorbs and shields external electromagnetic interference, reduces eddy current losses generated by the metal body in an alternating magnetic field, and improves the energy conversion efficiency of the receiver. The receiver power output module supports 500A instantaneous pulse discharge, meeting the instantaneous high-power requirements of emergency systems under conditions such as emergency cut-off and actuator drive. It is also equipped with a three-axis orthogonal receiving coil array, coupled with a dynamic matching network composed of variable capacitors and inductors. By monitoring coil impedance changes in real time and automatically adjusting matching parameters, it maintains stable energy coupling under different installation angles and orientations, ensuring efficient energy reception even under complex conditions such as vehicle vibration and assembly errors. This design, through a multi-dimensional adaptive adjustment mechanism, significantly improves the adaptability of the wireless emergency channel to vehicle assembly tolerances and the stability of energy transmission.

[0079] The wireless communication and control unit employs an in-band communication mechanism, utilizing an energy transmission carrier to achieve bidirectional data transmission at a rate of 2kbps. During communication, it integrates unique device ID verification and CRC16 cyclic redundancy check functions, effectively identifying unauthorized access devices and correcting random errors during transmission, ensuring the accuracy and reliability of data transmission. In terms of security, the system uses the AES-128 advanced encryption standard to encrypt communication data, combined with a dynamic key generation algorithm based on timestamps and device signatures. The communication key is automatically updated at fixed time intervals (e.g., every 30 seconds), fundamentally preventing data from being illegally stolen, tampered with, or replay attacks, thus ensuring the security of the wireless communication link. Through anti-interference design and multiple security mechanisms, this wireless communication and control unit can achieve stable and reliable communication in electromagnetic interference environments with multiple devices in the vehicle, further enhancing the reliability and security of the entire emergency energy system.

[0080] In some embodiments, the arbitration strategy of the intelligent arbitration module includes:

[0081] The wired emergency channel is enabled by default.

[0082] When real-time monitoring data determines that the wired emergency channel's charge status is below a set threshold or that there is a fault, it will automatically switch to the wireless emergency channel.

[0083] When real-time monitoring data determines that the wireless emergency channel has failed to handshake multiple times in a row, a forced switchback to the wired emergency channel will be initiated.

[0084] This arbitration strategy prioritizes the wired channel by default to fully utilize its advantages of fast response and high power output. When the intelligent arbitration module detects that the SOC of the wired emergency channel is below a set threshold, such as 20%, it promptly switches the wired emergency channel to the wireless emergency channel to ensure a continuous supply of emergency power. If the intelligent arbitration module detects that the wireless emergency channel has failed to connect multiple times consecutively, such as three times, it forcibly switches back to the wired emergency channel, thus ensuring that the system can operate normally under any circumstances. This method of dynamically adjusting the priority of wired and wireless emergency channels based on real-time status optimizes system response and improves system reliability and security.

[0085] In some embodiments, the intelligent arbitration module is also pre-configured with a three-level emergency protocol for performing the following operations when both the wired and wireless emergency channels are insufficient or unavailable:

[0086] a. Activate the backup supercapacitor bank;

[0087] b. Activate degraded power supply mode to limit output power;

[0088] c. Send the highest level of security alert to the vehicle control system.

[0089] To address special circumstances, the intelligent arbitration module is pre-configured with a three-level emergency protocol. When the intelligent arbitration module detects that the SOC of the wired emergency channel supercapacitor is less than 20% and the handshake failure count of the wireless emergency channel is greater than or equal to 3, it triggers the three-level emergency protocol, which specifically includes: a) activating the supercapacitor bank; b) initiating a degraded power supply mode, limiting the output power to 50% of the rated value; c) sending the highest level (ASIL-D) safety alarm to the vehicle control system (ECU), with a CAN message ID of 0x5FF. This effectively addresses situations where both the wired and wireless emergency channels are unavailable, improving system reliability and safety.

[0090] Furthermore, the intelligent arbitration module also includes an energy composite output control unit, which adopts an ORing circuit architecture to selectively or simultaneously obtain power from wired and wireless emergency channels and perform dynamic current sharing control to synthesize a total output that meets power requirements.

[0091] The energy composite output control module, as the core of the system's power integration, achieves coordinated power supply for wired and wireless emergency channels through circuit topology and intelligent control strategies. This module adopts a parallel output interface architecture, with a core configuration of an ORing (or gate) circuit composed of silicon carbide (SiC) diodes. Utilizing the short reverse recovery time and low conduction loss characteristics of SiC diodes, it effectively eliminates circulating current during channel switching. Each channel's SiC diode is equipped with an independent drive protection circuit, which can monitor the diode's junction temperature and forward voltage drop in real time. When an abnormal state is detected, current limiting protection is quickly triggered to ensure automatic current sharing when the two channels are operating in parallel. The current sharing error is controlled within ±5%, avoiding performance degradation or failure caused by single-channel overload.

[0092] During system dynamic operation, the energy composite output control module interacts with the self-detection unit in real time to obtain parameters such as voltage, current, power, and health status of the wired and wireless emergency channels. The built-in dynamic power allocation algorithm adjusts the output ratio of the two channels in real time. When the wired emergency channel is operating normally, the system prioritizes it as the main power supply circuit, with the wireless emergency channel serving as a backup. When the wired emergency channel experiences insufficient power or a minor fault, the output ratio of the wireless emergency channel is automatically increased to meet load demands through power aggregation. In emergency situations, both channels output at full load simultaneously, with a maximum combined output capacity of 600A / 50ms instantaneous pulse current. This parameter has been verified through multiple load tests and can fully cover the actuator drive requirements of the vehicle's high-voltage circuit isolation device, ensuring reliable operation of the high-voltage relay within the specified time.

[0093] The intelligent arbitration module also employs a multi-sensor fusion monitoring scheme, utilizing high-precision current sensors, voltage acquisition circuits, temperature probes, and insulation monitoring modules to acquire real-time comprehensive information on the main battery's SOC, voltage fluctuations, and state of health (SOH); wired channel contact resistance, transmission efficiency, and supercapacitor status; and wireless channel coupling strength, communication quality, and received power. The monitoring data is filtered, analyzed, and feature-extracted by a digital signal processor (DSP), providing precise data support for the system's power allocation decisions, fault diagnosis, and safety protection.

[0094] like Figure 4 As shown, this energy composite output control design combines hardware current sharing of silicon carbide ORing circuit with dynamic regulation of intelligent arbitration module. It not only achieves seamless coordinated power supply of wired and wireless emergency channels, greatly improving the system's output capability and power supply stability, but also accurately meets the instantaneous power demand of vehicle high-voltage circuit isolation under complex working conditions, providing core guarantee for the reliable operation of the system.

[0095] Furthermore, the emergency release execution module is an electromagnetically driven explosive bolt, which includes a bolt body connecting the high-voltage circuit and the vehicle body, a magnetic material disposed within the bolt body, an electromagnetic coil surrounding the magnetic material, and an detonation device linked to the magnetic material.

[0096] The high current provided by the system generates a strong magnetic field through the electromagnetic coil of the bolt, driving the magnetic material to move, thereby mechanically triggering the detonation device and completing the unhooking.

[0097] The electromagnetically driven explosive bolt, serving as an emergency separation actuator for high-voltage batteries from the vehicle body, mainly consists of a bolt body, magnetic material components, an electromagnetic coil winding, and an ignition triggering device. It can achieve rapid mechanical separation of the high-voltage battery from the vehicle body in emergency situations.

[0098] The bolt body serves as the physical carrier of the structural connection, bearing the mechanical stress of the connected components; the magnetic material component includes a permanent magnet (such as NdFeB) and a moving iron core, which locks the structure in place under normal conditions through strong magnetic force; the electromagnetic coil winding is used to generate a reverse magnetic field when energized, which cancels the magnetic force of the permanent magnet to release the moving iron core; the detonation triggering device includes an explosive charge and a mechanical impact structure, which is responsible for converting electromagnetic energy into separation action.

[0099] During normal system operation, the permanent magnet in the magnetic material component attracts the moving iron core with strong magnetic force, locking it tightly to the bolt body and maintaining the stability of the structural connection. When the electromagnetically driven explosive bolt receives energy output from the intelligent arbitration module, the electromagnetic coil winding is energized to generate a reverse magnetic field, instantly canceling the magnetic force of the permanent magnet. This causes the moving iron core to release and strike the explosive charge head in the detonation triggering device at high speed. After the explosive charge is detonated, the generated high-temperature and high-pressure gas pushes the bolt to break or separate the connecting parts, achieving physical isolation. If the electromagnetic path fails, the backup mechanical triggering system (such as manually pulling the handle) can release the energy of the stored spring through the shear pin, driving the secondary triggering mechanism to directly strike the charge head, completing redundant unhooking.

[0100] The system ensures trigger reliability and safety through millisecond-level response (<10ms) of electromagnetic drive and physical redundancy of mechanical path (response within 20ms), combined with a triple verification mechanism of temperature-voltage-CAN bus. Meanwhile, the explosion energy sealing design and optocoupler feedback closed-loop monitoring meet ISO 26262 functional safety standards and IEC 60079 explosion-proof requirements, making it widely applicable in scenarios such as spacecraft fairing separation, emergency decoupling of high-voltage batteries, and safe disconnection of industrial equipment.

[0101] In some embodiments, the system is powered by an onboard low-voltage power supply system;

[0102] The vehicle-mounted low-voltage power supply system continuously supplies power to the energy transmitter of the wireless emergency channel under normal and emergency conditions, and charges the supercapacitor energy storage module when the intelligent arbitration module determines that the wired emergency channel is activated.

[0103] The onboard low-voltage power supply system serves as a crucial auxiliary power source, providing unpredictable power support to the system. Specifically, this system is a 48V battery. Under normal operating conditions, the 48V battery powers the vehicle's low-voltage electrical system, ensuring the normal operation of all vehicle functions. In the event of thermal runaway or other malfunctions in the main battery, the 48V battery can rapidly charge the supercapacitor energy storage module in the wired emergency channel, enabling it to reach high-power output within a short time, thereby quickly cutting off the high-voltage circuit and achieving emergency disconnection. Furthermore, the 48V battery also provides a stable power supply to the energy transmitter of the wireless emergency channel, ensuring the efficiency and reliability of wireless energy transmission.

[0104] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery, activated upon receiving an emergency disconnection command, characterized in that, include: A wired emergency channel, including a supercapacitor energy storage module, is used to provide instantaneous high-power electrical energy to the system; A wireless emergency channel, constructed based on the principle of magnetic resonance coupling, is used to provide contactless power transmission for the system. The intelligent arbitration module is connected to the wired emergency channel and the wireless emergency channel to monitor the status parameters of each channel in real time, and selects the wired emergency channel first based on a predetermined arbitration strategy, and selects the wireless emergency channel when it is unavailable or has insufficient performance, or combines the power output of the two. The power output terminal of the system is connected to the emergency uncoupling execution module, which provides the power output to the emergency uncoupling execution module to trigger the uncoupling action.

2. The dual-mode emergency power supply system for emergency disconnection of high-voltage batteries according to claim 1, characterized in that, The wired emergency channel also includes: The physically isolated power supply network unit is installed in the positive output path of the vehicle-mounted low-voltage power supply system, electrically isolated from the high-voltage network, and includes a controlled disconnecting switch device for conducting the charging circuit from the vehicle-mounted low-voltage power supply system to the supercapacitor energy storage module when the emergency disconnection command is received. The self-detection and switching control unit is used to monitor the state of charge, key operating parameters and electrical safety status of the supercapacitor energy storage module in real time, and send a fault signal to the intelligent arbitration module when an abnormality is detected.

3. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 2, characterized in that, The supercapacitor energy storage module adopts a hybrid energy storage structure, including: The first-stage energy storage unit, consisting of a double-layer capacitor array, is used to provide instantaneous pulse power in the millisecond range. The second-stage energy storage unit, composed of lithium-ion capacitors, is used to provide continuous power output for a certain period of time after the first-stage energy storage unit has discharged.

4. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 1, characterized in that, The wireless emergency channel includes: The energy transmitting end includes a high-frequency inverter circuit and a transmitting coil, which is used to convert direct current into a high-frequency alternating magnetic field; The energy receiving end includes a receiving coil, a dynamic impedance matching network, and a rectifier circuit, used to receive the high-frequency alternating magnetic field and convert it into DC output. The wireless communication and control unit uses load modulation for in-band communication and executes a secure handshake protocol based on encryption algorithms to achieve device authentication and data transmission.

5. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 1, characterized in that, The arbitration strategies of the intelligent arbitration module include: The wired emergency channel is enabled by default. When the wired emergency channel is determined to be below a set threshold or to be faulty based on real-time monitoring data, it will automatically switch to the wireless emergency channel. When it is determined from real-time monitoring data that the wireless emergency channel has failed to handshake multiple times in a row, a forced switchback to the wired emergency channel is initiated.

6. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 1, characterized in that, The intelligent arbitration module is also pre-configured with a three-level emergency protocol, which is used to perform the following operations when both the wired and wireless emergency channels are insufficient or unavailable: a. Activate the backup supercapacitor bank; b. Activate degraded power supply mode to limit output power; c. Send the highest level of security alert to the vehicle control system.

7. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 1, 5, or 6, characterized in that, The intelligent arbitration module also includes an energy composite output control unit, which adopts an ORing circuit architecture to selectively or simultaneously obtain power from the wired emergency channel and the wireless emergency channel, and perform dynamic current sharing control to synthesize a total output that meets the power requirements.

8. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 1, characterized in that, The emergency unhooking execution module is an electromagnetically driven explosive bolt, which includes a bolt body connecting a high-voltage circuit and a vehicle body, a magnetic material disposed within the bolt body, an electromagnetic coil surrounding the magnetic material, and a detonation device linked to the magnetic material. The high current provided by the system generates a strong magnetic field through the electromagnetic coil of the bolt, driving the magnetic material to move, thereby mechanically triggering the detonation device and completing the unhooking.

9. A dual-mode emergency power supply system for emergency disconnection of a high-voltage battery according to claim 2, characterized in that, The system is powered by the on-board low-voltage power supply system; The vehicle-mounted low-voltage power supply system continuously supplies power to the energy transmitter of the wireless emergency channel under normal and emergency conditions, and charges the supercapacitor energy storage module when the intelligent arbitration module determines that the wired emergency channel is activated.

10. An electric vehicle, characterized in that, It is equipped with a dual-mode emergency power supply system for emergency disconnection of high-voltage batteries as described in any one of claims 1 to 9.

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