An anti-misconnection detection device for high-voltage wire harness connection of a battery box

Abstract

The present invention relates to an anti-misconnection detection device for high-voltage wire harness connections in a battery box, belonging to the technical field of electric vehicle battery management. The high-voltage wire harness connection detection device proposed by the present invention includes a detection circuit, the detection circuit includes a voltage detection module, a control module and a status output module for prompting misconnected wire harnesses. The input end of the control module is connected to the voltage detection module, and the output end of the control module is connected to the status output module. It also includes an MSD upper cover configured to match with the MSD base. The MSD upper cover is provided with two voltage detection points connected to the voltage detection module, and the voltage detection module and the control module are built into the MSD upper cover. When detecting whether the high-voltage wire harness is misconnected, the anti-misconnection detection device for high-voltage wire harness connections in the battery box proposed by the present invention can be directly installed, with a simple method and saving human resources.

Description

Technical Field

[0001] The present invention relates to an anti-misconnection detection device for high-voltage wire harness connection of a battery box, belonging to the technical field of electric vehicle battery management. Background Art

[0002] With the continuous consumption of energy and the continuous deterioration of the world environment, the demand for new energy vehicles and the market retention rate are increasing. The main energy source of new energy vehicles is electric energy. For electric buses, the battery system generally consists of more than 4 battery boxes, and the battery boxes are connected in series and parallel through high-voltage wire harnesses. If the high-voltage wire harness is connected wrongly, it may cause safety accidents.

[0003] At present, the connection method of the high-voltage wire of the battery box high-voltage wire harness is clearly specified. The battery box and the high-voltage wire harness are respectively provided with labels such as battery box numbers, positive and negative pole identifications, and the wire harness ends should be connected to the battery box numbers. Mainly, clear markings are made on the wire harness and the electric box, and process control is carried out to prevent misconnection of the battery box high-voltage wire harness.

[0004] Although the battery box high-voltage wire harness is controlled in terms of markings and processes, the problem of misconnection during worker operation still cannot be avoided. Because the current terminal adopts a bolt connection method, and the bolt connection is a standard part. If the worker cannot carefully check the markings, there will be a probability of misconnection.

[0005] A Chinese utility model patent authorization document with the publication number of CN 206193147 U discloses a portable intelligent battery pack sampling wire harness detection system. This system overcomes the limitation of using detection voltage for power supply and also strengthens the intensity of the alarm system. However, after the battery box is assembled, it is necessary to connect the sampling wire harness sockets to the positive and negative poles of the battery box one by one for detection, and the process is cumbersome and wastes human resources. Summary of the Invention

[0006] The purpose of the present invention is to provide an anti-misconnection detection device for high-voltage wire harness connection of a battery box, which is used to solve the problems of cumbersome existing detection processes and waste of human resources.

[0007] To achieve the above purpose, the present invention provides an anti-misconnection detection device for high-voltage wire harness connection of a battery box, including a detection circuit. The detection circuit includes a voltage detection module, a control module and a status output module for prompting misconnection of the wire harness. The input end of the control module is connected to the voltage detection module, and the output end of the control module is connected to the status output module. It also includes an MSD upper cover that is matched with the MSD base. The MSD upper cover is provided with two voltage detection points connected to the voltage detection module, and the voltage detection module and the control module are built into the MSD upper cover.

[0008] The present invention modifies the original MSD device by integrating the detection circuit into the upper cover of the MSD. Since each battery box is equipped with an MSD and there is a fixed installation relationship between the MSD base and the battery box, after connecting the MSD base in the battery box, assembling the MSD upper cover with the built-in detection circuit to the corresponding MSD bases can detect the voltage between the connection points of the MSD and the battery box, and thus it can be determined whether the high-voltage wiring harness of the battery box is connected wrongly. Directly modifying the MSD upper cover can not only achieve simple installation but also serve the purpose of detection. When conducting the detection, simply insert the MSD upper cover, which is a simple method and saves human resources.

[0009] Further, the status output module is an alarm module, and the alarm module includes at least an indicator light or a buzzer.

[0010] The status output module adopts an alarm module. When the wiring harness is connected wrongly, the alarm module gives an alarm in time to prompt the staff to correct the wiring method in time.

[0011] Further, the detection circuit further includes a power supply module and a power switch, and the power supply module is connected to the control module through the power switch.

[0012] The power supply module supplies power to the control module to ensure the normal operation of the control module.

[0013] Further, the control module is a single-chip microcomputer.

[0014] The technology of the single-chip microcomputer for measuring voltage is mature, accurate, and highly reliable.

[0015] Further, the detection circuit further includes an isolation chip, and the voltage detection module is connected to the control module through the isolation chip.

[0016] Since the single-chip microcomputer is vulnerable to abnormal high-voltage signals, an isolation chip is added to protect the single-chip microcomputer and prevent the abnormal high-voltage signals from damaging the single-chip microcomputer. The single-chip microcomputer is the core component of the entire detection device, and the damage of the single-chip microcomputer will cause the detection device to fail to operate normally. If the wrongly connected wiring harness is misdetected due to the damage of the single-chip microcomputer, it may lead to safety accidents.

[0017] Further, the anti-misconnection detection device for the high-voltage wiring harness of the battery box further includes an MSD base, and two contacts corresponding to the two voltage detection points are arranged on the MSD base.

[0018] Generally, the MSD base is directly installed on the battery box, and the MSD base is connected to the circuit of the battery box through two contacts. Therefore, directly detecting the voltage between the two contacts of the MSD base is simple, convenient, accurate, and reliable. Description of the Drawings

[0019] Figure 1System block diagram of the error-proof detection device for the connection of the high-voltage wire harness of the battery box of the present invention;

[0020] Figure 2 Schematic diagram of the error-proof detection device for the connection of the high-voltage wire harness of the battery box of the present invention;

[0021] Figure 3 Internal structure diagram of the modified MSD upper cover of the present invention;

[0022] Figure 4 External display diagram of the modified MSD upper cover of the present invention;

[0023] Figure 5 Principle block diagram of the battery box of the prior art;

[0024] Figure 6 Schematic diagram of the normal connection of the high-voltage wire harness of the present invention;

[0025] Figure 7 Schematic diagram of the abnormal connection of the high-voltage wire harness of the present invention. Detailed implementation manner

[0026] Embodiment of the error-proof detection device for the connection of the high-voltage wire harness of the battery box:

[0027] The existing MSD is a quick-break device on the battery box, which is divided into two parts: the MSD upper cover and the MSD base. The MSD base is provided with two contact points, and these two contact points are connected to the battery box circuit (since they are in contact connection with the battery box through the contact points, they can also be called contacts, hereinafter referred to as contacts); the MSD upper cover is matched with the MSD base. The MSD upper cover is internally provided with a fuse or a copper bar, and two contact points are also provided at both ends of the MSD upper cover, and these two connection points are correspondingly connected to the two contacts of the MSD base. The existing MSD first connects the MSD base into the battery box through two contacts, and then assembles the MSD upper cover with the MSD base, which plays a role in short-circuit protection of the battery box during operation.

[0028] The main concept of the present invention is to modify the MSD upper cover configured in the original battery box, and modify the fuse or copper bar inside the original MSD upper cover into a detection circuit, which can detect the voltage between two contacts of the MSD base. When the vehicle is not powered on, install the modified MSD upper cover on the MSD base on the battery box to detect the voltage between the contacts of the MSD base. Specifically: First, install the modified MSD upper cover on the first battery box. After the detection passes, it indicates that there is no voltage between the contacts of the MSD base of this battery box body, so this battery box is safe. Then unplug the modified MSD upper cover and install the MSD upper cover with an internal fuse or copper bar (hereinafter referred to as the existing MSD upper cover) on this battery box; then install the modified MSD upper cover on the second battery box. If the detection passes, unplug the modified MSD upper cover and install the existing MSD upper cover on this battery box; then install the modified MSD upper cover on the third battery box. If the detection fails, the modified MSD upper cover will give an alarm to prompt the staff to conduct a troubleshooting.

[0029] When the anti-misconnection detection device for the high-voltage wire harness of the battery box in this embodiment (hereinafter referred to as the anti-misconnection detection device) is modified, the fuse or copper bar inside the original MSD upper cover is removed and then the detection circuit for detecting voltage of the present invention is installed. As other embodiments, it is also possible not to remove the fuse or copper bar inside the original MSD upper cover and directly install the detection circuit of the present invention in the MSD upper cover. Just removing the fuse or copper bar can save space and is more conducive to the layout of the detection circuit of the present invention.

[0030] The anti-misconnection detection device of the present invention will be specifically described below in conjunction with the accompanying drawings. As Figure 1 , Figure 2 shown, the anti-misconnection detection device includes a detection circuit, and the detection circuit includes a voltage detection module, a control module and a status output module. The input end of the control module is connected to the voltage detection module, and the output end of the control module is connected to the status output module. It also includes an MSD upper cover configured to match the MSD base. The MSD upper cover is provided with two voltage detection points connected to the voltage detection module, namely detection point A and detection point B. The voltage detection module and the control module are built into the MSD upper cover. The control module and the voltage detection module are respectively connected to detection point A and detection point B for voltage detection.

[0031] To facilitate the staff to conduct troubleshooting, the status output module is an alarm module, which can promptly prompt whether the high-voltage wire harness of the battery box is misconnected. As other embodiments, the status output module can also be a display module for directly displaying the voltage. However, this method still requires the staff to check one by one. Using the alarm module is more convenient and direct. Of course, the display module and the alarm module can also be used simultaneously, such as Figure 3 to play a warning role.

[0032] Under normal circumstances, the status output module is built inside the upper cover of the MSD. However, the status output module can also be embedded on the surface of the upper cover of the MSD for easy viewing. As shown in Figure 4 the external display diagram of the upper cover of the MSD shown, the specific installation method of the status output module is not limited here, as long as it can play a role in prompting or displaying.

[0033] The detection circuit further includes a power supply module and a power switch. The power supply module is connected to the control module through the power switch. The power supply module is used to supply power to the control module, and the power switch is used to control the on and off of the detection circuit.

[0034] In this embodiment, the control module selects a single-chip microcomputer. Of course, the control module can also select other control chips or other control methods, such as a control circuit, etc. However, using a single-chip microcomputer can perform control more stably and accurately. In order to prevent the influence of abnormal high-voltage signals on the single-chip microcomputer, an isolation chip is connected between the single-chip microcomputer and the voltage detection module. The voltage detection module is connected to the control module through the isolation chip to prevent the single-chip microcomputer from being damaged by abnormal high-voltage signals.

[0035] The anti-error detection device of the present invention may further include an MSD base. There are two contacts on the MSD base that are correspondingly connected to the two voltage detection points of the modified upper cover of the MSD. Generally, the MSD base is directly installed on the battery box. As another implementation, the upper cover of the MSD and the modified upper cover of the MSD as a whole can also be used as the anti-error detection device.

[0036] The specific models adopted by each device in the detection circuit are as shown in Figure 2 shown. In this embodiment, the power supply module uses AAA batteries, with a single battery of 1.5V and 2 batteries for power supply. The batteries can be easily replaced. During normal use, the working duration can reach 266 hours. As another implementation, it can also be an internal rechargeable battery, which does not need to be replaced and can be directly charged.

[0037] The control module uses a low-power single-chip microcomputer. The single-chip microcomputer includes two I / O interfaces and one AD interface. The I / O interface is used to control the connection of the alarm module, and the AD interface is used to connect the voltage detection module. Using a single-chip microcomputer to control the sound and light alarm has good consistency, convenient judgment, and high reliability.

[0038] The alarm module combines an indicator light and a buzzer. When the high-voltage connection harness of the battery box is connected properly, the indicator light is always on; when the high-voltage connection harness of the battery box is abnormal, the indicator light flashes and there is an alarm sound at the same time; when the power supply module has insufficient power, the working light flashes and there is no alarm sound, prompting to replace the battery. The indicator light is a light-emitting diode indicator light with a working current ≤ 5 mA; the buzzer has an alarm current ≤ 40 mA. As another implementation, the alarm module can also have only an indicator light or only a buzzer, as long as it can play a prompting role.

[0039] Taking a single battery box as an example, the detection principle is described in detail: The base of the MSD is installed on the battery box. When the existing MSD upper cover has not been installed, the 2 contacts of the MSD base are in the open state. When the existing MSD upper cover is inserted into the base for installation, the 2 base contacts of the MSD are in the connected state. When the vehicle is not powered on and the existing MSD upper cover is not installed, with the high-voltage harness of the battery box installed properly, if the voltage between the contacts of the MSD base is measured with a multimeter, the multimeter shows a voltage < 5 V; in the case where the harness is installed incorrectly and there is a safety hazard, such as Figure 5 as shown in the case of a short circuit between the positive and negative poles of a single battery box, there is a stable voltage > 5 V at the contacts of the MSD base. At this time, the voltage between the MSD contacts is the voltage of the whole box of batteries. Taking a battery box with 33 single cells connected in series as an example for calculation, the voltage should be about 105.6 V at this time.

[0040] The basis for determining 5 V as the judgment point is:

[0041] Currently, the inside of the battery box body is composed of single cells connected in series and in parallel. Generally, they are connected in series, and the minimum difference between each battery box is 3 series-connected single cells (obtained through research). Calculated based on the minimum voltage of a single cell being 2 V, the voltage difference between battery box bodies is more than 6 V. If two battery box bodies are in a parallel situation, first install the modified MSD upper cover for the first battery box, and the detection passes. Then replace it with the existing MSD upper cover, and then install the modified MSD upper cover for the second battery box. The detected voltage is the voltage difference of 6 V between the two battery boxes. At this time, it is prompted that the harness is connected wrongly. Therefore, using 5 V as the judgment point for whether the harness is connected wrongly can ensure that various situations of wrong connection of the battery box harness are detected.

[0042] Next, taking three battery boxes connected in series as an example, the detection principle of the anti-misconnection detection device of the present invention is further described (the premise of the detection is that the high-voltage harness is connected, the vehicle is in the non-powered-on situation, and the existing MSD upper cover is not installed):

[0043] 1) As Figure 6In the normal connection situation of the high-voltage wire harness shown, first install the anti-misconnection detection device for the No. 3 battery box from the total negative pole. After the detection passes, pull out the anti-misconnection detection device for the No. 3 battery box, and install the existing MSD upper cover of the No. 3 battery box. Then, the No. 2 battery box and the No. 1 battery box repeat the above process for the No. 3 battery box. Since the load is not working at this time and the total positive pole and the total negative pole are in a disconnected state, theoretically there is no voltage at each MSD base contact when installing the anti-misconnection detection device, so the anti-misconnection detection device does not alarm.

[0044] 2) As Figure 7 In the abnormal connection situation of the high-voltage wire harness shown, if the negative pole of the No. 2 battery box is connected to the positive pole of the No. 1 battery box and the positive pole of the No. 2 battery box is connected to the negative pole of the No. 1 battery box, then there is a potential short circuit hazard between the No. 1 and No. 2 battery boxes. When the existing MSD upper cover is not installed, since the circuit is in a disconnected state, there is no safety risk. However, if the existing MSD upper covers are installed on both the No. 1 and No. 2 battery boxes, the two battery boxes will be in a short-circuit state. Therefore, it is very necessary to perform detection before installing the existing MSD upper cover.

[0045] First install the anti-misconnection detection device for the No. 3 battery box from the total negative pole. Since the wire harness connection of the No. 3 battery box is correct, the No. 3 battery box is in an open circuit state after installing the anti-misconnection detection device at this time, so the anti-misconnection detection device for the No. 3 battery box does not alarm. After the detection passes, pull out the anti-misconnection detection device for the No. 3 battery box, and install the existing MSD upper cover for the No. 3 battery box; then install the anti-misconnection detection device for the No. 2 battery box. Since the anti-misconnection detection device for the No. 1 battery box has not been installed yet, the entire circuit is in a disconnected state, and the voltage of the MSD base contact of the No. 2 battery box is theoretically 0, so the anti-misconnection detection device on the No. 2 battery box does not alarm. After the detection passes, pull out the anti-misconnection detection device for the No. 2 battery box, and install the existing MSD upper cover for the No. 2 battery box; then install the anti-misconnection detection device for the No. 1 battery box. Since the existing MSD upper cover is installed on the No. 2 battery box now, the inside of the No. 2 battery box is in a connected state. At this time, the MSD base contact of the No. 1 battery box is charged, and its voltage is the sum of the voltages of the No. 1 battery box and the No. 2 battery box, so the anti-misconnection detection device on the No. 1 battery box will alarm to indicate that the wire harness is misconnected.

[0046] In this embodiment, the anti-misconnection detection device is installed in sequence from the total negative pole. As other implementation manners, it can also be installed randomly. Because as long as the anti-misconnection detection device of the battery box does not alarm, then the battery box is safe and the existing MSD upper cover can be installed. Just installing in sequence can prevent situations such as missed installation and can perform detection more carefully.

[0047] The above is a specific description of the preferred embodiments of the present invention. However, the present invention is not limited to the above examples. Those skilled in the art can make various equivalent deformations and substitutions without departing from the spirit of the present invention, and these equivalent deformations and substitutions are all included within the scope defined by the claims of this application.

Claims

1. A wrong-connection prevention detection device for a high-voltage wire harness connection of a battery box, comprising a detection circuit. The detection circuit includes a voltage detection module, a control module, and a status output module for prompting wrong wire harness connection. The input end of the control module is connected to the voltage detection module, and the output end of the control module is connected to the status output module. It is characterized in that, It further includes an MSD upper cover, which is matched with an MSD base located on the battery box and electrically connected to the circuit of the battery box through two contacts; two voltage detection points connected to the voltage detection module are arranged on the MSD upper cover, and the two voltage detection points are used to be correspondingly connected to the two contacts on the MSD base after the MSD upper cover and the MSD base are assembled; the voltage detection module and the control module are built in the MSD upper cover, the voltage detection module is used to detect the voltage between the two contacts, and the control module judges whether the high-voltage wire harness of the battery box is wrongly connected according to the voltage.

2. The anti-misconnection detection device for the high-voltage wire harness connection of the battery box according to claim 1, wherein The status output module is an alarm module, and the alarm module at least includes an indicator light or a buzzer.

3. The anti-misconnection detection device for high-voltage wire harness connection of the battery box according to claim 1 or 2, characterized in that, The detection circuit further includes a power supply module and a power switch, and the power supply module is connected to the control module through the power switch.

4. The anti-misconnection detection device for the high-voltage wire harness connection of the battery box according to claim 3, characterized in that, The control module is a single-chip microcomputer.

5. The anti-misconnection detection device for the high-voltage wire harness connection of the battery box according to claim 4, characterized in that, The detection circuit further includes an isolation chip, and the voltage detection module is connected to the control module through the isolation chip.

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