Combinable Three-in-One Control System, Control Method and Electric Vehicle

Abstract

Combinable three-in-one control system, control method and electric vehicle, including a three-in-one controller. The three-in-one controller includes a DCDC controller, an oil pump controller, and an air pump controller. The positive terminal relay of the power battery is connected to the three-in-one controller through a three-in-one high-voltage relay and two adjustable relays. One output terminal of the positive terminal relay is connected to the three-in-one high-voltage relay, and the other output terminal is connected to the DCDC controller through a first adjustable relay. The three-in-one high-voltage relay has two output paths, which are respectively connected to the air pump controller and the oil pump controller. A second adjustable relay is also provided between the three-in-one high-voltage relay and the first adjustable relay. Different systems are formed by controlling the three-in-one high-voltage relay and the two adjustable relays. The system of the present invention can select the oil pump, air pump and DCDC high-voltage control modes according to the vehicle requirements, and through different control logics, reduce the energy consumption of the three-in-one system and prevent the battery from over-discharging.

Description

Technical Field

[0001] The present invention belongs to the technical field of vehicles, and particularly relates to a combinable three-in-one control system, a control method, and an electric vehicle. Background Art

[0002] According to national standards, the third-level fault of a pure electric bus is the highest-level fault. Generally, the third-level fault is divided into the third-level fault of the battery system and the third-level fault of the drive system (MCU, BMS, etc.). When the key is in the ACC or ON position and a non-battery-system third-level fault occurs, all the loads at the rear end are disconnected, and the power battery terminal remains closed. At this time, when the key is not turned to the OFF position, the low voltage of the controller (VCU, BMS, MCU, etc.) is still working. If the DCDC stops working, the battery supplies power to the low-voltage load, and the phenomenon of over-discharge of the battery will occur. In the traditional working mode, if only the battery and the DCDC need to be powered on at high voltage while other loads are still working, the system energy consumption is high. Or during charging, if only the DCDC needs to provide low voltage while other loads are still working, the system energy consumption is high. In the existing vehicle control system, the high-voltage relay often adheres, seriously affecting the high-voltage power supply safety during the driving of the electric vehicle and the charging safety of the vehicle. Summary of the Invention

[0003] The purpose of the present invention is to provide a combinable three-in-one control system to solve the technical problems of over-discharge of the battery and high energy consumption caused by the traditional electrical system when a third-level fault occurs.

[0004] To achieve the above purpose, the specific technical solution of a combinable three-in-one control system of the present invention is as follows:

[0005] A combinable three-in-one control system includes a three-in-one controller. The three-in-one controller includes a DCDC controller, an oil pump controller, and an air pump controller. The positive terminal relay of the power battery is connected to the three-in-one controller through a three-in-one high-voltage relay and two adjustable relays. One output terminal of the positive terminal relay is connected to the three-in-one high-voltage relay, and the other output terminal is connected to the DCDC controller through a first adjustable relay. The three-in-one high-voltage relay outputs two paths, which are respectively connected to the air pump controller and the oil pump controller. A second adjustable relay is also provided between the three-in-one high-voltage relay and the first adjustable relay. Different systems are formed by controlling the two adjustable relays.

[0006] Further, a pre-charge relay is also provided in the three-in-one controller to prevent the three-in-one high-voltage relay from adhering.

[0007] Further, the positive terminal relay of the battery power is arranged in the BMS main control box and is controlled by the BMS.

[0008] Further, the three-in-one high-voltage relay, the first adjustable relay, and the second adjustable relay are arranged in the power distribution unit (PDU), and are controlled by the vehicle control unit (VCU).

[0009] Further, by controlling the first adjustable relay to close and the second adjustable relay to open, the first control mode is formed to achieve energy conservation and prevent over-discharge of the battery. By controlling the second adjustable relay to close and the first adjustable relay to open, the second control mode is formed to achieve the same control logic for the DCDC, oil pump, and air pump.

[0010] The present invention also provides an electric vehicle, including the above-mentioned combinable three-in-one control system.

[0011] The present invention also provides a combinable three-in-one control method, and the control logic specifically includes:

[0012] When a third-level fault occurs in the drive system and the vehicle speed is 0, when it is in the first control mode at this time, first disconnect the three-in-one high-voltage relay, and the high voltages of the oil pump and the air pump are disconnected. At this time, the DCDC still works, charging the low-voltage battery and supplying power to the load at the same time. When the key is turned to the OFF position, then disconnect the first adjustable relay, and the DCDC stops working.

[0013] When it is in the second control mode at this time, the three-in-one high-voltage relay does not act. At this time, the oil pump, the air pump, and the DCDC are all working, and the high voltages of the oil pump and the air pump are disconnected. At this time, the DCDC still works, charging the low-voltage battery and supplying power to the load at the same time. When the key is turned to the OFF position, first disconnect the second adjustable relay, and then disconnect the three-in-one high-voltage relay. At this time, the oil pump, the air pump, and the DCDC all stop working.

[0014] After all the high voltages of the loads are disconnected, finally the BMS disconnects the battery power positive terminal relay, and the vehicle high-voltage power-off is completed.

[0015] Further, it also includes that when a third-level fault occurs in the battery system and the vehicle speed is 0, when it is in the first control mode at this time, first disconnect the three-in-one high-voltage relay, and the high voltages of the oil pump and the air pump are disconnected. At this time, the DCDC still works, charging the low-voltage battery and supplying power to the load at the same time.

[0016] When it is in the second control mode at this time, disconnect the second adjustable relay, and then disconnect the three-in-one high-voltage relay. At this time, the oil pump, the air pump, and the DCDC all stop working.

[0017] After all the high voltages of the loads are disconnected, finally the BMS disconnects the battery power positive terminal relay, and the vehicle high-voltage power-off is completed.

[0018] Further, it also includes that when first-level and second-level faults occur, the power is reduced for operation.

[0019] Further, it also includes that when pre-charging, the three-in-one controller sends out the real-time status of the pre-charge relay. When the key is turned to the ACC or ON gear, and at the same time when it is detected that the pre-charge relay is in the off state, the three-in-one high-voltage relay is closed, so that the three-in-one high-voltage relay is not stuck.

[0020] The combinable three-in-one control system, control method and electric vehicle of the present invention have the following advantages:

[0021] (1) The present invention designs a combinable three-in-one electrical system. According to the requirements of the whole vehicle, the oil pump, air pump and DCDC high-voltage control modes can be selected. Through different control logics, the purpose of reducing the energy consumption of the three-in-one system and preventing the over-discharge of the storage battery is achieved;

[0022] (2) The present invention designs a control logic for preventing the adhesion of the three-in-one high-voltage relay. By judging the closed state of the relay inside the three-in-one controller, the high-voltage power-on of the three-in-one system is controlled to protect the three-in-one high-voltage relay from adhesion. Description of the Drawings

[0023] Figure 1 It is a schematic diagram of a combinable three-in-one control system of the present invention;

[0024] Figure 2 It is of the present invention Figure 1 A schematic diagram of the system formed by controlling K1 and K2 in;

[0025] Figure 3 It is of the present invention Figure 1 A schematic diagram of the system formed by controlling K1 and K3 in;

[0026] Figure 4 It is a pre-charging working flow chart of the three-in-one system of the present invention;

[0027] Figure 5 It is a working flow chart of the three-in-one system in case of failure of the present invention. Detailed Embodiments

[0028] In order to better understand the purpose, structure and function of the present invention, the following will further describe in detail a combinable three-in-one control system and method of the present invention with reference to the drawings.

[0029] Air pump: used for inflating tires and mechanical braking.

[0030] Oil pump: used for power-assisted steering of the steering wheel.

[0031] DCDC: used for supplying low-voltage power to the whole vehicle. Generally, the low-voltage power of the whole vehicle is supplied by DCDC or the storage battery. When DCDC is not working, it is supplied by the storage battery; when DCDC is working, DCDC supplies low-voltage power to the whole vehicle and charges the storage battery at the same time.

[0032] K0: Battery-powered positive terminal relay (in the BMS main control box, controlled by the BMS)

[0033] K1: Three-in-one high-voltage relay (in the PDU, controlled by the VCU)

[0034] The first adjustable relay K3 and the second adjustable relay K2: Adjustable relays (placed in the PDU, controlled by the VCU)

[0035] K4, K5: Three-in-one internal pre-charge part relays (on the three-in-one internal control board, controlled by the three-in-one controller)

[0036] As Figure 1 shown, a combinable three-in-one control system of the present invention includes a three-in-one controller, and the three-in-one controller includes a DCDC controller, an oil pump controller, and an air pump controller. The positive terminal relay K0 of the power battery is connected to the three-in-one controller through the three-in-one high-voltage relay K1 and two adjustable relays; wherein, one output path of the positive terminal relay K0 is connected to the three-in-one high-voltage relay K1, and the other path is connected to the DCDC controller through the first adjustable relay K3. The three-in-one high-voltage relay K1 outputs two paths, which are respectively connected to the air pump controller and the oil pump controller. A second adjustable relay K2 is also provided between the three-in-one high-voltage relay K1 and the first adjustable relay K3. Different systems are formed by controlling the three-in-one high-voltage relay K1 and the two adjustable relays.

[0037] The present invention forms a first control mode by controlling the three-in-one high-voltage relay K1 and the first adjustable relay K3. Except for DCDC body faults, as long as the key is in the ACC or ON gear, the DCDC has high voltage and is in the working state (the DCDC charges the battery and supplies power to the low-voltage load at the same time. Only the DCDC works in the ACC gear; in the ON gear, the DCDC is working, and at the same time, it can control the high and low pressures and the working states of the oil pump and the air pump); when the key is in the OFF gear, the DCDC, the oil pump, and the air pump stop working and the high voltage is disconnected, realizing energy conservation and preventing the battery from over-discharging, as Figure 3 shown.

[0038] The present invention forms a second control mode by controlling the three-in-one high-voltage relay K1 and the second adjustable relay K2, realizing the same control logic for the DCDC, the oil pump, and the air pump, as Figure 2 shown.

[0039] The present invention can flexibly control the combination of K1, K2, and K3 to form 2 different systems, achieving the purpose of energy conservation and preventing the battery from over-discharging, and can be selected and controlled according to actual application requirements.

[0040] The control logic of the combinable three-in-one control system of the present invention is as follows: When a failure occurs in the vehicle system, the execution timing is as Figure 5 shown:

[0041] When first-level and second-level failures occur, the power is reduced for operation;

[0042] When a third-level failure occurs in the drive system and the vehicle speed is 0, in the case where the PDU mode is 1, that is, control K2 and K3 to form the first control mode. First, disconnect the K1 relay (when the PDU mode is not 1, the relay K1 does not act, and at this time, the oil pump, air pump, and DCDC are all working). The high voltage of the oil pump and air pump is disconnected. At this time, the DCDC is still working, charging the low-voltage battery and supplying power to the loads (BMS, MCU) at the same time. When the key is turned to the OFF position, then disconnect the K3 relay, and the DCDC stops working (when the PDU mode is not 1, first disconnect K2, and then disconnect K1. At this time, the oil pump, air pump, and DCDC all stop working). When the high voltage of all loads is disconnected, finally, the BMS disconnects the K0 relay. Thus, the vehicle high-voltage power-off is completed.

[0043] When a third-level failure occurs in the battery system and the vehicle speed is 0, in the case where the PDU mode is 1, first disconnect the K1 relay, and the high voltage of the oil pump and air pump is disconnected. At this time, the DCDC is still working, charging the low-voltage battery and supplying power to the loads (BMS, MCU) at the same time. When the PDU mode is not 1, first disconnect K2, and then disconnect K1. At this time, the oil pump, air pump, and DCDC all stop working. When the high voltage of all loads is disconnected, finally, the BMS disconnects the K0 relay. Thus, the vehicle high-voltage power-off is completed.

[0044] Currently, in vehicle control, the K1 relay often adheres. For some vehicle models, the three-in-one system is powered by low-voltage constant power, and the vehicle low-voltage power will only be cut off when the manual low-voltage switch is disconnected. Under normal circumstances, when the key is turned to the OFF position, first disconnect K1, then disconnect K5 (K4 has been disconnected after pre-charging is completed), and finally disconnect K0; when the key is turned to the ON position again, first close K0, then close K1, then close K4 for pre-charging, and finally close K5.

[0045] When the key is turned to the OFF position and then quickly turned to the ACC or ON position, due to the too short discharge time, when the K4 relay has not been disconnected yet (generally, the disconnection condition of K4 is that it is detected that the voltages of the three-in-one capacitors are all less than 400V, and 400V is calculated according to the vehicle model and the battery cell voltage, and some manufacturers will set it smaller), at this time, only the K1 in the entire circuit is in the disconnected state. After detecting the key signal, the K1 relay will immediately close. At this time, K1 is not pre-charged, and the voltage difference across it will be as high as 200V or even higher. The impedance in the circuit is very small, and an extremely large current will be generated instantaneously. K1 is closed with load, and at this time, it is easy to adhere, and the large current will also affect the connected electrical system.

[0046] In order to solve the problem of rapid power on and off and perform logic optimization control, the three-in-one controller needs to send the real-time status of K5. When the key is turned to ACC or ON, it also needs to detect that the K4 and K5 relays are in the disconnected state before K1 will be closed to effectively protect the K1 relay and related electrical systems.

[0047] Specifically, when the key is in ACC gear or charging, the execution sequence is as follows: Figure 4 As shown:

[0048] When the key is turned to ACC or charging, the VCU delays power-on. After the VCU self-checks and there is no fault, it controls the BMS, MCU, three-in-one and other low-voltage power-ons; if the low-voltage self-check of each system is fault-free, the VCU requests K0 to close, and the BMS controls K0 to close; the VCU receives the BMS high-voltage self-check and there is no fault and the DCDC controller feedback that the K4 and K5 relay states are disconnected and non-adhesive, otherwise it reports the corresponding fault; then the VCU sends the PDU control mode according to the vehicle application. If the mode is 1, the K3 relay is controlled to be energized, and the DCDC controller detects that the voltage at point B is greater than U0 (generally When the battery voltage deviation is about 30V), the DCDC controller controls K4 to close, otherwise a K3 disconnection fault is reported; if the control mode is not 1, the VCU controls K2 to close, and then delays the closing of K1. When the DCDC controller system detects that the voltage at point A is greater than U0, the DCDC controller controls K4 to close, otherwise a K2 or disconnection fault is reported; after K4 is closed, there is a delay of ts. If the DCDC pre-charge is completed, the DCDC controls the closing of K5 and delays the disconnection of K4, otherwise a pre-charge failure fault is reported. If the above faults occur, the fault handling mode is entered. At this point, the entire pre-charge process is completed.

[0049] When the key is turned directly to the ON position: When the key is turned directly to the ON position, the pre-charging logic of the ACC position is executed first, and then the oil pump and air pump pre-charging logic is executed (the oil pump and air pump pre-charging logic is the same as DCDC).

[0050] The charging logic is executed first when there is a charging signal, and then the key position logic is executed according to the key signal.

[0051] The system of the present invention can be expanded to add a high-voltage control board PDU, one end of the high-voltage control board is connected to the battery power positive terminal relay, and the other end is connected to the motor controller, thereby increasing the high-voltage pre-charging of the motor controller.

[0052] The present invention flexibly controls K1, K2, and K3 to form two different systems, thereby realizing a three-in-one electrical system with adjustable modes, thereby achieving energy saving and preventing battery over-discharge. When in use, the control can be selected according to actual application requirements, which can effectively prevent battery over-discharge, extend battery service life, and reduce the energy consumption of the three-in-one system.

[0053] The present invention adds a pre-charge protection logic to the three-in-one control system, and controls the application of high voltage to the three-in-one system by judging the closing state of the internal relay of the three-in-one controller, thereby protecting the three-in-one high-voltage relay from sticking.

[0054] It can be understood that the present invention is described through some embodiments. Those skilled in the art know that, without departing from the spirit and scope of the present invention, various changes or equivalent replacements can be made to these features and embodiments. In addition, under the teaching of the present invention, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application belong to the scope protected by the present invention.

Claims

1. A combinable three-in-one control system, characterized in that, It includes a three-in-one controller, and the three-in-one controller includes a DCDC controller, an oil pump controller, and an air pump controller. The positive terminal relay of the power battery is connected to the three-in-one controller through a three-in-one high-voltage relay K1 and two adjustable relays; among them, the output terminal of the positive terminal relay is connected to the three-in-one high-voltage relay K1 in one path, and the other path is connected to the DCDC controller through a first adjustable relay K3. The three-in-one high-voltage relay K1 outputs two paths, which are respectively connected to the air pump controller and the oil pump controller. A second adjustable relay K2 is also provided between the three-in-one high-voltage relay K1 and the first adjustable relay K3, and different systems are formed by controlling the two adjustable relays in combination; By controlling the first adjustable relay K3 to be closed and the second adjustable relay K2 to be opened, a first control mode is formed to achieve energy saving and prevent over-discharge of the storage battery. By controlling the second adjustable relay K2 to be closed and the first adjustable relay K3 to be opened, a second control mode is formed to achieve the same control logic for DCDC, the oil pump, and the air pump.

2. The combinable three-in-one control system according to claim 1, characterized in that A pre-charge relay is also provided in the three-in-one controller to control the three-in-one high-voltage relay K1 from sticking.

3. The combinable three-in-one control system according to claim 1, characterized in that, The positive terminal relay of the power battery is arranged in the BMS main control box and is controlled by the BMS.

4. A combinable three-in-one control system according to claim 1, characterized in that, The three-in-one high-voltage relay K1, the first adjustable relay K3, and the second adjustable relay K2 are arranged in the high-voltage distribution box PDU and are controlled by the vehicle controller VCU.

5. An electric vehicle, characterized in that, It includes a combinable three-in-one control system as described in any one of claims 1-4.

6. A combinable three-in-one control method, characterized in that, The control logic specifically includes: When a third-level fault occurs in the drive system and the vehicle speed is 0, when it is in the first control mode at this time, first disconnect the three-in-one high-voltage relay K1, and the high voltages of the oil pump and the air pump are disconnected. At this time, the DCDC still works, charging the low-voltage storage battery and supplying power to the load at the same time; when the key is turned to the OFF position, then disconnect the first adjustable relay K3, and the DCDC stops working, When it is in the second control mode at this time, the three-in-one high-voltage relay K1 does not act. At this time, the oil pump, the air pump, and the DCDC are all working. When the key is turned to the OFF position, first disconnect the second adjustable relay K2, and then disconnect the three-in-one high-voltage relay K1. At this time, the oil pump, the air pump, and the DCDC all stop working, After all the load high voltages are disconnected, finally the BMS disconnects the positive terminal relay of the power battery, and the vehicle high-voltage power-off is completed.

7. A combinable three-in-one control method according to claim 6, characterized in that It also includes that when a third-level fault occurs in the battery system and the vehicle speed is 0, when it is in the first control mode at this time, first disconnect the three-in-one high-voltage relay K1, and the high voltages of the oil pump and the air pump are disconnected. At this time, the DCDC still works, charging the low-voltage storage battery and supplying power to the load at the same time, When it is in the second control mode at this time, disconnect the second adjustable relay K2, and then disconnect the three-in-one high-voltage relay K1. At this time, the oil pump, the air pump, and the DCDC all stop working, After all the load high voltages are disconnected, finally the BMS disconnects the positive terminal relay of the power battery, and the vehicle high-voltage power-off is completed.

8. A combinable three-in-one control method according to claim 6, characterized in that, It also includes that when first-level and second-level faults occur, the power is reduced for operation.

9. A combinable three-in-one control method according to claim 6, characterized in that, It also includes that during pre-charging, the three-in-one controller sends out the real-time status of the pre-charging relay. When the key is turned to the ACC or ON position, and at the same time when it is detected that the pre-charging relay is in the open state, the three-in-one high-voltage relay K1 is closed, so that the three-in-one high-voltage relay K1 is not stuck.

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