An insulation inspection method for a new energy electric vehicle

Abstract

The present application relates to the technical field of vehicle detection, more particularly to an insulation inspection method for new energy electric vehicle, which comprises the following steps: step S1, the vehicle is segmented according to the high-voltage components of the new energy electric vehicle, an insulation inspection module is arranged for each segmented area, and the insulation state of the vehicle is detected; if the vehicle has insulation problems, step S2 is entered; step S2, the vehicle enters a degraded operation mode, the load is actively cut off, and whether the minimum operation capacity of the vehicle is met is judged; if the minimum operation capacity of the vehicle is not met, step S3 is entered; step S3, the vehicle enters an insulation inspection mode, and the insulation of each segmented area is detected in sequence by the insulation inspection module, so as to locate the fault position. The high-voltage components of the vehicle are segmented and detected synchronously, the insulation fault point can be quickly located, and the operation requirement of quick processing of the vehicle is met.

Description

Technical Field

[0001] This invention relates to the field of vehicle inspection technology, and more specifically, to an insulation inspection method for new energy electric vehicles. Background Technology

[0002] The new energy electric vehicle is a new type of rail transit product with virtual trajectory following capabilities, using fully electric rubber-tired vehicles as its transportation tool, and integrating the advantages of modern trams and buses. This vehicle does not require laid steel rails; instead, it uses ground markings painted on existing roads. Cameras and radar installed on the vehicle collect information about these markings, and uses a virtual trajectory based on the markings and a multi-axis steering system for trajectory tracking and control. The vehicle is equipped with energy storage batteries to store electricity, which then powers the vehicle to run on the road after charging.

[0003] The insulation performance between the new energy battery and the vehicle body directly determines the safety of the entire vehicle.

[0004] Currently, when new energy electric vehicles are in operation, the online insulation detection device installed in the battery management system (BMS) performs insulation detection on the vehicle's battery and positive and negative busbars.

[0005] When a vehicle's battery system or load experiences an insulation problem, the vehicle will directly lose high voltage, leaving the entire vehicle without a power source. Because vehicles have numerous loads, this requires a significant amount of manpower and time to test and inspect for insulation faults.

[0006] Meanwhile, in new energy electric vehicles with excessive vehicle loads, the first-level insulation detection can only locate the top load and cannot accurately pinpoint the fault location. There is also no corresponding implementation strategy for insulation problems to ensure the basic operation of the vehicle. Summary of the Invention

[0007] In multi-unit new energy electric vehicles, the probability of insulation problems increases due to the large number of loads. The purpose of this invention is to provide an insulation inspection method for new energy electric vehicles, which solves the problem that existing technologies make it difficult to accurately locate fault locations in insulation testing of new energy electric vehicles.

[0008] To achieve the above objectives, the present invention provides an insulation inspection method for new energy electric vehicles, comprising the following steps:

[0009] Step S1: Divide the vehicle into sections based on the high-voltage components of the new energy electric vehicle, set up an insulation inspection module for each section, and detect the insulation status of the whole vehicle. If the vehicle has an insulation problem, proceed to step S2.

[0010] Step S2: Enter the vehicle degraded operation mode, actively cut off the load, and determine whether the minimum operating capacity of the vehicle is met. If the minimum operating capacity of the vehicle is met, the vehicle is returned to the depot for maintenance. If the minimum operating capacity of the vehicle is not met, proceed to step S3.

[0011] Step S3: Enter the insulation inspection mode. The insulation inspection module performs insulation tests on each segment area in sequence to locate the fault location.

[0012] In one embodiment, step S1, which involves dividing the entire vehicle into regional segments based on the high-voltage components of the new energy electric vehicle, further includes:

[0013] Based on the high-voltage components of the new energy electric vehicle, the entire vehicle is divided into 5 sections, including the first auxiliary power supply section, the first switch box section, the roof high-voltage box section, the second switch box section, and the second auxiliary power supply section.

[0014] In one embodiment, the first auxiliary power supply segment region includes a first auxiliary power supply, a first insulation inspection module, a first load oil pump, a first air pump, and a first hydraulic motor. One side of the first auxiliary power supply is connected to the first insulation inspection module, and the other side is connected to the first load oil pump, the first air pump, and the first hydraulic motor, respectively.

[0015] The first switch box segmented area includes a first switch box, a second insulation inspection module, a first driver's cab air conditioner, a first passenger compartment air conditioner, a first defrost / heater, and a first traction motor. One side of the first switch box is connected to the second insulation inspection module, and the other side is connected to the first driver's cab air conditioner, the first passenger compartment air conditioner, the first defrost / heater, the first traction motor, and the first auxiliary power supply, respectively.

[0016] In one embodiment, the second auxiliary power supply segment region includes a second auxiliary power supply, a fifth insulation inspection module, a second load oil pump, a second air pump, and a second hydraulic motor. One side of the second auxiliary power supply is connected to the fifth insulation inspection module, and the other side is connected to the second load oil pump, the second air pump, and the second hydraulic motor, respectively.

[0017] The second switch box segmented area includes a second switch box, a fourth insulation inspection module, a first driver's cab air conditioner, a first passenger compartment air conditioner, a first defrost / heater, and a second traction motor. One side of the second switch box is connected to the fourth insulation inspection module, and the other side is connected to the first driver's cab air conditioner, the first passenger compartment air conditioner, the first defrost / heater, the second traction motor, and the second auxiliary power supply, respectively.

[0018] In one embodiment, the roof-mounted high-voltage box segmented area includes a roof-mounted high-voltage box, a pantograph, a second passenger compartment air conditioner, a battery high-voltage box, a power battery, a battery thermal management module, and a third insulation inspection module.

[0019] The rooftop high-voltage box is connected to the pantograph, the second passenger compartment air conditioner, the battery high-voltage box, and the third insulation inspection module, respectively.

[0020] The battery high-voltage box is connected to the first switch box, the second switch box, the roof high-voltage box, and the power battery, respectively.

[0021] The power battery is connected to the battery thermal management module.

[0022] In one embodiment, step S1, which involves detecting the insulation status of the entire vehicle, further includes:

[0023] During normal driving and charging conditions, the battery management system monitors the insulation status of the load oil pump at the inactive end online and continuously monitors the insulation status of the air compressor when it is not working.

[0024] When not charging, the battery management system monitors the insulation status of the roof-mounted high-voltage box online.

[0025] In one embodiment, after the vehicle experiences an insulation problem, step S1 further includes the following steps:

[0026] If the battery management system detects a Class 1 insulation fault, it sends a high-voltage command to the vehicle to disconnect the load contactor and forcibly disconnect the high voltage.

[0027] If a Class 1 insulation fault still occurs, it is determined to be a battery system insulation fault, and the vehicle requires assistance.

[0028] If the alarm for a Class 1 insulation fault disappears after the high voltage is disconnected, but the insulation fault is reported repeatedly after the high voltage is restored, then proceed to step S2.

[0029] In one embodiment, step S2, entering a vehicle degraded operation mode and actively cutting off the load, further includes the following steps:

[0030] Disconnect the contactors of the first driver's cab air conditioner, the first passenger compartment air conditioner, the first defrost / heater, the second driver's cab air conditioner, the second passenger compartment air conditioner, and the auxiliary power supply of the non-activated terminals, and perform corresponding insulation tests.

[0031] In one embodiment, step S3 further includes the following steps:

[0032] Disconnect all contactors in the first auxiliary power supply section area, the first switch box section area, the roof high voltage box section area, the second switch box section area, and the second auxiliary power supply section area;

[0033] The insulation inspection module sequentially performs insulation tests on each segment area and feeds back the insulation test status values ​​to the whole vehicle, thereby locating the fault location.

[0034] In one embodiment, in step S3, the detection priority order of the insulation inspection module is as follows:

[0035] First switch box and second switch box;

[0036] First traction motor and second traction motor;

[0037] First auxiliary power supply;

[0038] Second auxiliary power supply;

[0039] Jumper harness.

[0040] In one embodiment, step S3 further includes:

[0041] The human-machine interface unit sends messages via a soft switch to perform periodic insulation tests on the rescue wiring harness.

[0042] In one embodiment, step S3 further includes:

[0043] If the insulation test status value is less than 250kΩ, the corresponding test channel is considered to be faulty.

[0044] In one embodiment, after step S3, the following steps are further included:

[0045] Step S4: Continuously perform insulation testing on the faulty channel, send the insulation test status value to the vehicle network controller, and determine whether rescue is needed or to enter the vehicle degraded operation mode.

[0046] In one embodiment, step S4 further includes:

[0047] When an insulation fault occurs in the second power supply branch of the auxiliary power supply for single-end traction or non-activated end, the vehicle enters a degraded operation mode.

[0048] In one embodiment, step S4 further includes:

[0049] When an insulation failure occurs in a single detection channel, the vehicle enters a degraded operation mode.

[0050] In one embodiment, step S4 further includes:

[0051] The vehicle requires rescue when an insulation fault occurs in the first switch box, the second switch box, or the jumper harness.

[0052] In one embodiment, step S4 further includes:

[0053] When multiple insulation failures occur in the detection channels, the vehicle requires rescue.

[0054] In one embodiment, the contactors in the first switch box section area, the second switch box section area, and the roof high-voltage box section area are controlled by a network via hardwire.

[0055] The contactors in the first auxiliary power supply segment area and the second auxiliary power supply segment area are controlled by messages.

[0056] This invention provides an insulation inspection method for new energy electric vehicles. By dividing the high-voltage components of the vehicle into sections and setting up a total of 5 insulation inspection modules for simultaneous detection, the detection speed can be increased, insulation fault points can be quickly located, and the operational requirements for rapid vehicle handling can be met. Attached Figure Description

[0057] The above and other features, properties and advantages of the present invention will become more apparent from the following description taken in conjunction with the accompanying drawings and embodiments, in which the same reference numerals always denote the same features, wherein:

[0058] Figure 1 A flowchart of an insulation inspection method for a new energy electric vehicle according to an embodiment of the present invention is disclosed;

[0059] Figure 2 A segmented topology diagram of the high-voltage component area of ​​a vehicle according to an embodiment of the present invention is disclosed;

[0060] Figure 3 A topological schematic diagram of an insulation inspection module according to an embodiment of the present invention is disclosed;

[0061] Figure 4 A schematic diagram of the insulation inspection logic of a new energy electric vehicle according to an embodiment of the present invention is disclosed.

[0062] The meanings of the labels in the figures are as follows:

[0063] 100 First Auxiliary Power Supply;

[0064] 101 First Load Oil Pump;

[0065] 102 First Air Pump;

[0066] 103 First hydraulic motor;

[0067] 104 First Insulation Inspection Module;

[0068] 200 First Switch Box;

[0069] Air conditioning in the first driver's cab of vehicle 201;

[0070] Air conditioning in passenger compartment 202;

[0071] 203 First defrost / heater;

[0072] 204 First traction motor;

[0073] 205 Second Insulation Inspection Module;

[0074] 300 roof-mounted high-voltage box;

[0075] 301 pantograph;

[0076] Air conditioning in the second passenger compartment of room 302;

[0077] 303 battery high-voltage box;

[0078] 304 power battery;

[0079] 305 battery thermal management module;

[0080] 306 Third Insulation Inspection Module

[0081] 400 Second Switch Box;

[0082] 401 Second traction motor;

[0083] 405 Fourth Insulation Inspection Module;

[0084] 500 second auxiliary power supply;

[0085] 501 Second Load Oil Pump;

[0086] 502 Second Air Pump;

[0087] 503 Second Hydraulic Motor;

[0088] 504 Fifth Insulation Inspection Module;

[0089] 601 Vehicle Network Controller;

[0090] 602 Human-Machine Interface Unit;

[0091] 603 storage battery. Detailed Implementation

[0092] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for illustrative purposes only and are not intended to limit the invention.

[0093] Figure 1 A flowchart of an insulation inspection method for a new energy electric vehicle according to an embodiment of the present invention is disclosed, as follows: Figure 1 As shown, the present invention proposes an insulation inspection method for new energy electric vehicles, comprising the following steps:

[0094] Step S1: Divide the high-voltage components of the new energy electric vehicle into sections, set up an insulation inspection module for each section, and detect the insulation status of the whole vehicle. If the vehicle has an insulation problem, proceed to step S2.

[0095] Step S2: Enter the vehicle degraded operation mode, actively cut off the load, and determine whether the minimum operating capacity of the vehicle is met. If the minimum operating capacity of the vehicle is met, the vehicle is returned to the depot for maintenance. If the minimum operating capacity of the vehicle is not met, proceed to step S3.

[0096] Step S3: Enter the insulation inspection mode. The insulation inspection module performs insulation tests on each segment area in sequence to locate the fault location.

[0097] Figure 2 A segmented topology diagram of the high-voltage component region of a vehicle according to an embodiment of the present invention is disclosed, such as... Figure 2 As shown, the high-voltage components of the new energy electric vehicle are divided into regions. Based on the high-voltage topology of the whole vehicle, the vehicle is divided into 5 regions, including the first auxiliary power supply region, the first switch box region, the roof high-voltage box region, the second switch box region, and the second auxiliary power supply region.

[0098] The first auxiliary power supply section and the first switch box section belong to the first MC vehicle module. The second switch box section and the second auxiliary power supply section belong to the second MC vehicle module.

[0099] MC (Motor car with Cabin) vehicle module refers to a vehicle module with a driver's cab and equipped with a drive system.

[0100] The high-voltage box section on the roof belongs to the TP vehicle module.

[0101] TP (Trailer car with pantograph) vehicle module refers to a vehicle module without a drive unit but equipped with a pantograph.

[0102] An insulation inspection module is set up in each segment area and numbered sequentially from 1 to 5.

[0103] Each insulation inspection module can be set with multiple detection channels, and each detection channel can detect one high-voltage component or one wire harness.

[0104] In this embodiment, each insulation inspection module can be configured with up to 12 detection channels.

[0105] Figure 3 A topological schematic diagram of an insulation inspection module according to an embodiment of the present invention is shown, as follows: Figure 3The insulation inspection module shown uses a signal injection method to inject positive and negative signals of a certain frequency and amplitude between the high-voltage system circuit and the detection line (vehicle body). Based on the signal response, the insulation resistance between the high-voltage system circuit and the detection line (vehicle body) is calculated, thereby determining the insulation status between the vehicle's high-voltage system circuit and the detection line (vehicle body).

[0106] exist Figure 3 In the embodiment shown, the insulation inspection module includes a resistor group, a capacitor group, a switch group, an operational amplifier group, an excitation signal source, and a power supply.

[0107] The resistor group includes the insulation resistance between the negative busbar and the vehicle body R1, the insulation resistance between the positive busbar and the vehicle body R2, voltage sampling resistors R3 and R4, and resistors R5 and R6. Among them, the resistance of resistors R5 and R6 is 4.7MΩ.

[0108] The capacitor bank includes high-voltage filter capacitors C1 and C2.

[0109] The power supply includes DC power supplies BT1 and BT2.

[0110] The excitation signal source S injects positive and negative signals to detect insulation resistance.

[0111] Operational amplifiers OP1 and OP2 input response signals P and N to processor U1, respectively.

[0112] The processor U1 implements insulation detection status values ​​through signal processing and algorithms.

[0113] exist Figure 3 In the embodiment shown, the insulation inspection module has 12 switches added to the detection lines and high voltage input terminal, and the same insulation inspection module can cover 12 detection points, which is 12 detection channels.

[0114] The high-voltage components or wiring harnesses detected by the insulation inspection module include load oil pumps, air pumps, hydraulic motors, DC load motor controllers, driver's cab air conditioners, passenger cabin air conditioners, defrosters / heaters, as well as pantographs and bridging wiring harnesses.

[0115] In this embodiment, the load pump is an AC380V load pump, and the hydraulic motor includes a 1-6 axis hydraulic motor. Furthermore, the load pump is a power steering pump.

[0116] exist Figure 2 In the embodiment shown, the first auxiliary power supply segment area includes a first auxiliary power supply 100, a first insulation inspection module 104, a first load oil pump 101, a first air pump 102, and a first hydraulic motor 103.

[0117] The first auxiliary power supply 100 is connected to the first insulation inspection module 104 on one side, and to the first load oil pump 101, the first air pump 102 and the first hydraulic motor 103 on the other side.

[0118] exist Figure 2 In the embodiment shown, the first switch box segmented area includes a first switch box 200, a second insulation inspection module 205, a first driver's cab air conditioner 201, a first passenger cabin air conditioner 202, a first defrost / heater 203, and a first traction motor 104.

[0119] The first switch box 200 is connected to the second insulation inspection module 205 on one side, and to the first driver's cab air conditioner 201, the first passenger cabin air conditioner 202, the first defrost / heater 203, the first traction motor 104 and the first auxiliary power supply 100 on the other side.

[0120] exist Figure 2 In the illustrated embodiment, the roof-mounted high-voltage box segmented area includes a roof-mounted high-voltage box 300, a pantograph 301, a second passenger compartment air conditioner 302, a battery high-voltage box 303, a power battery 304, a battery thermal management module 305, and a third insulation inspection module 306.

[0121] The rooftop high-voltage box 300 is connected to the pantograph 301, the second passenger compartment air conditioner 302, the battery high-voltage box 303, and the third insulation inspection module 306, respectively.

[0122] The battery high-voltage box 303 is connected to the first switch box 200, the second switch box 400, the roof high-voltage box 300, and the power battery 304, respectively.

[0123] The power battery 304 is connected to the battery thermal management module 305.

[0124] exist Figure 2 In the embodiment shown, the second switch box segmented area includes a second switch box 400, a fourth insulation inspection module 402, a first driver's cab air conditioner 201, a first passenger compartment air conditioner 202, a first defrost / heater 203, and a second traction motor 401.

[0125] The second switch box 400 is connected to the fourth insulation inspection module 402 on one side, and to the first driver's cab air conditioner 201, the first passenger cabin air conditioner 202, the first defrost / heater 203, the second traction motor 401 and the second auxiliary power supply 500 on the other side.

[0126] exist Figure 2 In the embodiment shown, the second auxiliary power supply segment area includes a second auxiliary power supply 500, a fifth insulation inspection module 504, a second load oil pump 501, a second air pump 502, and a second hydraulic motor 503.

[0127] The second auxiliary power supply 500 is connected to the fifth insulation inspection module 504 on one side, and to the second load oil pump 501, the second air pump 502 and the second hydraulic motor 503 on the other side.

[0128] When the vehicle is in normal operation, one of the first auxiliary power supply 100 and the other of the second auxiliary power supply 500 is active and inactive.

[0129] The contactors of the first switch box 200, the second switch box 400, and the roof high-voltage box 300 are controlled by the vehicle network controller 601 via hard wiring.

[0130] The contactors of the first load oil pump 101, the first air pump 102, the first hydraulic motor 103, the second load oil pump 501, the second air pump 502, and the second hydraulic motor 503 in the first auxiliary power supply segment area and the second auxiliary power supply segment area are controlled by message.

[0131] In this embodiment, battery 603 is a 24V battery that supplies power to the entire vehicle.

[0132] The insulation inspection method for new energy electric vehicles proposed in this invention, when an insulation problem occurs, actively disconnects the load by setting a degraded operation mode to ensure the vehicle's minimum operating capacity. If the minimum operating capacity still cannot meet the vehicle's operating requirements, it enters the insulation inspection mode to locate the fault point, facilitating rapid handling by personnel.

[0133] Figure 4 A schematic diagram of the insulation inspection logic of a new energy electric vehicle according to an embodiment of the present invention is disclosed, combined with Figures 2-4 This invention further illustrates the insulation inspection method for new energy electric vehicles proposed in this invention.

[0134] Step S1: Divide the vehicle into sections based on the high-voltage components of the new energy electric vehicle, and set up an insulation inspection module for each section to detect the insulation status of the entire vehicle. If an insulation problem is found, proceed to step S2.

[0135] During normal driving and charging conditions, the insulation status of the entire vehicle is detected by the Battery Management System (BMS).

[0136] The battery management system monitors the insulation status of the load oil pump at the inactive end online through the vehicle network controller 601. The battery management system also monitors the insulation status of the air compressor when it is not working online through the vehicle network controller 601. When it is working, the detection channel is closed and the insulation status of the air compressor is not monitored. All other detection channels are closed.

[0137] When not charging, the battery management system controls the corresponding detection channel of the roof high voltage box 300 to start online monitoring of insulation status through the vehicle network controller 601, while the pantograph stops insulation detection.

[0138] If the battery management system detects a Class 1 insulation fault, it sends a high-voltage command to the vehicle to disconnect the load contactor and forcibly disconnect the high voltage. The Class 1 insulation fault is a serious fault, and the battery is not allowed to operate.

[0139] If the vehicle still shows a Class 1 insulation fault at this time, it indicates a battery system insulation fault and requires assistance.

[0140] If the alarm for insulation level 1 fault disappears after the high voltage is disconnected (in low voltage state), but the high voltage still reports an insulation fault and repeats this three times, then prompt the driver to enter the "vehicle degraded operation mode" in step S2.

[0141] Step S2: Enter the vehicle degraded operation mode, actively cut off the load, and determine whether the vehicle's minimum operating capacity is met. If the vehicle's minimum operating capacity is met, the vehicle is returned to the depot for maintenance. If the vehicle's minimum operating capacity is not met, proceed to step S3.

[0142] After the driver triggers the entry into the "vehicle degraded operation mode", the vehicle network controller 601 disconnects the contactors of the first driver's cab air conditioner 201, the first passenger compartment air conditioner 202, the first defrost / heater 203, the second passenger compartment air conditioner 302, and the auxiliary power supply of the non-activated end, and opens the corresponding detection channel of the insulation inspection module to perform insulation detection.

[0143] If the vehicle insulation fault can be repaired or the vehicle meets the minimum operating capacity at this time, the vehicle will enter a degraded operation mode and return to the depot for repair.

[0144] If a Class 1 insulation fault persists for more than 10 seconds after the vehicle enters the degraded operation mode, it indicates that the vehicle does not meet the minimum operating capability. In this case, the insulation inspection mode is triggered through the Human Machine Interface (HMI) 602, and the process proceeds to step S3.

[0145] Step S3: Enter the insulation inspection mode. The insulation inspection module performs insulation tests on each segment area in sequence to locate the fault location.

[0146] The vehicle network controller 601 disconnects all contactors in the first auxiliary power supply section area, the first switch box section area, the roof high voltage box section area, the second switch box section area, and the second auxiliary power supply section area.

[0147] The vehicle network controller 601 sends detection commands to all insulation inspection modules via the CAN bus in the form of messages to perform insulation detection on each channel.

[0148] The insulation inspection module starts from channel 0 and increments sequentially for inspection. After the inspection is completed, it sends the insulation inspection status value to the vehicle and provides feedback on the current channel inspection status.

[0149] Furthermore, the detection priority order of the insulation inspection module is as follows:

[0150] 1) The first switch box 200 and the second switch box 400 are not in any particular order;

[0151] 2) The first traction motor 204 and the second traction motor 401 are not in any particular order;

[0152] 3) First auxiliary power supply 100;

[0153] 4) Second auxiliary power supply 500;

[0154] 5) Jumper harness.

[0155] Because the jumper harnesses are interconnected, the insulation status of the jumper harnesses can be detected by simply opening one of the insulation detection channels in the first switch box 200 or the second switch box 400.

[0156] Furthermore, since the rescue harness is only used in rescue mode, quarterly checks can be performed via a soft switch based on the message through the HMI interface of the human-machine interface unit 602.

[0157] Furthermore, the insulation inspection module sends the insulation detection status value to the vehicle network controller 601 and displays it through the HMI interface of the human-machine interface unit 602. If the vehicle network controller 601 determines that the insulation detection status value is less than 250kΩ, it considers that the corresponding detection channel has an insulation fault, and the channel reports the fault to the HMI interface.

[0158] Since the present invention can accurately locate the fault location, furthermore, after step S3, the present invention further includes step S4, which is used to handle the insulation problem to ensure the basic operation of the vehicle.

[0159] Step S4: Continuously perform insulation testing on the faulty channel, send the insulation test status value to the vehicle network controller, and determine whether rescue is needed or to enter the vehicle degraded operation mode.

[0160] After all channels have been inspected, the inspection mode is exited. The vehicle network controller continues to send fault channel detection signals. At this time, the contactor of the faulty branch is in the open state. The insulation resistance of the faulty channel is detected. On-site, it is determined whether rescue is needed or whether the vehicle should enter a degraded operation mode based on the fault situation.

[0161] Furthermore, when an insulation fault occurs in the second power supply branch of the auxiliary power supply for single-end traction or non-activated end, the vehicle enters a degraded operation mode.

[0162] Furthermore, when an insulation failure occurs in a single detection channel, the vehicle enters a degraded operation mode.

[0163] However, in the event of an insulation failure in the first switch box 200, the second switch box 400, or the jumper harness, the vehicle requires assistance.

[0164] Furthermore, if insulation failure occurs in multiple detection channels, the vehicle will require rescue.

[0165] The insulation fault types of the multiple detection channels requiring rescue include:

[0166] Insulation fault in the contactor circuit of the first auxiliary power supply 100 and the second auxiliary power supply 500;

[0167] Insulation fault in the contactor circuit of the first traction motor 204 and the second traction motor 401.

[0168] Insulation fault in the contactor circuit of the first hydraulic motor 103 and the second hydraulic motor 503.

[0169] This invention provides an insulation inspection method for new energy electric vehicles, which has the following beneficial effects:

[0170] 1) In multi-load new energy electric vehicles, the load at the very end can be quickly located. The detection speed is improved by segmentation, and the load detection is improved by setting up a multi-channel method through the insulation inspection module.

[0171] 2) Degraded operation mode and insulation inspection strategy were defined to conduct insulation testing and improve the vehicle's ability to quickly handle insulation faults.

[0172] 3) When the vehicle is not in operation, the insulation detection function can also be used to monitor the status of the entire vehicle and detect insulation problems in advance.

[0173] Although the methods described above are illustrated and depicted as a series of actions for the sake of simplicity, it should be understood and appreciated that these methods are not limited by the order of the actions, as some actions may occur in a different order and / or concurrently with other actions from the illustrations and descriptions herein or not illustrated and described herein but which may be understood by those skilled in the art, according to one or more embodiments.

[0174] Those skilled in the art will understand that information, signals, and data can be represented using any of a variety of different techniques and arts. For example, the data, instructions, commands, information, signals, bits, symbols, and chips described throughout the above description can be represented by voltage, current, electromagnetic waves, magnetic fields or magnetic particles, light fields or optical particles, or any combination thereof.

[0175] Those skilled in the art will further appreciate that the various illustrative logic blocks, modules, circuits, and algorithm steps described in conjunction with the embodiments disclosed herein can be implemented as electronic hardware, computer software, or a combination of both. To clearly illustrate this interchangeability between hardware and software, the various illustrative components, blocks, modules, circuits, and steps are described above in a generalized manner in terms of their functionality. Whether such functionality is implemented as hardware or software depends on the specific application and the design constraints imposed on the overall system. Those skilled in the art may implement the described functionality in different ways for each specific application, but such implementation decisions should not be construed as departing from the scope of the invention.

[0176] The various illustrative logic modules and circuits described in conjunction with the embodiments disclosed herein may be implemented or performed using a general-purpose processor, a digital signal processor (DSP), an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA) or other programmable logic device, discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. The general-purpose processor may be a microprocessor, but in alternatives, it may be any conventional processor, controller, microcontroller, or state machine. The processor may also be implemented as a combination of computing devices, such as a combination of a DSP and a microprocessor, multiple microprocessors, one or more microprocessors cooperating with a DSP core, or any other such configuration.

[0177] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein may be embodied directly in hardware, in a software module executed by a processor, or in a combination of both. The software module may reside in RAM memory, flash memory, ROM memory, EPROM memory, EEPROM memory, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art. An exemplary storage medium is coupled to a processor such that the processor can read and write information to / from the storage medium. In an alternative, the storage medium may be integrated into the processor. The processor and storage medium may reside in an ASIC. The ASIC may reside in a user terminal. In an alternative, the processor and storage medium may reside as discrete components in the user terminal.

[0178] In one or more exemplary embodiments, the described functionality may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software as a computer program product, the functionality may be stored or transmitted as one or more instructions or code on or through a computer-readable medium. A computer-readable medium includes both computer storage media and communication media, encompassing any medium that facilitates the transfer of a computer program from one location to another. A storage medium may be any available medium accessible to a computer. By way of example and not limitation, such a computer-readable medium may include RAM, ROM, EEPROM, CD-ROM or other optical disc storage, disk storage or other magnetic storage devices, or any other medium that can be used to carry or store desired program code in the form of instructions or data structures and is accessible to a computer. Any connection is also legitimately referred to as a computer-readable medium. For example, if the software is transmitted from a website, server, or other remote source using coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of a medium. As used in this article, disk and disc include compact discs (CDs), laser discs, optical discs, digital multi-purpose discs (DVDs), floppy disks, and Blu-ray discs. Disks typically reproduce data magnetically, while discs reproduce data optically using lasers. Combinations of these should also be included within the scope of computer-readable media.

[0179] As indicated in this application and claims, unless the context clearly indicates otherwise, the words "a," "an," "an," and / or "the" are not specifically singular and may include plural forms. Generally speaking, the terms "comprising" and "including" only indicate the inclusion of explicitly identified steps and elements, which do not constitute an exclusive list, and the method or apparatus may also include other steps or elements.

[0180] The above embodiments are provided for those skilled in the art to implement or use the present invention. Those skilled in the art can make various modifications or changes to the above embodiments without departing from the inventive concept of the present invention. Therefore, the protection scope of the present invention is not limited to the above embodiments, but should be the maximum scope that conforms to the innovative features mentioned in the claims.

Claims

1. An insulation inspection method for new energy electric vehicles, characterized in that, Includes the following steps: Step S1: Divide the vehicle into sections based on the high-voltage components of the new energy electric vehicle, set up an insulation inspection module for each section, and detect the insulation status of the whole vehicle. If the vehicle has an insulation problem, proceed to step S2. Step S2: Enter the vehicle degraded operation mode, actively cut off the load, and determine whether the minimum operating capacity of the vehicle is met. If the minimum operating capacity of the vehicle is met, the vehicle is returned to the depot for maintenance. If the minimum operating capacity of the vehicle is not met, proceed to step S3. Step S3: Enter the insulation inspection mode, and use the insulation inspection module to perform insulation tests on each segment area in sequence to locate the fault location; In step S1, the process of dividing the entire vehicle into regional segments based on the high-voltage components of the new energy electric vehicle further includes: Based on the high-voltage components of the new energy electric vehicle, the entire vehicle is divided into 5 sections, including the first auxiliary power supply section, the first switch box section, the roof high-voltage box section, the second switch box section, and the second auxiliary power supply section. In step S1, the insulation status of the entire vehicle is detected, which further includes: During normal driving and charging conditions, the battery management system monitors the insulation status of the load oil pump at the inactive end online and continuously monitors the insulation status of the air compressor when it is not working. When not charging, the battery management system monitors the insulation status of the roof-mounted high-voltage box online.

2. The insulation inspection method for new energy electric vehicles according to claim 1, characterized in that, In step S1, after the vehicle experiences an insulation problem, the following steps are further included: If the battery management system detects an insulation level 1 fault, it sends a high-voltage command to the vehicle to disconnect the load contactor and forcibly disconnect the high voltage, and then determines whether the insulation level 1 fault still occurs. If a Class 1 insulation fault still occurs, it is determined to be a battery system insulation fault, and the vehicle requires assistance. If the alarm for a Class 1 insulation fault disappears, but the high voltage still reports an insulation fault repeatedly, then proceed to step S2.

3. The insulation inspection method for new energy electric vehicles according to claim 1, characterized in that, Step S2, which involves entering a degraded vehicle operation mode and actively cutting off the load, further includes the following steps: Disconnect the contactors of the first driver's cab air conditioner, the first passenger compartment air conditioner, the first defrost / heater, the second driver's cab air conditioner, the second passenger compartment air conditioner, and the auxiliary power supply of the non-activated terminals, and perform corresponding insulation tests.

4. The insulation inspection method for new energy electric vehicles according to claim 1, characterized in that, Step S3 further includes the following steps: Disconnect all contactors in the first auxiliary power supply section area, the first switch box section area, the roof high voltage box section area, the second switch box section area, and the second auxiliary power supply section area; The insulation inspection module sequentially performs insulation tests on each segment area and feeds back the insulation test status values ​​to the whole vehicle, thereby locating the fault location.

5. The insulation inspection method for new energy electric vehicles according to claim 4, characterized in that, In step S3, the detection priority order of the insulation inspection module is as follows: First switch box and second switch box; First traction motor and second traction motor; First auxiliary power supply; Second auxiliary power supply; Jumper harness.

6. The insulation inspection method for new energy electric vehicles according to claim 1, characterized in that, Step S1 further includes: The human-machine interface unit sends messages via a soft switch to perform periodic insulation tests on the rescue wiring harness.

7. The insulation inspection method for new energy electric vehicles according to claim 4, characterized in that, Step S3 further includes: If the insulation test status value is less than 250kΩ, the corresponding test channel is considered to be faulty.

8. The insulation inspection method for new energy electric vehicles according to claim 1, characterized in that, Following step S3, the following steps are further included: Step S4: Continuously perform insulation testing on the faulty channel, send the insulation test status value to the vehicle network controller, and determine whether rescue is needed or to enter the vehicle degraded operation mode.

9. The insulation inspection method for new energy electric vehicles according to claim 8, characterized in that, Step S4 further includes: When an insulation failure occurs in a single detection channel, the vehicle enters a degraded operation mode. When multiple insulation failures occur in the detection channels, the vehicle requires rescue.

10. The insulation inspection method for new energy electric vehicles according to claim 9, characterized in that, Step S4 further includes: The vehicle requires rescue when an insulation fault occurs in the first switch box, the second switch box, or the jumper harness.

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