Electronic insurance motor box and adapter, controller, associated electrical components, electric vehicle

Abstract

This invention discloses an electronic fuse motor box and adapter, controller, associated electrical components, and an electric vehicle. The motor box includes an MCU circuit, a communication circuit, a controller circuit, a taillight control circuit, and a human-machine interface circuit. The human-machine interface circuit includes one or more combinations of WIFI / GPS, BT / GPS, NFC, GSM / GPS, USB / GPS, electronic key, and remote anti-theft circuits. The motor box also adds a charger function circuit, improving the overall vehicle electrical management and BMS battery management functions, making the product more powerful. During charging, power-on, power-on, and power-off, it can comprehensively monitor the voltage, current, and temperature of the entire vehicle and provide a series of protections to reduce the occurrence of fires.

Description

Technical Field

[0001] In the field of electric vehicle technology, specifically "electric vehicle electrical systems". Background Technology

[0002] For ease of description, the following abbreviations will be used:

[0003] "Main wires" refers to the wire harnesses that connect the electrical components of an electric vehicle. They are usually bundled together and connected to various electrical components; some are called wire harnesses.

[0004] "Electric vehicles" refers to battery-powered vehicles including four-wheeled electric cars, electric sightseeing vehicles, electric sweepers, electric forklifts, children's vehicles, electric bicycles, electric-assisted bicycles, electric motorcycles, and electric tricycles.

[0005] "Electronic switching transistors" generally refers to Darlington transistors, IGBT transistors, or MOSFETs;

[0006] "BT" is the abbreviation for Bluetooth communication.

[0007] "Previous patent" refers to Chinese patent CN2022219551947;

[0008] The "Fault Information" includes: throttle fault, brake fault, HALL fault, motor wire phase loss, motor wire short circuit, controller fault (pipe failure), overvoltage protection, undervoltage protection, overcurrent protection, overtemperature protection, stall protection, P gear protection, stall stop protection, stall stop protection, overload protection, taillight short circuit, communication line break, side stand protection, seat removal protection, charger overcharge protection, battery charging overtemperature protection, converter overtemperature protection, converter fault, etc.

[0009] "Vehicle front electrical appliances" refers to all electrical appliances near the front instrument panel of an electric vehicle, such as ignition switch, brake switch, reverse switch, gear switch, P gear switch, repair switch, cruise control switch, various lights, wipers, horn, doors, air conditioner, audio system, etc.

[0010] "Main circuit": The circuit between the battery output and the motor controller, charging port, motor box power input port, and motor box monitoring system circuit. The main circuit is always energized.

[0011] "Secondary circuit": The circuits of the entire vehicle other than the main circuit, including the power lines in the main wiring harness.

[0012] The previous patented motor box lacked charger functionality circuitry, but this version adds it. Utilizing the motor box's surplus power circuitry, PWM module, FLASH, RAM, EEPROM, ADC, GPIO, UART, I2C, and other resources, the charger function is conveniently integrated, significantly reducing costs and offering a highly comprehensive level of intelligence. This charger is a built-in charger, urgently needed for certain vehicle models. Its integration with the motor box saves OEMs installation steps and space. It's far superior to chargers made with traditional analog chips. Even some smart chargers don't use our high-end chips.

[0013] The previous patented vehicle electrical and electronic fuse circuit did not achieve complete power cutoff for all secondary circuits after shutdown, thus still posing a fire risk. This design completely overcomes that limitation.

[0014] The previous patented charging protection circuit did not evolve into a BMS battery management function. This time, a charging current detection circuit has been added, which improves the BMS battery management, provides all-round protection for the battery, and prevents fires. Summary of the Invention

[0015] This invention discloses an electronic fuse box and adapter, controller, associated electrical components, and electric vehicle, the purpose of which is to overcome the aforementioned deficiencies of the previous patent.

[0016] This invention builds upon the previous patent by adding a charger function circuit, improving the vehicle's electrical management, enhancing the BMS battery management function, and comprehensively reducing the occurrence of fires.

[0017] A motor housing: The motor housing includes an MCU circuit, a communication circuit, a controller circuit, a taillight control circuit, and a human-machine interface circuit. See [link / reference] Figure 2 The MCU circuit connects to the communication circuit, the controller circuit, the taillight control circuit, and the human-machine interface circuit. The MCU circuit contains an MCU chip. The communication circuit is connected to an adapter via a mains cable. The mains cable includes a communication line. The motor box is connected to the adapter via the mains cable and exchanges data bidirectionally according to the communication protocol. The controller circuit is connected to the controller. The motor box receives the signals required by the controller from the adapter via the mains cable according to the communication protocol, and outputs them to the controller after conversion by the controller circuit. The motor box also receives the signals output by the controller, which are converted by the controller circuit and then sent to the adapter via the mains cable according to the communication protocol. See the previous patent.

[0018] The motor box is connected to the controller via a dedicated line or communication line and transmits signals bidirectionally. The dedicated line connection includes single or multiple combinations of signals such as throttle signal, brake signal, lockout signal, reverse signal, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft / hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, power supply positive terminal, and power supply negative terminal. The communication connection includes a communication line, power supply positive terminal, and power supply negative terminal. The number of wires on the communication line varies depending on the communication mode; the simplest is a single-wire full-duplex communication mode, requiring only one wire.

[0019] The motor box includes a taillight control circuit and is connected to the taillight. The MCU circuit is connected to the taillight control circuit. The taillight signal from the adapter is transmitted to the motor box via the main line according to the communication protocol, and then the taillight is controlled by the taillight control circuit. Details of the taillight control circuit can be found in the previous patent. To limit the maximum current during a short circuit in the taillight and protect the safe use of the electronic switch, a current-limiting resistor needs to be connected in series in the current loop of the electronic switch circuit. This current-limiting resistor can replace the sampling resistor in the taillight common-ground mode circuit. Details of the taillight control circuit can be found in CN202220040948X.

[0020] The human-computer interaction circuit includes one or more of the following: WIFI / GPS circuit, BT / GPS circuit, NFC circuit, GSM / GPS circuit, USB / GPS circuit, electronic key circuit, and remote control anti-theft circuit (see previous patent). Except for the USB / GPS circuit and electronic key circuit, which are wired communication, the other five modes are wireless communication.

[0021] Users can power on the system and start the circuit via a remote control, ignition lock, electronic key, mobile phone, or NFC card. See the description of the human-computer interaction circuit in the previous patent for details.

[0022] The GPS mentioned refers to GPS or Beidou with location positioning and timing functions, and is an optional feature. The motor box requires an independent positioning function to be used.

[0023] GSM refers to the general term for all mobile communication standards of China Mobile, China Unicom, and China Telecom.

[0024] The power supply of the motor box is connected to the battery, or connected to the battery through the controller. Its monitoring system circuit is always energized (including MCU circuit, human-machine interaction circuit, etc.) in order to respond to the owner's power-on / off operation, anti-theft monitoring, and power outage of the vehicle's secondary circuit at any time.

[0025] The motor box includes the vehicle's electrical and electronic fuse circuit. This circuit includes a comparator circuit, a sampling resistor circuit, and an electronic switch circuit. (See previous patent for details.) Figure 5 , Figure 6The comparator circuit is connected to the sampling resistor circuit or the electronic switch circuit to obtain the current range of the vehicle's electrical system. The MCU circuit is connected to the comparator circuit and the electronic switch circuit. The sampling resistor circuit is connected to the electronic switch circuit. The electronic switch circuit includes an electronic switch transistor; if its internal resistance is used to sample the current, the sampling resistor circuit is omitted. If the MCU circuit has an internal comparator module, the external comparator circuit is omitted. The vehicle's electrical electronic fuse circuit is also used as the electric vehicle's power-on / off circuit, i.e., controlling the vehicle's power supply. After shutdown, all electrical components from the rear plug of the main cable to the front of the vehicle are completely de-energized.

[0026] The vehicle's electrical and electronic fuse circuits are divided into positive control mode and negative control mode.

[0027] In the positive control mode, the output of the electronic switch circuit is connected to the positive terminal of the vehicle's electrical system (48-72V system) or, via a DC-DC converter, to the positive terminal of the vehicle's electrical system (12-24V system). The sampling resistor circuit is connected to the positive terminal of the battery. See [link / details]. Figure 5 .

[0028] In the negative control mode, the output of the electronic switch circuit is connected to the negative terminal of the battery, and the sampling resistor circuit is connected to the negative terminal of the vehicle's electrical system. (See...) Figure 6 .

[0029] When the electric vehicle system voltage uses the output voltage of a DC-DC converter, the power supply voltage value and battery voltage type collected by the motor box are transmitted to the instrument display associated with the front adapter via a communication protocol. The battery voltage types include 24V, 36V, 48V, 60V, 72V, 84V, or 96V. The battery voltage type is determined by the motor box based on the power supply voltage, the external connector, or by the user using a remote control or mobile phone. The instrument does not require traditional connector selection of the battery type. This is a technical solution for displaying the battery level on a 12V standard electric vehicle instrument.

[0030] The interchange of the sampling resistor circuit and the electronic switch circuit does not affect the performance of the vehicle's electrical and electronic fuse circuits, but the connection relationship will be adjusted accordingly.

[0031] When the vehicle owner turns on the device, if the total current of the vehicle's electrical systems (excluding the controller) exceeds the rated value, the output of the comparator circuit will change. The MCU circuit will then cut off the vehicle's power input via the electronic switch circuit (triggering short-circuit protection) to prevent electrical wiring from burning out or causing a fire. Protection is also provided even if the positive and negative terminals of the power lines in the main wiring harness are short-circuited.

[0032] After the vehicle owner shuts down the vehicle, the MCU circuit, through the electronic switch circuit, also cuts off the vehicle's power input and the battery output, ensuring that the voltage of the vehicle's secondary circuit is 0V. The power outage of the vehicle's secondary circuit completely disconnects power from the rear plug of the mains cable to all electrical appliances in the front of the vehicle, preventing fires caused by electrical short circuits.

[0033] The motor housing includes a BMS (Battery Management System) circuit. The BMS circuit includes a battery temperature detection circuit, a charging control circuit, a battery voltage detection circuit, and a charging current detection circuit. An MCU (Microcontroller Unit) circuit is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit. See [link / reference]. Figure 4 .

[0034] The battery temperature detection circuit includes a temperature sensor, which is installed near the battery (e.g., a thermal infrared sensor) or in close contact with the battery casing (e.g., a thermistor).

[0035] The BMS battery management includes a battery voltage detection circuit. At this time, the MCU circuit is also connected to the battery voltage detection circuit, which includes a voltage divider resistor and a filter capacitor.

[0036] The charging control circuit includes an electronic switch circuit. The MCU circuit is connected to the electronic switch circuit.

[0037] The charging control circuit is divided into charger DC output positive control mode, charger DC output negative control mode, and charger AC input control mode.

[0038] The charger's DC output positive control mode: The electronic switch circuit is connected between the charger's DC output positive line and the battery's positive terminal, used to control the circuit of the charger's DC output positive line. The electronic switch circuit includes an electronic switch transistor.

[0039] The charger's DC output negative control mode: The electronic switch circuit is connected between the charger's DC output negative line and the battery's negative terminal, used to control the circuit of the charger's DC output negative line. The electronic switch circuit includes an electronic switch transistor.

[0040] The charger AC input control mode: The electronic switch circuit connects the charger's AC mains input and the charger, and is used to control the AC mains input line path of the charger. The electronic switch circuit includes a bidirectional thyristor or a relay.

[0041] During charging, if the MCU circuit detects that the battery voltage or temperature exceeds the rated value, it triggers over-temperature and over-voltage protection. This involves cutting off the charger's charging current loop via the electronic switch circuit and transmitting the alarm information to the adapter via the main communication line, or triggering a local LED flashing or buzzer audible alarm. Alternatively, an alarm can be triggered via the USER-APP or a mobile device.

[0042] When the MCU circuit detects that the battery voltage is greater than the rated value during power-on, it uses the vehicle's electrical and electronic fuse circuit to cut off the power supply to the electric vehicle system, including the controller's operating power supply, to prevent the safety risks caused by the owner forgetting to unplug the charger and forcibly riding the vehicle. At the same time, it will sound an alarm through the sound alarm circuit, or through the USER-APP or mobile phone instrument panel.

[0043] When the MCU circuit detects that the battery temperature is higher than the rated value while the vehicle is in motion, it will stop the controller from working by using the lockout line or communication line of the controller circuit to prevent the safety risk of the battery overheating and exploding during the vehicle's operation. At the same time, it will sound an alarm through the audible alarm circuit, or through the USER-APP or mobile instrument panel.

[0044] The charging current detection circuit includes a sampling resistor circuit and an operational amplifier circuit. The sampling resistor circuit is connected in series in the main electrical circuit of the vehicle and is also connected to the operational amplifier circuit. The output of the operational amplifier circuit is connected to the ADC input port of the MCU circuit. During charging, if the MCU circuit detects that the charging current is greater than the rated value, it will cut off the charger output through the charging control circuit (triggering overcurrent protection) to prevent battery failure. Additionally, the battery capacity is indirectly determined by the integral value of the charging current over time, thus judging the battery's condition. Finally, an alarm is triggered via an audible alarm circuit, or via the USER-APP or mobile instrument panel. This provides overcurrent protection for the charger and adds another parameter for judging battery condition.

[0045] The motor housing includes a battery communication circuit. The MCU circuit connects to this circuit, enabling bidirectional data transmission with the battery according to a communication protocol. The communication protocol includes UART, 485, I2C, CAN, or LIN, with 485 being the most common. This battery communication circuit communicates not only with the battery but also with the charger and controller, as these are networked. Battery temperature, charging voltage, charging current, and charging control circuitry can all be monitored through the battery's internal protection board, saving the cost of the BMS battery management circuit. The battery's internal parameters can also be transmitted to the USER-APP or mobile instrument via the human-machine interface circuit, and further to the controller via the controller circuit.

[0046] The motor housing includes a charger circuit. The charger circuit includes an MCU circuit, a PWM output circuit, an isolation circuit, a drive circuit, an electronic switch circuit, a transformer circuit, a rectifier-filtered DC output circuit, a charging current detection circuit, a battery voltage detection circuit, and an AC input rectifier-filtered circuit. See [link / details]. Figure 3 .

[0047] The MCU circuit is connected to the PWM output circuit, the charging current detection circuit, and the battery voltage detection circuit. The rectified and filtered DC output circuit is connected to the charging current detection circuit, the battery voltage detection circuit, the transformer circuit, and the battery. The electronic switch circuit is connected to the drive circuit, the transformer circuit, and the AC input rectified and filtered circuit. The AC input rectified and filtered circuit is connected to the AC mains input and is the input power supply for the charger. The isolation circuit is connected to the PWM output circuit and the drive circuit.

[0048] The isolation circuit includes an optocoupler or isolation transformer. The drive circuit includes resistors, capacitors, transistors, and diodes. The electronic switching circuit includes electronic switching transistors (MOSFETs are the most common). The AC input rectifier and filter circuit includes a rectifier bridge and a filter electrolytic capacitor. The rectifier and filter DC output circuit includes rectifier diodes and a filter electrolytic capacitor (adding a filter inductor will improve the LC filtering effect). The charging current detection circuit includes a sampling resistor circuit and an operational amplifier circuit, and then connects to the ADC input port of the MCU circuit. The battery voltage detection circuit includes voltage divider resistors and a filter capacitor, and then connects to the ADC input port of the MCU circuit.

[0049] The charger's operation is as follows: The PWM signal from the MCU chip, after passing through the PWM output circuit, is isolated from the MCU system by opto-isolation or transformer isolation, thus isolating the connection loop between the MCU system and the high-voltage AC mains circuit. This is particularly important. The drive circuit then controls the electronic switching circuit to provide PWM oscillation to the primary winding of the transformer, the energy source being the rectified and filtered AC input. The primary oscillation energy is coupled to the secondary winding, rectified to obtain a low-voltage DC power supply, and then filtered before charging the battery. The MCU circuit adjusts and controls the charging current and voltage based on the charging current detection circuit and the battery voltage detection circuit until the battery is fully charged. This charger operation process is easily understood by experienced charger engineers.

[0050] High-power chargers also require fan control circuits and heat sink temperature detection circuits to ensure that the electronic switching transistors do not overheat.

[0051] The charger circuit includes a fan control circuit and a heatsink temperature detection circuit. The MCU circuit connects to both the fan control circuit and the heatsink temperature detection circuit. The fan control circuit is connected to an electric fan to blow air onto the heatsink for cooling. The heatsink temperature detection circuit is connected to a temperature sensor, which is in close contact with the heatsink. When the MCU circuit detects that the heatsink temperature is higher than the rated value, it activates the electric fan to cool the heatsink (which also cools the transformer). (This is specifically for high-power chargers; low-power chargers may not require this. If using a low-resistance switching transistor and a low-magnetic-resistance transformer, this circuit may also be omitted.)

[0052] An adapter: The adapter connects to the motor housing via a main cable and exchanges data bidirectionally with the motor housing according to a communication protocol. The adapter includes an MCU circuit, a functional circuit, a communication circuit, and a functional socket circuit.

[0053] The MCU circuit includes an MCU chip and is connected to the functional circuit and the communication circuit. The functional socket circuit connects the functional circuit and the communication circuit. The functional circuit includes a combination throttle circuit, a combination switch circuit, a voice broadcast circuit, a lighting control circuit, and an instrument display circuit. The combination throttle circuit, the combination switch circuit, the voice broadcast circuit, the lighting control circuit, and the instrument display circuit are all connected to the MCU circuit.

[0054] The functional socket circuit includes a single-row socket and / or a double-row socket corresponding to the functional circuit, and is connected to the functional circuit. The single-row socket and / or double-row socket are respectively connected to the vehicle's front electrical components. The functional socket circuit includes a single-row or double-row mains cable socket. The mains cable socket connects to the mains cable. The mains cable includes a communication cable, the front end of which connects to the adapter, and the rear end connects to the motor box. The voice broadcast circuit includes a voice chip circuit and a power amplifier circuit. The voice chip circuit is connected to the power amplifier circuit, and the power amplifier circuit is connected to the speaker. The voice chip circuit is connected to the MCU circuit and is used to play the electric vehicle's parameters (including fault information) and corresponding operation sounds. The lighting control circuit is connected to the MCU circuit. The lighting control circuit is connected to the combination throttle circuit, the combination switch circuit, and the instrument display circuit, and is used to control and display the status of the electric vehicle's lights. The combination throttle circuit is connected to the combination throttle via the functional socket circuit. The combination switch circuit is connected to the combination switch via the functional socket circuit. The lighting control circuit is connected to the headlights via the functional socket circuit. The instrument display circuit is connected to an external instrument cluster or the internal instrument display circuit of the adapter (the adapter has built-in instrument functionality) via the function socket circuit. The lighting control circuit also includes a flashing circuit. The flashing circuit includes an electronic switch and is connected to the MCU circuit. The instrument display circuit is connected to the MCU circuit and is used to display the vehicle's status and parameters.

[0055] The adapter connects to the individual plugs of all the vehicle's front electrical components via a dedicated socket, and after collecting and processing the relevant signals, transmits them to the motor box via the communication line in the main cable according to the communication protocol. The relevant parameters of the controller and the motor box are transmitted to the adapter via the communication line in the main cable according to the communication protocol for voice broadcasting and instrument display. The vehicle's front electrical components include multiple combinations of instruments, headlights, combination throttle, combination switch, horn, left brake, right brake, and foot brake.

[0056] A controller: The controller connects to the motor box via a wiring harness or communication connection and transmits signals bidirectionally. The wiring harness connection includes single or multiple combined signals such as throttle signal, brake signal, lockout line, reverse, third gear, cruise control, P gear, anti-theft lock motor, one-key repair, soft / hard start, rated voltage switching, motor learning, motor's linear speed, motor's linear speed, positive power supply, and negative power supply. The communication connection includes a communication line, a positive power supply, and a negative power supply.

[0057] The number of wires on the communication line varies depending on the communication mode. The simplest mode is single-wire full-duplex communication, which requires only one wire. The controller includes an MCU circuit and a communication circuit. The communication circuit connects to the motor box or the adapter via the communication line, transmitting data bidirectionally according to the communication protocol.

[0058] To save on the cost of the controller's primary power supply circuit, the wiring harness connection or communication connection also includes a working power output line. The voltage of the working power output line is in the range of 12V to 18V. The controller includes a motor control circuit. The MCU circuit is connected to the motor control circuit. The motor control circuit includes a three-phase bridge arm upper and lower motor phase line drive circuit, a three-phase bridge arm upper and lower electronic switch transistor circuit, a motor rotor position sensor circuit, a sampling resistor circuit, a comparator circuit, and an operational amplifier circuit.

[0059] The control signals required by the controller are acquired and processed by the adapter, then transmitted to the motor box via the main line according to the communication protocol, and finally processed and transmitted by the motor box. The internal parameters and fault information required by the controller to output are processed by the motor box and then transmitted to the adapter via the main line according to the communication protocol.

[0060] An associated electrical component: The associated electrical component connects to a motor box or adapter. All signals from the associated electrical component must be processed by the motor box, or its data originates from the transmission of the motor box (e.g., an instrument). The associated electrical component is a general term for a class of electrical components, with specific components being one of them, including DC-DC converters, chargers, taillights, main cables, instruments, combination throttles, combination switches, left brake, right brake, foot brake, horn, and ignition lock. Each associated electrical component has only one plug, which is inserted into a dedicated socket in the adapter or motor box.

[0061] The DC-DC converter is plugged into the motor box, and its positive input is connected to the output of the vehicle's electrical and electronic fuse circuit (specifically for 12-24V electric vehicle systems; otherwise, it is not needed). (See...) Figure 1 ).

[0062] The AC input or DC output of the charger is controlled by the motor box and plugged into a dedicated socket in the motor box (for external chargers; if using the internal charger of the motor box, this is not necessary). (See...) Figure 1 ).

[0063] The rear light is connected to the motor box, and its switching signal originates from the motor box. The rear light includes a left taillight, a right taillight, a center taillight, and an integrated taillight. (See...) Figure 1 ).

[0064] One end of the main cable connects to the motor box, and the other end connects to an adapter. The main cable includes a communication line. The motor box and the adapter transmit data bidirectionally via the communication line according to a communication protocol. The main cable has only one plug at each end. The main cable includes a power supply line, whose positive (48~72V or 12~24V) or negative terminal is controlled by the vehicle's electrical and electronic fuse circuit of the motor box. If a single-wire full-duplex communication mode (such as LIN or single-wire UART) is used, the main cable has only three wires (preferred mode of the invention).

[0065] The instrument is connected to the adapter, and its displayed data (speed, current, voltage, fault information, etc.) originates from the motor box transmitted via a mains cable. When the electric vehicle system voltage uses the output voltage of a DC-DC converter, the battery voltage value of the instrument is not obtained by itself through the ADC on the locked line, but is transmitted from the motor box via the communication line. The battery voltage type is determined not by manually selecting the plug, but by the motor box transmitted via the communication line.

[0066] The combined throttle is connected to the adapter. Its output signal needs to be transmitted by the adapter to the motor box for processing via the main cable according to the communication protocol.

[0067] The combination switch is connected to the adapter. Its output signal needs to be transmitted by the adapter to the motor box for processing via the main line according to the communication protocol.

[0068] The left brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the motor box for processing via the main cable according to the communication protocol.

[0069] The right brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the motor box for processing via the main cable according to the communication protocol.

[0070] The foot brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the motor box for processing via the main cable according to the communication protocol.

[0071] The speaker is connected to the adapter. The content it broadcasts originates from the motor box and is transmitted via a main cable according to the communication protocol.

[0072] The ignition switch is plugged into a dedicated socket in the motor box and connected to the MCU circuit of the motor box.

[0073] An electric vehicle: the electric vehicle is equipped with the motor box, or the adapter, or the controller, or one of the aforementioned associated electrical components.

[0074] Effects of the invention:

[0075] By utilizing the spare power circuitry, PWM module, FLASH, RAM, EEPROM, ADC, GPIO, UART, and I2C resources in the motor housing, the charger function is conveniently integrated, significantly reducing costs and offering a highly comprehensive level of intelligence. This charger is a built-in charger, urgently needed for certain vehicle models. Its integration with the motor housing saves OEMs installation steps and space. It is far superior to chargers made with traditional analog chips. Even some smart chargers don't use our high-end chips.

[0076] The vehicle's electrical and electronic fuse circuits are used to completely disconnect the power to all secondary circuits after the vehicle is turned off, preventing fires caused by electrical short circuits.

[0077] The application of a charging current detection circuit in the BMS battery management circuit improves BMS battery management, provides comprehensive battery protection, and prevents fires.

[0078] The charging current detection circuit of the BMS battery management circuit is used to determine the performance and quality of the battery by integrating the current value with time, which solves the problem that traditional electric vehicles cannot determine battery performance.

[0079] The charging voltage detection circuit of the BMS battery management circuit is used to cut off the power supply of the electric vehicle system, including the controller's operating power supply, by borrowing the vehicle's electrical and electronic fuse circuit. This prevents the safety risks caused by the owner forgetting to unplug the charger and forcibly riding the vehicle. At the same time, an alarm is triggered through the sound alarm circuit, or through the USER-APP or mobile phone instrument panel.

[0080] When the MCU circuit detects that the battery temperature is higher than the rated value while the vehicle is in motion, it uses the lockout line or communication line of the controller circuit to stop the controller from working, so as to prevent the battery from continuing to heat up and explode.

[0081] The motor box includes a battery communication circuit that transmits data bidirectionally with the battery according to a communication protocol. It also communicates with the charger and controller via network, which is one of the product's highlights.

[0082] The addition of a new type of charger to the original motor box, and the fact that it has full BMS functionality, is a significant feature that makes this product novel. Attached Figure Description

[0083] Figure 1 Electric vehicle electrical wiring system;

[0084] Figure 2 Motor box circuit;

[0085] Figure 3 Charger circuit;

[0086] Figure 4 BMS battery management circuit;

[0087] Figure 5 : Electronic fuse circuit for positive control mode of vehicle electrical system;

[0088] Figure 6 : Vehicle electrical and electronic fuse negative control mode circuit. Detailed Implementation

[0089] The most important component in the adapter and motor housing of this invention is the MCU chip, which will be introduced in detail here. The MCU functional circuit will not be repeated below.

[0090] The MCU circuit is the core, containing the MCU chip, known in the industry as a microcontroller. It is an intelligent chip that implements related algorithms and control through software programming. The main technical parameters to consider when selecting an MCU chip are: operating speed, temperature range, number of GPIOs, FLASH size, RAM size, and external communication port mode. Currently, many microcontrollers on the market can meet these requirements, with multiple brands from manufacturers such as Microchip, Freescale, ST, Infineon, and Cypress offering readily available technologies. Furthermore, there are also many domestic Chinese brands available.

[0091] The most important aspect of this invention is data communication between the adapter and the motor box, which will be discussed in detail first. Communication modes include: UART, Lin, CAN, I2C, 485, and GPIO analog communication. In low-end products such as electric bicycles, electric motorcycles, and electric tricycles, UART, I2C, and GPIO analog communication are generally chosen. In high-end applications such as electric cars, electric patrol cars, electric sightseeing vehicles, and electric fire trucks, 485, Lin, and CAN communication are generally used. The specific circuit varies depending on the communication mode. UART, I2C, and GPIO analog communication ports are directly connected. However, communication is master-slave; generally, the master communication module requires a pull-up resistor on its communication line. This invention recommends using the adapter as the master module and the motor box as the slave module. Lin, I2C, and 485 communication modes require additional communication driver chips or driver circuits. Many models of these chips are available and can be found on professional websites. In this case, the communication circuit needs to incorporate these communication driver chips or driver circuits. Specific circuit details can be found in the relevant chip datasheets. Some MCU chips have already integrated the driver chip for this communication mode. In this case, no additional components are needed for the communication circuit; simply lead out the communication line.

[0092] Figure 1 Electric vehicle electrical wiring system: This refers to the wiring system of the entire electric vehicle.

[0093] All front electrical components are connected to the adapter. After processing by the adapter, the signals are transmitted to the motor box via the communication lines in the main wiring harness, according to the communication protocol. The motor box decomposes these signals and then transmits them to the motor controller according to the communication protocol, or decomposes them into dedicated function lines and transmits them to the motor controller (such as throttle signal, brake, reverse, third gear, P gear, etc.). The taillight control signals from the adapter are processed by the motor box and then used to control the taillights through the taillight control circuit.

[0094] Fault information and parameters from the controller are transmitted to the motor box via a single-line or communication line. After processing, the motor box transmits the information through the mains communication line according to the communication protocol, and then to the adapter. The adapter then processes the information and transmits it to the instrument for display. Alternatively, it can be transmitted to a mobile instrument or USER_APP for display and alarm.

[0095] The DC-DC converter is an optional accessory, but it is mandatory according to national standards. The DC-DC converter connects to the motor housing, supplying 12V power to the entire vehicle's electrical system. The positive power input of the DC-DC converter is controlled by the electrical and electronic fuse circuits of the motor housing and the entire vehicle. If the motor housing is equipped with a converter function, the external DC-DC converter is omitted. See Chinese Patent CN2022206766620.

[0096] The functions and circuit structures of the vehicle wiring and signal transmission, adapters, motor boxes, and motor controllers are described in the previous patents. The communication circuits, anti-theft remote control circuits, and voice circuits of the adapters and motor boxes are also described in the previous patents.

[0097] The taillights are connected to a dedicated socket in the motor box, and their switch is controlled by the motor box.

[0098] The motor box has a dedicated socket for battery communication, enabling bidirectional communication with the battery. It also connects to the charger and controller for network communication.

[0099] Some models of the motor box can be used with an external charger, in which case there is a dedicated socket for this charger. If using its built-in charger, this can be omitted.

[0100] Figure 2 Motor box circuit: The MCU chip is the control core, and all functional circuits are connected to the MCU circuit. This is the overall circuit structure of the motor box of this invention. The implementation of the converter circuit, controller circuit, taillight control circuit, communication circuit, MCU circuit, and human-machine interaction circuit is described in the previous patent. The vehicle electrical and electronic fuse circuit is as follows. Figure 5 , 6 And related descriptions, charger circuit see Figure 3 See BMS battery management circuit. Figure 4 .

[0101] Figure 3 Charger Circuit: The PWM signal from the MCU chip charger, after passing through the PWM output circuit, is isolated from the MCU system by opto-isolation or transformer isolation, thus isolating the connection loop between the MCU system and the high-voltage AC mains circuit. This is particularly important. The drive circuit then controls the electronic switching circuit to provide PWM oscillation to the primary winding of the transformer, the energy source being the rectified and filtered AC input. The primary oscillation energy is coupled to the secondary winding, rectified to obtain a low-voltage DC power supply, and then filtered to charge the battery. The MCU circuit adjusts and controls the charging current and voltage based on the charging current detection circuit and the battery voltage detection circuit until the battery is fully charged. The charger's operation process is easily understood by engineers in the charger industry.

[0102] High-power chargers also require fan control circuits and heat sink temperature detection circuits to ensure that the electronic switching transistors do not overheat.

[0103] Figure 4 The BMS battery management circuit includes a battery temperature detection circuit, a charging control circuit, a battery voltage detection circuit, and a charging current detection circuit. The MCU circuit is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit.

[0104] When the MCU circuit detects that the battery voltage is greater than the rated value or the battery temperature is greater than the rated value during charging, it triggers over-temperature and over-voltage protection.

[0105] When the MCU circuit detects that the battery voltage is greater than the rated value during power-on, it uses the vehicle's electrical and electronic fuse circuit to cut off the power supply to the electric vehicle system, including the controller's operating power supply, to prevent the safety risks caused by the owner forgetting to unplug the charger and forcibly riding the vehicle. At the same time, it will sound an alarm through the audible alarm circuit.

[0106] When the MCU circuit detects that the battery temperature is higher than the rated value while the vehicle is in motion, it will use the lockout line or communication line of the controller circuit to stop the controller from working, so as to prevent the safety risk of the battery overheating and exploding and catching fire during the vehicle's operation.

[0107] During charging, if the MCU circuit detects that the charging current is greater than the rated value, it will cut off the charger output through the charging control circuit (triggering overcurrent protection) to prevent battery failure.

[0108] In addition, the battery capacity is indirectly determined by the integral of the charging current and time during charging, thereby judging the battery's condition.

[0109] Figure 5 The vehicle electrical system's positive control mode electronic fuse circuit works as follows: If the comparator circuit detects an abnormal current in the vehicle's electrical system through the sampling resistor circuit, it flips its output signal to trigger the MCU circuit's interrupt protection. This disconnects the battery's positive output by shutting down the electronic switch in the switching circuit, achieving overcurrent or short-circuit protection. Alternatively, the MCU circuit can detect a change in the comparator circuit's signal state by querying its output and then shuts down the battery's positive output by shutting down the electronic switch in the switching circuit, achieving protection. Swapping the positions of the sampling resistor circuit and the electronic switch circuit does not affect the performance of the vehicle electrical system's electronic fuse circuit, but the connection relationship will be adjusted accordingly. This protection applies to all vehicle electrical systems, including the power lines in the main wiring harness. The main wiring harness and the left and right front electrical systems are all without power.

[0110] The electronic switching circuit includes an electronic switching transistor. If its internal resistance is used to sample the current, the sampling resistor circuit is omitted. If the MCU circuit has an internal comparator module, the external comparator circuit is omitted. At this point, only the MCU circuit and the electronic switching circuit remain.

[0111] The voltage of the vehicle's electrical protection depends on the connection of the sampling resistor circuit. If the positive terminal of the vehicle's electrical components is directly connected to the output of the electronic switch circuit, it indicates that the voltage of the vehicle's electrical components is 48V, 60V, or 72V; if the positive terminal of the vehicle's electrical components is connected to the output of the electronic switch circuit through a DC-DC converter, it indicates that the voltage of the vehicle's electrical components is 12V or 24V.

[0112] Figure 6 Vehicle electrical negative control mode electronic fuse circuit: For working principle, please refer to the vehicle electrical positive control mode electronic fuse circuit.

[0113] The embodiments and descriptions above are merely illustrative of the principles of the present invention and one example. Various changes and modifications may be made based on these principles, and all such changes and modifications fall within the scope of protection of the present invention.

Claims

1. A motor box, characterized in that: The motor box includes an MCU circuit, a communication circuit, a controller circuit, a taillight control circuit, a vehicle electrical and electronic fuse circuit, and a human-machine interaction circuit. The MCU circuit is connected to the communication circuit, the controller circuit, the taillight control circuit, the vehicle electrical and electronic fuse circuit, and the human-machine interaction circuit. The MCU circuit includes an MCU chip; The communication circuit is connected to the adapter via a main line; the main line includes a communication line; the motor box is connected to the adapter via the main line and exchanges data bidirectionally according to the communication protocol; The controller circuit is connected to the controller; the motor box transmits the signals required by the controller from the adapter via the main line according to the communication protocol, and outputs them to the controller after conversion by the controller circuit; the motor box transmits the signals output by the controller to the adapter via the main line according to the communication protocol after conversion by the controller circuit; the motor box is connected to the controller via a dedicated line or communication line and transmits signals bidirectionally. The motor box includes a taillight control circuit and is connected to the taillight; the MCU circuit is connected to the taillight control circuit; the taillight signal of the adapter is transmitted to the motor box through the main line according to the communication protocol, and then the taillight is controlled by the taillight control circuit. The human-computer interaction circuit includes one or more of the following: WIFI / GPS circuit, BT / GPS circuit, NFC circuit, GSM / GPS circuit, USB / GPS circuit, electronic key circuit, and remote control anti-theft circuit. The power supply of the motor box is connected to the battery, or connected to the battery through the controller. Its monitoring system circuit is always energized in order to respond to the owner's power-on / off operation, anti-theft monitoring, and power outage of the vehicle's secondary circuit at any time. The vehicle electrical electronic fuse circuit includes a comparator circuit, a sampling resistor circuit, and an electronic switch circuit. The comparator circuit is connected to either the sampling resistor circuit or the electronic switch circuit to measure the current range of the vehicle's electrical system. The MCU circuit is connected to both the comparator circuit and the electronic switch circuit. The sampling resistor circuit is connected to the electronic switch circuit. The electronic switch circuit includes an electronic switch transistor; if its internal resistance is used to sample the current, the sampling resistor circuit is omitted. If the MCU circuit has an internal comparator module, the external comparator circuit is omitted.

2. The motor housing according to claim 1, characterized in that: The vehicle's electrical and electronic fuse circuit is divided into positive control mode and negative control mode; The output of the electronic switch circuit in the positive control mode is connected to the positive terminal of the vehicle's electrical system or to the positive terminal of the vehicle's electrical system via a DC-DC converter; the sampling resistor circuit is connected to the positive terminal of the battery. The output of the electronic switch circuit in the negative control mode is connected to the negative terminal of the battery, and the sampling resistor circuit is connected to the negative terminal of the vehicle's electrical system. When the electric vehicle system voltage uses the output voltage of a DC-DC converter, the power supply voltage value and battery voltage type collected by the motor box are transmitted to the instrument display associated with the front adapter via a communication protocol. The battery voltage types include 24V, 36V, 48V, 60V, 72V, 84V, or 96V. The battery voltage type is determined by the motor box based on the power supply voltage selection, the external connector selection, or the user's selection using a remote control or mobile phone. The instrument does not require the traditional connector selection of the battery type. Swapping the front and rear positions of the sampling resistor circuit and the electronic switch circuit does not affect the performance of the vehicle's electrical electronic fuse circuit, but the connection relationship will be adjusted accordingly. After the owner turns on the vehicle, if the total current of the vehicle's electrical system exceeds the rated value, the output of the comparator circuit will change, and the MCU circuit will cut off the vehicle's power input through the electronic switch circuit. After the owner turns off the vehicle, the MCU circuit will also cut off the vehicle's power input and the battery output through the electronic switch circuit, ensuring that the voltage of the vehicle's secondary circuit is 0V.

3. The motor housing according to claim 1, characterized in that: The motor box includes a BMS battery management circuit; the BMS battery management circuit includes a battery temperature detection circuit, a charging control circuit, a battery voltage detection circuit, and a charging current detection circuit. The MCU circuit is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit. The battery temperature detection circuit includes a temperature sensor, which is installed near the battery or in close contact with the battery casing. The battery voltage detection circuit includes voltage divider resistors and filter capacitors; The charging control circuit includes an electronic switch circuit; the MCU circuit is connected to the electronic switch circuit. The charging control circuit is divided into charger DC output positive control mode, charger DC output negative control mode, and charger AC input control mode. The charger DC output positive control mode: The electronic switch circuit is connected between the charger DC output positive line and the battery positive terminal to control the charger DC output positive line path; the electronic switch circuit includes an electronic switch tube; The charger DC output negative control mode: The electronic switch circuit is connected between the charger DC output negative line and the battery negative terminal to control the charger DC output negative line path; the electronic switch circuit includes an electronic switch tube; The charger AC input control mode: The electronic switch circuit is connected between the charger's AC mains input and the charger, and is used to control the AC mains input line path of the charger; the electronic switch circuit includes a bidirectional thyristor or a relay; When the MCU circuit detects that the battery voltage is greater than the rated value or the battery temperature is greater than the rated value during charging, it triggers over-temperature and over-voltage protection, cuts off the charger charging current loop through the electronic switch circuit, and alarms through the sound alarm circuit, or through the USER-APP or mobile phone instrument. When the MCU circuit detects that the battery voltage is greater than the rated value when the machine is turned on, it cuts off the power supply of the electric vehicle system, including the controller power supply, by using the vehicle's electrical and electronic fuse circuit. This prevents the safety risks caused by the owner forgetting to unplug the charger and forcibly riding the vehicle. At the same time, it will sound an alarm through the sound alarm circuit, or through the USER-APP or mobile phone instrument panel. When the MCU circuit detects that the battery temperature is higher than the rated value while driving, it stops the controller by using the lockout line or communication line of the controller circuit to prevent the safety risk of battery overheating and explosion during driving. At the same time, it will sound an alarm through the sound alarm circuit, or through the USER-APP or mobile instrument panel. The charging current detection circuit includes a sampling resistor circuit and an operational amplifier circuit; the sampling resistor circuit is connected in series in the main electrical circuit of the vehicle and connected to the operational amplifier circuit; the output of the operational amplifier circuit is connected to the ADC input port of the MCU circuit. During charging, if the MCU circuit detects that the charging current is greater than the rated value, the charging control circuit will cut off the charger output to prevent battery failure. In addition, the battery capacity is indirectly determined by the integral value of the charging current and time during charging, thereby judging the battery's condition. Finally, the alarm is announced by an audible alarm circuit, or by the USER-APP or mobile phone instrument.

4. The motor housing according to claim 1, characterized in that: The motor box includes a battery communication circuit; the MCU circuit is connected to the battery communication circuit and transmits data bidirectionally with the battery according to a communication protocol; the communication protocol includes UART, 485, I2C, CAN or LIN.

5. The motor housing according to claim 1, characterized in that: The motor box includes a charger circuit; the charger circuit includes a PWM output circuit, an isolation circuit, a drive circuit, an electronic switch circuit, a transformer circuit, a rectifier and filter DC output circuit, a charging current detection circuit, a battery voltage detection circuit, and an AC input rectifier and filter circuit. The MCU circuit is connected to the PWM output circuit, the charging current detection circuit, and the battery voltage detection circuit. The rectifier and filter DC output circuit is connected to the charging current detection circuit, the battery voltage detection circuit, the transformer circuit, and the battery; the electronic switch circuit is connected to the drive circuit, the transformer circuit, and the AC input rectifier and filter circuit; the AC input rectifier and filter circuit is connected to the AC mains input and is the input power supply for the charger; the isolation circuit is connected to the PWM output circuit and the drive circuit. The isolation circuit includes an optocoupler or an isolation transformer; the driving circuit includes resistors, capacitors, transistors, and diodes; the electronic switching circuit includes an electronic switching transistor; the AC input rectifier and filter circuit includes a rectifier bridge and a filter electrolytic capacitor; the rectifier and filter DC output circuit includes a rectifier diode and a filter electrolytic capacitor; the charging current detection circuit includes a sampling resistor circuit and an operational amplifier circuit, and is then connected to the ADC input port of the MCU circuit; the battery voltage detection circuit includes a voltage divider resistor and a filter capacitor, and is then connected to the ADC input port of the MCU circuit.

6. The motor housing according to claim 5, characterized in that: The charger circuit includes a fan control circuit and a radiator temperature detection circuit; the MCU circuit is connected to the fan control circuit and the radiator temperature detection circuit; the fan control circuit is connected to an electric fan to blow air to cool the radiator; the radiator temperature detection circuit is connected to a temperature sensor, which is in close contact with the radiator; when the MCU circuit detects that the temperature of the radiator is higher than the rated value, it starts the electric fan to cool the radiator.

7. An adapter, characterized in that: The adapter is connected to the motor box of claim 1 via a large cable and exchanges data bidirectionally with the motor box according to a communication protocol. The adapter includes an MCU circuit, a functional circuit, a communication circuit, and a functional socket circuit; The functional circuit includes a combination throttle circuit, a combination switch circuit, a voice broadcast circuit, a light control circuit, and an instrument display circuit; the combination throttle circuit, the combination switch circuit, the voice broadcast circuit, the light control circuit, and the instrument display circuit are all connected to the MCU circuit; The adapter connects to the individual plugs of all the vehicle's front electrical components via a dedicated socket, and after collecting and processing the relevant signals, transmits them to the motor box via the communication line in the main cable according to the communication protocol. The relevant parameters of the controller and the motor box are transmitted to the adapter via the communication line in the main cable according to the communication protocol for voice broadcasting and instrument display. The vehicle's front electrical components include multiple combinations of instruments, headlights, combination throttle, combination switch, horn, left brake, right brake, and foot brake.

8. A controller, characterized in that: The controller is connected to the motor box of claim 1 via a dedicated line or communication connection and transmits signals bidirectionally. The controller includes a motor control circuit; the MCU circuit is connected to the motor control circuit; the motor control circuit includes a three-phase bridge arm upper and lower motor phase line drive circuit, a three-phase bridge arm upper and lower electronic switch tube circuit, a motor rotor position sensor circuit, a sampling resistor circuit, a comparator circuit, and an operational amplifier circuit; The control signals required by the controller are collected and processed by the adapter and transmitted to the motor box via the main line according to the communication protocol, and then processed by the motor box before being transmitted back. The internal parameters and fault information that the controller needs to output are processed by the motor box and then transmitted to the adapter via the main line according to the communication protocol.

9. A related electrical component, characterized in that: The associated electrical components are connected to the motor box as described in claim 1 or the adapter as described in claim 7; the signals of the associated electrical components must be processed by the motor box, or their data originates from the transmission of the motor box; the associated electrical components are a general term for a class of electrical components, with specific components being one of them, including DC-DC converters, chargers, taillights, main cables, instruments, combination throttles, combination switches, left brakes, right brakes, foot brakes, horns, and ignition locks; each associated electrical component has only one plug, which is plugged into a dedicated socket in the adapter or motor box; The DC-DC converter is plugged into the motor box, and its positive input is connected to the output of the vehicle electrical and electronic fuse circuit of the motor box. The AC input or DC output of the charger is controlled by the motor box and plugged into a dedicated socket in the motor box; The taillight is connected to the motor box, and its switching signal comes from the motor box. The rear lights include a left taillight, a right taillight, a center taillight, and an integrated taillight; One end of the main cable is connected to the motor box, and the other end is connected to the adapter; the main cable includes a communication line; the motor box and the adapter transmit data bidirectionally according to a communication protocol via the communication line; the main cable has only one plug at each end; the main cable includes a power line, the positive or negative of which is controlled by the vehicle's electrical and electronic fuse circuit of the motor box; if a single-wire full-duplex communication mode is used, the main cable has only 3 wires; The instrument is connected to the adapter, and its displayed data comes from the motor box transmitted via the main line. When the electric vehicle system voltage is selected to be the output voltage of the DC-DC converter, the battery voltage value of the instrument is not obtained by itself through the ADC of the lockout line, but is transmitted by the motor box through the communication line. The battery voltage type is not determined by itself by selecting the plug, but is transmitted by the motor box through the communication line. The combined throttle is connected to the adapter; its output signal needs to be transmitted by the adapter to the motor box for processing via the main cable according to the communication protocol. The combination switch is connected to the adapter; Its output signal needs to be transmitted to the motor box for processing via the adapter through the main line according to the communication protocol; The left brake is connected to the adapter; Its output signal needs to be transmitted to the motor box for processing via the adapter through the main line according to the communication protocol; The right brake is connected to the adapter; Its output signal needs to be transmitted to the motor box for processing via the adapter through the main line according to the communication protocol; The foot brake is connected to the adapter; Its output signal needs to be transmitted to the motor box for processing via the adapter through the main line according to the communication protocol; The speaker is connected to the adapter; The content it broadcasts originates from the motor box, which transmits the data via a main cable according to the communication protocol. The ignition switch is plugged into a dedicated socket in the motor box and connected to the MCU circuit of the motor box.

10. An electric vehicle, characterized in that: The electric vehicle is equipped with a motor box as described in any one of claims 1 to 6, or with an adapter as described in claim 7, or with a controller as described in claim 8, or with an associated electrical component as described in claim 9.

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