A power strip and adapter, associated electrical components, and electric vehicles

Abstract

This invention discloses a plug-in board and adapter, associated electrical components, and an electric vehicle. The plug-in board includes an MCU circuit I, an adapter communication circuit, and a controller circuit. Some models also include a BMS battery management circuit, a vehicle electrical and electronic fuse circuit, a taillight control circuit, a communication line starting power supply circuit, a human-machine interaction circuit, and a battery communication circuit. The plug-in board is soldered to the controller's PCB circuit board via pins, or connected to the pins on the controller's PCB board via a socket. The plug-in board and the controller are housed in a single housing, saving space, material costs, and labor costs. The original controller's MCU chip can be improved to enhance controller performance and enable the application of bus control systems without modification, greatly simplifying the wiring harness and connectors throughout the vehicle.

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, and are sometimes 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, relays, or MOSFETs;

[0006] "Previous patent" refers to Chinese patent CN2022206766620;

[0007] "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.

[0008] "Main circuit": The circuit between the battery output and the motor controller, charging port, and controller monitoring system circuit. The main circuit is always energized.

[0009] "Secondary circuit": The circuits of the entire vehicle other than the main circuit, including the power lines in the main wiring harness.

[0010] The previous patent's structure involved an adapter and a motor box forming a bus control system based on a communication protocol, with the motor box then controlling the motor controller. However, the motor box is a separate housing, requiring separate installation, which is labor-intensive and occupies more space. It cannot be installed in some vehicle models. Furthermore, the separate motor box structure is more expensive.

[0011] In addition, implementing the functions of the motor box entirely with a motor controller has problems: the original MCU resources are insufficient, the PCB area is insufficient, and the system program is too complex, which affects the control of the motor.

[0012] The previous patent lacked a complete electrical and electronic fuse circuit for the entire vehicle and did not achieve a complete power cut-off of all secondary circuits after shutdown, thus still posing a fire risk. This has been completely overcome.

[0013] The previous patent lacked a charging protection circuit and 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.

[0014] The previous patent could not detect the battery capacity or determine the quality of the battery.

[0015] The previous patent lacked battery overheat protection during riding.

[0016] There is a safety hazard if the owner forgets to unplug the charger and insists on riding the bike, as the front patent has no protection or alarm. Summary of the Invention

[0017] This invention discloses a plug and adapter, associated electrical components, and an electric vehicle, the purpose of which is to overcome the aforementioned deficiencies of the previous patent.

[0018] Building upon previous patents, this invention integrates the functional circuitry of the motor box onto a plug-in board. This plug-in board is soldered to the controller's PCB circuit board via pins and is housed within the same casing as the controller. This improves the overall vehicle electrical management and BMS battery management functions, comprehensively ensuring riding safety and reducing the risk of fire.

[0019] An insert board: The insert board includes an MCU circuit I, an adapter communication circuit, and a controller circuit. The insert board is soldered to the controller's PCB circuit board via pins, or it connects to the pins on the controller's PCB board via a socket. In the latter case, a fixing clip is required to prevent it from falling off and to facilitate maintenance. The insert board and the controller are housed in the same housing.

[0020] The MCU circuit I connects the adapter communication circuit and the controller circuit.

[0021] The adapter's communication circuit is connected to the adapter via a large cable. This large cable includes a communication line. The plug-in board exchanges data bidirectionally with the adapter via the communication line according to a communication protocol. The communication protocols include UART, CAN, LIN, RS485, and I2C. The LIN includes a LIN driver circuit. This LIN driver circuit does not require a dedicated LIN communication driver chip; instead, it uses a combination circuit of transistors, Darlington transistors, or MOSFETs, significantly reducing the cost of the LIN node (see CN2023104825252). The controller circuit is connected to the controller via pins, which include a latching wire, a communication wire, a power wire, a ground wire, and a VCC wire.

[0022] The lock output line provides operating power (15V and 5V output) to the controller. The lock output line originates from the communication line's power-on circuit or the power-on circuit of the plug-in board. The power-on circuit of the plug-in board originates from the ignition lock or the output of the electronic switch tube controlled by the MCU circuit I.

[0023] The communication line provides a communication connection between the plug-in board and the controller. Signals required by the controller (such as throttle signal, brake signal, reverse signal, third gear signal, P gear signal, etc.) are transmitted from the adapter to the plug-in board via the main line according to the communication protocol. The plug-in board then processes these signals and transmits them to the controller via the communication line (i.e., the pins) according to the communication protocol. Signals required by the controller (such as voltage, speed, Hall effect fault, MOSFET failure, over-temperature, over-voltage, under-voltage, etc.) are transmitted to the plug-in board via the communication line (i.e., the pins) according to the communication protocol. The plug-in board processes these signals and transmits them to the adapter via the main line according to the communication protocol. Communication modes between the plug-in board and the controller include UART, LIN, I2C, SIF, GPIO, etc.

[0024] The power line and the ground line are directly connected to the positive and negative terminals of the battery through the controller, so there is always power as long as the battery is connected.

[0025] The VCC line connects to the VCC power supply of the controller MCU, providing the chip's VCC power to the connector board (borrowing the controller's VCC power). This VCC power supply (typically 3.3V or 5V) is intended to reduce the cost of the connector board's VCC power supply circuit and decrease its PCB area. If the connector board uses its own VCC power supply, this VCC line is unnecessary.

[0026] The plug-in board includes a human-machine interface circuit. The human-machine interface circuit includes a remote control receiving circuit, an electronic key circuit, an NFC receiving circuit, or a Bluetooth receiving circuit. The MCU circuit I is connected to the remote control receiving circuit, the ignition lock circuit, the electronic key circuit, the NFC receiving circuit, or the Bluetooth receiving circuit. The remote control receiving circuit includes a dedicated remote control receiving chip for receiving signals from the remote-controlled anti-theft device (such as power on / off, remote arming, silent arming, etc.). The ignition lock circuit is used to detect the on / off status of the ignition lock. The electronic key circuit reads the ID number of the electronic key via a wired connection (see CN2019213344299). The NFC receiving circuit is used to receive NFC card signals. The Bluetooth receiving circuit is used for Bluetooth communication with a mobile phone (see CN2022219521068).

[0027] The connector includes a taillight control circuit. The MCU circuit I is connected to the taillight control circuit, and the taillight control circuit is connected to the taillight. The taillight signal from the adapter is transmitted to the connector via the main line according to the communication protocol, and then the taillight control circuit controls the taillight.

[0028] The plug-in board includes a communication line power-on circuit. The communication signal between the adapter and the plug-in board is transmitted through the communication line power-on circuit (see Chinese Patent CN201822156710X), which turns on the power supply of the plug-in board. The power supply then acts as a lockout signal for the controller, thereby activating the controller's operating power.

[0029] The circuit board includes a vehicle electrical electronic fuse circuit. This 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 obtain the current range of the vehicle's electrical components. The MCU circuit I connects 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 switching transistor; if its internal resistance is used to sample the current, the sampling resistor circuit is omitted. If the MCU circuit I has an internal comparator module, the external comparator circuit is omitted. This vehicle electrical electronic fuse circuit also functions as the electric vehicle's power switch circuit, controlling the vehicle's power supply. After shutdown, it completely disconnects power from the rear connector of the main cable to all electrical components at the front of the vehicle.

[0030] The vehicle's electrical and electronic fuse circuits are divided into positive control mode and negative control mode.

[0031] 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.

[0032] 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.

[0033] 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 plug-in 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. There are four methods to determine the battery voltage type: the plug-in selects based on fuzzy logic of the power supply voltage using an ADC, selects using an external connector, or selects 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.

[0034] 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.

[0035] When the vehicle owner turns on the device, if the total current of the vehicle's electrical system (excluding the controller motor drive current) exceeds the rated value, the output of the comparator circuit will change. The MCU circuit I 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.

[0036] After the vehicle owner shuts down the vehicle, the MCU circuit I, 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.

[0037] The circuit board 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. The MCU circuit I is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit.

[0038] The power strip includes a dedicated socket for chargers.

[0039] 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).

[0040] The BMS battery management includes a battery voltage detection circuit. At this time, the MCU circuit I is also connected to the battery voltage detection circuit, which includes a voltage divider resistor and a filter capacitor.

[0041] The charging control circuit includes an electronic switch circuit. The MCU circuit I is connected to the electronic switch circuit.

[0042] 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.

[0043] 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.

[0044] 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.

[0045] 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.

[0046] During charging, if the MCU circuit I 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.

[0047] When the MCU circuit I 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.

[0048] When the MCU circuit I detects that the battery temperature is higher than the rated value while driving, it stops the motor from rotating to prevent the safety risk of the battery overheating and exploding during driving. At the same time, it will sound an alarm through the audible alarm circuit, or through the USER-APP or mobile instrument panel.

[0049] 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 connected to the operational amplifier circuit. The output of the operational amplifier circuit is connected to the ADC input port of the MCU circuit I. During charging, when the MCU circuit I detects that its charging current is greater than the rated value, it cuts off the charger output through the charging control circuit (triggers overcurrent protection) to prevent battery failure.

[0050] The circuit board includes a battery capacity testing circuit. The capacity testing circuit includes a charging current detection circuit and a charging timer circuit. The charging current detection circuit is connected in series with the charger's DC output main circuit. The charging timer circuit is completed by a timer in MCU circuit I. MCU circuit I is connected to the charging current detection circuit. The integral value of the charging current over time corresponds to the battery capacity, thus determining the battery's condition. Finally, an alarm is triggered via an audible alarm circuit, or via the USER-APP or a mobile device.

[0051] The plug-in board includes a battery communication circuit. The MCU circuit I is connected to the battery communication circuit, transmitting data bidirectionally with the battery according to a communication protocol. The communication protocol includes UART, 485, I2C, CAN, or LIN, with 485 being the most common. The communication connection between the battery communication circuit and the battery is also the connection to the charger, as the battery, charger, and controller are networked. The battery temperature, charging voltage, charging current, and charging control circuit can all be controlled through the battery's internal protection board, saving the cost of the BMS battery management circuit. The battery's internal parameters can also be sent to the USER-APP or mobile instrument via a human-machine interface circuit.

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

[0053] The MCU circuit II 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 II.

[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 is connected to a mains cable. The mains cable includes a communication cable, the front end of which is connected to the adapter, and the rear end is connected to the plug board. 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 II, 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 II. The lighting control circuit is connected to the combination throttle circuit, the combination switch circuit, and the instrument display circuit, 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 II. The instrument display circuit is connected to the MCU circuit II and is used to display the vehicle's status and parameters.

[0055] The adapter connects to a dedicated socket for each of the vehicle's front electrical components, processing and combining relevant signals according to a communication protocol. These signals are then transmitted to the power strip via a communication line in the main cable, and finally to the controller. The controller's parameters are first transmitted to the power strip according to the communication protocol. The power strip processes these parameters and then transmits them to the adapter via the communication line in the main cable for voice announcements and instrument panel displays. The vehicle's front electrical components include a combination of instruments, headlights, a combination throttle, a combination switch, a horn, left brake, right brake, and foot brake.

[0056] An associated electrical component: The associated electrical component is connected to the power strip or the adapter. All signals from the associated electrical component must be processed by the power strip, or its data originates from the power strip's transmission (e.g., an instrument). The associated electrical component is a general term for a class of electrical components, with a specific component being one of them, including controllers, DC-DC converters, chargers, taillights, main cables, instruments, combination throttles, combination switches, left brake, right brake, foot brake, horn, and ignition lock. The associated electrical component has only one plug or socket, which is plugged into a dedicated plug on the adapter or power strip.

[0057] The signals required by the controller (such as throttle signal, brake signal, reverse signal, third gear signal, P gear signal, etc.) are processed by the plug-in board and transmitted through the communication line (i.e., pins) according to the communication protocol. The signals that the controller needs to transmit (such as voltage, speed, Hall fault, MOSFET failure, over-temperature, over-voltage, under-voltage, etc.) are transmitted to the plug-in board through the communication line (i.e., pins) according to the communication protocol.

[0058] The DC-DC converter is plugged into the plug-in board, and its positive input is connected to the output of the vehicle's electrical and electronic fuse circuit of the plug-in board (dedicated to 12-24V electric vehicle systems, otherwise not required).

[0059] The charger's AC input or DC output is controlled by the power strip and plugged into a dedicated socket on the power strip.

[0060] The taillights are connected to the plug-in board, and their switching signals originate from the plug-in board. The taillights include a left taillight, a right taillight, a center taillight, and an integrated taillight.

[0061] One end of the main cable connects to the plug board, and the other end connects to the adapter. The main cable includes a communication line. The plug board 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 line, whose positive (48~72V or 12~24V) or negative terminal is controlled by the vehicle's electrical and electronic fuse circuit of the plug board. If a single-wire full-duplex communication mode (such as LIN, single-wire UART) is used, the main cable has only three wires. The instrument panel is connected to the adapter, and its displayed data (speed, current, voltage, fault information, etc.) originates from the data transmitted by the plug board through the main cable. When the electric vehicle system voltage uses a DC-DC converter output voltage, the battery voltage value of the instrument panel is not obtained by the user through the ADC lockout line, but is transmitted by the plug board through the communication line. The battery voltage type is determined not by the user selecting the plug, but by the data transmitted by the plug board through the communication line.

[0062] The combined throttle is connected to the adapter. Its output signal needs to be transmitted by the adapter to the plug-in board for processing via the main cable according to the communication protocol.

[0063] The combination switch is connected to the adapter. Its output signal needs to be transmitted by the adapter to the plug-in board for processing via the main line according to the communication protocol.

[0064] The left brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the plug-in board for processing via the main cable according to the communication protocol.

[0065] The right brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the plug-in board for processing via the main cable according to the communication protocol.

[0066] The foot brake is connected to the adapter. Its output signal needs to be transmitted by the adapter to the plug-in board for processing via the main cable according to the communication protocol.

[0067] The speaker lock is connected to the adapter. The content it broadcasts originates from the plug-in board and is transmitted via a main cable according to the communication protocol.

[0068] The ignition lock is plugged into a dedicated socket on the power strip and connected to the MCU circuit I of the power strip.

[0069] An electric vehicle: The electric vehicle is equipped with a controller welded to the plug-in board, or works with the USER-APP, or works with the mobile phone instrument, or is equipped with the adapter, or is equipped with the instrument, or is equipped with the headlight, or is equipped with the combination throttle, or is equipped with the combination switch, or is equipped with the taillight.

[0070] Effects of the invention:

[0071] The functional circuitry of the motor box is integrated onto a plug-in board, which is soldered onto the controller's PCB circuit board via pins. The plug-in board is housed within the same housing as the controller, saving space, material costs, and labor costs.

[0072] The plug-in board has a separate MCU circuit system, which can improve the controller performance and application bus control system without modifying the original controller's MCU chip, greatly simplifying the wiring harness of the whole vehicle.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] When the MCU circuit detects that the battery temperature is higher than the rated value while the vehicle is in motion, it stops the motor from rotating to prevent the battery from continuing to overheat and explode.

[0078] The plug-in board transmits data bidirectionally with the battery according to the communication protocol, and also communicates with the charger via network. Attached Figure Description

[0079] Figure 1 Electric vehicle electrical wiring system.

[0080] Figure 2 : Plug-in circuit.

[0081] Figure 3 : Battery communication circuit.

[0082] Figure 4 : BMS battery management circuit.

[0083] Figure 5 : Positive control mode circuit for vehicle electrical and electronic fuses.

[0084] Figure 6 : Vehicle electrical and electronic fuse negative control mode circuit.

[0085] Figure 7 : Charger DC output positive control mode circuit.

[0086] Figure 8 : Charger DC output negative control mode circuit.

[0087] Figure 9 Charger AC input control mode circuit. Detailed Implementation

[0088] The most important component in the adapter and plug-in board of this invention is the MCU chip, which will be introduced in detail here. The MCU functional circuit will not be repeated below.

[0089] The MCU circuit is the core, containing the MCU chip, known in the industry as a microcontroller. It is an intelligent chip that implements relevant algorithms and control through software programming.

[0090] 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. Many microcontrollers on the market can meet these requirements, including multiple brands from manufacturers such as Microchip, Freescale, ST, Infineon, and Cypress. Furthermore, there are also many domestic brands available.

[0091] The most important aspect of this invention is data communication between the adapter and the plug-in board, which will be discussed in detail first. Communication modes include: UART, Lin, CAN, I2C, RS485, 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, RS485, Lin, and CAN communication are generally selected. The specific circuitry varies depending on the communication mode.

[0092] UART, I2C, and GPIO analog communication ports are directly connected. However, communication is master-slave based, and generally, the master communication module requires a pull-up resistor on its communication line. This invention recommends using an adapter as the master module and the plug-in board as the slave module.

[0093] For Lin, I2C, and 485 communication modes, a separate communication driver chip or circuit is required. Many models of these chips are available and can be found on professional websites. In this case, the communication circuit needs to be designed in accordance with these communication driver chips or circuits. Specific circuit details can be found in the relevant chip's datasheet. Some MCU chips already integrate the driver chip for this communication mode; in this case, no additional components are needed, and the communication line can be directly led out.

[0094] Figure 1 Electric vehicle electrical wiring system: This refers to the wiring system of the entire electric vehicle.

[0095] All front electrical components are connected to the adapter. After processing by the adapter, the signals are transmitted to the circuit board via the communication lines in the main wiring harness, according to the communication protocol. The taillight control signals from the adapter are processed by the circuit board and then used to control the taillights through the taillight control circuit.

[0096] The controller's fault information and parameters are first transmitted to the plug-in board according to the communication protocol. The plug-in board then transmits the information to the adapter via the communication cable in the mains cable. After processing, the adapter sends the information to the instrument for display. Alternatively, it can send the information to a mobile instrument or USER_APP for display and alarm.

[0097] The DC-DC converter is an optional accessory, but it is mandatory according to national standards. The DC-DC converter connects to the power strip to supply 12V power to the entire vehicle's electrical system.

[0098] The functions and circuit structures of the vehicle wiring and signal transmission, adapters, motor boxes, and controllers are described in the previous patent. The communication circuits, anti-theft remote control circuits, and voice circuits of the adapters and plug-ins are also described in the previous patent.

[0099] The taillights have a dedicated socket for connecting to the power strip, and their switch is controlled by the power strip.

[0100] The power strip has a dedicated socket for battery communication, enabling bidirectional communication with the battery. It also connects to the charger for network communication.

[0101] The power strip has a dedicated socket for the charger, providing comprehensive and complete charging monitoring.

[0102] Figure 2 The plug-in circuit board uses the MCU chip as the control core, and all functional circuits are connected to MCU circuit I. This is the overall circuit structure of the plug-in board in this invention. The adapter communication circuit and controller circuit (including the controller communication line) are basic functions; the others are optional. The implementation of the controller circuit, taillight control circuit, communication circuit, MCU circuit I, and human-machine interaction circuit refers to previous patents. The vehicle's electrical and electronic fuse circuits are shown below. Figure 5 , 6 And related descriptions, see battery communication circuit. Figure 3 See BMS battery management circuit. Figure 4 .

[0103] Figure 3 Battery communication circuit: The circuit board has three communication networks. One is the system network (such as LIN) with the adapter, which completes the electrical control of the entire vehicle. Another is the battery communication network (such as 485) with the battery and charger, which mainly determines parameters such as charging current, charging voltage, battery temperature, discharge current, and battery protection. The third is communication with the controller. The battery communication network is based on the battery module and is completed by its internal protection board.

[0104] 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. MCU circuit I is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit.

[0105] When the MCU circuit I 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.

[0106] When the MCU circuit I 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 and notifies the motor to start, preventing 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.

[0107] When the MCU circuit I detects that the battery temperature is higher than the rated value while the vehicle is in motion, it stops the motor from rotating to prevent the safety risk of the battery overheating and exploding during driving.

[0108] During charging, if the MCU circuit I detects that its 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.

[0109] In addition, the battery capacity is indirectly determined by the integral of the charging current and time during charging, thereby judging the quality of the battery.

[0110] 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 interrupt protection of MCU circuit I. This disconnects the battery's positive output by shutting down the electronic switch in the switching circuit, achieving overcurrent or short-circuit protection. Alternatively, MCU circuit I checks the output of the comparator circuit and detects a change in its signal state. It then disconnects 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, and prevents power loss to the main wiring harness and the left and right front electrical systems.

[0111] 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 MCU circuit I has an internal comparator module, the external comparator circuit is omitted. At this point, only MCU circuit I and the electronic switching circuit remain.

[0112] 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.

[0113] 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.

[0114] Figure 7 : Charger DC output positive control mode circuit. Controls the positive terminal of the charger, and then outputs the power to the battery.

[0115] Figure 8 Charger DC output negative control mode circuit. Controls the path between the negative terminal of the battery and the negative terminal of the charger.

[0116] Figure 9 Charger AC input control mode circuit. Controls the AC mains power input of the charger.

[0117] 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 plug-in board, characterized in that: The plug-in board includes an MCU circuit I, an adapter communication circuit, a taillight control circuit, and a controller circuit; the plug-in board is soldered to the controller's PCB board via pins, or connected to the pins on the controller's PCB board via a socket; the plug-in board and the controller are housed in the same housing. The MCU circuit I is connected to the adapter communication circuit, the taillight control circuit, and the controller circuit; The adapter's communication circuit is connected to the adapter via a main cable; the main cable includes a communication line; the plug-in board exchanges data bidirectionally with the adapter via the communication line according to a communication protocol; the communication protocol includes UART, CAN, LIN, RS485, and I2C; the LIN includes a LIN driver circuit, which does not require a dedicated LIN communication driver chip. The controller circuit is connected to the controller via the pin, which includes a lead wire, a communication wire, a power wire, and a ground wire. The lockout line provides operating power to the controller; The communication line is used to provide a communication connection between the plug-in board and the controller; the signals required by the controller are transmitted to the plug-in board by the adapter through the main line according to the communication protocol, and then processed by the plug-in board and transmitted to the controller through the communication line according to the communication protocol; the signals that the controller needs to send out are transmitted to the plug-in board through the communication line according to the communication protocol, and then processed by the plug-in board and transmitted to the adapter through the main line according to the communication protocol. The power line and the ground line are directly connected to the positive and negative terminals of the battery through the controller, so there is always power as long as the battery is connected. The plug-in board includes a taillight control circuit; the MCU circuit I is connected to the taillight control circuit, and the taillight control circuit is connected to the taillight; the taillight signal of the adapter is transmitted to the plug-in board through the main line according to the communication protocol, and then the taillight is controlled by the taillight control circuit.

2. The insert plate according to claim 1, characterized in that: The plug-in board includes a human-machine interaction circuit; the human-machine interaction circuit includes a remote control receiving circuit, an ignition lock circuit, an electronic key circuit, an NFC receiving circuit, or a Bluetooth receiving circuit; the MCU circuit I is connected to the remote control receiving circuit, the electronic key circuit, the NFC receiving circuit, or the Bluetooth receiving circuit; the remote control receiving circuit includes a dedicated remote control receiving chip for receiving signals from the remote control anti-theft device; the ignition lock circuit is used to detect the on / off status of the ignition lock; the electronic key circuit reads the ID number of the electronic key via a wired connection; the NFC receiving circuit is used to receive NFC card signals; and the Bluetooth receiving circuit is used for Bluetooth communication with a mobile phone.

3. The insert plate according to claim 1, characterized in that: The plug-in board includes a communication line power-on circuit; the communication signal between the adapter and the plug-in board is transmitted through the communication line power-on circuit to turn on the power supply of the plug-in board, and the power supply serves as a lockout signal for the controller to turn on the operating power of the controller.

4. The insert plate according to claim 1, characterized in that: The circuit board includes a vehicle electrical and electronic fuse circuit; the vehicle electrical and electronic fuse circuit includes a comparator circuit, a sampling resistor circuit, and an electronic switch circuit. The comparison circuit is connected to the sampling resistor circuit or the electronic switch circuit to measure the range of electrical current in the vehicle. The MCU circuit I is connected to the comparator circuit and the electronic switch circuit; The sampling resistor circuit is connected to the electronic switch circuit; The electronic switching circuit includes an electronic switching transistor; 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 plug board 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. There are four methods to determine the battery voltage type: the plug board selects based on fuzzy judgment of the power supply voltage, the external connector selects, or the user selects using a remote control or mobile phone. The instrument does not need to select the battery type using the traditional connector method. After the vehicle owner turns on the device, if the total current of the vehicle's electrical system exceeds the rated value, the output of the comparison circuit will change, and the MCU circuit I will cut off the vehicle's power input through the electronic switch circuit. After the vehicle owner shuts down the vehicle, the MCU circuit I also cuts 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.

5. The insert plate according to claim 1, characterized in that: The socket 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 I is connected to the battery temperature detection circuit, the charging control circuit, the battery voltage detection circuit, and the charging current detection circuit; the socket includes a dedicated charger socket; 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 I 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 I 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 charging current loop of the charger 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 I detects that the battery voltage is greater than the rated value during power-on, it will use the vehicle's electrical and electronic fuse circuit to cut off the power supply to the electric vehicle system and stop the motor from rotating, preventing 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 I detects that the battery temperature is higher than the rated value while driving, it stops the motor from rotating to prevent the safety risk of the battery overheating and exploding 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 I. During charging, if the MCU circuit I detects that its charging current is greater than the rated value, the charger output is cut off through the charging control circuit to prevent battery failure. The integral value of the charging current over time corresponds to the battery capacity, thereby determining the battery's condition.

6. The insert plate according to claim 1, characterized in that: The plug-in board includes a battery communication circuit; the MCU circuit I 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.

7. An adapter, characterized in that: The adapter is connected to the plug-in board of claim 1 via a large cable, and exchanges data bidirectionally with the plug-in board according to a communication protocol; The adapter includes MCU circuit II, functional circuit, communication circuit, and 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 II; The adapter connects to a single plug for each of the vehicle's front electrical components via a dedicated socket. After collecting and processing relevant signals, the data is transmitted to the power strip via a communication line in the main cable according to a communication protocol. The power strip then transmits the data to the controller. The controller's relevant parameters are first transmitted to the power strip according to the communication protocol. After processing, the power strip transmits the data to the adapter via a communication line in the main cable for voice announcements 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 related electrical component, characterized in that: The associated electrical components are connected to the plug-in board of claim 1 or the adapter of claim 7; the signals of the associated electrical components must be processed by the plug-in board, or their data originates from the transmission of the plug-in board; the associated electrical components are a general term for a class of electrical components, and specific components are one of them, including controllers, DC-DC converters, chargers, taillights, main cables, instruments, combination throttles, combination switches, left brakes, right brakes, foot brakes, horns, and ignition locks; the associated electrical components have only one plug or socket, which is plugged into the dedicated plug of the adapter or plug-in board; The controller is connected to the plug board via pins; the signals required by the controller are processed by the plug board and transmitted via a communication line according to the communication protocol; the signals that the controller needs to output are transmitted to the plug board via a communication line according to the communication protocol. The DC-DC converter is plugged into the plug-in board, and its positive input terminal is connected to the output of the vehicle's electrical and electronic fuse circuit of the plug-in board; The AC input or DC output of the charger is controlled by the power strip and plugged into a dedicated socket on the power strip. The taillight is connected to the plug, and its switch signal comes from the plug; the taillight includes a left taillight, a right taillight, a middle taillight, and an integrated taillight; One end of the main cable is connected to the plug board, and the other end is connected to the adapter; the main cable includes a communication line; the plug board 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 plug board; 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 plug board transmitted through 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 locked line, but is transmitted by the plug board through the communication line; the battery voltage type is not determined by itself by selecting the plug, but is transmitted by the plug board through the communication line. The combined throttle is connected to the adapter; its output signal needs to be transmitted by the adapter to the plug board 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 plug-in board for processing via the adapter through the main cable according to the communication protocol; The left brake is connected to the adapter; Its output signal needs to be transmitted to the plug-in board for processing via the adapter through the main cable according to the communication protocol; The right brake is connected to the adapter; Its output signal needs to be transmitted to the plug-in board for processing via the adapter through the main cable according to the communication protocol; The foot brake is connected to the adapter; Its output signal needs to be transmitted to the plug-in board for processing via the adapter through the main cable according to the communication protocol; The speaker lock is connected to the adapter; the content it broadcasts originates from the plug board and is transmitted via a main cable according to the communication protocol. The ignition lock is plugged into a dedicated socket on the power strip and connected to the MCU circuit I of the power strip.

9. An electric vehicle, characterized in that: The electric vehicle is equipped with a controller welded to the plug-in board according to any one of claims 1 to 6, or with an adapter according to claim 7, or with one of the associated electrical components according to claim 8.

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