A battery powered device, vehicle and relay fault detection method

Abstract

The application discloses a battery-powered device, a vehicle and a relay fault detection method, wherein the battery-powered device comprises at least two battery packs and a control module; the battery pack comprises a battery pack, a first main positive relay and a first main negative relay; the at least two battery packs are connected in series to supply power to external equipment; the first main positive relay and the first main negative relay are arranged in the battery pack, the first main positive relay is connected between the positive electrode of the battery pack and the positive electrode of the battery pack, and the first main negative relay is connected between the negative electrode of the battery pack and the negative electrode of the battery pack; the control module is used for controlling the first main positive relay to be turned on or turned off and the first main negative relay to be turned on or turned off according to the output of the battery pack. The first main positive relay and the first main negative relay corresponding to the battery pack are arranged in the battery pack, the battery pack can be disconnected to supply power to the external equipment in time in an abnormal situation, and thus electric shock of personnel is prevented.

Description

Technical Field

[0001] This invention relates to the field of vehicle power technology, and in particular to a battery power supply device, a vehicle, and a method for detecting relay faults. Background Technology

[0002] In general, vehicles with high power demand, such as new energy buses, logistics vehicles, trucks, and other special vehicles, require multiple high-voltage battery packs. To facilitate transportation and installation, several standardized high-voltage battery packs can be matched in a modular fashion for different vehicles. This can significantly reduce costs, shorten battery development cycles, and achieve the power and voltage required by the entire vehicle.

[0003] Currently, high-voltage battery packs typically have a service switch inside and a shared relay for multiple high-voltage battery packs outside. However, if one of the high-voltage battery packs experiences an insulation failure due to cell leakage or other reasons, and the vehicle's high-voltage wiring harness leaks current due to damage or other reasons, failure to disconnect the service switch in time by the operator could lead to an electric shock risk. Summary of the Invention

[0004] This invention provides a method for detecting faults in battery-powered devices, vehicles, and relays to address the risk of electric shock posed by battery packs in the prior art.

[0005] According to one aspect of the present invention, a battery-powered device is provided, comprising: at least two battery packs and a control module; the battery packs include a battery array, a first main positive relay, and a first main negative relay;

[0006] The at least two battery packs are connected in series to supply power to external devices;

[0007] The first main positive relay and the first main negative relay are disposed inside the battery pack. The first main positive relay is connected between the positive terminal of the battery pack and the positive terminal of the battery assembly, and the first main negative relay is connected between the negative terminal of the battery assembly and the negative terminal of the battery pack.

[0008] The control module is used to control the first main positive relay to turn on or off, and to control the first main negative relay to turn on or off, based on the output of the battery pack.

[0009] Optionally, the battery power supply device further includes a second main positive relay, a first pre-charge relay, and a first pre-charge resistor. The first terminal of the second main positive relay is connected to the positive terminal of the battery pack and the first terminal of the first pre-charge relay. The second terminal of the first pre-charge relay is connected to the first terminal of the first pre-charge resistor, and the second terminal of the first pre-charge resistor is connected to the second terminal of the second main positive relay.

[0010] Optionally, the battery power supply device further includes a second pre-charge relay and a second pre-charge resistor, the second pre-charge relay and the second pre-charge resistor being disposed inside the battery pack, the first end of the second pre-charge relay being connected to the positive terminal of the battery pack, the second end of the second pre-charge relay being connected to the first end of the second pre-charge resistor, and the second end of the second pre-charge resistor being connected to the positive terminal of the battery pack.

[0011] Optionally, the battery power supply device further includes a first voltage sensor and a first current sensor, and the control module further includes a first battery management system. The first battery management system, the first voltage sensor, and the first current sensor are all installed in the distribution box. The first voltage sensor is used to detect the voltage signal output by the battery pack, and the first current sensor is used to detect the current signal output by the battery pack. The first battery management system is used to control the conduction and disconnection of the first main positive relay, the first main negative relay, the second main positive relay, and the first precharge relay according to the voltage signal output by the first voltage sensor and the current signal output by the first current sensor.

[0012] Optionally, the control module includes a second battery management system, which is disposed inside the battery pack. The second battery management system is used to control the first main positive relay, the first main negative relay, and the second precharge relay to be turned on or off according to the output of the battery pack.

[0013] Optionally, the battery power supply device further includes an inverter module, which is connected to an external device and the control module. The inverter module is used to convert the DC power output by the battery pack into AC power and supply power to the external device.

[0014] Optionally, the inverter module includes a first inverter, a second voltage sensor, and a first filter capacitor. The second voltage sensor is connected to the control module and is used to detect the voltage signal output by the battery pack. The first filter capacitor is used to filter the voltage signal output by the battery pack. The first inverter is connected to external devices and the control module and is used to invert the DC power output by the battery pack into AC power and supply power to the external devices.

[0015] According to another aspect of the present invention, a vehicle is provided, the vehicle including the battery power supply device.

[0016] According to another aspect of the present invention, a relay fault detection method is provided, the relay fault detection method being performed by the battery-powered device, the method comprising:

[0017] The vehicle is powered on;

[0018] When the voltage signal output by the first voltage sensor detected by the control module is greater than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault.

[0019] When the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, there is no sticking fault between the first main positive relay and the first main negative relay.

[0020] The control module controls the closing of the first main positive relay and the first main negative relay;

[0021] When the voltage signal output by the first voltage sensor detected by the control module is less than the first preset threshold, at least one of the first main positive relay and the first main negative relay has a failure to operate.

[0022] When the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the control module detects the voltage signal output by the second voltage sensor.

[0023] When the voltage signal output by the second voltage sensor detected by the control module is greater than the first preset threshold, the second main positive relay or the first precharge relay has a sticking fault, and the first main positive relay or the second precharge relay connected in parallel with the second precharge relay has a sticking fault.

[0024] When the voltage signal output by the second voltage sensor detected by the control module is not greater than the first preset threshold, the control module controls the first pre-charge relay and the second pre-charge relay to close.

[0025] When the voltage signal output by the second voltage sensor detected by the control module is less than the second preset threshold, the first precharge relay and the second precharge relay have a failure to operate.

[0026] When the voltage signal output by the second voltage sensor detected by the control module is not less than the second preset threshold, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to close, and controls the first pre-charge relay and the second pre-charge relay to open.

[0027] When the voltage signal output by the second voltage sensor detected by the control module is less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay have a failure to operate.

[0028] When the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay are fault-free.

[0029] The vehicle power-on process is complete.

[0030] Optionally, the method further includes:

[0031] When the vehicle is powered off, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to disconnect;

[0032] When the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay have a sticking fault.

[0033] The control module controls the corresponding first main positive relay and first main negative relay in the at least two battery packs to open and close sequentially. When the first main positive relay and the first main negative relay are open, and the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault. When the first main positive relay and the first main negative relay are closed, and the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, the first main positive relay and the first main negative relay have a non-operation fault.

[0034] The power-off process has ended, and the vehicle is now in sleep mode.

[0035] This invention provides a battery-powered device, including at least two battery packs and a control module. Each battery pack includes a battery array, a first positive relay, and a first negative relay. At least two battery packs are connected in series for supplying power to external devices. The first positive and first negative relays are located within the battery packs, with the first positive relay connected between the positive terminal of the battery array and the positive terminal of the battery pack, and the first negative relay connected between the negative terminal of the battery array and the negative terminal of the battery pack. The control module controls the first positive relay to turn on or off, and controls the first negative relay to turn on or off, based on the output of the battery packs. By setting first positive and first negative relays corresponding to the battery packs, this invention allows the control module to detect the output electrical signal of the battery pack and control the first positive and first negative relays to disconnect when the battery-powered device malfunctions. This timely disconnection of the battery pack from the power supply circuit avoids the risk of electric shock in abnormal situations, thus protecting the operator's safety and solving the problem of electric shock risk associated with battery packs in the prior art.

[0036] It should be understood that the description in this section is not intended to identify key or essential features of the embodiments of the present invention, nor is it intended to limit the scope of the invention. Other features of the invention will become readily apparent from the following description. Attached Figure Description

[0037] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0038] Figure 1 This is a power supply circuit diagram for a vehicle-mounted high-voltage battery pack in related technologies;

[0039] Figure 2 This is a schematic diagram of the power supply circuit contacts for a vehicle-mounted high-voltage battery pack in related technologies.

[0040] Figure 3 This is a schematic diagram of the structure of a battery-powered device provided in an embodiment of the present invention;

[0041] Figure 4 This is a circuit diagram of a battery-powered device provided in an embodiment of the present invention;

[0042] Figure 5 This is a schematic diagram of the electric contact of a battery-powered device provided in an embodiment of the present invention;

[0043] Figure 6 This is a circuit diagram of another battery-powered device provided in an embodiment of the present invention;

[0044] Figure 7 This is a flowchart of a relay fault detection method provided in an embodiment of the present invention;

[0045] Figure 8 This is a control timing diagram for relay detection provided in an embodiment of the present invention;

[0046] Figure 9 This is a control logic diagram for relay sticking detection and relay non-operation detection during the vehicle power-on process provided in this embodiment of the invention;

[0047] Figure 10 This is a control logic diagram for relay sticking detection and relay non-operation detection during the vehicle power-off process provided in an embodiment of the present invention. Detailed Implementation

[0048] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0049] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0050] Currently, vehicles with high power demand, such as new energy buses, logistics vehicles, trucks, and other special-purpose vehicles, generally require the use of multiple high-voltage battery packs. To facilitate transportation and installation, several standardized high-voltage battery packs can be matched in a modular fashion for different vehicles, which can significantly reduce costs, shorten battery development cycles, and achieve the power and voltage required by the entire vehicle. Figure 1 This is a power supply circuit diagram for a vehicle-mounted high-voltage battery pack in related technologies, such as... Figure 1 As shown, multiple high-voltage battery packs are connected in series and then connected to the vehicle body. A service switch is typically installed inside each high-voltage battery pack, and a common relay for multiple high-voltage battery packs is installed externally. The common positive relay and pre-charge relay are connected in parallel and housed in a distribution box. The distribution box also includes the service switch, pre-charge resistor, voltage sensor, current sensor, common negative relay, and battery management system (BMS). The power supply circuit for the vehicle's high-voltage battery packs also includes an inverter, which includes a voltage sensor and capacitors. The inverter converts direct current (DC) to alternating current (AC) to power external devices. If one of the high-voltage battery packs experiences an insulation failure (primary fault) due to cell leakage, and the vehicle's high-voltage wiring harness experiences leakage due to damage (secondary fault), there is a risk of electric shock if the operator does not promptly disconnect the service switch. Figure 2 This is a schematic diagram of the power supply circuit contacts for a vehicle-mounted high-voltage battery pack in related technologies, such as... Figure 2As shown, if an operator touches both the vehicle body and the high-voltage power supply circuit at the same time, and both a primary fault and a secondary fault occur simultaneously, the operator will be electrocuted.

[0051] To address the above problems, embodiments of the present invention provide a battery-powered device. Figure 3 This is a schematic diagram of the structure of a battery-powered device provided in an embodiment of the present invention, as shown below. Figure 3 As shown, the battery-powered device includes at least two battery packs 110 and a control module 120. Each battery pack 110 includes a battery group V, a first main positive relay K1, and a first main negative relay K2. The at least two battery packs 110 are connected in series for supplying power to external devices. The first main positive relay K1 and the first main negative relay K2 are disposed within the battery pack 110. The first main positive relay K1 is connected between the positive terminal of the battery group V and the positive terminal of the battery pack 110, and the first main negative relay K2 is connected between the negative terminal of the battery group V and the negative terminal of the battery pack 110. The control module 120 is used to control the first main positive relay K1 to be on or off, and to control the first main negative relay K2 to be on or off, based on the output of the battery pack 110.

[0052] In this embodiment, the battery pack 110 can be a high-voltage battery pack, which has higher output power. As the carrier of the battery group V, the battery pack 110 plays a crucial role in the safe operation and protection of the battery group. The battery group V is a battery module composed of multiple individual cells; for example, the battery group V is a group of cells stored within the battery pack 110. A first main positive relay K1 is connected between the positive terminal of the battery group V and the positive terminal of the battery pack 110, and can control the electrical signal output by the battery group V to be output through the positive terminal of the battery pack 110. A first main negative relay K2 is connected between the negative terminal of the battery group V and the negative terminal of the battery pack 110, and can control the electrical signal output by the battery group V to be output through the negative terminal of the battery pack 110. The control module 120 can be a processor or processing system that performs data processing and outputs control signals.

[0053] In this embodiment, the battery pack 110 supplies power to external devices. In case of vehicle malfunction or parking, the control module 120 detects the electrical signal output by the battery pack 110 and controls the first main positive relay K1 and the first main negative relay K2 in the battery pack to turn off, so that the positive and negative terminals of the battery pack cannot output electrical energy. At this time, even if the battery pack has an insulation failure due to cell leakage or other reasons, and the high-voltage wiring harness of the vehicle leaks current due to damage or other reasons, the operator will not be electrocuted when touching the vehicle, thus ensuring the personal safety of the operator.

[0054] This embodiment provides a battery-powered device, including at least two battery packs and a control module. Each battery pack includes a battery array, a first main positive relay, and a first main negative relay. At least two battery packs are connected in series for supplying power to external devices. The first main positive relay and the first main negative relay are located within the battery packs. The first main positive relay is connected between the positive terminal of the battery array and the positive terminal of the battery pack, and the first main negative relay is connected between the negative terminal of the battery array and the negative terminal of the battery pack. The control module controls the first main positive relay to turn on or off, and controls the first main negative relay to turn on or off, based on the output of the battery packs. By setting first main positive and first main negative relays corresponding to the battery packs, when an abnormality occurs in the battery-powered device, the control module detects the output electrical signal of the battery pack and controls the first main positive and first main negative relays to disconnect, thus timely disconnecting the battery pack from the power supply circuit. This avoids the risk of electric shock in abnormal situations, achieving safety protection for operators and solving the problem of electric shock risk associated with battery packs in existing technologies.

[0055] Figure 4 This is a circuit diagram of a battery-powered device provided in an embodiment of the present invention, such as... Figure 4 As shown, the battery power supply device also includes a second main positive relay K3, a first precharge relay K4 and a first precharge resistor R1. The first end of the second main positive relay K3 is connected to the positive terminal of the battery pack 110 and the first end of the first precharge relay K4. The second end of the first precharge relay K4 is connected to the first end of the first precharge resistor R1. The second end of the first precharge resistor R1 is connected to the second end of the second main positive relay K3.

[0056] In this embodiment, the battery power supply device also includes a fuse F, a second main positive relay K3 which is a shared relay for multiple battery packs located outside the battery pack, and a first pre-charge relay K4 which operates at the moment of power supply. The function of the first pre-charge relay K4 is to prevent the circuit and inverter from being damaged by a large current due to the charging of the capacitor in the inverter at the moment of power connection. In this way, the pre-charge relay limits the current at the moment of power connection, thereby reducing the impact.

[0057] Continue to refer to Figure 4The battery power supply device also includes a first voltage sensor T1 and a first current sensor T2. The control module 120 also includes a first battery management system BMS1. The first battery management system BMS1, the first voltage sensor T1, and the first current sensor T2 are all installed in the distribution box. The first voltage sensor T1 is used to detect the voltage signal output by the battery pack 110, and the first current sensor T2 is used to detect the current signal output by the battery pack 110. The first battery management system BMS1 is used to control the conduction and disconnection of the first main positive relay K1, the first main negative relay K2, the second main positive relay K3, and the first precharge relay K4 according to the voltage signal output by the first voltage sensor T1 and the current signal output by the first current sensor T2.

[0058] In this embodiment, the first voltage sensor T1 is connected between the positive and negative terminals of the battery pack, and the first current sensor T2 is connected to the negative terminal of the battery pack. The distribution box can rationally allocate the electrical energy output by the battery pack, facilitating circuit operation. The first battery management system (BMS1) determines whether the battery power supply device is malfunctioning based on the voltage signal output by the first voltage sensor T1 and the current signal output by the first current sensor T2. When the battery power supply device is malfunctioning, the first battery management system (BMS1) controls the first main positive relay K1 and the first main negative relay K2 in the battery pack to disconnect, so that the battery pack no longer outputs electrical energy.

[0059] Continue to refer to Figure 4 The battery-powered device also includes an inverter module, which connects to external devices and the control module 120. The inverter module converts the DC power output from the battery pack into AC power to supply power to the external devices. Specifically, the inverter module converts DC to AC to power AC devices, such as motors.

[0060] Specifically, the inverter module includes a first inverter U1, a second voltage sensor T3, and a first filter capacitor C1. The second voltage sensor T3 is connected to the control module 120 and is used to detect the voltage signal output by the battery pack. The first filter capacitor C1 is used to filter the voltage signal output by the battery pack. The first inverter U1 is connected to external devices and the control module 120. The first inverter U1 is used to invert the DC power output by the battery pack into AC power and supply power to the external devices.

[0061] In this embodiment, the first inverter U1 is a device that converts direct current into fixed-frequency, fixed-voltage or frequency- and voltage-regulated alternating current. The second voltage sensor T3 and the first filter capacitor C1 are both located inside the first inverter U1. The first battery management system BMS1 can determine whether the distribution box is malfunctioning based on the voltage signal output by the second voltage sensor T3. When the distribution box malfunction causes the battery power supply device to malfunction, the first battery management system BMS1 controls the first main positive relay K1 and the first main negative relay K2 in the battery pack to disconnect, so that the battery pack no longer outputs power.

[0062] Based on the above embodiments, Figure 5 This is a schematic diagram of the electric contact of a battery-powered device provided in an embodiment of the present invention, as shown below. Figure 5 As shown, the battery pack is connected to the vehicle body. When the first battery management system (BMS1) detects an abnormality in the battery pack or when the vehicle stops, the BMS1 controls the first main positive relay K1 and the first main negative relay K2 in the battery pack to disconnect, so that the battery pack no longer outputs power. At this time, even if the operator touches the vehicle body and the high-voltage power supply circuit at the same time, and a primary fault and a secondary fault occur simultaneously, the operator will not be electrocuted, thus ensuring the operator's personal safety.

[0063] Figure 6 This is another circuit diagram of a battery-powered device provided in an embodiment of the present invention, such as... Figure 6 As shown, the battery power supply device also includes a second pre-charge relay K5 and a second pre-charge resistor R2. The second pre-charge relay K5 and the second pre-charge resistor R2 are disposed inside the battery pack 110. The first end of the second pre-charge relay K5 is connected to the positive terminal of the battery pack V, and the second end of the second pre-charge relay K5 is connected to the first end of the second pre-charge resistor R2. The second end of the second pre-charge resistor R2 is connected to the positive terminal of the battery pack 110.

[0064] The second pre-charge relay K5 is connected in parallel with the first main positive relay K1 in one of the battery packs. The second pre-charge relay K5 works at the moment of power-on. The function of the second pre-charge relay K5 is to prevent the circuit and inverter from being damaged by the large current caused by the charging of the capacitor in the inverter at the moment of power-on. In this way, the pre-charge relay limits the current at the moment of power-on, thereby reducing the impact.

[0065] Continue to refer to Figure 6 The control module 120 includes a second battery management system (BMS2), which is located inside the battery pack 110. The second battery management system (BMS2) is used to control the first main positive relay K1, the first main negative relay K2, and the second precharge relay K5 to be turned on or off according to the output of the battery pack V.

[0066] In this embodiment, the second battery management system (BMS2) determines whether the battery power supply device is malfunctioning based on the electrical signals output by the battery pack. When the battery power supply device malfunctions, the BMS2 controls the first main positive relay K1 and the first main negative relay K2 within the battery pack to disconnect, causing the battery pack to stop outputting power. At this time, even if an operator simultaneously touches both the vehicle body and the high-voltage power supply circuit, and both primary and secondary faults occur simultaneously, the operator will not be electrocuted, ensuring the operator's personal safety.

[0067] This invention also provides a vehicle including a battery power supply device. The vehicle is a new energy bus, logistics vehicle, truck, or other special-purpose vehicle with high power demand, using multiple battery packs. The battery power supply device includes a first main positive relay K1 and a first main negative relay K2 in each battery pack. When the battery power supply device malfunctions, a first battery management system (BMS1) or a second battery management system (BMS2) detects the output electrical signal of the battery pack and controls the first main positive relay and the first main negative relay to disconnect, thus controlling the timely disconnection of the battery pack from the power supply circuit and avoiding the risk of electric shock in abnormal situations, achieving safety protection for operators. Applying the battery power supply device to a vehicle improves the safety of vehicle operation.

[0068] This invention also provides a relay fault detection method, which is executed by a battery-powered device. Figure 7 This is a flowchart of a relay fault detection method provided in an embodiment of the present invention, such as... Figure 7 As shown, the method includes:

[0069] S10, Vehicle powered on.

[0070] S20. When the voltage signal output by the first voltage sensor detected by the control module is greater than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault.

[0071] S30. When the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, there is no sticking fault between the first main positive relay and the first main negative relay.

[0072] S40, The control module controls the first main positive relay and the first main negative relay to close.

[0073] S50. When the voltage signal output by the first voltage sensor detected by the control module is less than the first preset threshold, it is determined that at least one of the first main positive relay and the first main negative relay has a failure to operate.

[0074] S60. When the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the control module detects the voltage signal output by the second voltage sensor.

[0075] S70. When the voltage signal output by the second voltage sensor detected by the control module is greater than the first preset threshold, the second main positive relay or the first precharge relay has a sticking fault, and the first main positive relay or the second precharge relay connected in parallel with the second precharge relay has a sticking fault.

[0076] S80. When the voltage signal output by the second voltage sensor detected by the control module is not greater than the first preset threshold, the control module controls the first precharge relay and the second precharge relay to close.

[0077] S90. When the voltage signal output by the second voltage sensor detected by the control module is less than the second preset threshold, the first precharge relay and the second precharge relay have a failure to operate.

[0078] S11. When the voltage signal output by the second voltage sensor detected by the control module is not less than the second preset threshold, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to close, and controls the first pre-charge relay and the second pre-charge relay to open.

[0079] S12. When the voltage signal output by the second voltage sensor detected by the control module is less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay have a failure to operate.

[0080] S13. When the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay are fault-free.

[0081] S14. Vehicle power-on complete.

[0082] In this embodiment, in order to ensure the effectiveness of the relay installed in the battery pack, the relay is subjected to adhesion detection and non-operation detection. The relay adhesion detection is performed by detecting the relay being disconnected, and the relay non-operation detection is performed by detecting the relay being closed.

[0083] Optionally, during the vehicle power-off phase, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to disconnect; when the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay have a sticking fault; the control module controls the corresponding first main positive relay and first main negative relay in at least two battery packs to disconnect and close sequentially; when the first main positive relay and the first main negative relay are disconnected, and the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault; when the first main positive relay and the first main negative relay are closed, and the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, the first main positive relay and the first main negative relay have a non-operation fault; after the power-off ends, the vehicle enters a sleep state.

[0084] For example, Figure 8 This is a control timing diagram for relay detection provided in an embodiment of the present invention, such as... Figure 8 As shown, after the vehicle enters IG-ON operation (i.e., the power-on phase), all relays are first checked for sticking. Then, all relays in the battery pack are closed. After closing all relays in the battery pack, a relay inactivity test is performed. When the vehicle enters READY-ON operation (i.e., the start-up mode of the power-on phase), the first pre-charge relay is closed, and a first pre-charge relay inactivity test is performed. Then, the second main positive relay is closed, the first pre-charge relay is opened, and a second main positive relay inactivity test is performed. When the vehicle enters IG-OFF operation (i.e., the power-off phase), the second main positive relay is opened, and a second voltage sensor in the inverter checks for sticking. Then, the first main positive relay in battery pack 1 is opened, and a first voltage sensor checks for sticking. After completion, the first main positive relay is closed, and a first voltage sensor checks for inactivity. This process is repeated for all first main positive and first main negative relays in the battery packs. After all tests are completed, the vehicle is powered off.

[0085] For example, Figure 9 This is a control logic diagram for relay sticking detection and relay non-operation detection during the vehicle power-on process provided in an embodiment of the present invention, as shown below. Figure 9As shown, after the vehicle performs IG-ON operation, the first battery management system detects whether the voltage Vb output by the first voltage sensor is greater than 30V (i.e., the first preset threshold). Ideally, it would determine whether it is greater than 0V. Considering the error of the voltage sensor, it is set to 30V. If it is greater than 30V, it is determined that all relays inside the battery pack are stuck together, the vehicle power is turned on and stopped, and the instrument fault light is lit. If it is less than or equal to 30V, all relays inside the battery pack are closed. Next, it checks whether the voltage output by the first voltage sensor is less than 30V. If it is less than 30V, it determines that at least one relay in the battery pack is not working, the vehicle stops powering on, and the instrument panel malfunction indicator light illuminates. If it is greater than or equal to 30V, it checks whether the voltage signal Vb2 output by the second voltage sensor in the inverter is greater than 30V. If it is greater than 30V, it determines that either the second main positive relay or the first precharge relay is stuck, the vehicle stops powering on, and the instrument panel malfunction indicator light illuminates. If it is less than or equal to 30V, and the vehicle has performed a READY-ON operation, the first battery management system controls the first precharge relay to close and checks whether the voltage signal output by the second voltage sensor in the inverter is less than 570V (i.e., the second preset threshold). If it is less than 570V, it determines that the first precharge relay is not working, the vehicle stops powering on, and the instrument panel malfunction indicator light illuminates. If it is greater than or equal to 570V, it closes the second main positive relay and opens the first precharge relay. Next, check if the voltage signal output by the second voltage sensor in the inverter is less than 30V. If it is less than 30V, it is determined that the second main positive relay is not working, the vehicle power-on stops, and the instrument fault light illuminates. If it is greater than 30V, it is determined to be normal, the vehicle power-on process ends, and the vehicle is in a driving state.

[0086] For example, Figure 10 This is a control logic diagram for relay sticking detection and relay non-operation detection during the vehicle power-off process provided in an embodiment of the present invention, as shown below. Figure 10As shown, when the vehicle performs an IG-OFF operation, the first battery management system controls the second main positive relay to disconnect. It then checks if the voltage output by the second voltage sensor in the inverter is less than 30V. If it is greater than or equal to 30V, the second main positive relay is considered to be stuck, and the system stops operation upon the next power-on, with the instrument panel malfunction indicator light illuminating. Next, the first main positive relay is disconnected, and the voltage signal output by the first voltage sensor is checked to see if it is less than 30V. If it is greater than or equal to 30V, the first main positive relay is considered to be stuck, and the system stops operation upon the next power-on, with the instrument panel malfunction indicator light illuminating. Afterward, the first main positive relay is closed, and the voltage signal output by the first voltage sensor is checked to see if it is greater than 30V. If it is less than or equal to 30V, the first main positive relay is considered to be malfunctioning, and the system stops operation upon the next power-on, with the instrument panel malfunction indicator light illuminating. Finally, the first main negative relay is disconnected, and the voltage signal output by the first voltage sensor is checked to see if it is less than 30V. If it is greater than or equal to 30V, the first main negative relay is considered to be stuck, and the system stops operation upon the next power-on, with the instrument panel malfunction indicator light illuminating. Then, the first main negative relay is closed, and the voltage signal output by the first voltage sensor is checked to see if it is greater than 30V. If it is less than or equal to 30V, the first main negative relay is considered to be malfunctioning, and the process stops upon the next power-on, with the instrument panel malfunction indicator light illuminating. This process is repeated sequentially to check for adhesion and malfunction of the first main positive and first main negative relays in multiple battery packs. After the tests are completed, all relays are disconnected, the process ends, and the vehicle enters sleep mode.

[0087] In this embodiment, the relays implement logic control according to the power-on sequence of the vehicle. The first voltage sensor and the second voltage sensor detect the sticking and non-operation faults of each relay to ensure the effectiveness of each relay. When the vehicle is abnormal or stopped, the power output of the battery pack can be effectively cut off, avoiding the risk of electric shock to personnel and further ensuring the safe operation of the vehicle.

[0088] It should be understood that the various forms of processes shown above can be used, with steps reordered, added, or deleted. For example, the steps described in this invention can be executed in parallel, sequentially, or in different orders, as long as the desired result of the technical solution of this invention can be achieved, and this is not limited herein.

[0089] The specific embodiments described above do not constitute a limitation on the scope of protection of this invention. Those skilled in the art should understand that various modifications, combinations, sub-combinations, and substitutions can be made according to design requirements and other factors. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A battery-powered device, characterized in that, include: At least two battery packs and a control module; the battery packs include a battery pack, a first main positive relay, and a first main negative relay; The at least two battery packs are connected in series to supply power to external devices; The first main positive relay and the first main negative relay are disposed inside the battery pack. The first main positive relay is connected between the positive terminal of the battery pack and the positive terminal of the battery assembly, and the first main negative relay is connected between the negative terminal of the battery assembly and the negative terminal of the battery pack. The control module is used to control the first main positive relay to turn on or off, and to control the first main negative relay to turn on or off, based on the output of the battery pack.

2. The battery-powered device according to claim 1, characterized in that, It also includes a second main positive relay, a first precharge relay and a first precharge resistor. The first end of the second main positive relay is connected to the positive terminal of the battery pack and the first end of the first precharge relay. The second end of the first precharge relay is connected to the first end of the first precharge resistor. The second end of the first precharge resistor is connected to the second end of the second main positive relay.

3. The battery-powered device according to claim 1, characterized in that, It also includes a second pre-charge relay and a second pre-charge resistor, which are disposed inside the battery pack. The first end of the second pre-charge relay is connected to the positive terminal of the battery pack, and the second end of the second pre-charge relay is connected to the first end of the second pre-charge resistor. The second end of the second pre-charge resistor is connected to the positive terminal of the battery pack.

4. The battery-powered device according to claim 2, characterized in that, The control module also includes a first voltage sensor and a first current sensor. The first battery management system, the first voltage sensor, and the first current sensor are all installed in the distribution box. The first voltage sensor is used to detect the voltage signal output by the battery pack, and the first current sensor is used to detect the current signal output by the battery pack. The first battery management system is used to control the conduction and disconnection of the first main positive relay, the first main negative relay, the second main positive relay, and the first precharge relay according to the voltage signal output by the first voltage sensor and the current signal output by the first current sensor.

5. The battery-powered device according to claim 3, characterized in that, The control module includes a second battery management system, which is located inside the battery pack. The second battery management system is used to control the first main positive relay, the first main negative relay and the second precharge relay to be turned on or off according to the output of the battery pack.

6. The battery-powered device according to claim 1, characterized in that, It also includes an inverter module, which is connected to the external device and the control module. The inverter module is used to convert the DC power output by the battery pack into AC power and to power the external device.

7. The battery-powered device according to claim 6, characterized in that, The inverter module includes a first inverter, a second voltage sensor, and a first filter capacitor. The second voltage sensor is connected to the control module and is used to detect the voltage signal output by the battery pack. The first filter capacitor is used to filter the voltage signal output by the battery pack. The first inverter is connected to the external device and the control module and is used to invert the DC power output by the battery pack into AC power and supply power to the external device.

8. A vehicle, characterized in that, Includes the battery-powered device according to any one of claims 1-7.

9. A relay fault detection method, characterized in that, Performed by the battery-powered device according to any one of claims 1-7, the method comprises: The vehicle is powered on; When the voltage signal output by the first voltage sensor detected by the control module is greater than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault. When the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, there is no sticking fault between the first main positive relay and the first main negative relay. The control module controls the closing of the first main positive relay and the first main negative relay; When the voltage signal output by the first voltage sensor detected by the control module is less than the first preset threshold, at least one of the first main positive relay and the first main negative relay has a failure to operate. When the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the control module detects the voltage signal output by the second voltage sensor. When the voltage signal output by the second voltage sensor detected by the control module is greater than the first preset threshold, the second main positive relay or the first precharge relay has a sticking fault, and the first main positive relay or the second precharge relay connected in parallel with the second precharge relay has a sticking fault. When the voltage signal output by the second voltage sensor detected by the control module is not greater than the first preset threshold, the control module controls the first pre-charge relay and the second pre-charge relay to close. When the voltage signal output by the second voltage sensor detected by the control module is less than the second preset threshold, the first precharge relay and the second precharge relay have a failure to operate. When the voltage signal output by the second voltage sensor detected by the control module is not less than the second preset threshold, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to close, and controls the first pre-charge relay and the second pre-charge relay to open. When the voltage signal output by the second voltage sensor detected by the control module is less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay have a failure to operate. When the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay are fault-free. The vehicle power-on process is complete.

10. The relay fault detection method according to claim 9, characterized in that, The method further includes: When the vehicle is powered off, the control module controls the second main positive relay and the first main positive relay connected in parallel with the second pre-charge relay to disconnect; When the voltage signal output by the second voltage sensor detected by the control module is not less than the first preset threshold, the second main positive relay and the first main positive relay connected in parallel with the second precharge relay have a sticking fault. The control module controls the corresponding first main positive relay and first main negative relay in the at least two battery packs to open and close sequentially. When the first main positive relay and the first main negative relay are open, and the voltage signal output by the first voltage sensor detected by the control module is not less than the first preset threshold, the first main positive relay and the first main negative relay have a sticking fault. When the first main positive relay and the first main negative relay are closed, and the voltage signal output by the first voltage sensor detected by the control module is not greater than the first preset threshold, the first main positive relay and the first main negative relay have a non-operation fault. The power-off process has ended, and the vehicle is now in sleep mode.

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