New energy automobile high-voltage wiring harness system and control method thereof

Abstract

The invention relates to the field of new energy automobile high-voltage wiring harnesses, in particular to a new energy automobile high-voltage wiring harness system and a control method thereof.The new energy automobile high-voltage wiring harness system comprises a data acquisition module, a CAN bus, a battery management system, a whole automobile controller and a safety mechanism module, and the data acquisition module comprises a current sensor, a voltage sensor and a temperature sensor; the current sensors, the voltage sensors and the temperature sensors are all arranged in the middle of the high-voltage wiring harness, the output end of the battery pack and the input end of the motor controller, and each set of current sensor, voltage sensor and temperature sensor is connected with the battery management system and the whole vehicle controller through a CAN bus. The battery management system processes collected voltage, current and temperature data and calculates SOC and SOH parameters of a battery, the vehicle control unit receives the processing data of the battery management system, the safety mechanism module and the battery management system are both connected with the vehicle control unit through a CAN bus, high-voltage wiring harnesses are comprehensively monitored, the state of a vehicle electrical system is ensured, and safety is guaranteed.

Description

Technical Field

[0001] The present invention relates to the field of high-voltage wiring harnesses for new energy vehicles, and more particularly to a high-voltage wiring harness system for new energy vehicles and a control method thereof. Background Art

[0002] As the global energy crisis intensifies and environmental pollution becomes increasingly serious, new energy vehicles, as a clean energy means of transportation, have received widespread attention and rapid development. In new energy vehicles, the high-voltage wiring harness system is an important component that connects key components such as battery packs, motor controllers, and on-board chargers. It is responsible for transmitting electrical energy and control signals, and plays a vital role in the performance and safety of the entire vehicle.

[0003] Existing high-voltage wiring harness systems for new energy vehicles usually use multiple sensors to monitor parameters such as current, voltage and temperature, and process and control data through battery management systems and vehicle controllers. However, these systems have the following problems in practical applications: Traditional high-voltage wiring harness systems often only set sensors at key nodes, which may lead to monitoring blind spots and fail to fully grasp the operating status of the entire system; in some high-voltage wiring harness systems, the response time of the safety mechanism is long, and the power supply cannot be quickly cut off in an emergency, increasing safety risks.

[0004] In summary, in order to solve the deficiencies in the prior art, it is necessary to design a new energy vehicle high-voltage wiring harness system with a simple structure and a control method thereof. Summary of the invention

[0005] In order to solve the problems of the prior art, the present invention provides a high-voltage wiring harness system for a new energy vehicle.

[0006] The objective of the present invention can be achieved through the following technical solutions: A high-voltage wiring harness system for new energy vehicles, comprising: a data acquisition module, a CAN bus, a battery management system, a vehicle controller and a safety mechanism module, the data acquisition module comprising a current sensor, a voltage sensor and a temperature sensor, the current sensor, the voltage sensor and the temperature sensor are all arranged in the middle of the high-voltage wiring harness, the output end of the battery pack and the input end of the motor controller, each group of the current sensor, the voltage sensor and the temperature sensor are connected to the battery management system and the vehicle controller through the CAN bus, the battery management system processes the collected voltage, current and temperature data, calculates the SOC and SOH parameters of the battery, the vehicle controller receives the processed data of the battery management system, and the safety mechanism module and the battery management system are both connected to the vehicle controller through the CAN bus.

[0007] As a further improvement, the safety mechanism module includes a high voltage contactor.

[0008] As a further improvement, a fault self-diagnosis module is provided inside the battery management system, and a high-voltage interlock circuit detection module is provided inside the vehicle controller.

[0009] A control method for a high-voltage wiring harness system of a new energy vehicle comprises the following steps:

[0010] S1: Data collection and transmission: Data is collected through three sets of current sensors, three sets of voltage sensors and three sets of temperature sensors set in the middle of the high-voltage wire harness, the output end of the battery pack and the input end of the motor controller. Then the collected current, voltage and temperature data are transmitted to the battery management system and the vehicle controller in real time through the CAN bus;

[0011] S2: SOC calculation analysis: The battery management system calculates the initial SOC0 based on the sensor data. Based on the ratio of the current power of the battery to the full power, the current value I measured by the three sets of current sensors is integrated, and the battery charge and discharge efficiency η is considered to calculate the change of SOC using the formula:

[0012] Among them C N is the rated capacity of the battery, I is the average value of the battery charge and discharge current, and η is the battery charge and discharge efficiency; then the data of the three groups of current sensors are compared to ensure the accuracy of the current integration. If the data are inconsistent, the majority voting or weighted average method is used to determine the final current value;

[0013] S3: SOH evaluation: The battery management system performs data fusion based on the data of three groups of voltage sensors, three groups of temperature sensors, and the data of the current sensor to comprehensively evaluate the SOH;

[0014] S4: Abnormal detection: The vehicle controller receives the data in the battery management system, and analyzes the data collected in S1, wherein the final current value, voltage value and temperature value are determined by majority voting or weighted average method for comparison with the preset safety threshold, and an alarm is issued when the set safety threshold is reached; if the safety threshold is exceeded and the final current value, voltage value and temperature value are determined by majority voting or weighted average method for comparison with the preset maximum value, when the set maximum value is reached, the high-voltage power supply is cut off through the high-voltage contactor;

[0015] S5: Record all sensor data, SOC and SOH calculation results, abnormal events and system response measures, and transmit these data to the vehicle's information system via the CAN bus for subsequent diagnosis and maintenance.

[0016] As a further improvement, the fault self-diagnosis module inside the battery management system monitors and diagnoses the battery status in real time, including battery parameter monitoring, fault detection, system integrity check and data comparison; the high-voltage interlock circuit detection module inside the vehicle controller performs real-time detection of the high-voltage interlock circuit, and immediately issues a fault alarm when it detects that the interlock circuit is disconnected.

[0017] As a further improvement, when the fault self-diagnosis module detects a fault inside the battery management system, it records the fault information and classifies it according to the fault type and severity; the vehicle controller receives the fault classification information from the fault self-diagnosis module and decides whether to immediately notify the driver or take other measures based on a preset fault handling strategy; when it is confirmed that the fault will not immediately affect vehicle safety, the vehicle controller may decide to continue vehicle operation, while providing suggestions or plans for fault repair and notifying the driver through the vehicle information system; if the fault may affect vehicle safety, the vehicle controller will immediately take measures through the safety mechanism module, such as limiting vehicle performance or guiding the driver to park safely, and notify the nearest service center for repairs.

[0018] Compared with the prior art, the new energy vehicle high voltage wiring harness system and control method thereof of the present invention have the following beneficial effects:

[0019] Sensors installed at key locations can comprehensively monitor the current, voltage and temperature of the high-voltage wiring harness, ensuring a real-time and comprehensive understanding of the status of the vehicle's electrical system; through accurate calculation of the battery's SOC and SOH, the system can ensure that the battery operates in the best condition, reduce the occurrence of failures, and enhance the reliability of the entire vehicle; data fusion combined with voltage, temperature and current data provides a more accurate SOH assessment, which helps to timely understand the battery health status; the abnormality detection step in the control method can monitor the battery status in real time, detect and respond to abnormal situations in a timely manner, and when an abnormality is detected, the system can take proactive measures, such as sounding an alarm or cutting off power, to protect the safety of the vehicle and passengers. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic diagram of the structure of the present invention

[0021] In the figure, 1-data acquisition module, 11-current sensor, 12-voltage sensor, 13-temperature sensor, 2-CAN bus, 3-battery management system, 4-vehicle controller, 5-safety mechanism module, 6-high-voltage wiring harness, 7-fault self-diagnosis module, 8-high-voltage interlock circuit detection module. DETAILED DESCRIPTION

[0022] In the description of the present invention, it should be noted that the terms "center", "up", "down", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate directions or positional relationships based on the directions or positional relationships shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction. Therefore, they cannot be understood as limitations on the present invention.

[0023] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected" and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] Below is a combination of the embodiments and the attached Figure 1 , the technical solution of the present invention is further elaborated.

[0025] Example 1

[0026] A high-voltage wiring harness system for new energy vehicles includes: a data acquisition module 1, a CAN bus 2, a battery management system 3, a vehicle controller 4 and a safety mechanism module 5, wherein the data acquisition module 1 includes a current sensor 11, a voltage sensor 12 and a temperature sensor 13, wherein the current sensor 11, the voltage sensor 12 and the temperature sensor 13 are all arranged in the middle of the high-voltage wiring harness 6, the output end of the battery pack and the input end of the motor controller, and each group of the current sensor 11, the voltage sensor 12 and the temperature sensor 13 are connected to the battery management system 3 and the vehicle controller 4 through the CAN bus 2, the battery management system 3 processes the collected voltage, current and temperature data, and calculates the SOC and SOH parameters of the battery, and the vehicle controller 4 receives the processed data of the battery management system 3, and the safety mechanism module 5 and the battery management system 3 are connected to the vehicle controller 4 through the CAN bus 2.

[0027] This system can provide real-time monitoring of the status of high-voltage wiring harnesses through comprehensive data collection, thereby improving the safety and reliability of new energy vehicles. Data transmission through the CAN bus ensures the real-time and accuracy of data, allowing the battery management system 3 and the vehicle controller 4 to respond and handle various situations in a timely manner.

[0028] A control method for a high-voltage wiring harness system of a new energy vehicle comprises the following steps:

[0029] S1: Data collection and transmission: Data is collected through three sets of current sensors 11, three sets of voltage sensors 12 and three sets of temperature sensors 13 arranged in the middle of the high-voltage wire harness 6, the output end of the battery pack and the input end of the motor controller, and then the collected current, voltage and temperature data are transmitted to the battery management system 3 and the vehicle controller 4 in real time through the CAN bus 2;

[0030] S2: SOC calculation analysis: The battery management system 3 calculates the initial SOC0 based on the sensor data. Based on the ratio of the current power of the battery to the full power, the current value I measured by the three sets of current sensors 11 is integrated, and the battery charge and discharge efficiency η is considered to calculate the change of SOC using the formula: Among them C N is the rated capacity of the battery, I is the average value of the battery charge and discharge current, and η is the battery charge and discharge efficiency; then the data of the three groups of current sensors 11 are compared to ensure the accuracy of the current integration. If the data are inconsistent, the final current value is determined by majority voting or weighted average method;

[0031] S3: SOH evaluation: The battery management system 3 performs data fusion based on the data of the three groups of voltage sensors 12 and the three groups of temperature sensors 13, as well as the data of the current sensor 11, and comprehensively evaluates the SOH;

[0032] S4: Abnormal detection: The vehicle controller 4 receives the data in the battery management system 3, and analyzes the data collected in S1, wherein the final current value, voltage value and temperature value are determined by majority voting or weighted average method for comparison with the preset safety threshold, and an alarm is issued after reaching the set safety threshold; if the safety threshold is exceeded and the final current value, voltage value and temperature value are determined by majority voting or weighted average method for comparison with the preset maximum value, after reaching the set maximum value, the high-voltage power supply is cut off through the high-voltage contactor;

[0033] S5: Record all sensor data, SOC and SOH calculation results, abnormal events and system response measures, and transmit these data to the vehicle's information system via CAN bus 2 for subsequent diagnosis and maintenance.

[0034] The current is monitored by the current sensor 11, and the data is used to calculate the battery charge and discharge state and the battery SOC. The current data is also used to detect abnormal current in the circuit, such as short circuit or overload conditions;

[0035] The voltage sensor 12 monitors the voltage of the battery pack and key electrical equipment to ensure that the voltage is within a safe range. The voltage data is used to calculate the SOC and SOH of the battery and detect voltage anomalies, such as excessively high or low voltage;

[0036] The temperature sensor 13 monitors the temperature of the battery pack, motor and other key components, and the data is used to prevent overheating and thermal management control. Abnormal temperature may indicate thermal runaway or other heat-related failures.

[0037] The current sensor, voltage sensor and temperature sensor are installed in the middle of the high-voltage harness, the output end of the battery pack and the input end of the motor controller respectively. The data collection of each sensor should be synchronized to ensure time consistency. The data of the three sets of current sensors are compared, and the current data is integrated to calculate the SOC of the battery, ensuring that the estimated value is within the range of 0% to 100%, ensuring that the SOC calculation is more accurate.

[0038] The data from three groups of voltage sensors and three groups of temperature sensors, as well as the data from the current sensor, are combined to comprehensively evaluate the SOH, and the SOH result is more accurate.

[0039] The abnormality detection in step S4 is to ensure the safety and stability of the system. The vehicle controller 4 receives data from the battery management system 3 and compares it with the preset safety threshold, so that the working status of the battery can be monitored in real time. When it is detected that the current, voltage or temperature exceeds the safety threshold, the system will sound an alarm to remind the driver or automatically take corresponding safety measures. If the detected value exceeds the preset maximum value, the system will immediately cut off the high-voltage power supply through the high-voltage contactor to prevent possible battery damage, fire or other safety accidents; it not only improves the safety performance of the vehicle, but also helps to improve the overall driving experience and vehicle maintenance efficiency.

[0040] In this way, the system can more accurately calculate and analyze the battery's SOC and SOH in real time, detect abnormal conditions in a timely manner, and take action when necessary. At the same time, all key data are recorded and transmitted to the vehicle's information system for subsequent diagnosis and maintenance.

[0041] As a further preferred embodiment, the safety mechanism module 5 includes a high-voltage contactor. The contactor is connected to the battery management system 3 and the vehicle controller 4 through the CAN bus 2. When the battery management system 3 detects an abnormal situation, such as battery overcharge, over discharge or abnormal temperature, it will immediately notify the vehicle controller 4. After receiving the signal, the vehicle controller 4 will cut off the high-voltage contactor through the safety mechanism module to cut off the high-voltage power supply to prevent the fault from spreading further.

[0042] As a further preferred embodiment, the battery management system 3 is provided with a fault self-diagnosis module 7, and the vehicle controller 4 is provided with a high-voltage interlock circuit detection module 8. The fault self-diagnosis module can timely detect and classify faults inside the battery management system, while the high-voltage interlock circuit detection module ensures the physical connection integrity of the high-voltage system. The integration of these two modules enables the system to take measures at the early stage of a fault, thereby improving the reliability and maintainability of the system.

[0043] As a further preferred embodiment, the fault self-diagnosis module 7 inside the battery management system 3 performs real-time monitoring and diagnosis of the battery status, including battery parameter monitoring, fault detection, system integrity check and data comparison; the high-voltage interlocking circuit detection module 8 inside the vehicle controller 4 performs real-time detection of the high-voltage interlocking circuit, and immediately issues a fault alarm when it detects that the interlocking circuit is disconnected.

[0044] As a further preferred embodiment, when the fault self-diagnosis module 7 detects a fault inside the battery management system 3, it records the fault information and classifies it according to the fault type and severity; the vehicle controller 4 receives the fault classification information from the fault self-diagnosis module 7, and decides whether to immediately notify the driver or take other measures according to the preset fault handling strategy; when it is confirmed that the fault will not immediately affect the safety of the vehicle, the vehicle controller 4 can decide to continue the vehicle operation, while providing suggestions or plans for fault repair, and notifying the driver through the vehicle information system; if the fault may affect the safety of the vehicle, the vehicle controller 4 will immediately take measures through the safety mechanism module 5, such as limiting the vehicle performance or guiding the driver to park safely, and notify the nearest service center for repair. The above fault handling strategy enables the system to respond flexibly according to the specific circumstances of the fault. For faults that do not affect safety, the system can continue to operate and provide repair suggestions; for faults that may affect safety, immediate measures are taken to ensure the safety of the vehicle and passengers.

[0045] The preferred specific embodiments of the present invention are described in detail above. It should be understood that a person skilled in the art can make many modifications and changes based on the concept of the present invention without creative work. Therefore, any technical solution that can be obtained by a person skilled in the art through logical analysis, reasoning or limited experiments based on the concept of the present invention on the basis of the prior art should be within the scope of protection determined by the claims.

Claims

1. A high voltage wiring harness system for new energy vehicles, It is characterized in that include: A data acquisition module, a CAN bus, a battery management system, a vehicle controller and a safety mechanism module. The data acquisition module includes a current sensor, a voltage sensor and a temperature sensor. The current sensor, voltage sensor and temperature sensor are all arranged in the middle of the high-voltage wire harness, the output end of the battery pack and the input end of the motor controller. Each group of the current sensor, voltage sensor and temperature sensor is connected to the battery management system and the vehicle controller through the CAN bus. The battery management system processes the collected voltage, current and temperature data and calculates the SOC and SOH parameters of the battery. The vehicle controller receives the processed data of the battery management system. The safety mechanism module and the battery management system are both connected to the vehicle controller through the CAN bus.

2. A new energy vehicle high voltage wiring harness system according to claim 1, It is characterized in that The safety mechanism module includes a high voltage contactor.

3. A new energy vehicle high voltage wiring harness system according to claim 1, It is characterized in that The battery management system is provided with a fault self-diagnosis module, and the vehicle controller is provided with a high-voltage interlock circuit detection module.

4. A control method for a high-voltage wiring harness system for a new energy vehicle according to any one of claims 1 to 3, It is characterized in that The steps include: S1: Data collection and transmission: Data is collected through three sets of current sensors, three sets of voltage sensors and three sets of temperature sensors set in the middle of the high-voltage wire harness, the output end of the battery pack and the input end of the motor controller. Then the collected current, voltage and temperature data are transmitted to the battery management system and the vehicle controller in real time through the CAN bus; S2: SOC calculation analysis: The battery management system calculates the initial SOC based on sensor data 0 , based on the ratio of the current power of the battery to the full power, by integrating the current values ​​I measured by the three sets of current sensors and considering the battery charge and discharge efficiency η, the change of SOC is calculated using the formula: Among them C N is the rated capacity of the battery, I is the average value of the battery charge and discharge current, and η is the battery charge and discharge efficiency; then the data of the three groups of current sensors are compared to ensure the accuracy of the current integration. If the data are inconsistent, the majority voting or weighted average method is used to determine the final current value; S3: SOH evaluation: The battery management system performs data fusion based on the data of three groups of voltage sensors, three groups of temperature sensors, and the data of the current sensor to comprehensively evaluate the SOH; S4: Abnormal detection: The vehicle controller receives data from the battery management system and analyzes the data collected in S1. It uses majority voting or weighted average method to determine the final current value, voltage value and temperature value and compares them with the preset safety threshold. When the set safety threshold is reached, an alarm is issued. If the safety threshold is exceeded and the final current value, voltage value and temperature value are determined by majority voting or weighted average method for comparison, when the set maximum value is reached, the high voltage power supply is cut off through the high voltage contactor; S5: Record all sensor data, SOC and SOH calculation results, abnormal events and system response measures, and transmit these data to the vehicle's information system via the CAN bus for subsequent diagnosis and maintenance.

5. The control method of a high-voltage wiring harness system for a new energy vehicle according to claim 4, It is characterized in that The fault self-diagnosis module inside the battery management system monitors and diagnoses the battery status in real time, including battery parameter monitoring, fault detection, system integrity check and data comparison; the high-voltage interlock circuit detection module inside the vehicle controller performs real-time detection of the high-voltage interlock circuit, and immediately issues a fault alarm when it detects that the interlock circuit is disconnected.

6. A control method for a high voltage wiring harness system of a new energy vehicle according to claim 5, It is characterized in that When the fault self-diagnosis module detects a fault inside the battery management system, it records the fault information and classifies it according to the fault type and severity; the vehicle controller receives the fault classification information from the fault self-diagnosis module and decides whether to immediately notify the driver or take other measures based on the preset fault handling strategy; if it is confirmed that the fault will not immediately affect the safety of the vehicle, the vehicle controller can decide to continue the vehicle operation, provide suggestions or plans for fault repair, and notify the driver through the vehicle information system; If the fault may affect vehicle safety, the vehicle controller will immediately take measures through the safety mechanism module, such as limiting vehicle performance or guiding the driver to park safely, and notify the nearest service center for repair.

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