A new energy vehicle high-voltage wiring harness system and control method thereof

Abstract

The present invention relates to the field of high-voltage wire harnesses for new energy vehicles, and relates to a high-voltage wire harness system for new energy vehicles and a control method thereof. The present invention comprises: a data acquisition module, a CAN bus, a battery management system, a vehicle controller and a safety mechanism module. The data acquisition module comprises 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 wire harness, the output end of the battery pack and the input end of the motor controller. Each group of current sensors, voltage sensors and temperature sensors 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 to comprehensively monitor the high-voltage wire harness, ensure the status of the vehicle electrical system, and ensure safety.

Description

Technical Field

[0001] The present invention relates to the field of high-voltage wiring harnesses for new energy vehicles, and in particular 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 (NEVs), as a clean energy transportation tool, have attracted widespread attention and are experiencing rapid development. In NEVs, the high-voltage wiring harness system is a crucial component connecting key components such as the battery pack, motor controller, and onboard charger. Responsible for transmitting electrical energy and control signals, it plays a vital role in the performance and safety of the entire vehicle.

[0003] Existing high-voltage wiring harness systems for new energy vehicles typically use multiple sensors to monitor parameters such as current, voltage, and temperature, and perform data processing and control through the battery management system and vehicle controller. However, these systems face the following challenges in practical applications: Traditional high-voltage wiring harness systems often only have sensors at key nodes, which can lead to monitoring blind spots and an inability to fully understand the operating status of the entire system. In some high-voltage wiring harness systems, the safety mechanism has a long response time, making it impossible to quickly cut off the power supply in an emergency, increasing safety risks.

[0004] In summary, in order to solve the deficiencies in the existing technology, 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 new energy vehicles.

[0006] The objectives 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, voltage sensor and 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, 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, 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 acquisition and transmission: Data is collected through three sets of current sensors, three sets of voltage sensors, and three sets of temperature sensors installed in the middle of the high-voltage wiring harness, at the output end of the battery pack, and at the input end of the motor controller. The collected current, voltage, and temperature data are then transmitted to the battery management system and vehicle controller in real time via the CAN bus.

[0011] S2: SOC calculation and analysis: The battery management system calculates the initial SOC0 based on the sensor data. Based on the ratio of the battery's current charge to the full charge, the current value I measured by the three sets of current sensors is integrated, and the battery charge and discharge efficiency η is taken into account to calculate the change in 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. The data from the three sets of current sensors are then compared to ensure the accuracy of the current integration. If the data are inconsistent, a majority vote or weighted average method is used to determine the final current value.

[0013] S3: SOH assessment: The battery management system integrates data from three groups of voltage sensors, three groups of temperature sensors, and current sensors to comprehensively assess SOH.

[0014] S4: Abnormal detection: The vehicle controller receives data from the battery management system and analyzes the data collected in S1. It uses a 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. If 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 a majority voting or weighted average method and compared with the preset maximum value, the high-voltage contactor is used to cut off the high-voltage power supply when the set maximum value is reached.

[0015] S5: Records all sensor data, SOC and SOH calculation results, abnormal events and system response measures, and transmits this 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 the preset fault handling strategy; if it is confirmed that the fault will not immediately affect vehicle safety, the vehicle controller can 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 optimal conditions, reduce the occurrence of failures, and enhance the reliability of the entire vehicle; data fusion based on 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. When an abnormality is detected, the system can take proactive measures, such as sounding an alarm or cutting off the power supply, to protect the safety of the vehicle and passengers. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A schematic structural diagram 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., indicating directions or positional relationships, are 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 limiting the present invention.

[0023] In the description of the present invention, it should be noted that, unless otherwise specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0024] Below with reference to the embodiment and the attached Figure 1 , further elaborating on the technical solution of the present invention.

[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. The data acquisition module 1 includes a current sensor 11, a voltage sensor 12 and a temperature sensor 13. 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. Each group of the current sensor 11, the voltage sensor 12 and the temperature sensor 13 is 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 to calculate the SOC and SOH parameters of the battery. The vehicle controller 4 receives the processed data of the battery management system 3. The safety mechanism module 5 and the battery management system 3 are both connected to the vehicle controller 4 through the CAN bus 2.

[0027] Through comprehensive data collection, this system provides real-time monitoring of the high-voltage wiring harness status, thereby improving the safety and reliability of new energy vehicles. Data transmission via the CAN bus ensures real-time and accurate data, enabling the battery management system 3 and vehicle controller 4 to respond and handle various situations promptly.

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

[0029] S1: Data acquisition 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, which are set in the middle of the high-voltage wire harness 6, at the output end of the battery pack and the input end of the motor controller. The collected current, voltage, and temperature data are then transmitted in real time to the battery management system 3 and the vehicle controller 4 via the CAN bus 2;

[0030] S2: SOC calculation and 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, by integrating the current value I measured by the three sets of current sensors 11 and taking into account the battery charge and discharge efficiency η, the change in 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; the data of the three sets of current sensors 11 are then compared to ensure the accuracy of the current integration. If the data are inconsistent, a majority vote or weighted average method is used to determine the final current value;

[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, to comprehensively evaluate the SOH;

[0032] S4: Abnormal detection: The vehicle controller 4 receives data from the battery management system 3 and analyzes the data collected in S1. It uses a 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 value. If the set safety threshold value is reached, an alarm is issued. If the safety threshold value is exceeded and the final current value, voltage value, and temperature value are determined by a majority voting or weighted average method and compared with the preset maximum value, the high-voltage power supply is cut off through the high-voltage contactor when the set maximum value is reached;

[0033] S5: Record all sensor data, SOC and SOH calculation results, abnormal events and system response measures, and transmit this 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's charge and discharge status and the battery's SOC. The current data is also used to detect abnormal current flow in the circuit, such as short circuits 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 battery's SOC and SOH, and to detect voltage anomalies such as excessively high or low voltage.

[0036] Temperature sensors 13 monitor the temperature of the battery pack, motor, and other key components. The data is used to prevent overheating and for thermal management control. Abnormal temperatures 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 wiring harness, at the output of the battery pack, and at the input of the motor controller, respectively. Data acquisition from each sensor should be synchronized to ensure time consistency. The data from the three sets of current sensors are compared and integrated to calculate the battery's SOC. The estimated value is ensured to be within the range of 0% to 100%, ensuring more accurate SOC calculations.

[0038] The SOH is evaluated comprehensively by combining the data from three groups of voltage sensors, three groups of temperature sensors, and the data from the current sensor. The SOH result is more accurate.

[0039] Abnormality detection in step S4 ensures system safety and stability. The vehicle controller 4 receives data from the battery management system 3 and compares it with preset safety thresholds, enabling real-time monitoring of the battery's operating status. When current, voltage, or temperature exceed safety thresholds, the system issues an alarm, alerting the driver or automatically implementing appropriate safety measures. If the detected value exceeds a preset maximum, the system immediately disconnects the high-voltage power supply via a high-voltage contactor to prevent potential battery damage, fire, or other safety incidents. This not only improves vehicle safety but also enhances the overall driving experience and vehicle maintenance efficiency.

[0040] This method allows the system to more accurately calculate and analyze the battery's SOC and SOH in real time, identifying abnormalities and taking action when necessary. At the same time, all critical data is 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. This contactor is connected to the battery management system 3 and the vehicle controller 4 via the CAN bus 2. When the battery management system 3 detects an abnormality, such as battery overcharge, overdischarge, or abnormal temperature, it immediately notifies the vehicle controller 4. Upon receiving the signal, the vehicle controller 4 disconnects the high-voltage contactor through the safety mechanism module, thereby cutting off the high-voltage power supply and preventing further spread of the fault.

[0042] As a further preferred embodiment, the battery management system 3 is equipped with a self-diagnosis module 7, and the vehicle controller 4 is equipped with a high-voltage interlock circuit detection module 8. The self-diagnosis module promptly detects and classifies faults within 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 action in the early stages of a fault, improving system reliability and maintainability.

[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 interlock circuit detection module 8 inside the vehicle controller 4 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.

[0044] As a further preferred embodiment, upon detecting a fault within the battery management system 3, the fault self-diagnosis module 7 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, based on a preset fault handling strategy, determines whether to immediately notify the driver or take other measures. If it is determined that the fault will not immediately affect vehicle safety, the vehicle controller 4 may decide to continue vehicle operation while providing fault repair suggestions or plans and notifying the driver through the vehicle information system. If the fault may affect vehicle safety, the vehicle controller 4 will immediately take measures through the safety mechanism module 5, such as limiting vehicle performance or guiding the driver to a safe stop, and notifying the nearest service center for repairs. The above-mentioned 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 operation and provide repair suggestions. For faults that may affect safety, immediate measures are taken to ensure the safety of the vehicle and its occupants.

[0045] The above describes in detail the preferred embodiments of the present invention. It should be understood that those skilled in the art can make numerous modifications and variations based on the concepts of the present invention without inventive effort. Therefore, any technical solutions that can be derived by those skilled in the art through logical analysis, reasoning, or limited experimentation based on the concepts of the present invention and the prior art should be within the scope of protection defined by the claims.

Claims

1. A high-voltage wiring harness system for new energy vehicles, characterized in that: include: Data acquisition module, CAN bus, battery management system, vehicle controller and 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, 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; The following steps are also included: S1: Data acquisition and transmission: Data is collected through three sets of current sensors, three sets of voltage sensors, and three sets of temperature sensors installed in the middle of the high-voltage wiring harness, at the output end of the battery pack, and at the input end of the motor controller. The collected current, voltage, and temperature data are then transmitted to the battery management system and vehicle controller in real time via the CAN bus. S2: SOC calculation analysis: The battery management system calculates the initial Based on the ratio of the battery's current capacity to its full capacity, the current value I measured by the three sets of current sensors is integrated, and the battery charge and discharge efficiency is taken into account. , calculate the change in SOC, using the formula: ,in is the current discharge capacity of the battery, I is the average value of the battery charge and discharge current, The battery charge and discharge efficiency is then compared with the data from the three sets of current sensors to ensure the accuracy of the current integration. If the data are inconsistent, a majority vote or weighted average method is used to determine the final current value. S3: SOH assessment: The battery management system integrates data from three sets of voltage sensors, three sets of temperature sensors, and current sensors to comprehensively assess SOH. S4: Abnormal detection: The vehicle controller receives data from the battery management system and analyzes the data collected in S1. It uses a majority voting or weighted average method to determine the final current, voltage, and temperature values ​​and compares them with the preset safety thresholds. If the set safety thresholds are reached, an alarm is issued. If the safety threshold is exceeded and the final current, voltage and temperature values ​​are determined by majority voting or weighted average method, they are compared with the preset maximum values. When the set maximum values ​​are reached, the high voltage power supply is cut off through the high voltage contactor. S5: Records all sensor data, SOC and SOH calculation results, abnormal events, and system response measures, and transmits this data to the vehicle's information system via the CAN bus for subsequent diagnosis and maintenance; The fault self-diagnosis module within 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 within the vehicle controller performs real-time detection of the high-voltage interlock circuit and immediately issues a fault alarm if it detects a disconnection in the interlock circuit. When the fault self-diagnosis module detects a fault within 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, based on the preset fault handling strategy, decides whether to immediately notify the driver or take other measures. If it is determined that the fault will not immediately affect vehicle safety, the vehicle controller may decide to continue vehicle operation, provide fault repair suggestions or plans, 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.

2. A new energy vehicle high voltage wiring harness system according to claim 1, 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, 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.

Images