An electric vehicle power domain controller

Abstract

This invention discloses an electric vehicle power domain controller. The power domain controller integrates seven controllers: a vehicle controller, a charging control unit, a motor controller, a main control board for the battery management unit, an on-board charger controller, a DC-DC converter controller, and a vehicle-to-charging station interconnection module. By integrating these seven controllers into a single power domain controller, this invention improves component reuse, reduces hard-wired connections, and saves on mounting brackets for each controller, resulting in a smaller and lighter vehicle, thus significantly saving space and weight. It also reduces communication signal interaction between the individual controllers, lowers the load on the communication network, and ensures more stable and reliable vehicle communication.

Description

Technical Field

[0001] This invention belongs to the field of vehicle technology, and more specifically, relates to a power domain controller for electric vehicles. Background Technology

[0002] With the rapid development of intelligent and connected vehicles, electric vehicles are becoming increasingly feature-rich and intelligent. Currently, vehicles have numerous electronic control units connected by wiring harnesses, such as... Figure 1 As shown, the current power domain of a vehicle includes seven controllers: Vehicle Control Unit (VCU), Charge Control Unit (CCU), Motor Controller (MCU), Battery Management Unit (BMS) main control board (slave board located inside the battery pack), On-Board Charger Controller (OBC), DC-DC Converter Controller (DCDC), and Vehicle-to-Pile Controller (VCIM). Because different electronic control units carry out different functions, the software of automotive electronics has increased significantly. Moreover, a large number of new functions require the coordinated implementation of multiple electronic control units, which in turn has led to a multiplied increase in wiring harness connections and communication interactions between the various electronic control units. Ensuring normal function implementation, timely data response, and secure and reliable communication has become another challenge facing electric vehicles.

[0003] The information disclosed in the background section of this invention is intended only to enhance the understanding of the general background of this invention, and should not be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art. Summary of the Invention

[0004] The purpose of this invention is to propose an electric vehicle power domain controller that integrates seven controllers—the main control board of the vehicle controller, charging control unit, motor controller, battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging interconnection module—into a single power domain controller. This improves the reusability of components, reduces communication interactions between the original controllers, reduces hard wiring connections, and saves on brackets for each controller, resulting in lower vehicle costs, enhanced communication stability, smaller size, and lighter weight.

[0005] To achieve the above objectives, the present invention proposes an electric vehicle power domain controller, comprising:

[0006] Power supply module, wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, control module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, insulation resistance detection module, level conversion module, isolation module, inverter, daisy-chain communication module, chopper module, resonant module, high-frequency rectification module, low-pass filter module, EMI filter module, power factor correction module, isolated DC-DC module, and output rectification and filtering module;

[0007] The control module is connected to the wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, and insulation resistance detection module, respectively.

[0008] The power domain controller integrates seven controllers: the vehicle controller, the charging control unit, the motor controller, the main control board of the battery management unit, the on-board charger controller, the DC-DC converter controller, and the vehicle-to-charging station interconnection controller.

[0009] Optionally, in the power domain controller, the power module rationally allocates the power to each module in the power domain controller according to the different power inputs of the vehicle system, and controls the power supply in POWERLATCH mode when the key is off; the wake-up module receives the wake-up signal and activates the corresponding module in the power domain controller based on the wake-up signal.

[0010] Optionally, in the power domain controller,

[0011] The analog input module acquires and processes analog signals related to the power domain controller, and then sends the processed analog signals to the control module.

[0012] The digital input module acquires and processes digital signals related to the power domain controller, and then sends the processed digital signals to the control module.

[0013] The frequency input module acquires and processes the frequency signals related to the power domain controller, and then sends the processed frequency signals to the control module.

[0014] Optionally, in the power domain controller,

[0015] The control module communicates with the vehicle system via the CAN communication module, and the CAN communication module has a protection circuit.

[0016] The control module communicates with the vehicle system via Ethernet through the Ethernet communication module.

[0017] The control module provides communication assistance for the CAN communication and the Ethernet communication through the LIN communication module, as well as performs data refresh and fault diagnosis. The LIN communication module has protection functions against short circuit to power supply and short circuit to ground.

[0018] The control module communicates with the charging pile via Bluetooth through the Bluetooth communication module.

[0019] The daisy-chain communication module communicates with the BMS slave board in the battery pack. The daisy-chain communication module has A and B bidirectional daisy-chain communication and reverse wake-up source identification functions.

[0020] Optionally, in the power domain controller,

[0021] The control module performs wake-up drive output and high-side control output corresponding to BMS-related PWM through the high-side drive module.

[0022] The control module controls fast and slow charging relays, thermal management related relays, solenoid valves, and various indicator lights through a low-side drive module.

[0023] The control module controls the fast and slow charging locks through the H-bridge drive module.

[0024] The control module controls the inverter through the IGBT drive module;

[0025] The inverter converts the DC power supplied by the battery pack into AC power to supply the motor. The inverter includes a three-phase full-bridge inverter circuit and IGBTs.

[0026] Optionally, the control module includes:

[0027] A 32-bit high-performance multi-core microcontroller and its minimum circuitry, and a 16-bit microcontroller;

[0028] The multi-core microcontroller enables the functions of the main control board for the vehicle controller, charging control unit, motor controller, battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging pile interconnection controller.

[0029] The 16-bit microcontroller is used to monitor the inputs from some acquisition ports that do not require real-time performance.

[0030] The 32-bit high-performance multi-core microcontroller communicates with the 16-bit microcontroller via SPI.

[0031] Optionally, in the power domain controller,

[0032] The control module monitors the vehicle's high-voltage system by acquiring the DC bus voltage, charging voltage, and three-phase voltage from the high-voltage signal acquisition module.

[0033] The control module monitors the vehicle's high-voltage system by acquiring phase current through the phase current acquisition module;

[0034] The safety protection module prevents overload and short circuit in the power domain controller, thus protecting the safety of the vehicle's electrical system and electrical equipment.

[0035] The insulation resistance detection module detects the insulation resistance of the on-board rechargeable energy storage system and the positive and negative voltages to ground, and transmits this information to the control module.

[0036] Optionally, in the power domain controller,

[0037] The chopper module converts the DC output voltage of the battery pack into a first DC voltage.

[0038] The resonant circuit processes the DC current of the first voltage to obtain sinusoidal AC current, and the resonant circuit has electrical isolation and voltage regulation functions.

[0039] The sinusoidal alternating current is rectified by the high-frequency rectifier module to obtain pulsating direct current;

[0040] The low-pass filter module filters the pulsating DC power to obtain a smooth and stable DC voltage output for powering the battery.

[0041] Optionally, in the power domain controller,

[0042] The EMI filter module filters the external DC power input from the external power grid, eliminating the interference of high-frequency pulses from the external power grid on the internal power supply of the electric vehicle, while reducing electromagnetic radiation to a minimum.

[0043] The power factor correction module converts the filtered external DC voltage into a stable second voltage.

[0044] The second voltage is boosted by an isolated DC-DC module to obtain DC power that meets the battery pack voltage level.

[0045] The voltage output from the isolated DC-DC module is filtered by the output rectifier and filter module to obtain a stable output voltage to power the battery pack.

[0046] Optionally, in the power domain controller,

[0047] The isolation module is used to isolate communication and data acquisition between high and low voltage sides to achieve isolation between high and low voltage signals within the power domain controller board.

[0048] The level conversion module performs level conversion on different level signals within the power domain controller board to enable interaction between different level signals within the power domain controller board.

[0049] The beneficial effects of this invention are as follows: By integrating seven controllers—the vehicle controller, charging control unit, motor controller, main control board of the battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging interconnection controller—into a single power domain controller, this invention improves the reuse rate of components, resulting in a smaller vehicle size and lighter weight, thus significantly saving space and weight. It also reduces the communication signal interaction between the original controllers, greatly reducing the load rate of the communication network and ensuring more stable and reliable vehicle communication, significantly reducing vehicle development costs. Furthermore, it reduces the corresponding hardwired connections, saving on the brackets for each controller and reducing the need for multiple data acquisitions from each controller, thus lowering costs and space requirements while making control more stable and reliable.

[0050] The system of the present invention has other features and advantages that will be apparent from or will be set forth in detail in the accompanying drawings and following detailed description, which together serve to explain the particular principles of the invention. Attached Figure Description

[0051] The above and other objects, features and advantages of the present invention will become more apparent from the accompanying drawings, in which like reference numerals generally denote like parts.

[0052] Figure 1 A schematic diagram of the power domain of an electric vehicle according to the prior art of the present invention is shown.

[0053] Figure 2 A schematic diagram of an electric vehicle power domain controller according to an embodiment of the present invention is shown. Detailed Implementation

[0054] The invention will now be described in more detail with reference to the accompanying drawings. While preferred embodiments of the invention are shown in the drawings, it should be understood that the invention can be implemented in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that the invention will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

[0055] An electric vehicle power domain controller according to the present invention includes:

[0056] Power supply module, wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, control module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, insulation resistance detection module, level conversion module, isolation module, inverter, daisy-chain communication module, chopper module, resonant module, high-frequency rectification module, low-pass filter module, EMI filter module, power factor correction module, isolated DC-DC module, and output rectification and filtering module;

[0057] The control module is connected to the wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, and insulation resistance detection module, respectively.

[0058] The power domain controller integrates seven controllers: the vehicle controller, the charging control unit, the motor controller, the main control board of the battery management unit, the on-board charger controller, the DC-DC converter controller, and the vehicle-to-charging station interconnection controller.

[0059] Specifically, this invention integrates seven controllers—the vehicle control unit (VCU), charging control unit (CCU), motor controller (MCU), main control board of battery management unit (BMS) (slave board located within the battery pack), on-board charger controller (OBC), DC-DC converter controller (DCDC), and vehicle-to-charging-initiative controller (VCIM)—into a single power domain controller. This power domain controller implements the functions of these seven controllers. The power domain controller comprises a power module, wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, control module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, insulation resistance detection module, level conversion module, isolation module, inverter, daisy-chain communication module, chopper module, resonant module, high-frequency rectification module, low-pass filter module, EMI filter module, power factor correction module, isolated DC-DC converter module, and output rectification and filtering module.

[0060] The control module is connected and communicates with the wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, and insulation resistance detection module via an on-board bus. The IGBT drive module is connected and communicates with the inverter via an on-board bus, and the inverter is electrically connected to the motor. The daisy-chain communication module communicates with the slave board of the solar panel. The battery pack, chopper module, resonant module, high-frequency rectifier module, low-pass filter module, and battery are connected in sequence. The chopper module, resonant module, high-frequency rectifier module, and low-pass filter module are connected via an on-board bus and supply power to the battery pack through the battery pack. The external power supply, EMI filter module, power factor correction module, isolated DC-DC module, output rectifier filter module, and battery pack are connected in sequence. The EMI filter module, power factor correction module, isolated DC-DC module, and output rectifier filter module are connected via an on-board bus and supply power to the battery pack through an external power supply for charging.

[0061] This invention integrates seven controllers—the vehicle controller, charging control unit, motor controller, main control board of the battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging interconnection controller—into a single power domain controller. This improves component reuse, reduces communication interactions between the original controllers, and results in a smaller and lighter vehicle, significantly saving space and weight. It also reduces communication signal interactions between the original controllers, greatly lowering the load on the communication network and ensuring more stable and reliable vehicle communication. Furthermore, it significantly reduces vehicle development costs, reduces corresponding hardwired connections, saves on controller mounting brackets, and reduces the need for multiple data acquisitions from each controller, lowering costs and space requirements while also making control more stable and reliable.

[0062] In one example, in the power domain controller, the power module allocates power to each module in the power domain controller according to the different power inputs of the vehicle system, and controls the power supply in POWERLATCH mode when the key is off; the wake-up module receives the wake-up signal and activates the corresponding module in the power domain controller based on the wake-up signal.

[0063] Specifically, the power module of this invention includes: an SBC system (electronic induction braking control system) circuit and a power supply conditioning circuit for each chip / circuit within the board; it can rationally allocate the power supply of the domain controller according to different power inputs of the vehicle system, such as the positive terminal of the battery, the ignition key power-on signal, and the voltage at the back end of the main relay, ultimately generating the power required by the microcontroller processing system, communication system, actuators, sensors, and all circuits within the domain controller. Simultaneously, it controls the power supply in POWERLATCH mode when the key is off. POWERLATCH mode typically refers to a power management or protection mechanism, mainly used to ensure the safe operation of electronic equipment under specific conditions. The wake-up module is mainly used to wake up the ignition key power-on signal, door opening wake-up signal, and signals such as CC, CP, CC2, and A+ required by national standard charging standards, as required by the vehicle system. Simultaneously, it needs to collect and detect each wake-up signal and implement circuit protection functions for charging inputs.

[0064] In one example, in the power domain controller,

[0065] The analog input module acquires and processes analog signals related to the power domain controller, and then sends the processed analog signals to the control module.

[0066] The digital input module acquires and processes digital signals related to the power domain controller, and then sends the processed digital signals to the control module.

[0067] The frequency input module acquires and processes the frequency signals related to the power domain controller, and then sends the processed frequency signals to the control module.

[0068] Specifically, the analog input module can acquire and process signals from the accelerator pedal sensor, brake signal sensor, thermal management-related temperature sensor, atmospheric pressure sensor, and other reserved resources, supporting the acquisition of various signal types such as 5V, 12V, NTC resistance signals, and Hall signals; the digital input module is used to acquire and process gear switch signals, mode selection switch signals, high-voltage interlock signals, charging wake-up signals, air conditioning switch signals, PTC switch signals, and other reserved signals, supporting the acquisition of high and low level signals; the frequency input module is used to acquire and process vehicle speed signals, collision signals, charging control signals, and other reserved signals, supporting the acquisition of 5V and 12V signals, and can identify frequency / duty cycle.

[0069] In one example, in the power domain controller,

[0070] The control module communicates with the vehicle system via a CAN communication module, which has a protection circuit.

[0071] The control module communicates with the vehicle system via Ethernet through the Ethernet communication module;

[0072] The control module uses the LIN communication module to assist in communication with CAN and Ethernet, as well as to perform data refresh and fault diagnosis. The LIN communication module has protection functions against short circuit to power supply and short circuit to ground.

[0073] The control module communicates with the charging pile via Bluetooth through the Bluetooth communication module;

[0074] The daisy-chain communication module communicates with the BMS slave board in the battery pack. The daisy-chain communication module has A and B bidirectional daisy-chain communication and reverse wake-up source identification functions.

[0075] Specifically, the CAN communication module enables communication and interaction with the vehicle, and also features protection circuitry; the Ethernet communication module facilitates Ethernet communication between the power domain controller and the vehicle system, supporting a communication rate of 100 Mbit / s; the LIN communication circuit, based on a serial communication protocol, supports a communication rate of 20 kbps, supports master / slave node communication protocols, supports remote wake-up, primarily provides data refresh and fault diagnosis functions, and also features short-circuit protection to power supply and short-circuit protection to ground; the Bluetooth communication module enables Bluetooth communication between the vehicle and the charging station, thus providing a communication loop for convenient functions between the vehicle and the charging station; and the daisy-chain communication module enables bidirectional daisy-chain communication between A and B, as well as reverse wake-up source identification, facilitating communication between the BMS master and slave boards.

[0076] In one example, in the power domain controller,

[0077] The control module performs wake-up drive output and BMS-related PWM high-side control output through the high-side drive module;

[0078] The control module controls fast and slow charging relays, thermal management relays, solenoid valves, and various indicator lights through the low-side drive module.

[0079] The control module controls the fast and slow charging locks via the H-bridge drive module;

[0080] The control module controls the inverter through the IGBT drive module;

[0081] The inverter converts the DC power supplied by the battery pack into AC power to supply the motor. The inverter includes a three-phase full-bridge inverter circuit and IGBTs.

[0082] Specifically, the high-side drive module is used for the wake-up drive output of the power domain controller, the high-side control output corresponding to the BMS-related PWM, etc., and adopts integrated drive chip control to reduce the increase in controller size caused by layout; the low-side drive circuit module is used for the control of fast and slow charging relays, thermal management related relays, solenoid valves and various indicator lights, etc., and supports ON / OFF and PWM type output; the H-bridge drive module is mainly used for the control of fast and slow charging locks; the IGBT drive module includes fault and diagnostic circuits, as well as drive board circuits, used to realize the control of the inverter; the inverter is mainly a three-phase full-bridge inverter circuit (including IGBTs (Insulated Gate Bipolar Transistors)), which converts the DC power provided by the battery pack into AC power to supply the motor.

[0083] In one example, the control module includes:

[0084] A 32-bit high-performance multi-core microcontroller and its minimum circuitry, and a 16-bit microcontroller;

[0085] The main control board of the vehicle controller, charging control unit, motor controller, battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging pile interconnection controller are implemented through a multi-core microcontroller.

[0086] Input monitoring is performed on some acquisition ports that do not require real-time performance using a 16-bit microcontroller;

[0087] A 32-bit high-performance multi-core microcontroller communicates with a 16-bit microcontroller via SPI.

[0088] Specifically, the control module includes a 32-bit high-performance multi-core microcontroller and its minimum circuit, as well as a low-performance 16-bit microcontroller. The 32-bit multi-core microcontroller mainly implements the acquisition of various input signals, actuator drive control, CAN / LIN / Ethernet communication, and control of logic such as motors, DC-DC converters, and OBCs (on-board chargers). The low-performance 16-bit microcontroller integrates a Bluetooth communication module and performs input monitoring for some acquisition ports with low real-time requirements. It also exchanges and shares information with the 32-bit multi-core microcontroller through SPI (Serial Peripheral Interface).

[0089] In one example, in the power domain controller,

[0090] The control module monitors the vehicle's high-voltage system by acquiring the DC bus voltage, charging voltage, and three-phase voltage from the high-voltage signal acquisition module.

[0091] The control module monitors the vehicle's high-voltage system by acquiring phase current through the phase current acquisition module;

[0092] The safety protection module prevents overload and short circuits in the power domain controller, protecting the vehicle's electrical system and electrical equipment.

[0093] The insulation resistance of the on-board rechargeable energy storage system and the positive and negative voltages to ground are detected by the insulation resistance detection module and transmitted to the control module.

[0094] Specifically, the high-voltage signal acquisition module is used for DC bus voltage acquisition, charging voltage acquisition, and three-phase voltage acquisition and monitoring, realizing the monitoring of relevant signals of the high-voltage system; the phase current acquisition module is used to acquire phase current, realizing the monitoring of relevant signals of the vehicle's high-voltage system; the safety protection module mainly consists of a microcontroller, a monitoring chip (SBC), redundant acquisition of key signals, signal safety threshold judgment, and actuator / output emergency shutdown processing circuit, which is used to improve the control stability of the power domain controller; the insulation resistance detection module is designed according to the insulation resistance detection method in the vehicle-mounted rechargeable energy storage system, and can accurately report the positive and negative voltages to ground.

[0095] In one example, in the power domain controller,

[0096] The output DC voltage of the battery pack is converted into a first DC voltage using a chopper module;

[0097] The first voltage DC current is processed by a resonant circuit to obtain sinusoidal AC current. The resonant circuit has electrical isolation and voltage regulation functions.

[0098] Pulsating direct current is obtained by rectifying sinusoidal alternating current through a high-frequency rectifier module;

[0099] The pulsating DC power is filtered by a low-pass filter module to obtain a smooth and stable DC voltage output to power the battery.

[0100] Specifically, the chopper module adopts a full-bridge inverter design, which converts the battery pack output voltage into the required output voltage; the resonant module adopts a transformer design, which can achieve both electrical isolation and voltage regulation, and performs secondary voltage reduction processing on the voltage generated by the chopper module to obtain sinusoidal AC power; the high-frequency rectifier module adopts a full-bridge rectifier design, which rectifies the sinusoidal AC power generated by the resonant module into pulsating DC power; the low-pass filter module is implemented using an R, C, L combination circuit, which is used to filter the pulsating DC power generated by the resonant module to obtain a smooth and stable DC voltage output to power the battery.

[0101] In one example, in the power domain controller,

[0102] The EMI filter module filters the external DC power input from the external power grid, eliminating the interference of high-frequency pulses from the external power grid on the internal power supply of the electric vehicle, while reducing electromagnetic radiation to a minimum.

[0103] The power factor correction module converts the filtered external DC voltage into a stable second voltage.

[0104] The second voltage is boosted by an isolated DC-DC module to obtain DC power that meets the voltage level of the battery pack;

[0105] The output voltage of the isolated DC-DC module is filtered by the output rectifier and filter module to obtain a stable output voltage to power the battery pack.

[0106] Specifically, the EMI filter module employs a two-stage EMI (electromagnetic interference) filter circuit to filter out high-frequency pulses from the external power grid that interfere with the internal power supply of the electric vehicle, while minimizing electromagnetic radiation. The power factor correction module uses an active PFC (power factor correction) design, which, through full-bridge rectification and highly integrated chips, converts the voltage obtained from the external power grid into a highly stable output voltage after filtering by the EMI filter module. The isolated DC-DC module uses a BOOST-type DC / DC converter to boost the stable voltage generated by the power factor correction module to achieve the voltage level required by the electric vehicle battery. The output filter module uses an R, C, L combination circuit to further filter the voltage generated by the isolated DC-DC module, obtaining a smooth and stable output voltage to power the battery pack.

[0107] In one example, in the power domain controller,

[0108] Isolation between high and low voltage signals within the power domain controller board is achieved by using isolation modules for communication and data acquisition isolation on both the high and low voltage sides.

[0109] The level conversion module converts different level signals within the power domain controller board to enable interaction between different level signals within the power domain controller board.

[0110] Specifically, the isolation module is used for communication isolation between high and low voltage sides (through a digital isolation chip) and acquisition isolation (through isolation of DC / DC step-up and step-down), mainly to achieve isolation between high and low voltage signals within the board; the level conversion module adopts an integrated chip design with multiple level conversion channels, each channel having a separate enable pin, to realize the interaction between different level signals within the power domain controller board.

[0111] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, but this is not intended to limit the invention. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the present invention can be combined with each other.

[0112] Example:

[0113] like Figure 2 As shown, this embodiment provides an electric vehicle power domain controller, including:

[0114] Power supply module, wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side driver module, low-side driver module, H-bridge driver module, control module ( Figure 2 The system includes: uC module, IGBT driver module, phase current acquisition module, high voltage signal acquisition module, resolver module, safety protection module, high voltage signal acquisition module, insulation resistance detection module, level conversion module, isolation module, inverter, daisy-chain communication module, chopper module, resonant module, high frequency rectification module, low-pass filter module, EMI filter module, power factor correction module, isolated DC-DC module, and output rectification and filtering module. Figure 2 Output rectification and filtering in the process;

[0115] The control module is connected to the wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, and insulation resistance detection module, respectively.

[0116] The power domain controller integrates seven controllers: the vehicle controller, the charging control unit, the motor controller, the main control board of the battery management unit, the on-board charger controller, the DC-DC converter controller, and the vehicle-to-charging station interconnection controller.

[0117] In the power domain controller, the power module rationally allocates the power to each module in the power domain controller according to the different power inputs of the whole vehicle system, and controls the power supply in POWERLATCH mode when the key is off; it receives the wake-up signal through the wake-up module and activates the corresponding module in the power domain controller based on the wake-up signal.

[0118] In the dynamic domain controller, analog signals related to the dynamic domain controller are acquired and processed through the analog input module, and the processed analog signals are sent to the control module; digital signals related to the dynamic domain controller are acquired and processed through the digital input module, and the processed digital signals are sent to the control module; frequency signals related to the dynamic domain controller are acquired and processed through the frequency input module, and the processed frequency signals are sent to the control module.

[0119] In the power domain controller, the control module communicates with the vehicle system via a CAN communication module, which has a protection circuit. The control module also communicates with the vehicle system via an Ethernet communication module. Furthermore, the control module uses a LIN communication module to assist in both CAN and Ethernet communication, as well as for data refresh and fault diagnosis. The LIN communication module provides protection against short circuits to power and ground. The control module communicates with the charging station via a Bluetooth communication module. Finally, it communicates with the BMS slave board within the battery pack via a daisy-chain communication module, which features bidirectional A / B daisy-chain communication and reverse wake-up source identification.

[0120] In the power domain controller, the control module performs wake-up drive output and high-side control output corresponding to BMS-related PWM through the high-side drive module; the control module performs fast and slow charging relay control, thermal management related relays, solenoid valves and various indicator lights control through the low-side drive module; the control module performs fast and slow charging lock control through the H-bridge drive module; the control module controls the inverter through the IGBT drive module; the inverter converts the DC power provided by the battery pack into AC power to supply the motor, and the inverter includes a three-phase full-bridge inverter circuit and IGBTs.

[0121] The control module includes: a 32-bit high-performance multi-core microcontroller and its minimum circuit, and a 16-bit microcontroller; the multi-core microcontroller implements the functions of the main control board of the vehicle controller, charging control unit, motor controller, battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging station interconnection controller; the 16-bit microcontroller monitors the input of some acquisition ports that do not require real-time performance; the 32-bit high-performance multi-core microcontroller communicates with the 16-bit microcontroller via SPI.

[0122] In the power domain controller, the control module monitors the vehicle's high-voltage system by acquiring DC bus voltage, charging voltage, and three-phase voltage through the high-voltage signal acquisition module; it also monitors the vehicle's high-voltage system by acquiring phase current through the phase current acquisition module; the safety protection module prevents overload and short circuits in the power domain controller, protecting the vehicle's electrical system and electrical equipment; and the insulation resistance detection module detects the insulation resistance of the on-board rechargeable energy storage system and the positive and negative voltages to ground, transmitting this information to the control module.

[0123] In the power domain controller, the DC output voltage of the battery pack is converted into a first voltage DC by a chopper module; the first voltage DC is processed by a resonant circuit to obtain sinusoidal AC, and the resonant circuit has electrical isolation and voltage regulation functions; the sinusoidal AC is rectified by a high-frequency rectifier module to obtain pulsating DC; the pulsating DC is filtered by a low-pass filter module to obtain a smooth and stable DC voltage output to power the battery.

[0124] In the power domain controller, the external DC power input from the external power grid is filtered by an EMI filter module to remove high-frequency pulses from the external power grid from interfering with the internal power supply of the electric vehicle, while minimizing electromagnetic radiation. The power factor correction module converts the filtered external DC power into a stable second voltage. The isolated DC-DC converter module boosts the second voltage to obtain DC power that meets the battery pack voltage level. The output rectifier filter module filters the voltage output from the isolated DC-DC converter module to obtain a stable output voltage to power the battery pack.

[0125] In the power domain controller, isolation modules are used to isolate communication and data acquisition between high and low voltage sides to achieve isolation between high and low voltage signals within the power domain controller board; and level conversion modules are used to convert different level signals within the power domain controller board to achieve interaction between different level signals within the power domain controller board.

[0126] The various embodiments of the present invention have been described above. These descriptions are exemplary and not exhaustive, nor are they limited to the disclosed embodiments. Many modifications and variations will be apparent to those skilled in the art without departing from the scope and spirit of the described embodiments.

Claims

1. An electric vehicle power domain controller, characterized by, include: Power supply module, wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, control module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, insulation resistance detection module, level conversion module, isolation module, inverter, daisy-chain communication module, chopper module, resonant module, high-frequency rectification module, low-pass filter module, EMI filter module, power factor correction module, isolated DC-DC module, and output rectification and filtering module; The control module is connected to the wake-up module, analog input module, digital input module, frequency input module, CAN communication module, Ethernet communication module, LIN communication module, Bluetooth communication module, high-side drive module, low-side drive module, H-bridge drive module, IGBT drive module, phase current acquisition module, high-voltage signal acquisition module, resolver module, safety protection module, high-voltage signal acquisition module, and insulation resistance detection module, respectively. The power domain controller integrates seven controllers: the vehicle controller, the charging control unit, the motor controller, the main control board of the battery management unit, the on-board charger controller, the DC-DC converter controller, and the vehicle-to-charging station interconnection controller. The control module includes: A 32-bit high-performance multi-core microcontroller and its minimum circuitry, and a 16-bit microcontroller; The multi-core microcontroller enables the functions of the main control board for the vehicle controller, charging control unit, motor controller, battery management unit, on-board charger controller, DC-DC converter controller, and vehicle-to-charging pile interconnection controller. The 16-bit microcontroller is used to monitor the inputs from some acquisition ports that do not require real-time performance. The 32-bit high-performance multi-core microcontroller communicates with the 16-bit microcontroller via SPI. In the power domain controller, The control module monitors the vehicle's high-voltage system by acquiring the DC bus voltage, charging voltage, and three-phase voltage from the high-voltage signal acquisition module. The control module monitors the vehicle's high-voltage system by acquiring phase current through the phase current acquisition module; The safety protection module prevents overload and short circuit in the power domain controller, thus protecting the safety of the vehicle's electrical system and electrical equipment. The insulation resistance detection module detects the insulation resistance of the on-board rechargeable energy storage system and the positive and negative voltages to ground, and transmits the data to the control module. In the power domain controller, The chopper module converts the DC output voltage of the battery pack into a first DC voltage. The resonant module processes the DC current of the first voltage to obtain sinusoidal AC current, and the resonant module has electrical isolation and voltage regulation functions. The sinusoidal alternating current is rectified by the high-frequency rectifier module to obtain pulsating direct current; The low-pass filter module filters the pulsating DC power to obtain a smooth and stable DC voltage output to power the battery. In the power domain controller, The EMI filter module filters the external DC power input from the external power grid, eliminating the interference of high-frequency pulses from the external power grid on the internal power supply of the electric vehicle, while reducing electromagnetic radiation to a minimum. The power factor correction module converts the filtered external DC voltage into a stable second voltage. The second voltage is boosted by an isolated DC-DC module to obtain DC power that meets the battery pack voltage level. The voltage output from the isolated DC-DC module is filtered by the output rectifier and filter module to obtain a stable output voltage to power the battery pack.

2. The electric vehicle power domain controller of claim 1, wherein, In the power domain controller, the power module rationally allocates the power to each module in the power domain controller according to the different power inputs of the vehicle system, and controls the power supply in POWERLATCH mode when the key is off; the wake-up module receives the wake-up signal and activates the corresponding module in the power domain controller based on the wake-up signal.

3. The electric vehicle power domain controller of claim 1, wherein, In the power domain controller, The analog input module acquires and processes analog signals related to the power domain controller, and then sends the processed analog signals to the control module. The digital input module acquires and processes digital signals related to the power domain controller, and then sends the processed digital signals to the control module. The frequency input module acquires and processes the frequency signals related to the power domain controller, and then sends the processed frequency signals to the control module.

4. The electric vehicle power domain controller of claim 1, wherein, In the power domain controller, The control module communicates with the vehicle system via the CAN communication module, and the CAN communication module has a protection circuit. The control module communicates with the vehicle system via Ethernet through the Ethernet communication module. The control module provides communication assistance for the CAN communication and the Ethernet communication through the LIN communication module, as well as performs data refresh and fault diagnosis. The LIN communication module has protection functions against short circuit to power supply and short circuit to ground. The control module communicates with the charging pile via Bluetooth through the Bluetooth communication module. The daisy-chain communication module communicates with the BMS slave board in the battery pack. The daisy-chain communication module has A and B bidirectional daisy-chain communication and reverse wake-up source identification functions.

5. The electric vehicle power domain controller of claim 1, wherein, In the power domain controller, The control module performs wake-up drive output and high-side control output corresponding to BMS-related PWM through the high-side drive module. The control module controls fast and slow charging relays, thermal management related relays, solenoid valves, and various indicator lights through a low-side drive module. The control module controls the fast and slow charging locks through the H-bridge drive module. The control module controls the inverter through the IGBT drive module; The inverter converts the DC power supplied by the battery pack into AC power to supply the motor. The inverter includes a three-phase full-bridge inverter circuit and IGBTs.

6. The electric vehicle power domain controller according to claim 1, characterized in that, In the power domain controller, The isolation module is used to isolate communication and data acquisition between high and low voltage sides to achieve isolation between high and low voltage signals within the power domain controller board. The level conversion module performs level conversion on different level signals within the power domain controller board to enable interaction between different level signals within the power domain controller board.

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