System and method for monitoring high voltage exposure hours of high voltage system of electric vehicle

Abstract

Methods and systems are provided for monitoring high voltage (HV) exposure hours of an HV system in an electric vehicle (EV). The predicted HV exposure hours are generated at one of a future vehicle age and a future EV range, and are based on the current HV exposure hours and the historical HV exposure hours. The current HV exposure hour and the historical HV exposure hour are based on the use of the battery system to power the vehicle propulsion load and at least one of the off-vehicle vehicle load and the on-board accessory load. When the predicted HV exposure hour is greater than the HV exposure hour threshold, an HV exposure hour alert associated with a limit related to power supply to at least one of the outside vehicle load and the on-board accessory load using the battery system is generated for display on a display device.

Description

[0001] The technical field generally relates to vehicles, and more particularly to systems and methods for monitoring high voltage exposure hours of a high voltage system in an electric vehicle. BACKGROUND OF THE INVENTION

[0002] An electric vehicle (EV) generally includes a rechargeable energy storage system (RESS) for powering electrical components that facilitate propulsion of the EV. An example of the RESS is a battery system. The battery system can include a battery pack, and the battery pack includes one or more battery modules. Each battery module can include a plurality of battery cells. In addition to providing power for propulsion of the EV, the battery system can also be used to power on-vehicle accessory loads of the EV. An example of an on-vehicle accessory load is a connected camera. When the EV is stationary, the battery system can also be used to power off-vehicle loads of the vehicle. The battery system is operatively coupled to the HV system. The HV system enables the battery system to supply power to a propulsion load, an on-vehicle accessory load, and an off-vehicle load of the vehicle.

[0003] Examples of off-vehicle loads of the vehicle include vehicle-to-grid (V2G), vehicle-to-home (V2H), vehicle-to-vehicle (V2V), vehicle-to-load (V2L), power take-off (PTO), and electronic PTO. Off-vehicle loads of the vehicle can be collectively referred to as vehicle-to-X (V2X) loads. The ability to supply power to V2X loads enables the EV to operate both as a transportation mode and as a power source. However, the service life of the HV system may be affected by using the battery system to supply power to an on-vehicle accessory load and / or an off-vehicle load of the vehicle in addition to a propulsion load. The evaluation of the HV system related to the HV system warranty generally does not identify the impact of supplying power to an on-vehicle accessory load and / or an off-vehicle load of the vehicle.

[0004] Accordingly, it is desirable to provide improved methods and systems for monitoring high voltage exposure hours of a high voltage system, which are based on using the battery system to supply power to an on-vehicle accessory load and / or an off-vehicle load of the vehicle in addition to a propulsion load. Other desirable features and characteristics will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. SUMMARY OF THE INVENTION

[0005] In various embodiments, a high-voltage (HV) exposure hour monitoring system for an electric vehicle (EV) includes at least one processor and at least one memory communicatively coupled to the at least one processor. The at least one memory includes instructions that, when executed by the at least one processor, cause the at least one processor to: generate predicted HV exposure hours of the EV's HV system at one of a future vehicle age and a future EV mileage, wherein: the HV system is operatively coupled to the EV's battery system and is configured to enable power supply from the battery system to at least one of a propulsion load and an off-vehicle load and an on-vehicle accessory load; the predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours of the HV system; and the current HV exposure hours and the historical HV exposure hours are based on using the battery system to supply power to at least one of a propulsion load and an off-vehicle load and an on-vehicle accessory load; determine whether the predicted HV exposure hours are greater than an HV exposure hour threshold at one of a future vehicle age and a future EV mileage; and based on the determination, generate an HV exposure hour alert associated with a limit related to using the battery system to supply power to at least one of an off-vehicle load and an on-vehicle accessory load for display on a display device of the EV.

[0006] In at least one embodiment, the HV exposure hour threshold is a first HV exposure hour threshold, and the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: based on a determination that the predicted HV exposure hours are greater than the first HV exposure hour threshold; disable the ability of the battery system to supply power to all loads of at least one of an off-vehicle load and an on-vehicle accessory load; and generate an HV exposure hour alert that includes a first notification that the ability of the battery system to supply power to all loads of at least one of an off-vehicle load and an on-vehicle accessory load has been disabled.

[0007] In at least one embodiment, the HV exposure hour threshold is a first HV exposure hour range between a first HV exposure hour threshold and a second HV exposure hour threshold, the second HV exposure hour threshold being less than the first HV exposure hour threshold; and based on a determination that a predicted HV exposure hour falls within the first HV exposure hour threshold range, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: limit the amount of power that can be supplied by the battery system to at least a first subset of an off-vehicle vehicle load and an on-vehicle accessory load; disable the ability of the battery system to supply power to at least a second subset of the off-vehicle vehicle load and the on-vehicle accessory load; and generate an HV exposure hour alert that includes a second notification that the amount of power that can be supplied by the battery system to at least a first subset of an off-vehicle vehicle load and an on-vehicle accessory load has been limited and the ability of the battery system to supply power to at least a second subset of the off-vehicle vehicle load and the on-vehicle accessory load has been disabled.

[0008] In at least one embodiment, the HV exposure hour threshold is a second HV exposure hour threshold range between a second HV exposure hour threshold and a third HV exposure hour threshold, the third HV exposure hour threshold being less than the second HV exposure hour threshold; and based on a determination that a predicted HV exposure hour falls within the second HV exposure hour threshold range, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: recommend limiting the use of the battery system to supply power to at least one of the off-vehicle vehicle load and the on-vehicle accessory load; limit the amount of power that can be supplied by the battery system to at least a third subset of the off-vehicle vehicle load and the on-vehicle accessory load; and generate an HV exposure hour alert that includes a third notification to recommend limiting the use of the battery system to supply power to at least one of the off-vehicle vehicle load and the on-vehicle accessory load and that the amount of power that can be supplied to at least a third subset of the off-vehicle vehicle load and the on-vehicle accessory load has been limited.

[0009] In at least one embodiment, the HV exposure hour threshold is a third HV exposure hour threshold range between a third HV exposure hour threshold and a fourth HV exposure hour threshold, the fourth HV exposure hour threshold being less than the third HV exposure hour threshold; and based on a determination that a predicted HV exposure hour falls within the third HV exposure hour threshold range, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to generate an HV exposure hour alert that includes a fourth notification to recommend limiting the use of the battery system to supply power to at least one of the off-vehicle vehicle load and the on-vehicle accessory load.

[0010] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate predicted HV exposure hours at a future vehicle age, wherein the predicted HV exposure hours are based on current HV exposure hours and historical predicted HV exposure hours corresponding to historical vehicle ages; and determine whether the predicted HV exposure hours are greater than an HV exposure hour threshold at the future vehicle age.

[0011] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to generate predicted HV exposure hours at a future vehicle age, wherein the predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours corresponding to historical vehicle ages within a predefined vehicle age window.

[0012] In at least one embodiment, the future vehicle age is the vehicle age warranty.

[0013] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate predicted HV exposure hours at a future EV mileage, wherein the predicted HV exposure hours are based on current HV exposure hours at the current EV mileage and historical HV exposure hours corresponding to historical EV mileages; and determine whether the predicted HV exposure hours are greater than an HV exposure hour threshold at the future EV mileage.

[0014] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to generate predicted HV exposure hours at a future EV mileage, wherein the predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours corresponding to historical EV mileages within a predefined EV mileage window.

[0015] In at least one embodiment, the future EV mileage is the vehicle warranty mileage.

[0016] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: determine current HV exposure hours; determine current vehicle age; determine current EV mileage; and use a predefined relationship among HV exposure hours, vehicle age, EV mileage, and an HV exposure hour threshold to identify an HV exposure hour threshold associated with the current HV exposure hours, current vehicle age, and current EV mileage.

[0017] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate a first predicted HV exposure hour at a future vehicle age, wherein the first predicted HV exposure hour is based on a current HV exposure hour and historical HV exposure hours corresponding to historical vehicle ages; generate a second predicted HV exposure hour at a future EV mileage, wherein the second predicted HV exposure hour is based on the current HV exposure hour and historical HV exposure hours corresponding to historical EV mileages; determine whether both the first predicted HV exposure hour and the second predicted HV exposure hour are greater than an HV exposure hour threshold; and generate an HV exposure hour alert based on the determination.

[0018] In at least one embodiment, at least one of the in-vehicle accessory loads includes a connected camera system.

[0019] In at least one embodiment, the off-vehicle vehicle load includes at least one of vehicle-to-grid (V2G), vehicle-to-home (V2H), vehicle-to-vehicle (V2V), vehicle-to-load (V2L), power take-off (PTO), and electronic PTO.

[0020] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate a predicted HV exposure hour at one of a future vehicle age and a future EV mileage, wherein: the predicted HV exposure hour is based on a current HV exposure hour and historical HV exposure hours; and the current HV exposure hour and the historical HV exposure hours are at least partially based on powering at least one of the off-vehicle vehicle load and the in-vehicle accessory load using a battery system; generate another predicted HV exposure hour at one of a future vehicle age and a future total EV mileage, wherein the another predicted HV exposure hour is based on ceasing to power at least one of the off-vehicle vehicle load and the in-vehicle accessory load using the battery system; determine whether the predicted HV exposure hour is greater than the HV exposure hour threshold and the another predicted HV exposure hour is less than the HV exposure hour threshold; and generate an HV exposure hour alert based on the determination.

[0021] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate a predicted number of cycles of an HV contactor at one of a future vehicle age and a future EV mileage, wherein: the HV system is operably coupled to the battery system via the HV contactor; the predicted number of cycles is based on a current number of cycles and a historical number of cycles; and the current number of cycles and the historical number of cycles are based on the closing of the HV contactor to enable the battery system to supply power to at least one of a propulsion load and an off-vehicle vehicle load and an on-vehicle accessory load; determine whether the predicted number of cycles is greater than a cycle threshold at one of the future vehicle age and the future EV mileage; and based on the determination, generate a cycle alert associated with a limitation related to using the battery system to supply power to at least one of the off-vehicle vehicle load and the on-vehicle accessory load for display on a display device of the EV.

[0022] In at least one embodiment, at least one memory includes further instructions that, when executed by at least one processor, cause the at least one processor to: generate a current HV exposure hour based on a sum of durations for which the HV contactor has been closed during HV cycles; and generate each historical HV exposure hour based on a sum of durations for which the HV contactor has been closed at each historical vehicle age.

[0023] In various embodiments, a method for monitoring high voltage (HV) exposure hours of an electric vehicle (EV) includes: generating a predicted HV exposure hour of an HV system of the EV at one of a future vehicle age and a future EV mileage, wherein: the HV system is operably coupled to a battery system of the EV and is configured to enable power to be supplied from the battery system to at least one of a propulsion load and an off-vehicle vehicle load and an on-vehicle accessory load; the predicted HV exposure hour is based on a current HV exposure hour and a historical HV exposure hour of the HV system; and the current HV exposure hour and the historical HV exposure hour are based on using the battery system to supply power to at least one of the propulsion load and the off-vehicle vehicle load and the on-vehicle accessory load; determining whether the predicted HV exposure hour is greater than an HV exposure hour threshold at one of the future vehicle age and the future EV mileage; and based on the determination, generating an HV exposure hour alert associated with a limitation related to using the battery system to supply power to at least one of the off-vehicle vehicle load and the on-vehicle accessory load for display on a display device of the EV.

[0024] In various embodiments, an electric vehicle (EV) includes at least one processor; and at least one memory communicatively coupled to the at least one processor. The at least one memory includes instructions that, when executed by the at least one processor, cause the at least one processor to: generate a predicted HV exposure hour of an HV system of the EV at one of a future vehicle age and a future EV mileage, wherein: the HV system is operatively coupled to a battery system of the EV and is configured to enable power supply from the battery system to at least one of a propulsion load and an off-vehicle load and an on-vehicle accessory load outside the vehicle; the predicted HV exposure hour is based on a current HV exposure hour and a historical HV exposure hour of the HV system; and the current HV exposure hour and the historical HV exposure hour are based on using the battery system to supply power to at least one of a propulsion load and an off-vehicle load and an on-vehicle accessory load outside the vehicle; determine whether the predicted HV exposure hour is greater than an HV exposure hour threshold at one of the future vehicle age and the future EV mileage; and based on the determination, generate an HV exposure hour alert associated with a limit related to using the battery system to supply power to at least one of an off-vehicle load and an on-vehicle accessory load outside the vehicle for display on a display device of the EV. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Exemplary embodiments will be described below in conjunction with the following drawings, where the same numbers represent the same elements, and where:

[0026] Figure 1 is a functional block diagram of a system including an electric vehicle (EV) according to at least one embodiment, the electric vehicle including a high-voltage (HV) exposure hour monitoring system;

[0027] Figure 2 illustrates an example of an interface for controlling power supplied to various off-vehicle loads according to at least one embodiment;

[0028] Figure 3 is a functional block diagram of an EV including an HV exposure hour monitoring system according to at least one embodiment;

[0029] Figure 4 is a flowchart representation of a method for monitoring HV exposure hours as a function of vehicle age according to at least one embodiment;

[0030] Figure 5 is a flowchart representation of a method for monitoring HV exposure hours as a function of EV mileage according to at least one embodiment;

[0031] Figure 6 is an exemplary graphical illustration of the relationship between the HV exposure hours of an EV as a function of the vehicle age of the EV and an HV exposure hour threshold according to at least one embodiment;

[0032] Figure 7 is an exemplary graphical illustration of the relationship between HV exposure hours for an EV as a function of EV range relative to a HV exposure hour threshold according to at least one embodiment;

[0033] Figure 8 is a flowchart representation of a method of generating HV exposure hour alerts associated with different HV exposure hour thresholds according to at least one embodiment; and

[0034] Figure 9 is an exemplary graphical illustration of a predefined relationship between HV exposure hours, vehicle age, EV mileage, and HV exposure hours threshold according to at least one embodiment. Specific implementation method

[0035] The following detailed description is merely exemplary in nature and is not intended to limit application and use. In addition, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background technology, inventive content, or the following detailed description. As used herein, the term module refers to an application-specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that executes one or more software or firmware programs, a combinational logic circuit, and / or other suitable components that provide the described functionality.

[0036] Embodiments of the present disclosure may be described herein in terms of functional and / or logical block components and various processing steps. It should be understood that such block components may be implemented by any number of hardware, software, and / or firmware components configured to perform the specified functions. For example, embodiments of the present disclosure may employ various integrated circuit components, such as memory elements, digital signal processing elements, logic elements, lookup tables, etc., which may perform various functions under the control of one or more microprocessors or other control devices. In addition, those skilled in the art will understand that embodiments of the present disclosure may be practiced in conjunction with any number of systems, and that the systems described herein are merely exemplary embodiments of the present disclosure.

[0037] For the sake of brevity, conventional techniques related to signal processing, data transmission, signaling, control, and other functional aspects of the systems (and the individual operating components of the systems) may not be described in detail herein. In addition, the connecting lines shown in the various figures contained herein are intended to represent example functional relationships and / or physical couplings between the various elements. It should be noted that many alternative or additional functional relationships or physical connections may exist in embodiments of the present disclosure.

[0038] References Figure 1, shows a functional block diagram of a system including an electric vehicle (EV) 110 according to at least one embodiment. The electric vehicle includes a high-voltage (HV) exposure hour monitoring system 144. The EV 110 includes a battery system 112. An example of the battery system 112 is a battery pack such as a high-voltage (HV) battery. The EV 110 includes a powertrain 114 that includes an electric motor, a gearbox, and / or a differential to propel one or more wheels 116 of the EV 110. A utility 118 or other power source supplies power to an electric vehicle supply equipment (EVSE) 122. In various embodiments, the EVSE 122 supplies power from the utility 118 to an on-board charging module (OBCM) 126 that controls charging of the battery system 112. In various embodiments, direct current (DC) fast charging (DCFC) is used and the OBCM 126 is bypassed.

[0039] During driving, the battery system 112 supplies power to the powertrain 114 via a power inverter module 130 to propel one or more wheels 116 of the EV 110. The battery system 112 also supplies power to on-board accessory loads 132. An example of an on-board accessory load is a connected camera system. In at least one embodiment, the battery system 112 can also be used to supply power to off-vehicle loads 136 (also referred to as V2X components or V2X loads). Examples of off-vehicle loads 136 include, but are not limited to, vehicle-to-grid (V2G), vehicle-to-home (V2H), vehicle-to-vehicle (V2V), vehicle-to-load (V2L), power take-off (PTO), and electronic PTO. The EV 110 can operate both as a power source and as a transportation mode.

[0040] One or more sensors 138, such as current and / or voltage sensors, sense the power output by the battery system 112 to the powertrain 114, the on-board accessory loads 132, and / or the off-vehicle loads 136. In various embodiments, the controller 140 includes the HV exposure hour monitoring system 144. The controller 140 receives the output from one or more sensors 138. The HV system is operably coupled to the battery system 112 of the EV 110 and is configured to enable power to be supplied from the battery system 112 to the propulsion load, the on-board accessory loads 132, and the off-vehicle loads 136. For example, the HV system can include a power inverter module 130 and a power converter 175. An example of a propulsion load is the powertrain 114. The HV exposure hours are based on using the battery system 112 to supply power to the propulsion load, the accessory loads 132, and the off-vehicle loads 136. The HV system is operably coupled to the battery system 112 via an HV contactor.

[0041] The interface 148 includes display and input devices (such as buttons or touchscreens), such as a dashboard display or an infotainment display. The display shows the HV exposure hour alert, HV exposure hour data, and notifications associated with the HV exposure hours. The interface 148 allows the customer to change settings that control the power supplied to the off-vehicle load 136 and / or the on-vehicle accessory load 132. An example of the on-vehicle accessory load 132 is a connected camera. In various embodiments, the interface 148 enables the customer to selectively deactivate, limit, or disable the EV 110 from powering the off-vehicle load 136 and / or the on-vehicle accessory load 132. The telematics system 160 can be used to wirelessly communicate with a remote server to exchange information associated with the HV exposure hours and the manufacturer's warranty information, and / or setting changes, limitations, and / or manufacturer recommendations.

[0042] In various embodiments, when the HV exposure hour monitoring system 144 determines that the HV exposure hours are high enough to indicate that the HV system may be degrading at a rate that could invalidate the warranty associated with the HV, an HV exposure hour alert is provided via the interface 148, recommending limiting the use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. In various embodiments, when the HV exposure hour monitoring system 144 determines that the HV exposure hours are high enough to indicate that the HV system may be degrading at a rate that could invalidate the warranty associated with the HV, a disable option is provided via the interface 148 to disable the ability of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. In various embodiments, when the HV exposure hour monitoring system 144 determines that the HV exposure hours are high enough to indicate that the HV system may be degrading at a rate that could invalidate the warranty associated with the HV, the ability to use the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 is automatically disabled.

[0043] In various embodiments, the EV 110 includes a vehicle V2X interface 171 configured to exchange information with an external V2X interface 173 of an out-of-vehicle vehicle load 136. In various embodiments, a power converter 175 converts the power output by the battery system 112 for use by the out-of-vehicle vehicle load 136. In various embodiments, the power converter 175 is arranged on the vehicle side of the EV 110. In various embodiments, the exchanged information includes an identification of the type of the out-of-vehicle vehicle load 136, the required power, and / or other information. The controller 140 and the interface 148 are configured to set an activation / deactivation state for powering various types of out-of-vehicle vehicle loads 136 from the battery system 112, and / or set a limit for power supply within a predetermined period (e.g., one or more hours, days, weeks, months, years, other periods). In various embodiments, the manufacturer may override customer settings associated with the battery system 112 based on HV exposure hours and / or provide recommendations that can be used as defaults or selected by the customer.

[0044] Reference Figure 2 , a display interface 200 is shown that a customer can access via an infotainment system, a dashboard, or other devices for setting an activation / deactivation state for powering the out-of-vehicle vehicle load 136. The display interface 200 allows the customer to select and adjust out-of-vehicle vehicle loads 210, an activation / deactivation state 214 of the out-of-vehicle vehicle load 210, and / or a daily power limit 218 for each out-of-vehicle vehicle load 136. In some examples, a recommended limit for each out-of-vehicle vehicle load by the manufacturer is provided at 222. In some examples, the customer can use an input 230 such as a checkbox to select the manufacturer-recommended daily limit. Additionally, the manufacturer may override the user selection by disabling an optional activation / deactivation state 214 of the out-of-vehicle vehicle load 210 and / or remotely setting other daily power limits 218 for each out-of-vehicle vehicle load based on the SOH of the battery system 112, the predicted SOH of the battery system 112, the total EV mileage, the virtual EV mileage, and / or the driving EV mileage.

[0045] Reference Figure 3 , a functional block diagram of an EV including an HV exposure hour monitoring system 144 according to at least one embodiment is shown. The EV 110 includes a controller 140. The controller 140 includes at least one processor 300 and at least one memory 302. The at least one processor 300 is communicatively coupled to the at least one memory 302. The at least one processor 300 is a programmable device that includes one or more instructions stored in or associated with the at least one memory 302. The at least one memory 302 includes instructions that the processor 300 is configured to execute.

[0046] At least one memory 302 is a computer-readable storage device or medium. At least one processor 300 can be any custom or commercially available processor, a central processing unit (CPU), a graphics processing unit (GPU), a secondary processor among several processors, a semiconductor-based microprocessor (in the form of a microchip or chipset), a macroprocessor, any combination thereof, or any device generally used to execute instructions. For example, the computer-readable storage device or medium can include volatile and non-volatile storage in a read-only memory (ROM), random access memory (RAM), and keep-alive memory (KAM). KAM is persistent or non-volatile memory that can be used to store various operating variables when the processor 300 is powered down. The computer-readable storage device or medium can be implemented using any of a number of known memory devices, such as PROM (programmable read-only memory), EPROM (electrical PROM), EEPROM (electrically erasable PROM), flash memory, or any other electrical, magnetic, optical, or combination memory device capable of storing data, some of which represents executable instructions used by the HV exposure hour monitoring system 144. The instructions can include one or more separate programs, each program including an ordered list of executable instructions for implementing a logical function. When executed by the processor 300, the instructions perform the logic, calculations, methods, and / or algorithms for implementing the monitoring of the HV exposure hours of the HV system of the EV 110.

[0047] Reference Figure 4 , a flowchart representation of a method 400 for monitoring HV exposure hours as a function of vehicle age is shown according to at least one embodiment. Method 400 will be described with reference to an exemplary implementation of the HV exposure hour monitoring system 144. It will be understood from the present disclosure that the order of operations within method 400 is not limited to being executed in the order shown in Figure 4 but can be executed in one or more variant orders, where applicable and in accordance with the present disclosure.

[0048] At 402, the current HV exposure hours are calculated by the HV exposure hour monitoring system 144. The HV contactor operably couples the battery system 112 to the HV system. The HV system includes a plurality of HV components. Examples of HV components include, but are not limited to, an inverter, a refrigerant compressor, a resistance heater, and a charging module. The battery system 112 is operably coupled to the HV system via the HV contactor. The HV contactor can be placed in an open state or a closed state. When the battery system 112 is used to power a propulsion load, an on-vehicle vehicle accessory load 132, and / or an off-vehicle vehicle load 136, the HV contactor providing the operable coupling between the battery system 112 and the load is placed in the closed state. When the battery system 112 is not used to power a propulsion load, an on-vehicle vehicle accessory load 132, and / or an off-vehicle vehicle load 136, the HV contactor providing the operable coupling between the battery system 112 and the load is placed in the open state. When all HV contactors are placed in the open state, the propulsion load, the on-vehicle vehicle accessory load 132, and / or the off-vehicle vehicle load 136 are de-energized and isolated from the battery system 112. A cycle includes the HV contactor being placed in the open state and then being placed in the closed state. In at least one embodiment, the current HV exposure hours are the sum of the durations that the HV contactor has been closed during HV cycles during a predefined vehicle age window. In at least one embodiment, the predefined vehicle age window extends from when the vehicle age of the EV 110 is zero to the current vehicle age of the EV 110.

[0049] At 404, historical HV exposure hours are retrieved by the HV exposure hour monitoring system 144. HV exposure hours are calculated periodically at different vehicle ages of the EV 110. For example, the period can be daily, every few days, every few months, or annually. Each of these times represents a different vehicle age of the EV 110. The HV exposure hours are maintained by the HV exposure hour monitoring system 144. In at least one embodiment, the HV exposure hour monitoring system 144 retrieves all historical HV exposure hours starting from when the vehicle age is zero. In at least one embodiment, the HV exposure hour monitoring system 144 retrieves historical HV exposure hours that fall within a predefined vehicle age window. In various embodiments, the HV exposure hours are related to the usage of the EV 110. If the EV 110 is leased, the first lease owner and the second vehicle owner may have different usage trends of the EV 110, resulting in different HV exposure hour accumulation rates. Using the predefined vehicle age window enables filtering out the previous customer usage of the EV 110 (e.g., the first lease owner's usage). For example, the first two years of the vehicle age may correspond to the lease period. The predefined window can extend from two years of vehicle age to the current vehicle age. This predefined vehicle age window provides the HV exposure hour accumulation of the second vehicle owner by filtering out the HV exposure hour accumulation of the first lease owner. The HV exposure hour monitoring system 144 uses the historical HV exposure hours starting from the end of the lease period and extending to the current vehicle age. In various embodiments, the predefined vehicle age window can be a moving window through the vehicle age time domain. The predefined vehicle age window is a fixed time period that moves through the vehicle age time domain.

[0050] At 406, predicted HV exposure hours are generated at future vehicle ages based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. For example, the HV system may have a vehicle age warranty of 8 years specified by the manufacturer. Predicted HV exposure hours are generated at the 8-year vehicle age warranty based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. The vehicle age warranty is used as the future vehicle age. The predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 are based on the current HV exposure hours and the historical HV exposure hours.

[0051] At 408, predicted HV exposure hours are generated at future vehicle ages based on stopping using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132.

[0052] At 410, the predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 are compared with a plurality of different HV exposure hour thresholds. In various embodiments, the predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 and the predicted HV exposure hours based on ceasing to use the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 are compared with a plurality of different HV exposure hour thresholds.

[0053] At 412, based on the comparison, one of a plurality of different HV exposure hour alerts associated with a limit related to using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 is generated for display on the interface 148 of the EV 110. The different HV exposure hour thresholds and the associated HV exposure hour alerts will be described in more detail below.

[0054] Reference Figure 5 , shows a flowchart representation of a method 500 for monitoring HV exposure hours as a function of EV mileage according to at least one embodiment. Method 500 will be described with reference to an exemplary implementation of the HV exposure hour monitoring system 144. It will be understood from the present disclosure that the order of operations within method 500 is not limited to being performed in the order shown in Figure 5 but may be performed in one or more varied orders, where applicable and in accordance with the present disclosure.

[0055] At 502, the current HV exposure hours are calculated by the HV exposure hour monitoring system 144. The HV contactor operably couples the battery system 112 to the HV system. The HV system includes a plurality of HV components. Examples of HV components include, but are not limited to, an inverter, a refrigerant compressor, a resistive heater, and a charging module. The battery system 112 is operably coupled to the HV system via the HV contactor. The HV contactor can be placed in an open state or a closed state. When the battery system 112 is used to power a propulsion load, an on-vehicle vehicle accessory load 132, and / or an off-vehicle vehicle load 136, the HV contactor providing the operable coupling between the battery system 112 and the load is placed in the closed state. When the battery system 112 is not used to power a propulsion load, an on-vehicle vehicle accessory load 132, and / or an off-vehicle vehicle load 136, the HV contactor providing the operable coupling between the battery system 112 and the load is placed in the open state. When all HV contactors are placed in the open state, the propulsion load, the on-vehicle vehicle accessory load 132, and / or the off-vehicle vehicle load 136 are de-energized and isolated from the battery system 112. A cycle includes the HV contactor being placed in the open state and then being placed in the closed state. In at least one embodiment, the current HV exposure hours are the sum of the durations that the HV contactor has been closed during HV cycles during a predefined EV mileage window. In at least one embodiment, the predefined time period extends from when the EV mileage is zero to the current EV vehicle mileage.

[0056] At 504, historical HV exposure hours are retrieved by the HV exposure hour monitoring system 144. HV exposure hours are calculated periodically at different EV mileages. For example, the period can be every predefined number of EV miles. For example, HV exposure hours can be calculated every 1000 EV miles. The HV exposure hour monitoring system 144 maintains the HV exposure hours. In at least one embodiment, the HV exposure hour monitoring system 144 retrieves all historical HV exposure hours starting from when the EV mileage is zero. In at least one embodiment, the HV exposure hour monitoring system 144 retrieves historical HV exposure hours that fall within a predefined EV mileage window. In various embodiments, the HV exposure hours are related to the use of the EV 110. If the EV 110 is leased, the first lease owner and the second vehicle owner may have different EV 110 usage trends, resulting in different HV exposure hour accumulation rates. Using the predefined EV mileage window enables filtering out the previous customer usage of the EV 110 (e.g., the first lease owner's usage). For example, the first 24,000 miles of the EV mileage may correspond to the lease period. The predefined window can extend from 24,000 miles of EV mileage to the current EV mileage. The predefined EV mileage window provides the HV exposure hour accumulation for the second vehicle owner by filtering out the HV exposure hour accumulation of the first lease owner. The HV exposure hour monitoring system 144 uses the historical HV exposure hours starting from the end of the lease mileage and extending to the current EV mileage. In various embodiments, the predefined EV mileage window can be a moving window through the EV mileage distance domain. The predefined EV mileage window is a fixed EV mileage that moves through the EV mileage distance domain.

[0057] At 506, predicted HV exposure hours are generated at future EV mileages based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. For example, the HV system may have a vehicle mileage warranty of 100,000 miles specified by the manufacturer. Predicted HV exposure hours are generated at the 100,000-mile vehicle mileage warranty based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132. The vehicle mileage warranty is used as the future EV mileage. The predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 are based on the current HV exposure hours and the historical HV exposure hours.

[0058] At 508, predicted HV exposure hours are generated at future EV mileages based on stopping using the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132.

[0059] At 510, the predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 are compared with a plurality of different HV exposure hour thresholds. In various embodiments, the predicted HV exposure hours based on continuously using the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 and the predicted HV exposure hours based on ceasing to use the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 are compared with a plurality of different HV exposure hour thresholds.

[0060] At 512, based on the comparison, one of a plurality of different HV exposure hour alerts associated with a limit related to using the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 is generated for display on the interface 148 of the EV 110. The different HV exposure hour thresholds and the associated HV exposure hour alerts will be described in more detail below.

[0061] Reference Figure 6 , shows an exemplary graphical illustration of the relationship between the HV exposure hours of the EV 110 as a function of the vehicle age of the EV 110 and the HV exposure hour threshold according to at least one embodiment. The future vehicle age of 8 years is the vehicle age warranty of the EV 110. If the HV exposure hours exceed the HV exposure hour threshold before the expiration of the 8-year vehicle age warranty, the warranty of certain HV components may be at risk. When the EV 110 is within the warranty period, the predicted HV exposure hours exceeding the HV exposure hour threshold may expose the HV system components to a greater risk of failure. This may increase the risk of warranty claims due to HV component failures. Due to the increased risk of HV component failures and the resulting warranty costs, it is desirable to limit non-propulsion functions (e.g., the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132) when the predicted HV exposure hours exceed the HV exposure hour threshold.

[0062] The dots represent data points of HV exposure hours, including the current HV exposure hours and the historical HV exposure hours. The squares represent the predicted HV exposure hours at a future vehicle age of 8 years based on continuously using the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load. The predicted HV exposure hours at a future vehicle age of 8 years based on continuously using the battery system 112 to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load are greater than the HV exposure hour threshold. Since the predicted HV exposure hours exceed the HV exposure hour threshold before the expiration of the 8-year vehicle age warranty, the warranty of certain HV components may be at risk as the battery system 112 continues to be used to power the off-vehicle vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load.

[0063] The triangle represents the predicted HV exposure hours based on the discontinued use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 at an 8-year future vehicle age. The predicted HV exposure hours based on the discontinued use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 at an 8-year future vehicle age remain below the HV exposure hour threshold. Since the predicted HV exposure remains below the HV exposure hour threshold before the expiration of the 8-year vehicle age warranty, an HV exposure hour alert will be generated, recommending discontinuing the use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132, so that the HV system remains functional throughout the warranty period.

[0064] Reference Figure 7 , shows an exemplary graphical illustration of the relationship between the HV exposure hours of the EV 110 as a function of the EV mileage and the HV exposure hour threshold according to at least one embodiment. The 100,000-mile future EV mileage is the vehicle mileage warranty of the EV110. If the HV exposure hours exceed the HV exposure hour threshold before the expiration of the 100,000-mile vehicle mileage warranty, the warranty of some HV components may be at risk.

[0065] The dots represent the current HV exposure hours and the historical HV exposure hours. The square represents the predicted HV exposure hours based on the continued use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load at a 100,000-mile future EV mileage. The predicted HV exposure hours based on the continued use of the battery system 112 to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load at a 100,000-mile future EV mileage are greater than the HV exposure hour threshold. Since the predicted HV exposure hours exceed the HV exposure hour threshold before the expiration of the 100,000-mile vehicle mileage warranty, the warranty will become invalid as the battery system 112 continues to power the off-vehicle load 136 and / or the on-vehicle accessory load 132 in addition to the propulsion load.

[0066] The triangle represents the predicted HV exposure hours based on the battery system 112 being out of service to supply power to the off-vehicle load 136 and / or the on-vehicle accessory load 132 at a future EV mileage of 100,000 miles. The predicted HV exposure hours based on the battery system 112 being out of service to supply power to the off-vehicle load 136 and / or the on-vehicle accessory load 132 at a future EV mileage of 100,000 miles remain below the HV exposure hour threshold. Since the predicted HV exposure remains below the HV exposure hour threshold before the expiration of the vehicle mileage warranty at 100,000 miles, an HV exposure hour alert will be generated, recommending that the battery system 112 be out of service to supply power to the off-vehicle load 136 and / or the on-vehicle accessory load 132, so that the HV system remains within warranty throughout the warranty period.

[0067] Reference Figure 8 , shows a flowchart representation of a method 800 for generating HV exposure hour alerts associated with different HV exposure hour thresholds. The method 800 will be described with reference to an exemplary implementation of the HV exposure hour monitoring system 144. It can be understood from the present disclosure that the order of operations within the method 800 is not limited to being executed in the order shown in Figure 8 but can be executed in one or more variant orders, where applicable and in accordance with the present disclosure.

[0068] At 802, based on the determination that the predicted HV exposure hours are greater than the first HV exposure hour threshold, the HV exposure hour monitoring system 144: disables the ability of the battery system to supply power to all off-vehicle loads 136 and on-vehicle accessory loads 132, and generates an HV exposure hour alert including a first notification for display on the interface 148 of the EV 110. The first notification indicates that the ability of the battery system to supply power to all off-vehicle loads 136 and on-vehicle accessory loads 132 has been disabled. When the predicted HV exposure hours are above the first threshold, the current HV exposure hours are extremely high.

[0069] At 804, based on the determination that the predicted HV exposure hours fall within the first HV exposure hour threshold range, the HV exposure hour monitoring system 144: limits the amount of power that can be supplied by the battery system to a first subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132, disables the ability of the battery system 112 to supply power to a second subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132, and generates an HV exposure hour alert that includes a second notification for display on the interface 148 of the EV 110. The second notification indicates that the amount of power that can be supplied by the battery system 112 to the first subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132 has been limited, and the ability of the battery system 112 to supply power to the second subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132 has been disabled. The first HV exposure hour threshold range is between a first HV exposure hour threshold and a second HV exposure hour threshold. The second HV exposure hour threshold is less than the first HV exposure hour threshold. When the predicted HV exposure hours fall within the first HV exposure hour threshold range, the current HV exposure hours are very high.

[0070] At 806, based on the determination that the predicted HV exposure hours fall within the second HV exposure hour threshold range, the HV exposure hour monitoring system 144: recommends limiting the use of the battery system 112 to supply power to the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132, limits the amount of power that can be supplied by the battery system 112 to a third subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132, and generates an HV exposure hour alert that includes a third notification for display on the interface 148 of the EV 110. The third notification includes a recommendation to limit the use of the battery system 112 to supply power to the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132, and indicates that the amount of power that can be supplied to the third subset of the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132 has been limited. The second HV exposure hour threshold range is between a second HV exposure hour threshold and a third HV exposure hour threshold. The third HV exposure hour threshold is less than the second HV exposure hour threshold. When the predicted HV exposure hours fall within the second HV exposure hour threshold range, the current HV exposure hours are high.

[0071] At 808, based on the determination that the predicted HV exposure hours fall within the third HV exposure hour threshold range, the HV exposure hour monitoring system 144 generates an HV exposure hour alert that includes a fourth notification. The fourth notification includes a recommendation to limit the use of the battery system 112 to supply power to the off-vehicle vehicle loads 136 and the on-vehicle accessory loads 132. The third HV exposure hour threshold range is between a third HV exposure hour threshold and a fourth HV exposure hour threshold. The fourth HV exposure hour threshold is less than the third HV exposure hour threshold. When the predicted HV exposure hours fall within the third HV exposure hour threshold range, the current HV exposure hours are slightly high.

[0072] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a first predicted HV exposure hour at a future vehicle age. The future vehicle age is the vehicle age warranty. The predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours. The current HV exposure hours and historical HV exposure hours are at least partially based on using the battery system 112 to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads in addition to powering the propulsion load. The HV exposure hour monitoring system 144 is configured to generate a second predicted HV exposure hour at a future vehicle age. The second predicted HV exposure hour is based on ceasing to use the battery system to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads 132. The HV exposure hour monitoring system 144 is configured to determine whether the first predicted HV exposure hour is greater than an HV exposure hour threshold and the second predicted HV exposure hour is less than the HV exposure hour threshold. The HV exposure hour monitoring system 144 is configured to generate an HV exposure hour alert for display on the interface 148 if the first predicted HV exposure hour is greater than the HV exposure hour threshold and the second predicted HV exposure hour is less than the HV exposure hour threshold. The HV exposure hour alert is associated with a limit related to using the battery system 112 to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads 132. An example of the interface 148 is the display device of the EV 110.

[0073] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a first predicted HV exposure hour at a future EV mileage. The future EV mileage is the vehicle mileage warranty. The predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours. The current HV exposure hours and historical HV exposure hours are at least partially based on using the battery system 112 to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads in addition to powering the propulsion load. The HV exposure hour monitoring system 144 is configured to generate a second predicted HV exposure hour at a future vehicle mileage. The second predicted HV exposure hour is based on ceasing to use the battery system to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads 132. The HV exposure hour monitoring system 144 is configured to determine whether the first predicted HV exposure hour is greater than an HV exposure hour threshold and the second predicted HV exposure hour is less than the HV exposure hour threshold. The HV exposure hour monitoring system 144 is configured to generate an HV exposure hour alert for display on the interface 148 if the first predicted HV exposure hour is greater than the HV exposure hour threshold and the second predicted HV exposure hour is less than the HV exposure hour threshold. The HV exposure hour alert is associated with a limit related to using the battery system 112 to power vehicle loads outside the vehicle 136 and / or on-vehicle accessory loads 132. An example of the interface 148 is the display device of the EV 110.

[0074] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a first predicted HV exposure hour at a future vehicle age. The future vehicle age is the vehicle age warranty. The first predicted HV exposure hour is based on the current HV exposure hour and the historical HV exposure hours corresponding to historical vehicle ages. The HV exposure hour monitoring system 144 is configured to generate a second predicted HV exposure hour at a future EV mileage. The future EV mileage is the vehicle mileage warranty. The second predicted HV exposure hour is based on the current HV exposure hour and the historical HV exposure hours corresponding to historical EV mileages. The HV exposure hour monitoring system 144 is configured to determine whether both the first predicted HV exposure hour and the second predicted HV exposure hour are greater than an HV exposure hour threshold. The HV exposure hour monitoring system 144 is configured to generate an HV exposure hour alert if both the first predicted HV exposure hour and the second predicted HV exposure hour are greater than the HV exposure hour threshold. The HV exposure hour alert is associated with a limitation related to using the battery system 112 to power an off-vehicle load 136 and / or an on-vehicle accessory load 132. An example of the interface 148 is a display device of the EV 110.

[0075] Reference Figure 9 , an exemplary graphical illustration of a predefined relationship between HV exposure hours, vehicle age, EV mileage, and an HV exposure hour threshold according to at least one embodiment is shown. Modeling many hypothetical customer use cases for HV exposure hours under all conditions for determining the HV exposure hour threshold, without imposing limitations on the use of the off-vehicle load 136 and / or the on-vehicle accessory load 132, this threshold is unlikely to meet the warranty conditions of most customers.

[0076] The predefined relationship is based on interpolation between the following values: (i) zero EV mileage and zero vehicle age—zero HV exposure hours, (ii) all values at the vehicle age warranty—[durability threshold] hours of HV exposure hours, and (iii) all values at the vehicle warranty mileage—[durability threshold] hours of HV exposure hours. The HV exposure hour threshold is defined by a surface and is a function of the current EV mileage and the current vehicle age. For example, the warranty period can be 8 years and / or 100,000 miles. For example, the durability period can be 15 years and / or 150,000 miles. Other mile and / or year definitions corresponding to internal design requirements or consistent with any regulations or warranties can be used.

[0077] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to determine a current HV exposure hour, a current vehicle age, and a current EV mileage. The HV exposure hour monitoring system 144 is configured to identify an HV exposure hour threshold associated with the current HV exposure hour, the current vehicle age, and the current EV mileage using a predefined relationship among the HV exposure hour, the vehicle age, the EV mileage, and the HV exposure hour threshold shown in an exemplary chart.

[0078] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a predicted number of cycles of the HV contactor at a future vehicle age. The future vehicle age is the vehicle age warranty. The HV system is operably coupled to the battery system via the HV contactor. The predicted number of cycles is based on a current number of cycles and a historical number of cycles. The current number of cycles and the historical number of cycles are based on the closing of the HV contactor to enable the battery system to supply power to a propulsion load and an off-vehicle load 136 and / or an on-vehicle accessory load 132. The HV exposure hour monitoring system 144 is configured to determine whether the predicted number of cycles is greater than a cycle threshold at the future vehicle age. If the predicted number of cycles is greater than the cycle threshold at the future vehicle age, the HV exposure hour monitoring system 144 is configured to generate a cycle alert associated with a limitation related to using the battery system 112 to supply power to the off-vehicle load 136 and / or the on-vehicle accessory load 132 for display on a display device of the EV 110.

[0079] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a predicted number of cycles of the HV contactor at a future EV mileage. The future EV mileage is the vehicle mileage warranty. The HV system is operably coupled to the battery system via the HV contactor. The predicted number of cycles is based on a current number of cycles and a historical number of cycles. The current number of cycles and the historical number of cycles are based on the closing of the HV contactor to enable the battery system to supply power to a propulsion load and an off-vehicle load 136 and / or an on-vehicle accessory load 132. The HV exposure hour monitoring system 144 is configured to determine whether the predicted number of cycles is greater than a cycle threshold at the future EV mileage. If the predicted number of cycles is greater than the cycle threshold at the future vehicle mileage, the HV exposure hour monitoring system 144 is configured to generate a cycle alert associated with a limitation related to using the battery system 112 to supply power to the off-vehicle load 136 and / or the on-vehicle accessory load 132 for display on a display device of the EV 110.

[0080] In at least one embodiment, the HV exposure hour monitoring system 144 is configured to generate a current HV exposure hour based on a sum of durations for which the HV contactor has been closed during a cycle, and to generate each historical HV exposure hour based on a sum of durations for which the HV contactor has been closed at each historical vehicle age.

[0081] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are numerous variations. It should also be understood that the exemplary embodiment or exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of the present disclosure in any way. On the contrary, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A high voltage (HV) exposure hours monitoring system for an electric vehicle (EV), comprising: at least one processor; as well as at least one memory communicatively coupled to the at least one processor, the at least one memory comprising instructions that, when executed by the at least one processor, cause the at least one processor to: Generate predicted HV exposure hours for the HV system of the EV at one of a future vehicle age and a future EV mileage, where: The HV system is operably coupled to a battery system of the EV and is configured to enable power to be supplied from the battery system to a propulsion load and at least one of an off-board vehicle load and an on-board accessory load; The predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours of the HV system; and the current HV exposure hours and the historical HV exposure hours are based on using the battery system to power the propulsion load and the at least one of the off-board vehicle load and the on-board accessory load; determining whether the predicted HV exposure hours is greater than an HV exposure hours threshold at the one of the future vehicle age and the future EV range; and Based on the determination, a HV exposure hours alert associated with a restriction related to using the battery system to power the at least one of the off-board vehicle load and the on-board accessory load is generated for display on a display device of the EV.

2. The system according to claim 1, wherein: The HV exposure hour threshold is a first HV exposure hour threshold, and the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: based on a determination that the predicted HV exposure hours are greater than the first HV exposure hours threshold; disabling the ability of the battery system to power all of the at least one of the off-board vehicle loads and the on-board accessory loads; as well as The HV exposure hour alarm is generated, the HV exposure hour alarm including a first notification that the ability of the battery system to power all of the at least one of the off-board vehicle loads and the on-board accessory loads has been disabled.

3. The system according to claim 2, wherein: the HV exposure hour threshold comprises a first HV exposure hour range between the first HV exposure hour threshold and a second HV exposure hour threshold, the second HV exposure hour threshold being less than the first HV exposure hour threshold; as well as Based on a determination that the predicted HV exposure hours fall within a first HV exposure hours threshold range, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: limiting an amount of power that can be supplied by the battery system to a first subset of the at least one of the off-board vehicle loads and the on-board accessory loads; disabling the ability of the battery system to power a second subset of the at least one of the off-board vehicle loads and the on-board accessory loads; as well as Generate the HV exposure hours alarm, the HV exposure hours alarm including a second notification that the amount of power that can be supplied by the battery system to the first subset of at least one of the off-vehicle vehicle loads and the on-vehicle accessory loads has been limited, and the ability of the battery system to supply power to the second subset of at least one of the off-vehicle vehicle loads and the on-vehicle accessory loads has been disabled.

4. The system according to claim 3, wherein: the HV exposure hour threshold comprises a second HV exposure hour threshold range between the second HV exposure hour threshold and a third HV exposure hour threshold, the third HV exposure hour threshold being less than the second HV exposure hour threshold; as well as Based on a determination that the predicted HV exposure hours fall within the second HV exposure hours threshold range, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to: recommending limiting use of the battery system to power the at least one of the off-vehicle vehicle load and the on-vehicle accessory load; limiting the amount of power supplied by the battery system to a third subset of the at least one of the off-board vehicle loads and the on-board accessory loads; as well as The HV exposure hour alert is generated, the HV exposure hour alert including a third notification to recommend limiting use of the battery system to power at least one of the off-vehicle vehicle loads and the on-vehicle accessory loads, and the amount of power that can be supplied to the at least one of the off-vehicle vehicle loads and the on-vehicle accessory loads has been limited.

5. The system of claim 4, wherein: The HV exposure hour threshold comprises a third HV exposure hour threshold range between the third HV exposure hour threshold and a fourth HV exposure hour threshold, the fourth HV exposure hour threshold being less than the third HV exposure hour threshold; as well as Based on a determination that the predicted HV exposure hours fall within the third HV exposure hour threshold range, the at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to generate the HV exposure hours alert, the HV exposure hours alert including a fourth notification to recommend limiting use of the battery system to power at least one of the off-vehicle vehicle loads and the on-vehicle accessory loads.

6. The system according to claim 1, wherein: The at least one memory comprises further instructions which, when executed by the at least one processor, cause the at least one processor to: generating the predicted HV exposure hours at the future vehicle age, wherein the predicted HV exposure hours are based on the current HV exposure hours and the historical HV exposure hours corresponding to historical vehicle ages; and A determination is made as to whether the predicted HV exposure hours is greater than the HV exposure hours threshold at the future vehicle age.

7. The system according to claim 6, wherein: The at least one memory includes further instructions that, when executed by the at least one processor, cause the at least one processor to generate the predicted HV exposure hours at the future vehicle age, wherein the predicted HV exposure hours are based on the current HV exposure hours and the historical HV exposure hours corresponding to the historical vehicle age within a predefined vehicle age window.

8. The system according to claim 1, wherein: The future vehicle age is the vehicle age warranty.

9. The system according to claim 1, wherein: The at least one memory comprises further instructions which, when executed by the at least one processor, cause the at least one processor to: generating the predicted HV exposure hours at the future EV range, wherein the predicted HV exposure hours are based on the current HV exposure hours at a current EV range and the historical HV exposure hours corresponding to historical EV ranges; and A determination is made as to whether the predicted HV exposure hours is greater than the HV exposure hours threshold at the future EV range.

10. A method for monitoring high voltage (HV) exposure hours of an electric vehicle (EV), comprising: Generate predicted HV exposure hours for the HV system of the EV at one of a future vehicle age and a future EV mileage, where: The HV system is operably coupled to a battery system of the EV and is configured to enable power to be supplied from the battery system to a propulsion load and at least one of an off-board vehicle load and an on-board accessory load; The predicted HV exposure hours are based on current HV exposure hours and historical HV exposure hours of the HV system; and The current HV exposure hours and the historical HV exposure hours are based on using the battery system to power the propulsion load and the at least one of an off-board vehicle load and an on-board accessory load; determining whether the predicted HV exposure hours is greater than an HV exposure hours threshold at the one of the future vehicle age and the future EV range; and Based on the determination, a HV exposure hours alert associated with a restriction related to using the battery system to power the at least one of the off-board vehicle load and the on-board accessory load is generated for display on a display device of the EV.

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