Fault monitoring device of thermal management controller

Abstract

The invention discloses a fault monitoring device of a thermal management controller, and belongs to the technical field of fault monitoring of thermal management controllers. The device comprises a fault detection unit which is used for detecting the operation state of each component in the heat source management system; the fault state indication module comprises a red LED indication lamp, a blue LED indication lamp, a green LED indication lamp and a red-blue double-color LED indication lamp, the fault state indication module is electrically connected with the fault detection unit, and each LED indication lamp corresponds to different fault states or operation states; the fault detection unit and the fault state indication module are arranged in the waterproof shell; the fault detection unit finds various fault hidden dangers in time through the CAN fault detection circuit, the fan set fault detection circuit, the temperature sensor fault detection circuit and the water pump fault detection circuit. And the fault type and position are visually judged through the LED indicating lamps with different colors and a specific flicker mode, so that the troubleshooting efficiency is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of fault monitoring of a thermal management controller, and more specifically, to a fault monitoring device for a thermal management controller. Background Art

[0002] In the field of new energy vehicles, the battery management system (BMS) plays a crucial role in the safety, driving range, and overall performance of the vehicle. As a key component of BMS thermal management, the ATS controller occupies a core position in the entire system and undertakes a pivotal function of connecting the upper and lower levels. On the one hand, it needs to conduct efficient data interaction with the upper control unit of the BMS, receive and execute instructions from the vehicle control system, and on the other hand, it has to precisely regulate various lower-level thermal management execution components, such as fan groups, water pumps, and temperature sensors, to ensure that the battery pack is always within an appropriate operating temperature range. However, the current new energy thermal management system faces many severe challenges in fault monitoring and troubleshooting. When a fault occurs in the ATS controller or its associated components, the problem is mainly located and solved by manual troubleshooting. However, the overall vehicle environment of new energy vehicles is extremely complex and full of uncertainties. During the installation, commissioning, and daily use of the vehicle, this traditional troubleshooting method has obvious drawbacks. Since the fault phenomenon may be comprehensively affected by various factors such as vehicle driving conditions, environmental temperature and humidity, and electromagnetic interference, on-site personnel often find it difficult to quickly and accurately determine the root cause of the fault based on their own experience and limited tools. In this case, it is often necessary for vehicle manufacturers, controller development manufacturers, and on-site workers to jointly cooperate and try to eliminate the fault through repeated remote communication. However, due to the limitations of information transmission in remote communication, many key details are difficult to accurately convey, resulting in extremely low fault troubleshooting efficiency. Even more troublesome is that in some complex fault scenarios, it is even necessary to rely on professional developers to visit the site and cooperate with all parties to handle the problem, consuming a large amount of human, material, and time costs. Even so, due to the lack of effective fault monitoring and directional positioning technology, it is still difficult to achieve precise orientation of the problem, making the fault troubleshooting work like looking for a needle in a haystack, seriously affecting the production efficiency of new energy vehicles, the timeliness of after-sales maintenance, and the user experience. At the same time, with the rapid expansion of the new energy vehicle market, the vehicle ownership has increased sharply, and the frequency of faults has also risen accordingly. The traditional manual troubleshooting method can no longer meet the growing demand for fault handling. There is an urgent need for an efficient, intelligent, and fault-precise directional monitoring device to ensure the stable operation of the new energy vehicle thermal management system. In view of this, we propose a fault monitoring device for a thermal management controller. Summary of the Invention

[0003] The object of the present invention is to provide a fault monitoring device for a thermal management controller to solve the problems raised in the above-mentioned background technology.

[0004] To achieve the above object, the present invention provides the following technical solutions: A fault monitoring device for a thermal management controller includes a fault detection unit for detecting the operating states of various components in a heat source management system, and the components at least include a CAN bus, a fan group 1-4, temperature sensors 1-4, and a water pump; The fault detection unit integrates an AI algorithm module, constructs a fault prediction model based on historical operation data, analyzes data trends through machine learning algorithms, and identifies potential fault hazards of components in advance; at the same time, it integrates a multi-sensor fusion unit, and the multi-sensor fusion unit is electrically connected to a data acquisition unit. The data acquisition unit includes a vibration sensor, a pressure sensor, and an infrared temperature measurement module; the multi-sensor fusion unit fuses the real-time data of the vibration sensor, the pressure sensor, and the infrared temperature measurement module, and improves the fault diagnosis accuracy under complex working conditions through the D-S evidence theory or the Kalman filtering algorithm; A fault status indication module includes a red LED indicator, a blue LED indicator, a green LED indicator, and a red-blue dual-color LED indicator. The fault status indication module is electrically connected to the fault detection unit. Each LED indicator corresponds to a different fault status or operating state, and indicates the specific fault type through a specific flashing mode; it also integrates an AR visualization module, which generates a three-dimensional fault location guide through a touch screen or an external intelligent terminal, and can mark the position of the faulty component on the virtual model of the device and overlay the animation of the maintenance steps; A waterproof housing, the fault detection unit, the fault status indication module, the AI algorithm module, the multi-sensor fusion unit, and the AR visualization module are all arranged inside the waterproof housing. A touch screen is arranged on the surface of the waterproof housing, and the touch screen is electrically connected to the fault detection unit, the fault status indication module, the AI algorithm module, the multi-sensor fusion unit, and the AR visualization module; It further includes an edge computing module, which is integrated inside the waterproof housing 1 and is electrically connected to the fault detection unit, and is used for locally preprocessing the real-time monitoring data and remotely updating the fault diagnosis algorithm through OTA technology.

[0005] A communication module is arranged on the side of the waterproof housing 1 and is electrically connected to the edge computing module, and is used for remote real-time transmission of fault information and cloud data synchronization.

[0006] A wire harness interface is arranged on the side of the waterproof housing.

[0007] The host computer is connected to the fault monitoring device of the present application through a software debugging interface, and can intuitively display the fault status to assist the staff in troubleshooting. The host computer software has a fault recording function, which can record information such as the time of fault occurrence, fault type, and fault duration, and can generate a fault report to facilitate the subsequent analysis and processing by the staff.

[0008] Preferably, the blinking mode of the LED indicator of the fault status indication module is specifically as follows: When a fault occurs in the CAN bus, the red LED indicator blinks once and then stops for one second; when a fault occurs in the wind turbine group 1, the blue LED indicator blinks once and then stops for one second; when a fault occurs in the wind turbine group 2, the blue LED indicator blinks twice and then stops for one second; when a fault occurs in the wind turbine group 3, the blue LED indicator blinks three times and then stops for one second; when a fault occurs in the wind turbine group 4, the blue LED indicator blinks four times and then stops for one second; when a fault occurs in the temperature sensor 1, the red and blue dual-color LED indicators blink simultaneously once and then stop for one second; when a fault occurs in the temperature sensor 2, the red and blue dual-color LED indicators blink simultaneously twice and then stop for one second; when a fault occurs in the temperature sensor 3, the red and blue dual-color LED indicators blink simultaneously three times and then stop for one second; when a fault occurs in the temperature sensor 4, the red and blue dual-color LED indicators blink simultaneously four times and then stop for one second; when a fault occurs in the water pump, the green LED indicator blinks once and then stops for one second.

[0009] Preferably, the fault detection unit includes: A CAN fault detection circuit for detecting the data transmission of the CAN bus; A wind turbine group fault detection circuit, which is respectively connected to the wind turbine groups 1-4; A temperature sensor fault detection circuit, which is respectively connected to the temperature sensors 1-4; A water pump fault detection circuit for monitoring whether the water pump is faulty.

[0010] Preferably, an installation seat is provided at the bottom of the waterproof housing, and the installation seat is used to install the fault detection unit and the fault status indication module; Fixing plates are provided on both sides of the installation seat, and a plurality of wire fixing components are movably connected to the fixing plates.

[0011] Preferably, the wire fixing component includes a fixing tube. An opening is provided at the upper end of the fixing tube. A limiting screw is penetrated through one side of the fixing tube. The limiting screw is in threaded cooperation with the fixing tube. A limiting block is rotatably connected to the end of the limiting screw. The limiting block is of an arc-shaped structure.

[0012] Preferably, an installation frame is provided on one side of the fixing tube. A slot is provided on the side of the fixing tube. The inner side of the installation frame is matched with the slot. The installation frame is of an L-shaped structure, and the bottom of the installation frame can contact the bottom surface of the fixing tube; The fixed plate is provided with a slide rail, and the mounting frame is provided with a slider, and the slider is slidably engaged with the slide rail.

[0013] Preferably, two sliders are provided, the two sliders are arranged oppositely, and the slider is rotatably connected to the mounting frame; An elastic member is arranged between the two sliders, hinge seats are arranged at both ends of the elastic member, and the hinge seats are rotatably connected to the slider.

[0014] Preferably, multiple groups of fixed plates are provided. A connection groove is arranged on one side of the fixed plate, and a limiting strip is arranged on the other side of the fixed plate. The limiting strips and the connection grooves on adjacent two fixed plates are movably connected.

[0015] Preferably, a mounting plate is arranged between the two oppositely arranged fixed plates, and the side of the mounting plate is inserted and matched with the mounting frame.

[0016] The fault monitoring device of the thermal management controller of the present application is used to communicate with the vehicle control system of a new energy vehicle, and transmit fault information to the vehicle control system in real time, so that the vehicle control system can take corresponding protection measures according to the fault situation.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) The fault detection unit of the present invention respectively monitors the operating states of components such as the CAN bus, the fan group, the temperature sensor, and the water pump from multiple dimensions such as data transmission, current, rotation speed, and water pressure through the CAN fault detection circuit, the fan group fault detection circuit, the temperature sensor fault detection circuit, and the water pump fault detection circuit, so as to ensure timely detection of various potential fault hazards. And through different color LED indicators and specific flashing modes, such as the red LED flashes once and pauses for one second to indicate a CAN fault, and the blue LED indicates the faults of each fan group according to different flashing times, etc., so that the staff can quickly and intuitively judge the type and location of the fault, greatly improving the efficiency of fault troubleshooting.

[0018] (2) The fault detection unit of the present invention integrates an AI algorithm module, analyzes data trends through machine learning algorithms, and can identify potential fault hazards of components in advance; at the same time, it integrates a multi-sensor fusion unit, fuses the real-time data of vibration sensors, pressure sensors, and infrared temperature measurement modules, and improves the fault diagnosis accuracy under complex working conditions through the D-S evidence theory or the Kalman filtering algorithm. It also integrates an AR visualization module, generates a three-dimensional fault location guide through a touch screen or an external intelligent terminal, and can mark the position of the faulty component on the virtual model of the device and overlay the animation of the maintenance steps, which is convenient for improving the maintenance efficiency; the edge computing module preprocesses the real-time monitoring data locally and remotely updates the fault diagnosis algorithm through OTA technology; the communication module can remotely transmit the fault information in real time and synchronize the cloud data.

[0019] (3) The present invention is provided with a circuit fixing component for fixing the connected circuits, enabling the connected circuits to be neatly arranged. The circuit fixing component supports the adaptive clamping of wire harnesses with different diameters and integrates the automatic recognition function of wire harness labels. It greatly shortens the on-site maintenance time, supports flexible hardware version upgrades, and meets the requirements of the rapid iteration of new energy vehicle technologies. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 is a schematic diagram of the overall structure of the present invention; Figure 2 is a side view schematic diagram of the overall structure of the present invention; Figure 3 is a schematic diagram of the connection between the mounting base and the fixing plate of the present invention; Figure 4 is a schematic diagram of the connection of multiple fixing plates of the present invention; Figure 5 is a schematic diagram of the installation of the circuit fixing component of the present invention; Figure 6 is a schematic diagram of the blinking mode of the LED indicator light of the present invention.

[0021] Description of the reference numerals in the drawings: 1, waterproof housing; 2, mounting base; 3, fixing plate; 301, slide rail; 302, limiting strip; 4, circuit fixing component; 401, fixing tube; 402, limiting screw; 403, limiting block; 5, mounting bracket; 501, slider; 6, elastic member; 7, mounting plate. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0022] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Embodiment

[0023] Please refer to Figure 1-6 , a fault monitoring device for a thermal management controller, including a fault detection unit for detecting the operating states of various components in the heat source management system, and the components at least include a CAN bus, a fan group 1-4, temperature sensors 1-4, and a water pump.

[0024] The fault detection unit integrates an AI algorithm module, constructs a fault prediction model based on historical operation data, analyzes data trends through machine learning algorithms (LSTM neural network or random forest), and identifies potential fault hazards of components in advance. At the same time, it integrates a multi-sensor fusion unit, which is electrically connected to a data acquisition unit. The data acquisition unit includes a vibration sensor, a pressure sensor, and an infrared temperature measurement module. The multi-sensor fusion unit fuses the real-time data of the vibration sensor, the pressure sensor, and the infrared temperature measurement module, and improves the fault diagnosis accuracy under complex working conditions through the D-S evidence theory or the Kalman filtering algorithm. By fusing the data of these different types of sensors, the multi-sensor fusion unit can more comprehensively and accurately reflect the operating state of the thermal management controller. The vibration sensor is mainly used to monitor the vibration of components during operation in the heat source management system, the pressure sensor is used to measure the pressure change in the system, and the infrared temperature measurement module is used to detect the surface temperature of the equipment or key parts. The vibration sensor, the pressure sensor, and the infrared temperature measurement module transmit the collected real-time data to the multi-sensor fusion unit. The multi-sensor fusion unit relies on the real-time data provided by the vibration sensor, the pressure sensor, and the infrared temperature measurement module for fusion processing, while these three sensors rely on the multi-sensor fusion unit to comprehensively analyze the data they collect to achieve accurate monitoring of the faults of the thermal management controller and early identification of potential fault hazards. Multiple vibration sensors can be set: they are respectively installed on the outer shells of equipment prone to vibration such as the fan groups 1-4 and the water pump, and as close as possible to the bearing parts or vibration sources of the equipment to more accurately collect the vibration signals during equipment operation; the pressure sensor: it is installed on the pipeline of the thermal management system, such as the inlet and outlet pipelines of the water pump or the coolant circulation pipeline, to measure the pressure change of the fluid in the pipeline; the infrared temperature measurement module: it is installed on the surfaces of various components in the heat source management system, such as the outer shells of the fan groups 1-4 and the water pump, to monitor the surface temperature of the components in real time. For the CAN bus, the infrared temperature measurement module can be installed near its key nodes or parts prone to heat generation to detect temperature anomalies that may be caused by faults in a timely manner.

[0025] Fault status indication module, which includes multiple LED indicators of different colors, specifically red LED indicator, blue LED indicator, green LED indicator and red-blue dual-color LED indicator. The fault status indication module is electrically connected to the fault detection unit. The fault detection unit sends corresponding signals to the fault status indication module according to different fault types. Each LED indicator corresponds to a different fault status or operating status; the LED indicators use high-brightness and long-life LED lamp beads, and the installation positions of the LED lamp beads are provided with transparent window areas on the waterproof housing for easy observation to ensure that the flashing status of the LED can be clearly observed in various environments, and specific fault types are indicated through specific flashing modes; an AR visualization module is also integrated, which generates three-dimensional fault location guidance through a touch screen or an external intelligent terminal, and can mark the positions of faulty components on the virtual model of the device and overlay animation of repair steps.

[0026] Waterproof housing 1, the fault detection unit, the fault status indication module, the AI algorithm module, the multi-sensor fusion unit and the AR visualization module are all arranged inside the waterproof housing 1. A touch screen is arranged on the surface of the waterproof housing 1, and the touch screen is electrically connected to the fault detection unit, the fault status indication module, the AI algorithm module, the multi-sensor fusion unit and the AR visualization module, and is used to view and display the status of the fault detection unit and the fault status indication module. The touch screen has functions of interactive operation, information display, and data recording and analysis; the waterproof housing ensures the normal operation of the device in a complex environment without affecting the fault detection and indication functions. The waterproof housing adopts a variety of waterproof technologies such as sealing rubber strips and waterproof coatings to reach an IP67 or higher waterproof level, effectively preventing water and dust and other impurities from entering the device and affecting its normal operation. The AR visualization module solves the difficulty of troubleshooting caused by the complex wiring harness layout of the new energy vehicle chassis, enabling non-professionals to quickly locate faults through visual guidance, and shortening the repair time by more than 40%. It is especially suitable for installation environments with small space and dense components.

[0027] Exemplarily, users can query the historical operation data and fault records of the thermal management system through the touch screen to understand the working conditions of the system in the past period of time. This helps to analyze the operation trend of the system, find potential problems, and provide a basis for the maintenance and optimization of the system. For example, technicians can query the maximum and minimum values of the battery temperature in the past week and the corresponding time points to evaluate the thermal management effect of the battery. The touch screen has certain data analysis functions and can perform simple statistics and analysis on the collected data, such as calculating the average value, standard deviation, etc., and generating data reports. Users can formulate more reasonable thermal management strategies based on these analysis results to improve the performance and reliability of the system.

[0028] It also includes an edge computing module, which is integrated inside the waterproof housing 1 and electrically connected to the fault detection unit. It is used for local preprocessing (filtering, outlier detection) of real-time monitoring data and remotely updating the fault diagnosis algorithm through OTA technology. The edge computing module performs local preprocessing (filtering, outlier detection, feature extraction) on the real-time monitoring data, and only uploads the key fault features (such as the abnormal current waveform eigenvalue of the fan group) through the CAN bus or communication module, reducing the above-mentioned invalid data transmission, and supporting the OTA remote update of the fault diagnosis algorithm (such as the sensor threshold configuration of new vehicle models). It meets the low-latency requirements (fault response time < 100ms) of the real-time control scenario of new energy vehicles. At the same time, the device function iteration is realized through remote algorithm upgrade, and there is no need to physically replace the hardware.

[0029] A communication module is arranged on the side of the waterproof housing 1 and is electrically connected to the edge computing module, and is used for remote real-time transmission of fault information and cloud data synchronization.

[0030] A wiring harness interface is arranged on the side of the waterproof housing 1. The wiring harness interface includes a wiring harness interface connected to the ATS controller, a PC external USB interface, etc. The communication module supports 5G / Ultra Wideband (UWB) communication and uploads the fault context data (vehicle driving speed, battery SOC, ambient temperature, etc.) to the cloud operation and maintenance platform in real time. Through big data analysis of the fault distribution rules under different vehicle models and working conditions, it feeds back and optimizes the local detection strategy (such as the dynamic adjustment of the water pump fault threshold in winter low-temperature environment). It constructs a three-level management system of "device end - vehicle end - cloud end", supports remote fault consultation and batch monitoring of fleet health, and realizes the leap from single-point fault handling to systematic optimization.

[0031] The upper computer is connected to the fault monitoring device of the present application through a software debugging interface, and can intuitively display the fault status to assist the staff in fault troubleshooting. The upper computer software has a fault recording function, which can record information such as the time of fault occurrence, fault type, and fault duration, and can generate a fault report to facilitate the staff's subsequent analysis and processing.

[0032] Specifically, the flashing mode of the LED indicator of the fault status indication module is specifically as follows: When the CAN bus fails, the red LED indicator flashes once and then stops for one second; when the wind turbine unit 1 fails, the blue LED indicator flashes once and then stops for one second; when the wind turbine unit 2 fails, the blue LED indicator flashes twice and then stops for one second; when the wind turbine unit 3 fails, the blue LED indicator flashes three times and then stops for one second; when the wind turbine unit 4 fails, the blue LED indicator flashes four times and then stops for one second; when the temperature sensor 1 fails, the red and blue dual-color LED indicator flashes once simultaneously and then stops for one second; when the temperature sensor 2 fails, the red and blue dual-color LED indicator flashes twice simultaneously and then stops for one second; when the temperature sensor 3 fails, the red and blue dual-color LED indicator flashes three times simultaneously and then stops for one second; when the temperature sensor 4 fails, the red and blue dual-color LED indicator flashes four times simultaneously and then stops for one second; when the water pump fails, the green LED indicator flashes once and then stops for one second.

[0033] In this application, the fault detection unit includes: The CAN fault detection circuit is used to detect the data transmission condition of the CAN bus. When the data transmission is abnormal, it is determined as a CAN fault and a corresponding control signal is sent to the fault status indication module; The wind turbine unit fault detection circuits are respectively connected to the wind turbine units 1-4. By monitoring parameters such as the current and rotational speed of the wind turbine units, it is judged whether the wind turbine units are faulty. When a wind turbine unit fault is detected, a control signal corresponding to the wind turbine unit fault is sent to the fault status indication module; The temperature sensor fault detection circuits are respectively connected to the temperature sensors 1-4. By comparing the output signal of the temperature sensor with the preset normal range, it is judged whether the temperature sensor is faulty. When a temperature sensor fault is detected, a control signal corresponding to the temperature sensor fault is sent to the fault status indication module; The water pump fault detection circuit is used to monitor whether the water pump is faulty. By monitoring parameters such as the working current and water pressure of the water pump, it is judged whether the water pump is faulty. When a water pump fault is detected, a control signal of the water pump fault is sent to the fault status indication module.

[0034] In this application, an installation base 2 is provided at the bottom of the waterproof housing 1. The installation base 2 is used to install the fault detection unit, the fault status indication module, and each connection circuit; As Figure 3 shown, fixing plates 3 are provided on both sides of the installation base 2. A plurality of line fixing components 4 are movably connected to the fixing plates 3. The line fixing components 4 are used to fix the connected lines so that each connection line can be neatly arranged.

[0035] In this application, the circuit fixing component 4 includes a fixing tube 401. An opening is provided at the upper end of the fixing tube 401, through which the circuit to be connected can be placed inside the fixing tube 401 for fixing. A limiting screw 402 is disposed through one side of the fixing tube 401. The limiting screw 402 is in threaded cooperation with the fixing tube 401. A limiting block 403 is rotatably connected to the end of the limiting screw 402. The limiting block 403 is in an arc-shaped structure. By rotating the limiting screw 402, the limiting block 403 can be brought into contact with the surface of the circuit, thereby fixing the circuit inside the fixing tube 401. The size of the fixing tube 401 can be designed according to needs.

[0036] In this application, an installation frame 5 is provided on one side of the fixing tube 401. A slot is provided on the side of the fixing tube 401. The inner side of the installation frame 5 is matched with the slot. The installation frame 5 is in an L-shaped structure, and the bottom of the installation frame 5 can contact the bottom surface of the fixing tube 401. By the way of the movable connection between the fixing tube 401 and the installation frame 5, it is convenient to disassemble the fixing tube 401, and the structure of the L-shaped installation frame 5 restricts the fixing tube 401 in the vertical position.

[0037] A slide rail 301 is provided on the fixing plate 3, and a slider 501 is provided on the installation frame 5. The slider 501 is in sliding cooperation with the slide rail 301, which is convenient to move the position of the installation frame 5. The number of the installation frames 5 can also be set according to needs.

[0038] In this application, two sliders 501 are provided. The two sliders 501 are arranged oppositely, and the sliders 501 are rotatably connected to the installation frame 5, which is convenient to put the two sliders 501 into the slide rail 301. An elastic member 6 is provided between the two sliders 501. The elastic member 6 can adopt a spring telescopic rod. Hinged seats are provided at both ends of the elastic member 6, and the hinged seats are rotatably connected to the sliders 501. When installing the installation frame 5 into the slide rail 301, the two sliders 501 are squeezed inward. At this time, the elastic member 6 is compressed. When the end of the slider 501 enters the inside of the slide rail 301, the elastic member 6 pushes the two ends of the two sliders 501 to move relatively outward and snap into the slide rail 301, so that the sliders 501 cannot fall off from the slide rail 301, improving the connection stability of the installation frame 5.

[0039] In this application, multiple groups of fixing plates 3 are provided. A connection groove is provided on one side of the fixing plate 3, and a limiting strip 302 is provided on the other side of the fixing plate 3. The limiting strips 302 on adjacent two fixing plates 3 are in movable connection with the connection groove. By providing multiple groups of fixing plates 3, it is convenient to sort and classify the circuits in the vertical direction, increasing the fixing space of the circuits.

[0040] In this application, an installation plate 7 is provided between two oppositely arranged fixing plates 3. The side of the installation plate 7 is in plug-in cooperation with the installation frame 5. Through the setting of the installation plate 7, different units or modules can be installed in layers, and the installation plate 7 can be set as a mesh structure, which is convenient for the heat dissipation of each unit or module.

[0041] In a possible embodiment, a self-check module is further included, which regularly performs self-checks on components such as the fault detection unit, the fault status indication module, the wiring harness interface, and the software debugging interface to ensure that the device itself is in a normal working state. When a fault of the device itself is detected, a warning signal with a specific flashing pattern is sent through the fault status indication module.

[0042] The AI algorithm module, the multi-sensor fusion unit, the edge computing module, the fault detection unit, and the fault status indication module are highly integrated in the waterproof housing 1. Quick plugging and unplugging replacement is achieved through a magnetic snap / card interface (single-module replacement time < 3 minutes). The wiring fixing component supports adaptive clamping of wiring harnesses with different diameters (2mm² - 16mm²) and integrates the function of automatic identification of wiring harness labels. This significantly shortens the on-site repair time, supports flexible hardware version upgrades (such as separately replacing the edge computing module with higher computing power), and meets the requirements of the rapid iteration of new energy vehicle technologies.

[0043] A fault monitoring device for a thermal management controller is used to communicate and connect with the vehicle control system of a new energy vehicle, and transmits fault information to the vehicle control system in real time, so that the vehicle control system can take corresponding protection measures according to the fault situation, such as adjusting the battery charge and discharge strategy, restricting the vehicle power, etc., to improve the overall safety and reliability of the new energy vehicle.

[0044] The above shows and describes the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and the descriptions in the specification are only preferred examples of the present invention and are not used to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed. The scope of protection claimed by the present invention is defined by the appended claims and their equivalents.

Claims

1. A fault monitoring device for a thermal management controller, characterized in that: include: A fault detection unit, used to detect the operating status of each component in the heat source management system; The fault detection unit integrates an AI algorithm module, builds a fault prediction model based on historical operation data, analyzes data trends through a machine learning algorithm, and identifies potential fault hazards of components in advance; at the same time, it integrates a multi-sensor fusion unit, which is electrically connected to a data acquisition unit, and the data acquisition unit includes a vibration sensor, a pressure sensor, and an infrared temperature measurement module; A fault status indication module includes a plurality of LED indicators of different colors, the fault status indication module is electrically connected to the fault detection unit, and each LED indicator corresponds to a different fault state or operating state; an AR visualization module is also integrated, which generates a three-dimensional fault location guide through a touch screen or an external smart terminal, and can mark the location of the faulty component on the virtual model of the equipment and superimpose a maintenance step animation; A waterproof housing (1), wherein the fault detection unit, the fault status indication module, the AI ​​algorithm module, the multi-sensor fusion unit and the AR visualization module are all arranged inside the waterproof housing (1), and a touch screen is arranged on the surface of the waterproof housing (1), and the touch screen is electrically connected to the fault detection unit, the fault status indication module, the AI ​​algorithm module, the multi-sensor fusion unit and the AR visualization module; It also includes an edge computing module, which is integrated inside the waterproof housing (1) and electrically connected to the fault detection unit, and is used to perform local pre-processing on real-time monitoring data and remotely update the fault diagnosis algorithm through OTA technology; A communication module, arranged on a side of the waterproof housing (1), electrically connected to the edge computing module, and used for remote real-time transmission of fault information and cloud data synchronization; A plurality of line fixing components (4) are arranged inside the waterproof housing (1).

2. The fault monitoring device of a thermal management controller according to claim 1, characterized in that: The components at least include a CAN bus, a fan unit 1-4, a temperature sensor 1-4 and a water pump; The fault detection unit comprises: CAN fault detection circuit, used to detect the data transmission status of CAN bus; The fan group fault detection circuit is connected to the fan groups 1-4 respectively; A temperature sensor fault detection circuit is connected to temperature sensors 1-4 respectively; The water pump fault detection circuit is used to monitor whether the water pump is faulty.

3. The fault monitoring device of a thermal management controller according to claim 2, characterized in that: A mounting seat (2) is provided at the bottom of the waterproof housing (1), and the mounting seat (2) is used to install a fault detection unit and a fault status indication module; Fixing plates (3) are provided on both sides of the mounting seat (2), and a plurality of line fixing components (4) are movably connected to the fixing plates (3).

4. The fault monitoring device for a thermal management controller according to claim 3, characterized in that: The line fixing assembly (4) comprises a fixing tube (401), the upper end of the fixing tube (401) is provided with an opening, a limiting screw (402) is provided through one side of the fixing tube (401), the limiting screw (402) is threadedly matched with the fixing tube (401), the end of the limiting screw (402) is rotatably connected to a limiting block (403), and the limiting block (403) is an arc-shaped structure.

5. The fault monitoring device of a thermal management controller according to claim 4, characterized in that: A mounting frame (5) is provided on one side of the fixed tube (401); a slot is provided on the side of the fixed tube (401); the inner side of the mounting frame (5) cooperates with the slot; the mounting frame (5) is an L-shaped structure; the bottom of the mounting frame (5) is capable of contacting the bottom surface of the fixed tube (401); The fixing plate (3) is provided with a slide rail (301), the mounting frame (5) is provided with a slide block (501), and the slide block (501) is slidably matched with the slide rail (301).

6. The fault monitoring device of a thermal management controller according to claim 5, characterized in that: The sliders (501) are provided in two numbers, the two sliders (501) are arranged opposite to each other, and the sliders (501) are rotatably connected to the mounting frame (5); An elastic member (6) is provided between the two sliders (501), and capstan seats are provided at both ends of the elastic member (6), and the capstan seats are rotatably connected to the sliders (501).

7. The fault monitoring device for a thermal management controller according to claim 5, characterized in that: The fixing plates (3) are arranged in a plurality of groups, a connection groove is arranged on one side of the fixing plates (3), a limit strip (302) is arranged on the other side of the fixing plates (3), and the limit strips (302) on two adjacent fixing plates (3) are movably connected to the connection groove.

8. The fault monitoring device of a thermal management controller according to claim 7, characterized in that: A mounting plate (7) is arranged between two fixing plates (3) arranged opposite to each other, and a side edge of the mounting plate (7) is plug-fitted with the mounting frame (5).

9. The fault monitoring device for a thermal management controller according to claim 7, characterized in that: The fault status indication module includes a red LED indicator light, a blue LED indicator light, a green LED indicator light, and a red and blue dual-color LED indicator light; The flashing mode of the LED indicator of the fault status indication module is specifically: When the CAN bus fails, the red LED indicator flashes once and then stops for one second; when the fan unit 1 fails, the blue LED indicator flashes once and then stops for one second; when the fan unit 2 fails, the blue LED indicator flashes twice and then stops for one second; when the fan unit 3 fails, the blue LED indicator flashes three times and then stops for one second; when the fan unit 4 fails, the blue LED indicator flashes four times and then stops for one second; when the temperature sensor 1 fails, the red and blue dual-color LED indicators flash once at the same time and then stop for one second; when the temperature sensor 2 fails, the red and blue dual-color LED indicators flash twice at the same time and then stop for one second; when the temperature sensor 3 fails, the red and blue dual-color LED indicators flash three times at the same time and then stop for one second; when the temperature sensor 4 fails, the red and blue dual-color LED indicators flash four times at the same time and then stop for one second; when the water pump fails, the green LED indicator flashes once and then stops for one second.

10. The fault monitoring device of a thermal management controller according to claim 1, characterized in that: It is used to communicate with the vehicle control system of new energy vehicles and transmit fault information to the vehicle control system in real time so that the vehicle control system can take corresponding protection measures according to the fault situation.

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