Online air tightness detection method for high-voltage parts of electric automobile

Abstract

The invention discloses an online air tightness detection method for high-pressure parts of an electric vehicle. The online air tightness detection method comprises the following steps: (1) providing dry compressed air or nitrogen for a plurality of high-pressure parts through an air source module; (2) a controller is used for controlling the on-off of a multi-way electromagnetic valve so as to adjust the input of the air source to each high-pressure component; (3) detecting a pressure signal in real time through a pressure sensor arranged in each high-pressure component, and inputting the signal into a controller; (4) the controller compares the detection values of the pressure sensors with a preset pressure range, and if the detection values exceed the preset range, the corresponding electromagnetic valves are closed, and timing is started; (5) calculating a pressure drop rate, and if the pressure drop rate exceeds a preset threshold value, judging that the air tightness of the corresponding high-pressure component is poor; and (6) transmitting the information of the high-voltage component with poor air tightness and the fault code to a multimedia screen for displaying and alarming through the whole vehicle bus, and synchronously sending the information and the fault code to a control center or a user APP.

Description

Technical Field

[0001] The present invention relates to the technical field of air tightness detection of high-voltage components of electric vehicles, and in particular to an online air tightness detection method for high-voltage components of electric vehicles. Background Art

[0002] In the prior art, the air tightness testing of electric vehicle high-voltage components (such as power battery housings, battery high-voltage distribution boxes, and all-in-one controllers) is typically performed using offline static testing. For example, Patent No. CN202010537026.5 discloses a battery pack air tightness testing method that requires the battery pack to be removed from the vehicle for pressure differential or pressure testing. This method has the following drawbacks:

[0003] 1. Low offline testing efficiency: High-voltage components need to be disassembled, which is cumbersome and time-consuming. It is particularly unsuitable for vehicles with multiple components and large volumes, such as electric heavy trucks and mining trucks.

[0004] 2. Inability to monitor in real time: Only single components can be tested, and the air tightness of multiple components cannot be monitored in real time during vehicle operation, resulting in delayed fault detection;

[0005] 3. Difficulty in fault location: When an insulation fault is reported on a vehicle, components must be checked one by one, and the source of the leak cannot be quickly located, affecting maintenance efficiency and safety. Summary of the Invention

[0006] The purpose of the present invention is to provide an online air tightness detection method for high-voltage components of electric vehicles, which can detect the air tightness of high-voltage components of electric vehicles in real time, and can issue an alarm when the air tightness of the high-voltage components is poor. The specific high-voltage components with poor air tightness can be displayed through a multimedia screen. It is convenient and fast, and can also prevent problems before they occur, and remind the owner in advance to perform airtight treatment or replace high-voltage components, thereby protecting and reminding the electrical safety of the entire vehicle.

[0007] In order to achieve the above object, the present invention adopts the following technical solutions:

[0008] An online air tightness detection method for high-voltage components of an electric vehicle comprises the following steps:

[0009] (1) Provide dry compressed air or nitrogen to multiple high-pressure components through the air source module;

[0010] (2) Use the controller to control the on and off of the multi-way solenoid valve to adjust the input of the gas source to each high-pressure component;

[0011] (3) Detecting pressure signals in real time through pressure sensors installed in each high-voltage component and inputting the signals into a controller;

[0012] (4) The controller compares the detection value of each pressure sensor with the preset pressure range. If the detection value exceeds the preset range, the corresponding solenoid valve is closed and the timing is started;

[0013] (5) Calculating the pressure drop rate. If the pressure drop rate exceeds a preset threshold, it is determined that the corresponding high-pressure component has poor air tightness;

[0014] (6) The information and fault code of the high-voltage components with poor airtightness are transmitted to the multimedia screen through the vehicle bus to display the alarm, and are simultaneously sent to the control center or user APP.

[0015] In some embodiments, the gas source module includes a pressure reducing valve for stabilizing the gas source pressure to a preset low pressure value.

[0016] In some embodiments, the high-voltage component includes at least one of a power battery box, a battery high-voltage distribution box, and an all-in-one controller, and each high-voltage component corresponds to an independent solenoid valve and pressure sensor.

[0017] In some embodiments, the controller receives the detection value of the pressure sensor via an analog signal or a digital signal, and performs signal conversion and processing.

[0018] In some embodiments, the pressure drop rate is calculated by recording the time required for the pressure to drop from an upper limit setting value to a lower limit setting value after the solenoid valve is closed, and calculating the rate based on the pressure difference and the time difference.

[0019] In some embodiments, the controller is connected to the T-BOX communication module via the vehicle bus to transmit the alarm information wirelessly to the control center or user APP.

[0020] In some embodiments, the preset pressure range and the pressure drop rate threshold are dynamically adjusted according to the type of the high-pressure component and the working environment.

[0021] In some embodiments, the controller supports simultaneous detection of pressure signals of no less than four high-pressure components, and the detection and alarm of each channel are independent of each other.

[0022] In some embodiments, the alarm information displayed on the multimedia screen includes the name, location and suggested treatment measures of the specific faulty high-voltage component.

[0023] In some embodiments, the method is applicable to electric sanitation vehicles, heavy trucks, and mining trucks equipped with multiple high-voltage components.

[0024] The beneficial effects that may be brought about by the online air tightness detection method for high-voltage components of electric vehicles disclosed in this application include but are not limited to:

[0025] Online real-time detection: The air tightness of multiple high-voltage components can be dynamically monitored while the vehicle is in operation without disassembling the components;

[0026] Multi-channel parallel processing: supports simultaneous detection of no less than four high-voltage components, with independent control and judgment of each channel;

[0027] Accurate fault location: Quickly identify leaking components and display their specific locations by calculating the pressure drop rate;

[0028] Remote alarm function: Fault information is uploaded to the multimedia screen and user terminal in real time to facilitate timely maintenance;

[0029] High cost-effectiveness: The overall system cost is controlled between 600 and 1,000 yuan, suitable for large-scale application in commercial electric vehicles. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 Schematic diagram of the online air tightness detection system for high-voltage components of electric vehicles.

[0031] Figure 2 This is the module diagram of the online air tightness detection system for high-voltage components of electric vehicles.

[0032] Figure 3 The figure is a flow chart of the online air tightness detection method for high-voltage components of electric vehicles. DETAILED DESCRIPTION

[0033] In order to make the purpose, technical solutions and advantages of this application more clearly understood, the present application is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain this application and are not intended to limit this application.

[0034] On the contrary, this application covers any alternatives, modifications, equivalents, and solutions made within the spirit and scope of this application as defined by the claims. Furthermore, to facilitate a better understanding of this application, certain specific details are described in detail below in the detailed description of this application. Those skilled in the art will be able to fully understand this application without these details.

[0035] The following is a detailed description of an online air tightness detection method for high-voltage components of an electric vehicle involved in an embodiment of the present application.

[0036] Explanation of relevant terms

[0037] Gas source: refers to dry compressed air or dry nitrogen, which provides gas source for the air tightness detection device.

[0038] Pressure reducing valve: Its purpose is to reduce the pressure of the gas source and provide a relatively constant low-pressure gas source for the air tightness detection device.

[0039] Gas source on-off control: The controller controls the on-off of the solenoid valve to control the on-off of the gas source, and can control multiple solenoid valves; in the present invention, the solenoid valve controls the power battery box, the power battery box, the battery high-voltage distribution box, and the all-in-one controller.

[0040] Air tightness detection and control: The signal (which can be an analog signal or a digital signal) of the pressure sensor in the power battery box, the control power battery box, the battery high-voltage distribution box, and the all-in-one controller is input into the controller (the controller is composed of a single-chip microcomputer) for signal conversion and processing, and is compared and judged with the set value, thereby controlling the on and off of the solenoid valve.

[0041] Air tightness alarm: When the controller confirms that one or more of the power battery box, control power battery box, battery high-voltage distribution box, and all-in-one controller has an air tightness fault, the controller sends an air tightness fault display signal and an alarm signal to the multimedia screen through the vehicle bus. The multimedia screen displays the specific high-voltage component air tightness fault and issues an alarm, or sends a high-voltage component alarm to the vehicle operation platform.

[0042] Multimedia screen: connected to the bus of the entire vehicle, receives bus information, and can display and alarm information.

[0043] Automobile bus: All nodes on the bus realize the function of sending and receiving information between each node according to the communication protocol.

[0044] TBOX: It can transmit the information on the entire vehicle to the control center through wireless communication.

[0045] See also Figure 1-3 An online air tightness detection method for high-voltage components of electric vehicles is implemented based on an online air tightness detection system for high-voltage components of electric vehicles. The detection system includes the following modules:

[0046] The air source module 100 provides the air source for the vehicle air tightness detection device, which is generally dry compressed air or dry nitrogen; it consists of an air source 1 and a pressure reducing valve 2.

[0047] The gas source on-off control 200 is a module that controls the on-off of the gas source by controlling the on-off of the solenoid valve, and can control multiple solenoid valves; in the present invention, it is composed of the first solenoid valve 3, the second solenoid valve 8, the third solenoid valve 10, and the fourth solenoid valve 12.

[0048] The airtightness detection and control 300 is composed of a first power battery box pressure sensor 4, a second power battery box pressure sensor 9, a third battery high-voltage distribution box pressure sensor 11, and a fourth all-in-one controller pressure sensor 13. These pressure sensor signals (which can be analog signals or digital signals) are input into the controller 5 (composed of a single-chip microcomputer) for signal conversion and processing, and are compared and judged with the set values to control the on and off of the corresponding solenoid valve.

[0049] The airtightness alarm 400 comprises the vehicle bus 6, a multimedia screen display, and an alarm 7. When the controller 5 determines that one or more of the power battery housing, control power battery housing, battery high-voltage distribution box, or all-in-one controller has an airtightness fault, it sends an airtightness fault display signal and an alarm signal to the multimedia screen via the vehicle bus 6. The multimedia screen then displays the specific high-voltage component airtightness fault and issues an alarm. Alternatively, the controller 5 sends a specific high-voltage component alarm to the control center or user app via the vehicle's T-BOX.

[0050] A pressure sensor is provided at the inlet of the high-pressure component or in the box.

[0051] The outlet ends of the first solenoid valve 3, the second solenoid valve 8, the third solenoid valve 10, and the fourth solenoid valve 12 are respectively connected to the power battery box, the control power battery box, the battery high-voltage distribution box, the explosion-proof valve or the dedicated air pipe interface of the all-in-one controller, and the first power battery box pressure sensor 4, the second power battery box pressure sensor 9, the third battery high-voltage distribution box pressure sensor 11, and the fourth all-in-one controller pressure sensor 13 are installed at the connection points of the power battery box, the control power battery box, the battery high-voltage distribution box, and the explosion-proof valve or the dedicated air pipe interface of the all-in-one controller; they are used to realize the detection of the pressure of the corresponding high-voltage components.

[0052] The controller 5 controls the gas source by turning the electromagnetic valve on and off.

[0053] The controller 5 is equipped with a first power battery box pressure sensor 4, a second power battery box pressure sensor 9, a third battery high-voltage distribution box pressure sensor 11, and a fourth all-in-one controller pressure sensor 13 at the connection point of the power battery box, the control power battery box, the battery high-voltage distribution box, the explosion-proof valve or the dedicated air pipe interface of the all-in-one controller. The pressure sensor values are compared and identified with the pressure setting values of the corresponding high-voltage components, and the on and off of the solenoid valve of the corresponding high-voltage component can be controlled.

[0054] The controller 5 determines the air tightness of the high-pressure component by comparing the air pressure change rate of the high-pressure component with the set value of the corresponding high-pressure component.

[0055] The pressure drop rate of the high-pressure component is calculated by starting to time the pressure drop change of the corresponding pressure sensor in the high-pressure component of the closed solenoid valve until the lower limit pressure setting value of the corresponding high-pressure component is reached; if the pressure drop rate of the high-pressure component is greater than or equal to the pressure drop rate of the corresponding high-pressure component set by the controller 5, it is determined that there is a problem with the air tightness of the high-pressure component, and an alarm signal and fault code of the high-pressure component are issued.

[0056] The controller 5 uploads the high-voltage component alarm signal and fault code to the multimedia screen, control center or user APP through the vehicle bus 6.

[0057] The controller 5 can upload the alarm signal and fault code of the high-voltage component to the vehicle bus 6; through the vehicle bus 6, the multimedia screen receives these signals, and converts the alarm signal and fault code of the high-voltage component through multimedia, and displays and alarms on the multimedia 7; the alarm signal and fault code of the high-voltage component can also be sent to the control center or user APP through the vehicle bus 6 and T-BOX.

[0058] An online air tightness detection method for high-voltage components of an electric vehicle comprises the following steps:

[0059] Step 1: Provide dry compressed air or nitrogen to multiple high-pressure components through the air source module;

[0060] Step 2: Use the controller to control the on and off of the multi-way solenoid valve to adjust the input of the gas source to each high-pressure component;

[0061] Step 3: Detect the pressure signal in real time through the pressure sensor installed in each high-voltage component and input the signal into the controller;

[0062] Step 4: The controller compares the detection value of each pressure sensor with the preset pressure range. If the detection value exceeds the preset range, the corresponding solenoid valve is closed and the timing is started;

[0063] Step 5: Calculate the pressure drop rate. If the pressure drop rate exceeds a preset threshold, it is determined that the corresponding high-pressure component has poor air tightness.

[0064] Step 6: The information of the high-voltage component with poor airtightness and the fault code are transmitted to the multimedia screen through the vehicle bus to display the alarm, and are simultaneously sent to the control center or the user APP.

[0065] Working principle:

[0066] After the dry, high-pressure compressed air or nitrogen gas source 1 is stabilized by a pressure reducing valve, it is input into the inlet ends of the first solenoid valve 3, the second solenoid valve 8, the third solenoid valve 10, and the fourth solenoid valve 12 through the air pipe. The outlet ends of the first solenoid valve 3, the second solenoid valve 8, the third solenoid valve 10, and the fourth solenoid valve 12 are respectively connected to the power battery box, the control power battery box, the battery high-voltage distribution box, the explosion-proof valve or the dedicated air pipe interface of the all-in-one controller, and the first power battery box pressure sensor 4, the second power battery box pressure sensor 9, the third battery high-voltage distribution box pressure sensor 11, and the fourth all-in-one controller pressure sensor 13 are installed at the connection point of the power battery box, the control power battery box, the battery high-voltage distribution box, and the explosion-proof valve or the dedicated air pipe interface of the all-in-one controller; the output signals of these pressure sensors are respectively input into the controller 5 composed of a single-chip computer, and the controller 5 converts the signals of each input pressure sensor into electrical signals and compares them with the pressure set values of each high-voltage component.

[0067] When the gas source 1 is opened, passes through the pressure reducing valve 2, and is connected to the explosion-proof valve or dedicated air pipe interface of the power battery box, the control power battery box, the battery high-voltage distribution box, and the all-in-one controller, the first power battery box pressure sensor 4, the second power battery box pressure sensor 9, the third battery high-voltage distribution box pressure sensor 11, and the fourth all-in-one controller, when the pressure sensor values are less than the lower limit pressure setting value of the corresponding high-voltage component, the controller 5 outputs a high level to drive the solenoid valve of the corresponding high-voltage component to be turned on; when the actual pressure of the pressure sensors of the first power battery box pressure sensor 4, the second power battery box pressure sensor 9, the third battery high-voltage distribution box pressure sensor 11, and the fourth all-in-one controller, which are connected to the explosion-proof valve or dedicated air pipe interface of the power battery box, the control power battery box, the battery high-voltage distribution box, and the all-in-one controller, exceeds the upper limit pressure setting value of the corresponding high-voltage component set by the controller 5, the controller 5 outputs a low level to turn off the solenoid valve of the corresponding high-voltage component.

[0068] At this time, the controller 5 starts to time the pressure drop change of the corresponding pressure sensor in the high-pressure component of the closed solenoid valve, and calculates the pressure drop rate of this high-pressure component when the lower limit pressure setting value of the corresponding high-pressure component is reached; if the pressure drop rate of the high-pressure component is greater than or equal to the pressure drop rate of the corresponding high-pressure component set by the controller 5, it is determined that there is a problem with the air tightness of this high-pressure component, and an alarm signal and fault code of this high-pressure component are issued; the alarm signal and fault code of this high-pressure component are then uploaded to the vehicle bus 6; through the vehicle bus 6, the multimedia screen receives these signals, and after the alarm signal and fault code of this high-pressure component are converted through the multimedia, they are displayed and alarmed on the multimedia 7.

[0069] The high-voltage component's alarm signal and fault code can also be sent to the control center or user app via the vehicle bus 6 and T-BOX. The controller 5 can simultaneously detect, alarm, and control the pressure sensors of four or more high-voltage components, enabling real-time detection and alarm functions for multiple high-voltage components on the electric vehicle via the vehicle bus 6.

[0070] The controller 5 composed of a single-chip microcomputer starts to time the pressure drop change of the corresponding pressure sensor in the high-pressure component of the closed solenoid valve, and calculates the pressure drop rate of this high-pressure component when the lower limit pressure setting value of the corresponding high-pressure component is reached; if the pressure drop rate of the high-pressure component is greater than or equal to the pressure drop rate of the corresponding high-pressure component set by the controller 5, it is determined that there is a problem with the air tightness of this high-pressure component, and an alarm signal and fault code of this high-pressure component are issued; this patent only lists four pressure sensors, but in fact it can be more than four, as long as it does not exceed the input AD port of the controller 5 composed of a single-chip microcomputer.

[0071] The controller 5 can upload the alarm signal and fault code of the high-voltage component to the vehicle bus 6; through the vehicle bus 6, the multimedia screen receives these signals, and converts the alarm signal and fault code of the high-voltage component through multimedia, and displays and alarms on the multimedia 7; the alarm signal and fault code of the high-voltage component can also be sent to the control center or user APP through the vehicle bus 6 and T-BOX.

[0072] In this application, the controller 5 is used to install a first power battery box pressure sensor 4, a second power battery box pressure sensor 9, a third battery high-voltage distribution box pressure sensor 11, and a fourth multi-in-one controller pressure sensor 13 at the connection point of the power battery box, the control power battery box, the battery high-voltage distribution box, the explosion-proof valve or the dedicated air pipe interface of the multi-in-one controller. The pressure sensor values are compared and identified with the pressure setting values of the corresponding high-voltage components, so as to control the on and off of the solenoid valve of the corresponding high-voltage component; if the pressure drop rate of the high-voltage component is greater than or equal to the pressure drop rate of the corresponding high-voltage component set by the controller 5, it is determined that there is a problem with the air tightness of this high-voltage component, and an alarm signal and fault code of this high-voltage component are issued; the controller 5 uploads the high-voltage component alarm signal and fault code to the multimedia screen, control center or user APP through the vehicle bus 6.

[0073] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for online air tightness detection of high-voltage components of electric vehicles, characterized in that: The following steps are involved: (1) Provide dry compressed air or nitrogen to multiple high-pressure components through the air source module; (2) Use the controller to control the on and off of the multi-way solenoid valve to adjust the input of the gas source to each high-pressure component; (3) Detecting pressure signals in real time through pressure sensors installed in each high-voltage component and inputting the signals into a controller; (4) The controller compares the detection value of each pressure sensor with the preset pressure range. If the detection value exceeds the preset range, the corresponding solenoid valve is closed and the timing is started; (5) Calculating the pressure drop rate. If the pressure drop rate exceeds a preset threshold, it is determined that the corresponding high-pressure component has poor air tightness; (6) The information and fault code of the high-voltage components with poor airtightness are transmitted to the multimedia screen through the vehicle bus to display the alarm, and are simultaneously sent to the control center or user APP.

2. The method according to claim 1, characterized in that The gas source module includes a pressure reducing valve for stabilizing the gas source pressure to a preset low pressure value.

3. The method according to claim 1, characterized in that The high-voltage components include at least one of a power battery box, a battery high-voltage distribution box, and an all-in-one controller, and each high-voltage component corresponds to an independent solenoid valve and pressure sensor.

4. The method according to claim 1, wherein The controller receives the detection value of the pressure sensor through an analog signal or a digital signal, and performs signal conversion and processing.

5. The method according to claim 1, wherein The pressure drop rate is calculated as follows: after the solenoid valve is closed, the time required for the pressure to drop from the upper limit setting value to the lower limit setting value is recorded, and the rate is calculated based on the pressure difference and the time difference.

6. The method according to claim 1, characterized in that The controller is connected to the T-BOX communication module through the vehicle bus and transmits the alarm information wirelessly to the control center or user APP.

7. The method according to claim 1, characterized in that The preset pressure range and pressure drop rate threshold are dynamically adjusted according to the type of high-pressure component and the working environment.

8. The method according to claim 1, characterized in that The controller supports simultaneous detection of pressure signals of no less than four high-pressure components, and the detection and alarm of each channel are independent of each other.

9. The method according to claim 1, characterized in that The alarm information displayed on the multimedia screen includes the name, location and recommended treatment measures of the specific faulty high-voltage component.

10. The method according to claim 1, characterized in that The method is applicable to electric sanitation vehicles, heavy trucks, and mining trucks equipped with multiple high-voltage components.

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