High-voltage line cooling detection and allocation system and method

Abstract

The invention relates to the field of vehicle control of new energy vehicles, in particular to a high-voltage line cooling detection and allocation system and method.The high-voltage line cooling detection and allocation system comprises a control box, an ECU is arranged in the control box, a plurality of control elements are further included, a water pump is arranged in a liquid cooling box, all the control elements are connected with the ECU, and the liquid cooling box is in signal connection with the ECU. The control element and the control box are both provided with high-voltage connectors, the control element and the control box are connected through a cooling pipeline high-voltage wire, the ECU is in signal connection with the high-voltage connectors on the control element and the high-voltage connectors on the control box, a cooling liquid pipeline is arranged in the control box, the cooling liquid pipeline is communicated with the liquid cooling box, and the cooling liquid pipeline is communicated with the liquid cooling box. The control elements are all provided with cooling liquid return pipes, the cooling liquid return pipes are communicated with the liquid cooling box through the radiator, and the problems that at the present stage, PID parameters are fixed, rapid charging or rapid acceleration violent temperature changes cannot be dealt with, uniform pressurization of the whole pipeline is achieved, energy is wasted due to overcooling of a low-temperature area, and the response is slow after shutdown and leakage due to misinformation of a single sensor are solved.

Description

Technical Field

[0001] The present invention relates to the field of new energy vehicle whole vehicle control, and in particular to a system and method for high-voltage wire cooling detection and allocation. Background Art

[0002] Currently, PID parameters are fixed and cannot cope with the drastic temperature changes caused by fast charging or rapid acceleration. The fixed proportional (P), integral (I), and differential (D) parameters cannot adapt to the sudden temperature rise caused by transient high-power input (such as fast charging), resulting in delayed regulation and response lag. During drastic temperature changes, the fixed integral term (I) may accumulate excessive errors, causing temperature overshoot or continuous oscillation. If the differential term (D) is too small, the system will not be able to adequately suppress the temperature change rate; if it is too large, it may amplify noise.

[0003] When the battery is fast charged, the heat generation rate is fast during high current charging, and the fixed PID cannot quickly adjust the response strength of the cooling system;

[0004] When the motor accelerates rapidly or the motor load changes suddenly, the temperature may rise nonlinearly, and fixed parameters make it difficult to take into account both dynamic response and stability.

[0005] At present, most people rely on experience to adjust PID parameters, but they cannot adapt to dynamic working conditions in real time, or they use "compromise parameters" to cover the worst working conditions, sacrificing the performance of some scenarios.

[0006] At present, the entire pipeline is pressurized uniformly, the low-temperature area is overcooled and wastes energy, a single sensor false alarm causes shutdown, the reaction is slow after a leak, only the instantaneous temperature is monitored, and the accumulated heat load easily damages components. Many problems have emerged.

[0007] At present, a system and method for detecting and adjusting high-voltage wire cooling is proposed to solve the problems raised in the above background technology. Summary of the Invention

[0008] The purpose of the present invention is to provide a system and method for high-voltage line cooling detection and allocation, which can independently control the sections, open a large valve in the high-temperature section, and a small valve in the low-temperature section. The use of dual sensors to verify each other solves the problems of fixed PID parameters at the current stage, which cannot cope with the drastic temperature changes caused by fast charging or rapid acceleration, unified pressurization of the entire pipeline, waste of energy due to over-cooling in the low-temperature zone, false alarms from single sensors, and slow response after leakage.

[0009] A system for high-voltage line cooling detection and adjustment includes a control box, an ECU is provided in the control box, and several control elements, the control elements including a battery pack, a DC-DC, a PTC heater, a motor and a charging stand, and a liquid cooling box. The liquid cooling box is provided with a water pump, the liquid cooling box is connected to a radiator, the battery pack, DC-DC, PTC heater, motor, and charging stand are all connected to the ECU, the liquid cooling box and the ECU are signal-connected, the ECU controls the operation of the control elements, high-voltage connectors are provided on the control elements, high-voltage connectors are provided at corresponding positions where the control box and the control elements are connected, the control elements and the control box are connected via a cooling pipe high-voltage wire, the high-voltage connectors on the ECU and the control elements and the high-voltage connector on the control box are all signal-connected, a coolant pipeline is provided in the control box, the coolant pipeline is connected to the liquid cooling box, a coolant return pipe is provided on the control element, and the coolant return pipe is connected to the liquid cooling box through the radiator.

[0010] It is further defined that a plurality of solenoid valves are provided on the coolant pipeline in the control box, and the solenoid valves are connected to the ECU signals.

[0011] It is further defined that the high-voltage connector includes a device-end socket, a wiring harness-end plug and a temperature sensor, the wiring harness-end plug is plugged into the device-end socket, and there are two temperature sensors, one contact type and one non-contact type.

[0012] To further define, the specific steps are as follows:

[0013] Step S10: The ECU collects the wiring harness temperature collected by the temperature sensors on each high-voltage connector, and the MCU performs calculations and processing, generates pressure control instructions through a hierarchical algorithm, and transmits the control instructions to each solenoid valve and water pump;

[0014] In step S20, each solenoid valve receives a control instruction from the ECU to control the valve opening range, thereby regulating the flow rate of the cooling pipeline in the high-voltage line in sections to achieve the effect of controlling the cooling intensity;

[0015] Step S30: transmitting the resistance change in the wire to the ECU, which calculates the temperature of the wire based on the resistance change, and thus calculates the required cooling intensity;

[0016] In step S40, the water pump runs and intelligently controls the extraction volume and pressure according to the instructions issued by the MCU to prevent the liquid cooling pipe in the control box from overloading and ensure that its pressure is at a balanced value. After the coolant cools the wire, it flows back to the liquid cooling box through the equipment end.

[0017] It is further defined that the segmented regulation of the flow rate of the cooling pipeline in the high-voltage line described in step S20 refers to the liquid cooling pipeline being divided into independent pressure sections, each section being equipped with an independent solenoid valve, and the ECU can control the opening of each section valve separately, with the high-temperature section being opened at a high opening first and the low-temperature section being maintained at a low opening to avoid energy waste caused by excessive cooling.

[0018] Further limitations are imposed on the installation of two temperature sensors at key node locations for cross-checking. When the data difference exceeds 5%, the backup signal is automatically switched. At the same time, a pressure sensor is installed on the coolant pipeline to monitor the actual pressure value in real time. The valve opening instruction is corrected after comparison with the target pressure value. When a leak in the cooling system or sensor failure is detected, the ECU switches to "safety mode", limits the output power of the high-voltage system and issues an alarm.

[0019] It is further defined that step S10 is divided into four levels, V0-V3, through a grading algorithm. The temperature range of level V0 is T≤50℃, and the basic pressure of the pipeline is maintained at 1-2MPA, and only monitoring is performed. The temperature range of level V1 is 50℃<T≤70℃. At this time, linear pressurization is performed, and the pressure is maintained at 2-4MPA, and PID closed-loop control is used. The temperature range of level V2 is 70℃<T≤90℃, and stepped pressurization is performed, and the pressure is maintained at 4-6MPA. Fuzzy control and over-limit warning are used. The temperature range of level V3 is T>90℃. At this time, maximum pressure release is performed, and the pressure is maintained at 6-8MPA, triggering emergency cooling and reporting a fault. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 A system diagram of the control box regulating the cooling system of the present invention;

[0021] Figure 2 This is the architecture diagram of the control box high-voltage wire system of the present invention;

[0022] The markings in the figure correspond to: 1-control box, 2-ECU, 3-control element, 4-liquid cooling box, 5-radiator, 6-high-voltage connector, 7-cooling pipe high-voltage line, 8-coolant pipeline, 9-solenoid valve, 10-coolant return pipe. DETAILED DESCRIPTION

[0023] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention is further described below with reference to the accompanying drawings and embodiments.

[0024] Example:

[0025] like Figure 1 and Figure 2As shown, a system for high-voltage line cooling detection and deployment includes a control box 1, in which an ECU 2 is provided, and also includes several control elements 3. The control element 3 includes a battery pack, a DC-DC, a PTC heater, a motor and a charging stand, and also includes a liquid cooling box 4. A water pump is provided in the liquid cooling box 4. The liquid cooling box 4 is connected to a radiator 5. The battery pack, DC-DC, PTC heater, motor and charging stand are all connected to the ECU 2. The liquid cooling box 4 is signal-connected to the ECU 2. The ECU 2 controls the operation of the control element 3. A high-voltage connector 6 is provided on each control element 3. A high-voltage connector 6 is provided at the corresponding position where the control box 1 and each control element 3 are connected. The control element 3 and the control box 1 are connected through a cooling pipe high-voltage line 7. The high-voltage connectors 6 on the ECU 2 and each control element 3 and the high-voltage connector 6 on the control box 1 are all signal-connected. A coolant pipeline is provided in the control box 1. 8. The coolant pipeline 8 is connected to the liquid cooling tank 4. Several solenoid valves 9 are provided on the coolant pipeline 8. The solenoid valves 9 are all connected to the ECU2 signal. The control elements 3 are all provided with a coolant return pipe 10. The coolant return pipe 10 is connected to the liquid cooling tank 4 through the radiator 5. The high-voltage connector 6 includes a device-end socket, a wiring harness-end plug and a temperature sensor. The wiring harness-end plug is plugged into the device-end socket. There are two temperature sensors, one contact and one non-contact. Two temperature sensors are set at key node positions for cross-checking. When the data difference exceeds 5%, the backup signal is automatically switched. At the same time, a pressure sensor is provided on the coolant pipeline 8. The actual pressure value is monitored in real time by the pressure sensor. The valve opening instruction is corrected after comparison with the target pressure value. When a liquid cooling system leak is detected or the sensor fails, the ECU switches to "safe mode", limits the output power of the high-voltage system and alarms. Figure 1 The arrow in the figure indicates the return direction of the coolant.

[0026] A method for detecting and adjusting high-voltage wire cooling system, comprising the following steps:

[0027] In step S10, the ECU 2 collects the wiring harness temperature collected by the temperature sensor on each high-voltage connector 6, and the MCU performs calculation processing, generates a pressure control instruction through a hierarchical algorithm, and transmits the control instruction to each solenoid valve 9 and water pump. It is divided into four levels, V0-V3. The temperature range of the V0 level is T≤50℃, and the basic pressure of the pipeline is maintained at 1-2MPA. It is only monitored. The temperature range of the V1 level is 50℃<T≤70℃. At this time, linear supercharging is performed, and the pressure is maintained at 2-4MPA. PID closed-loop control is used. The temperature range of the V2 level is 70℃<T≤90℃. Step-by-step supercharging is performed, and the pressure is maintained at 4-6MPA. Fuzzy control and over-limit warning are used. The V1 and V2 levels use variable parameter PID control, and the proportional coefficient (Kp) and integral time (Ti) are dynamically adjusted according to the temperature rise rate (dT / dt).

[0028] The temperature range for the V3 level is T>90℃. At this time, maximum pressure release is performed and the pressure is maintained at 6-8MPA, triggering emergency cooling and reporting a fault. The multi-objective optimized pressure value is generated based on the temperature distribution uniformity and battery load status.

[0029] In step S20, each solenoid valve 9 receives a control instruction from the ECU 2 to control the valve opening range, thereby regulating the flow of the coolant pipeline 8 in the high-voltage line in sections. The coolant pipeline 8 is divided into independent pressure sections, each of which is equipped with an independent solenoid valve 9. The ECU can independently control the opening of each section of the valve, with the high-temperature section being preferentially opened to a high opening, while the low-temperature section is maintained at a low opening, thereby avoiding energy waste caused by excessive cooling and achieving the effect of controlling the cooling intensity.

[0030] Step S30: transmitting the resistance change in the wire to the ECU, which calculates the temperature of the wire based on the resistance change, and thus calculates the required cooling intensity;

[0031] In step S40, the liquid cooling water pump is running. According to the instructions issued by the MCU, the extraction volume and pressure are intelligently controlled to prevent the coolant pipeline 8 in the control box 1 from being overloaded, ensuring that its pressure is at a balanced value. After the coolant cools the wire, it flows back to the liquid cooling box through the equipment end.

[0032] Based on the harness temperature distribution map generated by the temperature sensor array, the pressure level can be increased in the section where the local high temperature area (temperature difference ≥ 10°C) is located;

[0033] If the same section remains above V2 level for 5 consecutive minutes, the "cumulative overload protection" will be triggered and the pressure will be forcibly increased to the next level.

[0034] The above is a detailed introduction to the system and method for high-voltage line cooling detection and adjustment provided by the present invention. The description of the specific embodiments is only used to help understand the method and core idea of ​​the present invention. It should be pointed out that for ordinary technicians in this technical field, without departing from the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A system for detecting and adjusting high-voltage line cooling, characterized by: The invention comprises a control box (1), wherein an ECU (2) is arranged in the control box (1), and further comprises a plurality of control elements (3), wherein the control elements (3) comprise a battery pack, a DC-DC, a PTC heater, a motor and a charging stand, and further comprises a liquid cooling box (4), wherein a water pump is arranged in the liquid cooling box (4), wherein the liquid cooling box (4) is connected to a radiator (5), wherein the battery pack, the DC-DC, the PTC heater, the motor and the charging stand are all connected to the ECU (2), wherein the liquid cooling box (4) is signal-connected to the ECU (2), wherein the ECU (2) controls the control elements (3) to operate, wherein the control elements (3) are all provided with high-voltage connectors (6), wherein the The control box (1) and the control element (3) are connected at corresponding positions with high-voltage connectors (6). The control element (3) and the control box (1) are connected via a cooling pipe high-voltage line (7). The high-voltage connectors (6) on the ECU (2) and the control element (3) and the high-voltage connector (6) on the control box (1) are all connected by signals. A coolant pipeline (8) is provided in the control box (1), and the coolant pipeline (8) is connected to the liquid cooling box (4). A coolant return pipe (10) is provided on each control element (3), and the coolant return pipe (10) is connected to the liquid cooling box (4) via the radiator (5).

2. The high-voltage line cooling detection and adjustment system according to claim 1, characterized in that: A plurality of solenoid valves (9) are provided on the coolant pipeline (8) in the control box (1), and the solenoid valves (9) are signal-connected to the ECU (2).

3. The high-voltage line cooling detection and adjustment system according to claim 2, characterized in that: The high-voltage connector (6) comprises a device-end socket, a wiring harness-end plug and a temperature sensor. The wiring harness-end plug is plugged into the device-end socket. There are two temperature sensors, one contact type and one non-contact type.

4. The method of a high-voltage line cooling detection and deployment system according to claim 3, characterized in that: The specific steps are as follows: In step S10, the ECU (2) collects the wiring harness temperature collected by the temperature sensor on each high-voltage connector (6), and the MCU performs calculation processing, generates a pressure control instruction through a hierarchical algorithm, and transmits the control instruction to each solenoid valve (9) and the water pump; In step S20, each solenoid valve (9) receives a control instruction transmitted by the ECU (2) to control the valve opening range, and adjusts the flow rate of the coolant pipeline (8) in the high-voltage line in sections to achieve the effect of controlling the cooling intensity; Step S30, transmitting the resistance change in the wire to the ECU (2), and the ECU (2) calculates the temperature of the wire based on the resistance change, thereby calculating the required cooling intensity; In step S40, the water pump is running, and according to the instructions issued by the MCU, the pumping amount and pressure are intelligently controlled to prevent the pressure of the coolant pipeline (8) in the control box (1) from being overloaded, and to ensure that its pressure is at a balanced value. After the coolant cools the wire, it flows back to the liquid cooling box through the equipment end.

5. A method for detecting and adjusting high-voltage wire cooling according to claim 4, characterized in that The segmented regulation of the flow rate of the cooling pipeline in the high-voltage line described in step S20 means that the coolant pipeline (8) is divided into independent pressure sections, each section is equipped with an independent solenoid valve (9), and the ECU (2) can independently control the opening of each section valve, with the high-temperature section being opened with a high opening first and the low-temperature section being maintained at a low opening, so as to avoid energy waste caused by excessive cooling.

6. The method of a high-voltage line cooling detection and deployment system according to claim 4, characterized in that: Two temperature sensors are set at key node positions for cross-checking. When the data difference exceeds 5%, the backup signal is automatically switched. At the same time, a pressure sensor is installed on the coolant pipeline to monitor the actual pressure value in real time. After comparing it with the target pressure value, the valve opening instruction is corrected. When a liquid cooling system leak or sensor failure is detected, the ECU switches to "safe mode", limits the output power of the high-voltage system, and issues an alarm.

7. The method of a high-voltage line cooling detection and deployment system according to claim 3, characterized in that: In step S10, the system is divided into four levels, V0-V3, through a grading algorithm. The temperature range of level V0 is T≤50℃, and the basic pressure of the pipeline is maintained at 1-2MPA. Only monitoring is performed. The temperature range of level V1 is 50℃<T≤70℃. At this time, linear pressurization is performed, and the pressure is maintained at 2-4MPA. PID closed-loop control is used. The temperature range of level V2 is 70℃<T≤90℃. Step-by-step pressurization is performed, and the pressure is maintained at 4-6MPA. Fuzzy control and over-limit warning are used. The temperature range of level V3 is T>90℃. At this time, maximum pressure release is performed, and the pressure is maintained at 6-8MPA, triggering emergency cooling and reporting a fault.

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