High-voltage electrical safety control method and system of electric drive system

Abstract

The invention discloses a high-voltage electrical safety control method and system of an electric driving system, and belongs to the technical field of safety of electric driving systems of electric automobiles. The method comprises the following steps: in response to a discharge trigger signal, acquiring system state information and a hardware configuration flag bit; comparing the state information with a preset condition to generate a winding discharge or resistance discharge instruction; performing discharge operation and voltage monitoring according to the instruction in combination with the hardware configuration flag bit; and finally generating and outputting a discharge state signal. The system comprises a signal acquisition module, a data processing module, a discharge execution and monitoring module and an output module. The core of the method is that a hardware configuration flag bit is introduced, so that the same set of control logic can be adaptively compatible with a hardware platform containing a physical discharge resistor and a hardware platform without the physical discharge resistor, and the problem of repeated software development and maintenance caused by product cost reduction iteration is effectively solved on the premise of ensuring the function safety and integrity; the cost is obviously reduced; and the universality and the reliability of the system are improved.

Description

Technical Field

[0001] This invention relates to the field of electric vehicle electric drive system safety technology, and in particular to a high-voltage electrical safety control method and system for an electric drive system. Background Technology

[0002] High-voltage electrical safety is central to the overall safety of electric vehicles. The electric drive system must discharge the bus voltage to below a safe level within a specified time after a collision or power failure. Currently, the mainstream solution combines winding discharge with resistor discharge.

[0003] In existing technologies, such as Chinese patent application CN117944456A, the discharge strategy is mainly selected intelligently by analyzing fault types and collision signals. However, their core architectures all assume that the hardware platform must include a usable active discharge resistor. With increasing market competition, eliminating the active discharge resistor has become an effective solution to reduce costs. However, directly removing this hardware would render all existing safety architectures that rely on resistor discharge ineffective, forcing companies to develop and maintain two different software systems for both new and old hardware platforms, significantly increasing development costs, testing and verification costs, and supply chain management complexity.

[0004] Therefore, there is an urgent need in this field for an innovative high-voltage safety architecture that can seamlessly support both hardware solutions with and without discharge resistors through unified software logic. Summary of the Invention

[0005] To address the technical problems existing in the background art, the present invention proposes a high-voltage electrical safety control method and system for electric drive systems.

[0006] This invention proposes a high-voltage electrical safety control method for an electric drive system, comprising:

[0007] In response to a discharge trigger signal or a collision signal, the current status information and hardware configuration flag of the electric drive system are acquired. The current status information includes bus voltage value, motor speed value and fault status signal. The hardware configuration flag has a first status value and a second status value. The first status value indicates that the current hardware platform contains a physical discharge resistor, and the second status value indicates that the current hardware platform does not contain a physical discharge resistor.

[0008] The current status information is compared with the preset winding discharge conditions, which include: no drive-type faults affecting winding discharge, no over-temperature faults, motor speed lower than the preset speed threshold and bus voltage higher than the safety voltage threshold.

[0009] If the current state information simultaneously satisfies all the preset winding discharge conditions, a winding discharge enable signal is generated; if any information in the current state information does not satisfy the preset winding discharge conditions, a resistor discharge command is generated.

[0010] Based on the winding discharge enable signal or the resistor discharge command, and in conjunction with the hardware configuration flag, the corresponding discharge operation and voltage monitoring operation are executed.

[0011] Based on the results of the voltage monitoring operation, a final discharge success signal or discharge failure signal is generated within the preset total discharge monitoring time.

[0012] Output a discharge success signal or a discharge failure signal to the vehicle network.

[0013] Preferably, the step of performing the corresponding discharge operation and voltage monitoring operation based on the winding discharge enable signal specifically includes:

[0014] If the winding discharge enable signal is generated, a control signal containing a given direct-axis current command and a zero quadrature-axis current command is sent to the motor controller to drive the motor to perform winding discharge.

[0015] Start the first timer T1 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T1 period;

[0016] If the bus voltage drops below the safe voltage threshold within time T1, a discharge success signal is generated.

[0017] If the bus voltage value does not drop below the safe voltage threshold within time T1, then the resistor discharge command is generated.

[0018] Preferably, the step of performing the corresponding discharge operation and voltage monitoring operation according to the resistor discharge command specifically includes:

[0019] If the resistor discharge command is generated, then the hardware configuration flag bit is accessed;

[0020] If the hardware configuration flag indicates that a physical discharge resistor is included, a drive signal is output to the discharge resistor drive circuit to close the discharge loop.

[0021] If the hardware configuration flag indicates that a physical discharge resistor is not included, then the output of the drive signal is blocked;

[0022] Start the second timer T2 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T2 period;

[0023] If the bus voltage drops below the safe voltage threshold within time T2, a discharge success signal is generated.

[0024] If the bus voltage value does not drop below the safe voltage threshold within time T2, a discharge failure signal is generated.

[0025] Preferably, the preset total discharge monitoring time is determined as follows:

[0026] If winding discharge has been performed, the total discharge monitoring time is the sum of the duration of the first timer T1 and the duration of the second timer T2;

[0027] If winding discharge is not performed and resistor discharge is performed directly, the total discharge monitoring time is the duration of the second timer T2.

[0028] Preferably, the safe voltage threshold ranges from 55V to 60V.

[0029] This invention proposes a high-voltage electrical safety control system for an electric drive system, used to implement the high-voltage electrical safety control method for an electric drive system as described in any one of the above claims, the system comprising:

[0030] The signal acquisition module is used to acquire discharge trigger signals, collision signals, bus voltage signals, motor speed signals, fault status signals, and hardware configuration flags.

[0031] The data processing module is connected to the signal acquisition module and is used to receive the signals acquired by the signal acquisition module, compare the current status information with the preset winding discharge conditions, and generate a winding discharge enable signal or a resistor discharge command.

[0032] The discharge execution and monitoring module is connected to the data processing module and is used to receive the winding discharge enable signal or the resistor discharge command, access the hardware configuration flag bit, and execute the corresponding discharge and monitoring strategy to generate a discharge success signal or a discharge failure signal.

[0033] The output module, connected to the discharge execution and monitoring module, is used to send a discharge success signal or a discharge failure signal to the vehicle network.

[0034] Preferably, the discharge execution and monitoring module includes:

[0035] The winding discharge control unit is used to control the motor controller to perform winding discharge when the winding discharge enable signal is received.

[0036] A resistor discharge control unit is used to access a hardware configuration flag bit and control the on / off state of the discharge resistor drive circuit according to the flag bit when the resistor discharge command is received.

[0037] The voltage monitoring unit is used to monitor the bus voltage value during the discharge process and to send a discharge success signal or a discharge failure signal after the timer times out.

[0038] Preferably, the resistor discharge control unit further includes a hardware abstraction layer submodule, which is configured to receive a resistor discharge command and query a hardware configuration flag bit. If the hardware configuration flag bit indicates that there is no discharge resistor, the output of the drive signal is blocked.

[0039] This invention presents a high-voltage electrical safety control method and system for electric drive systems. By introducing hardware configuration flags and a hardware abstraction layer, the same high-voltage safety control logic can seamlessly adapt to two different hardware platforms: one with a physical discharge resistor and the other without. This innovative architecture effectively solves the problem of software system redevelopment, testing, verification, and maintenance required due to product cost reduction iterations (removal of discharge resistors), significantly reducing R&D and time costs. Simultaneously, the system maintains a complete functional safety monitoring process under any hardware configuration, ensuring the controllability and observability of the high-voltage discharge process, fully meeting the requirements of functional safety standards. Thus, while achieving cost reduction goals, it ensures the high-voltage safety of the entire vehicle and the reliability of the system. Attached Figure Description

[0040] Figure 1 This is a schematic diagram of the workflow of a high-voltage electrical safety control method for an electric drive system proposed in this invention;

[0041] Figure 2 This is a schematic diagram of the processing flow of one embodiment of the high-voltage electrical safety control method for an electric drive system proposed in this invention;

[0042] Figure 3 This is a schematic diagram of the system architecture of a high-voltage electrical safety control system for an electric drive system proposed in this invention. Detailed Implementation

[0043] Reference Figure 1-3 The present invention proposes a high-voltage electrical safety control method for an electric drive system, comprising the following steps:

[0044] S1. In response to a discharge trigger signal or a collision signal, obtain the current status information and hardware configuration flag of the electric drive system. The current status information includes the bus voltage value, motor speed value and fault status signal. The hardware configuration flag has a first status value and a second status value. The first status value indicates that the current hardware platform contains a physical discharge resistor, and the second status value indicates that the current hardware platform does not contain a physical discharge resistor.

[0045] In this embodiment, if the discharge trigger signal or collision signal does not respond, the active discharge monitoring is not enabled, and the discharge status is invalid.

[0046] S2. Compare the current status information with the preset winding discharge conditions. The preset winding discharge conditions include: no drive-type faults affecting winding discharge, no over-temperature faults, motor speed lower than the preset speed threshold and bus voltage higher than the safety voltage threshold.

[0047] S3. If the current status information simultaneously meets all the preset winding discharge conditions, a winding discharge enable signal is generated; if any information in the current status information does not meet the preset winding discharge conditions, a resistor discharge command is generated.

[0048] S4. Based on the winding discharge enable signal or resistor discharge command, and in conjunction with the hardware configuration flag, execute the corresponding discharge operation and voltage monitoring operation.

[0049] In this embodiment, the corresponding discharge operation and voltage monitoring operation are performed according to the winding discharge enable signal, specifically as follows:

[0050] If a winding discharge enable signal is generated, a control signal containing a given direct-axis current command and a zero quadrature-axis current command is sent to the motor controller to drive the motor to perform winding discharge.

[0051] Start the first timer T1 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T1 period;

[0052] If the bus voltage drops below the safe voltage threshold within time T1, a discharge success signal is generated.

[0053] If the bus voltage does not drop below the safe voltage threshold within time T1, a resistance discharge command is generated.

[0054] In this embodiment, the corresponding discharge operation and voltage monitoring operation are executed according to the resistor discharge command, specifically as follows:

[0055] If a resistor discharge command is generated, the hardware configuration flags are accessed;

[0056] If the hardware configuration flag indicates that a physical discharge resistor is included, a drive signal is output to the discharge resistor drive circuit to close the discharge loop.

[0057] If the hardware configuration flag does not indicate that a physical discharge resistor is included, the output of the drive signal is blocked.

[0058] Start the second timer T2 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T2 period;

[0059] If the bus voltage drops below the safe voltage threshold within time T2, a discharge success signal is generated.

[0060] If the bus voltage does not drop below the safe voltage threshold within time T2, a discharge failure signal is generated.

[0061] Specifically, the safe voltage threshold ranges from 55V to 60V.

[0062] S5. Based on the results of voltage monitoring operations, generate the final discharge success signal or discharge failure signal within the preset total discharge monitoring time.

[0063] In this embodiment, the preset total discharge monitoring time is determined as follows:

[0064] If winding discharge has been performed, the total discharge monitoring time is the sum of the duration of the first timer T1 and the duration of the second timer T2;

[0065] If winding discharge is not performed and resistor discharge is performed directly, the total discharge monitoring time is the duration of the second timer T2.

[0066] S6 outputs a discharge success signal or a discharge failure signal to the vehicle network.

[0067] Specifically, such as Figure 2 As shown, the safe voltage threshold is 60V, and the execution flow of the method is as follows:

[0068] After the system is powered on, the hardware configuration flag is initialized. This flag can be pre-written into the controller's non-volatile memory. When a discharge trigger signal (such as a vehicle power-off command) or a collision signal is received, the high-voltage discharge safety procedure is initiated.

[0069] First, the current status of the system is collected, including bus voltage, motor speed, and various fault statuses, and the hardware configuration flags are read.

[0070] Subsequently, the status information is compared with the preset winding discharge conditions. If all conditions are met (i.e., no related faults, speed below the threshold, and voltage above the safe value), a winding discharge enable signal is generated, and the winding discharge process is executed: an Id current command (Iq = 0) is sent to the motor controller, and timer T1 is started to monitor the voltage drop. If the voltage drops below 60V within T1 time, a successful discharge is reported; if it does not drop to the safe value, a resistance discharge command is generated.

[0071] If the status information does not meet the winding discharge conditions, a resistor discharge command is directly generated. During the resistor discharge process, the hardware configuration flag is first checked. If the flag is in the first state (indicating resistance), a normal drive signal is output, closing the discharge circuit; if the flag is in the second state (indicating no resistance), the drive signal output is blocked. Regardless of whether a resistor is actually driven, timer T2 is started to monitor voltage changes. Finally, based on whether the voltage drops below a safe value within T2 time, a discharge success or failure signal is generated and sent to the vehicle controller via the CAN bus.

[0072] Reference Figure 1-3 This invention proposes a high-voltage electrical safety control system for an electric drive system, used to implement the high-voltage electrical safety control method for an electric drive system as described in any of the above-mentioned claims. The system includes:

[0073] The signal acquisition module is used to acquire discharge trigger signals, collision signals, bus voltage signals, motor speed signals, fault status signals, and hardware configuration flags.

[0074] The data processing module, connected to the signal acquisition module, is used to receive signals acquired by the signal acquisition module, compare the current status information with the preset winding discharge conditions, and generate a winding discharge enable signal or a resistor discharge command.

[0075] The discharge execution and monitoring module is connected to the data processing module. It is used to receive the winding discharge enable signal or the resistor discharge command, access the hardware configuration flag, and execute the corresponding discharge and monitoring strategy to generate a discharge success signal or a discharge failure signal.

[0076] The output module, connected to the discharge execution and monitoring module, is used to send a discharge success signal or a discharge failure signal to the vehicle network.

[0077] In this embodiment, the discharge execution and monitoring module includes:

[0078] The winding discharge control unit is used to control the motor controller to perform winding discharge when a winding discharge enable signal is received.

[0079] The resistor discharge control unit is used to access the hardware configuration flag bit and control the on / off state of the discharge resistor drive circuit according to its indication when a resistor discharge command is received.

[0080] The voltage monitoring unit is used to monitor the bus voltage value during the discharge process and to send a discharge success signal or a discharge failure signal after the timer times out.

[0081] In this embodiment, the resistor discharge control unit further includes a hardware abstraction layer submodule, which is configured to receive a resistor discharge command and query a hardware configuration flag. If the hardware configuration flag indicates that there is no discharge resistor, the output of the drive signal is blocked.

[0082] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-voltage electrical safety control method for an electric drive system, characterized in that, include: In response to a discharge trigger signal or a collision signal, the current status information and hardware configuration flag of the electric drive system are acquired. The current status information includes bus voltage value, motor speed value and fault status signal. The hardware configuration flag has a first status value and a second status value. The first status value indicates that the current hardware platform contains a physical discharge resistor, and the second status value indicates that the current hardware platform does not contain a physical discharge resistor. The current status information is compared with the preset winding discharge conditions, which include: no drive-type faults affecting winding discharge, no over-temperature faults, motor speed lower than the preset speed threshold and bus voltage higher than the safety voltage threshold. If the current state information simultaneously satisfies all the preset winding discharge conditions, a winding discharge enable signal is generated; if any information in the current state information does not satisfy the preset winding discharge conditions, a resistor discharge command is generated. Based on the winding discharge enable signal or the resistor discharge command, and in conjunction with the hardware configuration flag, the corresponding discharge operation and voltage monitoring operation are executed. Based on the results of the voltage monitoring operation, a final discharge success signal or discharge failure signal is generated within the preset total discharge monitoring time. Output a discharge success signal or a discharge failure signal to the vehicle network.

2. The high-voltage electrical safety control method for an electric drive system according to claim 1, characterized in that, The specific steps for performing the corresponding discharge operation and voltage monitoring operation based on the winding discharge enable signal are as follows: If the winding discharge enable signal is generated, a control signal containing a given direct-axis current command and a zero quadrature-axis current command is sent to the motor controller to drive the motor to perform winding discharge. Start the first timer T1 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T1 period; If the bus voltage drops below the safe voltage threshold within time T1, a discharge success signal is generated. If the bus voltage value does not drop below the safe voltage threshold within time T1, then the resistor discharge command is generated.

3. The high-voltage electrical safety control method for an electric drive system according to claim 2, characterized in that, The specific steps for executing the corresponding discharge operation and voltage monitoring operation according to the resistor discharge command are as follows: If the resistor discharge command is generated, then the hardware configuration flag bit is accessed; If the hardware configuration flag indicates that a physical discharge resistor is included, a drive signal is output to the discharge resistor drive circuit to close the discharge loop. If the hardware configuration flag indicates that a physical discharge resistor is not included, then the output of the drive signal is blocked; Start the second timer T2 and monitor whether the bus voltage value drops below the safe voltage threshold within the time T2 period; If the bus voltage drops below the safe voltage threshold within time T2, a discharge success signal is generated. If the bus voltage value does not drop below the safe voltage threshold within time T2, a discharge failure signal is generated.

4. The high-voltage electrical safety control method for an electric drive system according to claim 3, characterized in that, The preset total discharge monitoring time is determined as follows: If winding discharge has been performed, the total discharge monitoring time is the sum of the duration of the first timer T1 and the duration of the second timer T2; If winding discharge is not performed and resistor discharge is performed directly, the total discharge monitoring time is the duration of the second timer T2.

5. The high-voltage electrical safety control method for an electric drive system according to claim 3, characterized in that, The safe voltage threshold ranges from 55V to 60V.

6. A high-voltage electrical safety control system for an electric drive system, characterized in that, A high-voltage electrical safety control method for implementing an electric drive system as described in any one of claims 1 to 5, the system comprising: The signal acquisition module is used to acquire discharge trigger signals, collision signals, bus voltage signals, motor speed signals, fault status signals, and hardware configuration flags. The data processing module is connected to the signal acquisition module and is used to receive the signals acquired by the signal acquisition module, compare the current status information with the preset winding discharge conditions, and generate a winding discharge enable signal or a resistor discharge command. The discharge execution and monitoring module is connected to the data processing module and is used to receive the winding discharge enable signal or the resistor discharge command, access the hardware configuration flag bit, and execute the corresponding discharge and monitoring strategy to generate a discharge success signal or a discharge failure signal. The output module, connected to the discharge execution and monitoring module, is used to send a discharge success signal or a discharge failure signal to the vehicle network.

7. The high-voltage electrical safety control system for the electric drive system according to claim 6, characterized in that, The discharge execution and monitoring module includes: The winding discharge control unit is used to control the motor controller to perform winding discharge when the winding discharge enable signal is received. A resistor discharge control unit is used to access a hardware configuration flag bit and control the on / off state of the discharge resistor drive circuit according to the flag bit when the resistor discharge command is received. The voltage monitoring unit is used to monitor the bus voltage value during the discharge process and to send a discharge success signal or a discharge failure signal after the timer times out.

8. The high-voltage electrical safety control system for the electric drive system according to claim 7, characterized in that, The resistor discharge control unit also includes a hardware abstraction layer submodule, which is configured to receive a resistor discharge command and query a hardware configuration flag. If the hardware configuration flag indicates that there is no discharge resistor, the output of the drive signal is blocked.

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