Low-cost extensible PDU high-voltage architecture design method

Abstract

The invention relates to a low-cost extensible PDU (Protocol Data Unit) high-voltage architecture design method, which solves the problem that the design and management cost and the hardware cost are increased because PDU products in various hardware technical states need to be designed at present. Components needing to be pre-charged are intensively designed in a circuit framework with pre-charging, meanwhile, the independently-controlled contactor is designed, the requirement for pre-charging control is met by changing software parameters and a control model, and pre-charging control over the power utilization components by the PDU is achieved. On the premise that the PDU function is met, the number of PDU product hardware technology states is reduced, platform PDU hardware design is facilitated, and the hardware cost is reduced.

Description

Technical Field

[0001] This invention belongs to the field of new energy vehicle technology, specifically relating to a low-cost and scalable PDU high-voltage architecture design method. Background Technology

[0002] Currently, all new energy commercial vehicles must be designed with a high-voltage distribution unit (PDU) to distribute the DC high voltage of the power battery to various high-voltage power consumption units. However, due to the different manufacturers and models of some high-voltage components, the pre-charge control modes are inconsistent. Therefore, the PDU pre-charge circuit design needs to meet different requirements, which requires the design of PDU products with multiple hardware technical states, greatly increasing the design, management and hardware costs. Summary of the Invention

[0003] The purpose of this invention is to design a low-cost, scalable high-voltage architecture design method for PDUs. This method centralizes the pre-charge-requiring components within a pre-charge-enabled circuit framework, while simultaneously designing individually controlled contactors. By modifying software parameters and the control model, the pre-charge control requirements are met, enabling the PDU to pre-charge the electrical components. While fulfilling the PDU's functional requirements, this method reduces the number of hardware technical states in the PDU product, facilitating platform-based PDU hardware design and lowering hardware costs.

[0004] This invention is achieved through the following technical solutions:

[0005] A low-cost, scalable PDU high-pressure architecture design method includes the following steps:

[0006] S1: Design separate power circuits and pre-charge circuits for ultra-high power electrical equipment:

[0007] S2: Optimized design for all low-power electrical equipment in auxiliary drive circuit and pre-charge circuit control;

[0008] S3: For low-power electrical equipment that requires pre-charging, a contactor with separate control is designed at the back end of the auxiliary drive pre-charging circuit;

[0009] S4: When low-power electrical equipment needs to be pre-charged when powered on, the software needs to control the contactor of the corresponding low-power electrical equipment to be normally closed after low-voltage power-on. When powered on, the corresponding low-power electrical equipment can be pre-charged through the pre-charge circuit of the auxiliary drive. After the pre-charge is completed, the vehicle inputs the enable signal of the corresponding low-power electrical equipment, and the corresponding low-power electrical equipment can work normally.

[0010] S5: When low-power electrical equipment is powered on, it does not need to be pre-charged. When the corresponding low-power electrical equipment needs to work, the contactor of the corresponding low-power electrical equipment is closed by software control to supply power to the corresponding low-power electrical equipment; when the corresponding low-power electrical equipment does not need to work, the contactor of the corresponding low-power electrical equipment is opened by software control to stop supplying power to the corresponding low-power electrical equipment.

[0011] The high-power electrical equipment includes a motor controller, a range extender, and an upper structure.

[0012] The low-power electrical equipment includes air conditioners and PTC devices.

[0013] By adopting the high-voltage PDU architecture designed in this invention, the hardware specifications of the PDU can be significantly reduced, different functional requirements can be implemented according to different software, and strong scalability can be achieved. At the same time, the cost of the two pre-charge circuits of the PDU system is reduced. Attached Figure Description

[0014] Figure 1 This is a high-voltage architecture diagram designed by the method of this invention. Detailed Implementation

[0015] The technical solution of this invention is to centrally allocate components requiring pre-charging within a pre-charging circuit, while designing a separately controlled contactor. Through changes in software parameters and the control model, flexible switching on whether to pre-charge electrical components is required is achieved. Its high-voltage architecture is as follows: Figure 1 As shown. The design method is as follows:

[0016] Step 1: Design separate power circuits and pre-charge circuits for ultra-high power electrical equipment such as motor controllers, range extenders, and superstructure power supplies.

[0017] Step 2: Optimize the design of auxiliary drive circuit and pre-charge circuit control for all low-power electrical equipment.

[0018] Step 3: For low-power electrical equipment that requires pre-charging, design a separately controlled contactor at the back end of the auxiliary drive pre-charging circuit, such as MC9 and MC12 in the figure.

[0019] Step 4: When the air conditioner or PTC needs to be pre-charged when powered on, the software needs to control the MC12 or MC9 contactor to be normally closed after the low voltage is powered on. When powered on, the air conditioner can be pre-charged through the pre-charge circuit of the auxiliary drive. After the pre-charge is completed, the vehicle inputs the air conditioner enable signal, and the air conditioner or PTC can work normally.

[0020] Step 5: When the air conditioner or PTC is powered on, no pre-charging is required. When the air conditioner or PTC needs to work, the MC12 or MC9 contactor is closed via software control to supply power to the air conditioner or PTC. When the air conditioner or PTC does not need to work, the MC12 or MC9 contactor is opened via software control to stop supplying power to the air conditioner or PTC.

[0021] This invention achieves the control of pre-charging for low-power electrical equipment by designing and optimizing a standardized pre-charging circuit and changing software, thereby reducing the hardware requirements of vehicle manufacturers' PDUs. Compared with existing products, it reduces the number of pre-charging contactors, pre-charging resistors, and pre-charging circuits, thus lowering PDU costs.

Claims

1. A low-cost, scalable PDU high-pressure architecture design method, characterized by: Includes the following steps: S1: Design separate power circuits and pre-charge circuits for ultra-high power electrical equipment: S2: Optimized design for all low-power electrical equipment in auxiliary drive circuit and pre-charge circuit control; S3: For low-power electrical equipment that requires pre-charging, a contactor with separate control is designed at the back end of the auxiliary drive pre-charging circuit; S4: When low-power electrical equipment needs to be pre-charged when powered on, the software needs to control the contactor of the corresponding low-power electrical equipment to be normally closed after low-voltage power-on. When powered on, the corresponding low-power electrical equipment can be pre-charged through the pre-charge circuit of the auxiliary drive. After the pre-charge is completed, the vehicle inputs the enable signal of the corresponding low-power electrical equipment, and the corresponding low-power electrical equipment can work normally. S5: When low-power electrical equipment is powered on, it does not need to be pre-charged. When the corresponding low-power electrical equipment needs to work, the contactor of the corresponding low-power electrical equipment is closed by software control to supply power to the corresponding low-power electrical equipment; when the corresponding low-power electrical equipment does not need to work, the contactor of the corresponding low-power electrical equipment is opened by software control to stop supplying power to the corresponding low-power electrical equipment.

2. The low-cost, scalable PDU high-voltage architecture design method according to claim 1, characterized in that: The high-power electrical equipment includes a motor controller, a range extender, and an upper structure.

3. The low-cost, scalable PDU high-voltage architecture design method according to claim 1, characterized in that: The low-power electrical equipment includes air conditioners and PTC devices.

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