High-voltage power distribution system for commercial vehicle and control method of high-voltage power distribution system
Through an independent high-voltage power distribution system and temperature control design, the problems of insufficient power supply and mutual interference of equipment on commercial vehicles have been solved, realizing independent power supply, fault isolation and temperature management, and improving the safety and reliability of the equipment.
Patent Information
- Application Number
- CN202511577830.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-31
- Publication Date
- 2025-12-23
AI Technical Summary
In existing technologies, the high-voltage systems of equipment mounted on commercial vehicles lack an independent power distribution architecture, resulting in severe mutual interference during faults. The chassis battery capacity is insufficient to meet the high-power power demand, and there is a lack of temperature management mechanisms, which affects the safety and reliability of the equipment.
Design an independent high-voltage power distribution system, including a battery box module, an all-in-one controller module, a battery management compressor module, a battery thermal management heater module, etc., to achieve signal interaction through a CAN bus, integrate insulation detection and temperature control functions, realize independent power supply and fault isolation for the upper-mounted equipment, and use the upper-mounted VCU control module for logic control.
It enables independent power supply for the upper structure equipment, increases power capacity, ensures driving safety, optimizes battery performance, and enhances the system's scalability and reliability.
Smart Images
Figure CN121179986A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of high-voltage power distribution on commercial vehicles, and in particular to a high-voltage power distribution system for commercial vehicles and a control method thereof. BACKGROUND
[0002] Currently, with the rapid development of new energy commercial vehicles, the demand for high-voltage power of refitted special vehicles and sanitation vehicles and other superstructure equipment is increasing. However, the existing technology generally uses a chassis energy storage device to directly power the superstructure equipment, which has the following outstanding problems: first, if an insulation fault occurs in the superstructure high-voltage system, it will directly trigger the chassis insulation protection mechanism, causing the high-voltage system of the whole vehicle to be powered off, which seriously affects the normal driving of the vehicle and poses a safety hazard; second, the limited capacity of the chassis battery makes it difficult to meet the power demand of the continuous high-load operation of superstructure high-power motors (such as fan motors, hydraulic pump motors, high-pressure water pump motors, etc.), which restricts the performance of the superstructure function.
[0003] Currently, the industry mainly relies on the chassis high-voltage system for unified power distribution, and lacks an independent high-voltage power distribution architecture for the superstructure. Although this method is simple in structure, it cannot achieve electrical isolation between the chassis and the superstructure, and the fault interference is serious, and it is difficult to expand the power capacity of the superstructure. In addition, the existing system lacks a temperature management mechanism specifically for the superstructure battery, and it is difficult to ensure the optimal working state of the battery in extreme temperature environments, further limiting the working efficiency and reliability of the superstructure equipment.
[0004] Therefore, it is urgent to develop a high-voltage power distribution system with independent energy storage, independent temperature control, and fault isolation capability to achieve decoupling of the chassis and superstructure electrical systems, and improve the safety, reliability of the whole vehicle, and power adaptation capability of the superstructure equipment. SUMMARY
[0005] The present application provides a high-voltage power distribution system for commercial vehicles and a control method thereof to solve the above problems.
[0006] In one aspect, the application provides a high-voltage power distribution system for a commercial vehicle, comprising a battery box module, an upper-mounted all-in-one controller module, a battery management compressor module, a battery thermal management heater module, an upper-mounted motor 1 module, an upper-mounted motor 2 module, a DC-DC output module, an upper-mounted VCU control module, and an upper-mounted display screen module; all the above modules are connected through CAN bus for signal interaction; the system adopts an upper-mounted independent high-voltage power distribution architecture, and the upper-mounted VCU control module integrates the core control logic: before the system is powered on, the insulation states of the chassis high-voltage system and the upper-mounted high-voltage system are detected respectively, and only when both meet the preset insulation requirements, the battery thermal management heater module or the battery management compressor module is controlled to start the battery temperature pre-regulation; after the temperature meets the standard, the upper-mounted all-in-one controller module is controlled to execute the contactor closing process to complete the power-on; if an insulation fault of the upper-mounted high-voltage system is detected during operation, only the upper-mounted high-voltage main circuit in the upper-mounted all-in-one controller module is cut off, without affecting the normal work of the chassis travel high-voltage system.
[0007] In one implementation of the application, the battery box module is composed of multiple battery boxes, has the rapid charging and discharging capacity suitable for the high-power power demand of the upper-mounted commercial vehicle, provides independent energy storage support for the upper-mounted power supply, and has no high-voltage electrical connection with the chassis energy storage device.
[0008] In one implementation of the application, the upper-mounted all-in-one controller module integrates the functions of thermal management power distribution, compressor power distribution, DC-DC conversion power distribution, upper-mounted motor 1 drive power distribution, and upper-mounted motor 2 drive power distribution, and has a built-in insulation detector that can monitor the insulation resistance of the upper-mounted high-voltage circuit in real time and send the detection data to the upper-mounted VCU control module through the CAN bus.
[0009] In one implementation of the application, the battery management compressor module is used to regulate the battery temperature during the charging and discharging process of the battery box module, and the control logic is issued by the upper-mounted VCU control module; the battery thermal management heater module is used to regulate the battery temperature in a low-temperature environment, and the control logic is also issued by the upper-mounted VCU control module, and the two modules work together to maintain the battery in a temperature range suitable for optimal charging and discharging.
[0010] In one implementation of the application, the upper-mounted motor 1 module and the upper-mounted motor 2 module are both driven by the three-phase power output by the upper-mounted all-in-one controller module, wherein the upper-mounted motor 1 module can serve as the power source of the upper-mounted fan, the upper-mounted motor 2 module can serve as the power source of the upper-mounted hydraulic system and high-pressure water system, and both of them feed back the running state data to the upper-mounted VCU control module through the rotary transformer line.
[0011] In an implementation form of the application, the DC-DC output module provides power for the upper-mounted 24VDC high-power electrical equipment, has a continuous power supply power suitable for the upper-mounted conventional high-power low-voltage electrical equipment, and can be selectively integrated in the upper-mounted all-in-one controller module, and mainly supplies power for the upper-mounted heat dissipation water pump, heat dissipation fan and conventional low-voltage electrical equipment.
[0012] Secondly, the application further provides a control method of a high-voltage power distribution system for a commercial vehicle, which is applied to a power-on control process, and the method comprises the following steps: the upper-mounted VCU control module first reads the states of each module through a CAN bus, confirms that the insulation states of the chassis and the upper-mounted part are up to standard, and then starts battery temperature pre-regulation; after the battery temperature enters an interval suitable for optimal charging and discharging, the upper-mounted all-in-one controller module is controlled to first close a main negative contactor, then close a main pre-charging contactor, close the main contactor and disconnect the main pre-charging contactor after pre-charging is completed, and finally close a battery management compressor contactor, a battery thermal management heater contactor and a DC-DC contactor, thereby completing power-on of the upper-mounted high-voltage system.
[0013] Thirdly, the application further provides a control method of a high-voltage power distribution system for a commercial vehicle, which is applied to a battery temperature control process, and the method comprises the following steps: when the battery box module is charging and discharging, if the upper-mounted VCU control module detects that the battery temperature reaches an upper limit temperature suitable for optimal charging and discharging, the battery management compressor module is controlled to start refrigeration; after the temperature drops to a target cooling temperature suitable for the refrigeration, the refrigeration is stopped and a self-circulation mode with a preset time length is entered; after the self-circulation ends, the mode is switched to a standby mode; if it is detected that the battery temperature is lower than a lower limit temperature suitable for optimal discharging and does not reach a reference temperature, the battery thermal management heater module is controlled to start heating; and after the temperature reaches a target heating temperature suitable for the heating or exceeds the reference temperature, the heating is stopped.
[0014] Fourthly, the application further provides a control method of a high-voltage power distribution system for a commercial vehicle, which is applied to a fault handling process, and the method comprises the following steps: during operation, the upper-mounted VCU control module receives fault information sent by each module through a CAN bus in real time; if it is detected that an insulation fault of the upper-mounted high-voltage system occurs, the upper-mounted high-voltage main circuit in the upper-mounted all-in-one controller module is immediately cut off, and the fault information is sent to the upper-mounted display screen module for display; if it is detected that the operating parameters of the upper-mounted motor module and the DC-DC output module are abnormal, the corresponding module is controlled to stop working, and a circuit power-off protection is performed.
[0015] Finally, the application also provides a control method of a high-voltage power distribution system for a commercial vehicle, which is applied to a power-down control process, comprising: after the upper-mounted VCU control module receives the power-down instruction issued by the upper-mounted display screen module, the upper-mounted motor 1 module and the upper-mounted motor 2 module are first controlled to stop running, and the upper-mounted high-voltage loop current is monitored; when the current decreases to a threshold value suitable for safe power-down of the high-voltage system, the battery management compressor contactor, the battery thermal management heater contactor, the DC-DC contactor and the upper-mounted high-voltage main contactor are sequentially disconnected, and finally the main negative contactor is disconnected; if an abnormal loop current is detected during the power-down process, the upper-mounted VCU control module suspends the power-down process and sends fault information to the upper-mounted display screen module for alarm, and after the current decreases to the safety threshold value, the contactor disconnection operation is continued to complete the power-down.
[0016] The high-voltage power distribution system for a commercial vehicle and the control method thereof provided by the application have the following beneficial effects: 1. Realize independent power supply of the upper-mounted part and improve power capacity: the system supplies power to the upper-mounted equipment through an independent battery box module, solves the bottleneck of insufficient capacity of the chassis battery, can meet the continuous high-load operation demand of high-power electrical equipment such as a fan and a hydraulic pump, and significantly expands the function of the upper-mounted part.
[0017] 2. Realize fault electrical isolation and ensure driving safety: through independent insulation monitoring and power distribution architecture of the upper-mounted part, when an insulation fault occurs in the upper-mounted high-voltage system, only the upper-mounted high-voltage loop is cut off, without affecting the chassis running system, and the safety hazard of vehicle breakdown caused by the upper-mounted problem is completely eliminated.
[0018] 3. Possess an intelligent temperature control system and optimize battery performance: the system integrates an independent compressor and a battery thermal management heater module, accurately controls the logic to make the battery always maintain in an optimal charging and discharging temperature interval, effectively improves the working efficiency, service life of the battery and the reliability of the system in extreme environments.
[0019] 4. Adopt a highly integrated design and enhance system expandability: a variety of power distribution functions are integrated around the upper-mounted all-in-one controller, and modular interaction is realized through a CAN bus, the system structure is compact, control is centralized, and flexible configuration and function expansion can be easily carried out according to the power demand of different upper-mounted equipment. BRIEF DESCRIPTION OF DRAWINGS
[0020] The drawings described herein are used to provide further understanding of the application, constitute a part of the application, the illustrative embodiments of the application and the description thereof are used to explain the application, and do not constitute an improper limitation on the application. In the drawings: Figure 1 A high-voltage power distribution system for a commercial vehicle provided by the embodiments of the application; Figure 2A diagram of a low-voltage power distribution system for a commercial vehicle provided in an embodiment of this application; Figure 3 The power-on and power-off control flowchart provided in the embodiments of this application; Figure 4 The power distribution schematic diagram of the all-in-one control module provided in the embodiments of this application; Figure 5 The complete system low-voltage schematic diagram provided in the embodiments of this application. Detailed Implementation
[0021] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below in conjunction with specific embodiments and corresponding drawings. Obviously, the described embodiments are only a part of the embodiments of this application, and not all of them. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0022] This application provides a high-voltage power distribution system and its control method for commercial vehicles. The technical solution proposed in this application will be described in detail below with reference to the accompanying drawings.
[0023] System composition and connections, such as Figure 1 As shown, Figure 1 A diagram of a high-voltage power distribution system for a commercial vehicle provided in this application embodiment. The specific components are as follows: The high-voltage power distribution system includes a battery box module, an upper-mounted multi-function controller module, a battery management compressor module, a battery thermal management heater module, an upper-mounted motor 1 module, an upper-mounted motor 2 module, a DC-DC output module, an upper-mounted VCU control module, and an upper-mounted display module. All modules are interconnected via a CAN bus with a baud rate of 250kHz, and each node transmits and receives data at a preset frequency.
[0024] Battery box module: Composed of multiple battery boxes in the upper structure, with a voltage range of 450VDC~720VDC, it has fast charging and discharging capabilities, provides independent energy storage support for the upper structure system, and has no high-voltage electrical connection with the chassis energy storage device.
[0025] The upper-mount multi-function controller module integrates thermal management power distribution, compressor power distribution, DC-DC conversion power distribution, upper-mount motor 1 drive power distribution and upper-mount motor 2 drive power distribution functions. It has a built-in insulation detector to monitor the insulation resistance value of the upper-mount high-voltage circuit in real time and send the data to the upper-mount VCU control module via CAN bus.
[0026] The battery management compressor module and the battery thermal management heater module are used for cooling and heating during battery charging and discharging, respectively. The upper-mounted VCU control module issues control logic based on the battery temperature status to ensure that the battery is in the optimal charging and discharging temperature range.
[0027] Upper structure motor 1 module and upper structure motor 2 module: The three-phase electric drive output by the upper structure multi-in-one controller module can be used as the power source for the upper structure fan, hydraulic system and high-pressure water circuit system, and the operating status data is fed back to the upper structure VCU control module through the resolver.
[0028] DC-DC output module: Provides continuous power to 24VDC high-power electrical equipment with a rated power of 6kW. The main power supply objects include radiator water pumps, cooling fans and other conventional low-voltage electrical equipment.
[0029] The upper-mounted VCU control module serves as the system's control core, responsible for data processing, logical judgment, and command issuance. It interacts with other modules via the CAN bus to achieve power-on / power-off, temperature control, and fault handling of the upper-mounted high-voltage system.
[0030] The upper-mounted display module serves as a human-machine interface, displaying system status and fault information, receiving operation commands, and communicating with the upper-mounted VCU control module via the CAN bus.
[0031] This system is divided into a high-voltage section and a low-voltage section. The high-voltage output is controlled by a low-voltage signal. After high-voltage output, the operating data from the multi-function control module, battery management compressor module, battery thermal management heater module, and DC-DC output module is transmitted via CAN bus to the upper-mounted VCU control module. The VCU control module then sends important information to the upper-mounted display module for display and human-machine interaction. The system provides feedback on the voltage values, operating current, and operating status of the feedback components. Based on the feedback of the normal operating voltage and current, the system can determine whether the high-voltage power distribution system is operating well. Important parameter information is displayed on the upper-mounted display screen to inform the operator whether the power distribution system is operating safely. The low-voltage power distribution system diagram is shown below. Figure 2 As shown.
[0032] Power-on / off control process as follows Figure 3 As shown, the details are as follows.
[0033] Power-on control process: The power-on control process includes the following steps: Status detection and insulation verification: The upper-mount VCU control module reads the status data of each module via the CAN bus, and first checks the insulation status of the chassis high-voltage system and the upper-mount high-voltage system respectively. Only when the insulation resistance values of both meet the preset requirements (e.g., the insulation resistance value of the upper-mount is greater than 500Ω / V) will the process proceed to the next step.
[0034] Battery temperature pre-regulation: The upper-mounted VCU control module determines whether temperature regulation needs to be initiated based on the temperature data from the battery box module. If the battery's maximum temperature (Tmax) is ≥30℃, the battery management compressor module will start cooling until Tmax ≤28℃, at which point cooling will stop, and the battery will enter self-circulation mode for 10 minutes before switching to standby mode.
[0035] If the battery's minimum temperature (Tmin) is less than 10℃ and Tmax is less than 20℃, the battery thermal management heater module will start PTC heating with a target temperature of 60℃, and heating will stop when Tmin reaches 15℃ or Tmax reaches 20℃.
[0036] High-voltage power-on execution: After the battery temperature enters the optimal range, the upper-mounted VCU control module controls the upper-mounted multi-in-one controller module to execute contactor closing in sequence: first close the main negative contactor; then close the main pre-charge contactor to perform the pre-charge process; after the pre-charge is completed, close the main contactor and open the main pre-charge contactor; finally, close the battery management compressor contactor, battery thermal management heater contactor and DC-DC contactor in sequence.
[0037] Power-on completion and status feedback: After the superstructure high voltage system is powered on, the superstructure VCU control module collects the operating parameters of each module (such as voltage, current, and temperature) through the CAN bus and sends important data to the superstructure display module for display by the operator.
[0038] Power-down control procedure: includes the following steps: Power-down command reception: The upper-mounted VCU control module receives the power-down command sent from the upper-mounted display module.
[0039] Load stop and current monitoring: Control the upper motor 1 module and upper motor 2 module to stop running, and monitor the upper high voltage circuit current in real time.
[0040] Contactor disconnection sequence: When the high-voltage circuit current drops to a safe threshold (e.g., ≤1A), disconnect the contactors in the following order: first disconnect the battery management compressor contactor, battery thermal management heater contactor, and DC-DC contactor; then disconnect the upper high-voltage main contactor; finally disconnect the main negative contactor.
[0041] Abnormal Handling: If an abnormal circuit current is detected during power-down (such as continuously exceeding the safety threshold), the upper-mounted VCU control module extends the contactor disconnection time and sends the fault information to the upper-mounted display module for alarm until the current reaches the standard and then the power-down is completed.
[0042] The fault handling process is as follows: During system operation, the upper-mounted VCU control module monitors the status of each module in real time. The fault handling process includes: Insulation fault handling: If an insulation fault is detected in the superstructure high-voltage system (such as insulation resistance below the threshold), the superstructure VCU control module immediately cuts off the superstructure high-voltage main circuit in the superstructure multi-in-one controller module, and at the same time sends the fault information to the superstructure display module for display, to ensure that the chassis high-voltage system is not affected.
[0043] Module operation anomaly handling: If abnormal operating parameters (such as overcurrent or overtemperature) are detected in the upper motor module or DC-DC output module, the upper VCU control module will control the corresponding module to stop working and execute the circuit power-off protection.
[0044] Fault information recording and display: All fault information is sent to the upper display module via the CAN bus, recording the fault code and the time of occurrence for easy subsequent maintenance.
[0045] The battery temperature control process is as follows: After the system is powered on, in order to maintain the battery module within the optimal charging and discharging temperature range, the upper-mounted VCU control module continuously monitors the battery temperature and executes the following control strategies: Cooling Control: When the detected maximum battery temperature (Tmax) reaches or exceeds the upper limit of the optimal charge / discharge range (e.g., 30°C), the upper-mounted VCU control module controls the battery management compressor module to start the cooling mode. Once the battery temperature drops to the preset target cooling temperature (e.g., 28°C), the compressor cooling stops. After cooling stops, the system enters a self-circulation mode and runs continuously for a preset duration (e.g., 10 minutes) to equalize the internal temperature of the battery pack.
[0046] After the self-loop mode ends, the system switches to standby mode.
[0047] Heating Control: When the battery's minimum temperature (Tmin) is detected to be below the lower limit of optimal discharge temperature (e.g., 10°C), and the battery's maximum temperature (Tmax) has not reached the reference temperature (e.g., 20°C), the upper-mounted VCU control module controls the battery thermal management heater module to start the heating mode (PTC heating). PTC heating stops when the battery's minimum temperature (Tmin) reaches 15°C or the battery's maximum temperature (Tmax) exceeds 20°C. The potentially ambiguous phrase "the target temperature for PTC heating is set to 60°C" should be removed, or it should be interpreted as "the upper limit of the PTC heater's internal temperature protection is 60°C."
[0048] Standby mode: If the battery temperature is within the optimal range when the system is powered on or running, and no cooling or heating conditions are triggered, both the battery management compressor module and the battery thermal management heater module are in standby mode to reduce system energy consumption.
[0049] In this application, the power distribution schematic diagram of the multi-functional module is as follows: Figure 4As shown, it includes conventional all-in-one components such as contactors, pre-charge circuits, insulation testers, and MSDs required for the upper structure.
[0050] In this application, the low-voltage schematic diagram of the entire system is as follows: Figure 5 As shown, it includes an upper-mount VCU module, a battery management compressor module, an upper-mount display module, a battery box module, a DC-DC module, a battery thermal management heating module, an upper-mount multi-function control module, and a motor resolver module, etc. The various embodiments in this application are described in a progressive manner. Similar or identical parts between embodiments can be referred to mutually. Each embodiment focuses on describing the differences from other embodiments. In particular, the device embodiments are basically similar to the method embodiments, so the description is relatively simple; relevant parts can be referred to the descriptions of the method embodiments.
[0051] It should also be noted that the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0052] The above description is merely an embodiment of this application and is not intended to limit the scope of this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the scope of the claims of this application.
Claims
1. A high-voltage power distribution system for commercial vehicles, characterized in that, The system includes a battery box module, an upper-mount multi-function controller module, a battery management compressor module, a battery thermal management heater module, an upper-mount motor 1 module, an upper-mount motor 2 module, a DC-DC output module, an upper-mount VCU control module, and an upper-mount display module. All of the above modules are interconnected via a CAN bus. The system adopts an independent high-voltage power distribution architecture for the upper-mount, and the upper-mount VCU control module integrates core control logic: before the system is powered on, the insulation status of the chassis high-voltage system and the upper-mount high-voltage system is checked separately. Only when both meet the preset insulation requirements is the battery thermal management heater module or the battery management compressor module controlled to start the battery temperature pre-adjustment. After the temperature reaches the standard, the upper-mount multi-function controller module is controlled to execute the contactor closing process to complete the power-on. If an insulation fault is detected in the upper-mount high-voltage system during operation, only the upper-mount high-voltage main circuit in the upper-mount multi-function controller module is cut off, without affecting the normal operation of the chassis walking high-voltage system.
2. The high-voltage power distribution system for commercial vehicles according to claim 1, characterized in that, The battery box module consists of multiple battery boxes and has the ability to quickly charge and discharge to meet the high power demand of commercial vehicle superstructures. It provides independent energy storage support for superstructure power supply and has no high-voltage electrical connection with the chassis energy storage device.
3. A high-voltage power distribution system for commercial vehicles according to claim 1, characterized in that, The upper-mount multi-function controller module integrates thermal management power distribution, compressor power distribution, DC-DC conversion power distribution, upper-mount motor 1 drive power distribution, and upper-mount motor 2 drive power distribution functions. It also has a built-in insulation detector that can monitor the insulation resistance of the upper-mount high-voltage circuit in real time and send the detection data to the upper-mount VCU control module via the CAN bus.
4. A high-voltage power distribution system for commercial vehicles according to claim 1, characterized in that, The battery management compressor module is used to regulate the battery temperature during the charging and discharging process of the battery box module, and the control logic is issued by the upper-mounted VCU control module; the battery thermal management heater module is used to regulate the battery temperature in low-temperature environments, and the control logic is also issued by the upper-mounted VCU control module. The two work together to keep the battery in the optimal charging and discharging temperature range.
5. A high-voltage power distribution system for commercial vehicles according to claim 1, characterized in that, Both the upper-mount motor 1 module and the upper-mount motor 2 module are driven by three-phase electricity output from the upper-mount multi-in-one controller module. The upper-mount motor 1 module can be used as the power source for the upper-mount fan, and the upper-mount motor 2 module can be used as the power source for the upper-mount hydraulic system and high-pressure water circuit system. Both of them feed back the operating status data to the upper-mount VCU control module through a resolver.
6. A high-voltage power distribution system for commercial vehicles according to claim 1, characterized in that, The DC-DC output module provides power to the 24VDC high-power electrical equipment in the upper part of the device. It has the continuous power supply to meet the conventional high-power low-voltage power needs of the upper part of the device. It can be selectively integrated into the upper part of the multi-in-one controller module and mainly supplies power to the upper part of the device's cooling water pump, cooling fan and conventional low-voltage electrical equipment.
7. A control method for a high-voltage power distribution system in commercial vehicles, applied to the power-on control process, characterized in that, The method includes: the upper-mount VCU control module first reads the status of each module through the CAN bus, and after confirming that the insulation status of the chassis and the upper-mount are up to standard, it starts the battery temperature pre-adjustment; after the battery temperature enters the range suitable for optimal charging and discharging, it controls the upper-mount multi-in-one controller module to first close the main negative contactor, then close the main pre-charge contactor, after the pre-charge is completed, close the main contactor and open the main pre-charge contactor, and finally close the battery management compressor contactor, the battery thermal management heater contactor and the DC-DC contactor to complete the power-on of the upper-mount high-voltage system.
8. A control method for a high-voltage power distribution system in commercial vehicles, applied to a battery temperature control process, characterized in that, include: When the battery module is charging or discharging, if the upper-mounted VCU control module detects that the battery temperature has reached the upper limit temperature for optimal charging and discharging, it controls the battery management compressor module to start cooling. After the temperature drops to the target cooling temperature, it stops cooling and enters a self-circulation mode for a preset duration. After the self-circulation ends, it switches to standby mode. If the battery temperature is detected to be lower than the lower limit temperature for optimal discharging but has not reached the reference temperature, it controls the battery thermal management heater module to start heating. After the temperature reaches the target heating temperature or exceeds the reference temperature, it stops heating.
9. A control method for a high-voltage power distribution system in commercial vehicles, applied in a fault handling process, characterized in that, include: During operation, the upper-mount VCU control module receives fault information sent by each module via the CAN bus in real time. If an insulation fault is detected in the upper-mount high-voltage system, the upper-mount high-voltage main circuit in the upper-mount multi-controller module is immediately cut off, and the fault information is sent to the upper-mount display module for display. If abnormal operating parameters are detected in the upper-mount motor module or DC-DC output module, the corresponding module is controlled to stop working, and circuit power-off protection is executed.
10. A control method for a high-voltage power distribution system in commercial vehicles, applied to a power-down control process, characterized in that, include: After receiving the power-down command from the upper-mount display module, the upper-mount VCU control module first controls the upper-mount motor 1 module and upper-mount motor 2 module to stop running, while monitoring the upper-mount high-voltage circuit current. When the current drops to the threshold for safe power-down of the adapted high-voltage system, the battery management compressor contactor, battery thermal management heater contactor, DC-DC contactor, and upper-mount high-voltage main contactor are disconnected in sequence, and finally the main negative contactor is disconnected. If an abnormal circuit current is detected during the power-down process, the contactor disconnection time is extended, and fault information is sent to the upper-mount display module until the current reaches the standard and the power-down is completed.