System and method for solving thermal runaway of vehicle body system

Abstract

The invention discloses a system and method for solving thermal runaway of a vehicle body system, and relates to the technical field of automobile electronic safety. The system comprises a whole vehicle storage battery, an intelligent distribution box unit and at least one vehicle body module unit integrated with a temperature acquisition unit. The vehicle body module unit collects the internal temperature in real time and reports the internal temperature through a CAN bus; and the intelligent distribution box unit receives the data, controls an EFUSE chip in the intelligent distribution box unit to cut off power supply to the module when judging that the temperature of a certain vehicle body module unit continuously exceeds a configurable cut-off threshold value, and records a fault at the same time. The intelligent power distribution box unit receives the temperature data reported by each vehicle body module unit; comparing the data with a turn-off threshold and tracking an over-temperature state; when the continuous over-temperature times of a certain module reach a set value, a thermal runaway fault is judged; and shutting off the power supply of the fault module and recording. Through active monitoring and intelligent power-off, the problems that traditional fusing protection is slow in response and local overheating cannot be prevented are solved.

Description

Technical Field

[0001] This invention relates to the field of automotive electronic control technology, and more specifically to a solution and control method for preventing and curbing thermal runaway in automotive body control systems. Background Technology

[0002] As the level of intelligence and electrification of automobiles continues to improve, the functions of body electronic control modules, such as the body control module (BCM), door and window modules, and lighting controllers, are becoming increasingly complex and integrated, resulting in a corresponding increase in power density and heat generation. These modules are typically distributed throughout various areas of the vehicle body and connected to the central power supply and power distribution unit via wiring harnesses.

[0003] When a vehicle operates for extended periods, in extreme environments, or experiences faults such as short circuits or overloads within modules, the relevant control modules may generate abnormally high temperatures, leading to thermal runaway. Traditional circuit protection primarily relies on one-time blown fuses. However, fuses only blow when the current severely exceeds the limit, resulting in a slow response time and an inability to effectively prevent thermal runaway caused by localized overheating without a significant current exceedance, such as component thermal failure or increased contact resistance. Once a module experiences thermal runaway, the high temperature may ignite itself, surrounding wiring harnesses, or interior materials, posing a fire risk and potentially causing severe vehicle-wide ablation.

[0004] Therefore, existing technologies lack an intelligent protection scheme that can actively and in real time monitor the temperature status of various control modules of the vehicle body and promptly cut off the power supply to the fault point in the early stage of thermal runaway to prevent the fault from spreading. Summary of the Invention

[0005] This invention aims to overcome the shortcomings of existing technologies and provide a system and control method for resolving thermal runaway in vehicle body systems. This solution can monitor the internal temperature of each control module in the vehicle body in real time, intelligently assess the risk of thermal runaway, and quickly cut off the power supply to the faulty module when the risk occurs, thereby effectively preventing the spread of thermal runaway and ensuring the safety of the entire vehicle.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A system for resolving thermal runaway in a vehicle body system includes: a vehicle battery 1, at least one body module unit 2, and an intelligent power distribution box unit 3; the body module unit 2 integrates a temperature acquisition unit to collect the internal temperature data of the body module unit 2 in real time and transmit it via a CAN bus; the intelligent power distribution box unit 3 is powered by the vehicle battery 1 and includes a primary power distribution unit and a secondary power distribution unit, the secondary power distribution unit providing controlled power to at least one body module unit 2.

[0007] Furthermore, the intelligent power distribution box unit 3 receives temperature data from each body module unit 2 via the CAN bus; based on the received temperature data, it determines whether the corresponding body module unit 2 has experienced a thermal runaway fault; when it is determined that a certain body module unit 2 has experienced a thermal runaway fault, it controls the secondary power distribution unit to shut off the power supply to that body module unit to prevent the thermal runaway from spreading, and records the fault information.

[0008] Furthermore, the intelligent power distribution box unit 3 has a preset shutdown temperature threshold, which is a configurable parameter; when the temperature data reported by any body module unit 2 continuously exceeds the shutdown temperature threshold, it is determined that the body module unit 2 has experienced a thermal runaway fault.

[0009] Furthermore, the secondary power distribution unit of the intelligent power distribution box unit 3 integrates an EFUSE chip to replace the traditional one-time fuse, thereby providing overvoltage, overcurrent and overtemperature protection for the body module unit 2 and monitoring the working status of the power supply circuit in real time.

[0010] Furthermore, after the intelligent power distribution box unit 3 shuts down the power supply to a certain body module unit 2 due to a thermal runaway fault, it automatically attempts to restore the power supply to the body module unit 2 after a configurable delay recovery time; if the temperature data still exceeds the shutdown temperature threshold after the power supply is restored, the shutdown operation is performed again.

[0011] Furthermore, the body module unit 2 periodically transmits its temperature data via the CAN bus in a first configurable cycle; when the internal temperature of the body module unit 2 reaches or exceeds a preset warning temperature threshold, it switches to transmitting temperature data in a second configurable cycle, wherein the second configurable cycle is shorter than the first configurable cycle.

[0012] Furthermore, the first configurable period is 100ms, and the second configurable period is 20ms.

[0013] Furthermore, the body module unit 2 is a body controller, whose control functions include at least one of the following: vehicle lights, wipers, windows, and central locking.

[0014] Furthermore, the fault information recorded by the intelligent power distribution box unit 3 includes at least the identifier of the body module unit 2 that caused the fault, the time of the fault, the temperature data at the time of the fault, and the protection actions performed.

[0015] The present invention also provides a control method for resolving thermal runaway in a vehicle body system, comprising the following steps: S1: The intelligent power distribution box unit 3 receives the internal temperature data reported by each body module unit 2 in real time via the CAN bus; S2: Compare the received temperature data with the preset shutdown temperature threshold; S3: If the temperature data of any body module unit 2 continues to exceed the shutdown temperature threshold, it is determined that the body module unit 2 has experienced thermal runaway. S4: Control the intelligent power distribution box unit 3 to shut off the power supply to the body module unit that has experienced thermal runaway, and record the relevant fault information.

[0016] Compared with the prior art, the beneficial effects of the present invention are as follows: (1) By directly monitoring the temperature rise inside the vehicle body control module, the most direct manifestation of thermal runaway, this invention can intervene before the high temperature causes open flame or severe ablation, transforming passive melting into active protection and significantly improving the electrical safety level of the whole vehicle.

[0017] (2) Each body control module independently reports the temperature. The intelligent power distribution box can accurately pinpoint the source of thermal runaway and achieve millisecond-level power shutdown through EFUSE, effectively preventing the fault from spreading to surrounding modules and wiring harnesses.

[0018] (3) Some key parameters of the present invention, such as the shutdown temperature threshold, temperature reporting cycle, and power supply recovery delay, can be configured by software to adapt to the needs of different vehicle models and different modules, and have good versatility.

[0019] (4) The system of the present invention has complete fault monitoring and recording functions, providing effective data support for post-fault analysis and quality improvement.

[0020] (5) This invention utilizes existing vehicle network and smart power distribution box / EFUSE technology, without significantly increasing hardware costs, and mainly achieves enhanced safety functions through software logic. Attached Figure Description

[0021] This manual includes the following figures, which illustrate the following: Figure 1 This is an overall system block diagram of a system for solving thermal runaway in a vehicle body system according to the present invention; Figure 2 This is a specific system block diagram of the system described in this invention; Figure 3 This is an overall control flowchart of the method described in this invention; Among them, 1. Vehicle battery; 2. Body control unit; 3. Intelligent power distribution box unit. Detailed Implementation

[0022] The specific embodiments of the present invention will be further described in detail below with reference to the accompanying drawings, in order to help those skilled in the art to have a more complete, accurate and in-depth understanding of the inventive concept and technical solution of the present invention, and to facilitate its implementation.

[0023] This invention provides a system and method for solving thermal runaway in vehicle body systems. It aims to prevent thermal propagation and ensure vehicle safety by actively and in real-time monitoring and intelligent power management to cut off power supply in a timely manner when thermal runaway precursors occur in the vehicle body control module.

[0024] like Figure 1 and Figure 2 As shown, the system hardware architecture of this embodiment mainly includes three core parts: a vehicle battery 1, an intelligent power distribution box unit 3, and at least one body module unit 2. These parts are connected through power harnesses and a vehicle network CAN bus to form a distributed body control system with real-time temperature control protection function.

[0025] The vehicle battery 1 is typically a 12V or 24V lead-acid battery or a lithium-ion battery. It provides the raw power input to the intelligent power distribution box unit 3.

[0026] The intelligent power distribution box unit 3 is a highly integrated electronic control unit. Its internal hardware structure mainly includes: a main control microcontroller, responsible for running the control logic of this invention, processing CAN communication messages, judging temperature data, and generating power control commands; a primary power distribution unit, directly drawing power from the vehicle's battery, including a pre-charging circuit and main relay control, providing a stable and initially protected power supply to the secondary power distribution unit; and a secondary power distribution unit composed of multiple independent, controllable power distribution channels. Each channel corresponds to one or a group of body module units 2. In this invention, each power distribution channel does not use a traditional chip fuse, but integrates an EFUSE chip.

[0027] An EFUSE, or electronic fuse, is a resettable circuit protection device based on semiconductor technology. Internally, it integrates MOSFET switches, current sensing, thermal protection, and control logic. The main microcontroller can precisely control the on / off state of each EFUSE channel using simple digital signals such as high / low levels or serial communication such as SPI or I2C.

[0028] The advantages of EFUSE lie in its ability to set precise overcurrent protection points, such as 10A±0.5A, with a response speed in the microsecond range, far exceeding the millisecond range of traditional fuses. It can also provide real-time feedback of channel current, voltage, switching status, and fault indicators (overcurrent, overvoltage, overtemperature) to the main control MCU. After a protective shutdown, power can be restored automatically or by command from the main control MCU after the fault conditions are removed and a configurable cooling time has elapsed, without the need for manual replacement. Furthermore, in addition to overcurrent protection, EFUSE typically integrates overvoltage protection and overtemperature protection based on chip junction temperature, providing safety assurance for the power distribution circuit itself.

[0029] The intelligent power distribution box unit 3 also includes a CAN communication controller and transceiver, which communicates with the vehicle's CAN network, receives temperature messages from the body module unit 2, and can send system status or fault information to other gateways or diagnostic interfaces.

[0030] Body module unit 2 consists of electronic control units distributed throughout the body that perform specific functions, such as: Body control controller: integrates functions such as controlling lights, wipers, door locks, and windows; Door control module: controls power windows, rearview mirrors, door locks, etc.; Seat control module: controls electric seat adjustment, heating, ventilation, etc.; Other area controllers; Each body module unit 2 has a built-in temperature acquisition unit located on the module's printed circuit board, near key heat-generating components such as the main control MCU, power drive MOSFETs, and voltage regulator chips. A digital temperature sensor, such as the DS18B20, can be used, directly outputting a digital signal with high accuracy and strong anti-interference capabilities. Alternatively, an analog temperature sensor, such as an NTC thermistor, can be used; it is low-cost but requires sampling via an ADC pin. The sensor should be securely mounted or soldered to ensure accurate sensing of the module's internal temperature rise.

[0031] In this invention, in addition to the original control functions, it is necessary to add the task of periodically reading the temperature sensor value, and encapsulating this temperature value into a CAN message with a specific identifier and sending it to the CAN bus.

[0032] The positive and negative terminals of the vehicle battery 1 are connected to the power input terminal of the intelligent power distribution box unit 3 via a large wiring harness. Each EFUSE output terminal inside the intelligent power distribution box unit 3 is connected to the power input terminal of each body module unit 2 via an independent wiring harness.

[0033] All body module units 2 and intelligent power distribution box units 3 are connected to the same body CAN bus (either via twisted-pair cables) or the same area of ​​the vehicle. Temperature data, control commands, and status information are all exchanged through this network.

[0034] like Figure 3 The diagram shown is an overall control flowchart of the method described in this invention. The specific steps are as follows: S1: After the vehicle is powered on, each body module unit 2 enters the normal working mode. Its internal software performs the following operations at a fixed time of a relatively long and configurable first period T1 = 100 ms: Read the value of the integrated temperature sensor. Then, package the temperature value, the source address of its own module ID, and other necessary status information into a standard CAN data frame. Send this data frame to the CAN bus. To capture abnormal temperature rise earlier, a warning temperature threshold Twarn is preset inside each body module unit 2. This threshold is lower than the final shutdown threshold and can be set to 80 °C or 100 °C, and this temperature value is configurable. When the temperature value read by the MCU of the body module unit 2 reaches or exceeds Twarn, it is considered to enter the "warning state". The body module unit 2 automatically switches the temperature reporting period to a shorter and configurable second period T2 = 20 ms. Report the temperature data to the intelligent power distribution box unit 3 at a higher frequency.

[0035] S2: After the CAN controller of the intelligent power distribution box unit 3 receives the message, the MCU analyzes it according to the preset communication matrix, extracts the ID of the sending module and the corresponding temperature value Tc. The MCU inside the intelligent power distribution box unit 3 maintains a logic processing unit for the ID of each known body module unit 2 and stores its corresponding shutdown temperature threshold Ts, and this value can be configured online through a diagnostic tool.

[0036] S3: The MCU inside the intelligent power distribution box unit 3 sets a counter and a flag bit for each module. Each time the temperature message of a certain body module unit 2 is received, it is judged: If Tc < Ts, the counter is cleared, and if it is an instantaneous over-temperature caused by a single interference, it will not be accumulated. If Tc >= Ts, the counter is incremented by 1. When the counter of a certain body module unit 2 reaches a preset number of consecutive over-temperature times N (set N = 3), it is considered that the module has a continuous and non-interference abnormal high temperature, and it is determined as a "thermal runaway fault", and its flag bit is set. Assuming that the reporting period T = 20 ms in the warning state, three consecutive over-temperatures mean that the temperature is higher than the shutdown threshold within 60 ms.

[0037] S4: Once a body module unit 2 is determined to have a thermal runaway fault, the intelligent power distribution box unit 3 immediately executes a protection action: the MCU inside the intelligent power distribution box unit 3 sends a shutdown command to the specific EFUSE channel controlling the power supply to the faulty body module unit 2. The EFUSE chip disconnects its internal MOSFET within microseconds, thereby physically cutting off the current flowing to the faulty module. Simultaneously, the MCU inside the intelligent power distribution box unit 3 generates a detailed fault log entry in its non-volatile memory, including at least: the ID of the faulty body module unit 2, the timestamp of the fault occurrence, the temperature value that triggered the fault, the fault type, and the status of the EFUSE channel. This log can be read by after-sales personnel using a diagnostic tool for precise problem localization and root cause analysis.

[0038] Considering that some overheating situations may be transient or self-recoverable, such as overheating of the motor drive caused by a brief stall, this invention designs an automatic recovery and verification mechanism.

[0039] After power to a body module unit 2 is cut off due to thermal runaway, the smart power distribution box unit 3 starts a configurable delayed recovery timer Tr (Tr=1s) for that module. This "cooling-off period" is designed to allow the faulty body module unit 2 sufficient time to dissipate heat and reduce its internal temperature.

[0040] After the timer expires, the intelligent power distribution box unit 3 enters the "retesting and verification" phase. The MCU of the intelligent power distribution box unit 3 will actively re-enable the corresponding EFUSE channel to restore power to the body module unit 2.

[0041] If, after power is restored, the temperature data received from the vehicle body module unit 2 is consistently below Ts in the following reporting cycles, the transient fault is considered to have disappeared. The system then clears the module's flag and counter, returning it to normal monitoring status.

[0042] If, after power is restored, the module receives another over-temperature report within the next 20ms cycle, and the counter accumulates to N times again, it is determined to be a "persistent fault." The intelligent power distribution box unit 3 will immediately shut off its power again and update the fault log to "fault again after retry." After this, the system may enter a locked state, no longer automatically attempting recovery, and will only be allowed to attempt recovery after the entire vehicle is powered off and restarted to prevent repeated power-on operations from exacerbating the risk, requiring manual inspection.

[0043] This invention represents a fundamental shift from passive fuse breaking to proactive intelligent protection. Traditional fuses only irreversibly blow after the current has severely exceeded the limit, resulting in slow response and an inability to prevent fires caused by localized overheating. This invention integrates temperature sensors within each vehicle body module to directly monitor the temperature rise during thermal runaway, enabling the system to proactively intervene before high temperatures ignite open flames or cause severe carbonization, thus preventing accidents from occurring in their early stages.

[0044] Each body module unit of this invention independently reports temperature data with its own ID, enabling the intelligent power distribution box unit to accurately pinpoint the source module of thermal runaway. Combined with the EFUSE electronic fuse, which replaces traditional fuses, the execution time for power shutdown can be reduced from hundreds of milliseconds to microseconds, significantly reducing the time the faulty module receives fault energy and effectively preventing heat from spreading to surrounding wiring harnesses and interior materials.

[0045] It possesses high flexibility and configurability, and strong adaptability: Key parameters of the system of this invention, such as the shutdown temperature threshold Ts, the warning temperature threshold T, the normal and accelerated temperature reporting cycles T1 and T2, the number of consecutive over-temperature judgments N, and the power supply recovery delay time Tr, can all be configured through software. This allows the same hardware solution to flexibly adapt to the temperature resistance requirements of different vehicle models, different locations, and different functional modules, demonstrating excellent versatility.

[0046] The intelligent power distribution box of this invention records detailed fault logs, including the faulty module, time, temperature, and protection actions. This not only facilitates quick and accurate fault location during after-sales maintenance but also provides valuable data support for early quality analysis, fault mode research, and design optimization. Simultaneously, the "continuous over-temperature" judgment logic and "recovery attempt" mechanism effectively avoid false protection caused by momentary interference, improving the reliability of the system.

[0047] This invention fully utilizes the existing CAN network and widely used EFUSE smart power distribution box in modern automobiles as its hardware foundation. The main innovation lies in the software logic and the addition of low-cost temperature sensors within the modules. Therefore, this solution can significantly improve the overall electrical safety level of a vehicle with minimal hardware modifications and software upgrades, possessing extremely high practical value and market potential.

[0048] The present invention has been described above by way of example with reference to the accompanying drawings. Obviously, the specific implementation of the present invention is not limited to the above-described manner. Any non-substantial improvements made using the inventive concept and technical solution; or the direct application of the inventive concept and technical solution to other situations without modification, are all within the protection scope of the present invention.

Claims

1. A system for resolving thermal runaway in a vehicle body system, characterized in that, include: The vehicle battery (1), at least one body module unit (2), and intelligent power distribution box unit (3) are provided. The body module unit (2) has an integrated temperature acquisition unit that collects the internal temperature data of the body module unit (2) in real time and sends it through the CAN bus. The intelligent power distribution box unit (3) is powered by the vehicle battery (1) and includes a primary power distribution unit and a secondary power distribution unit. The secondary power distribution unit provides controlled power supply to the at least one body module unit (2).

2. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, The intelligent power distribution box unit (3) receives temperature data from each body module unit (2) via the CAN bus; based on the received temperature data, it determines whether the corresponding body module unit (2) has experienced thermal runaway; when it is determined that a certain body module unit (2) has experienced thermal runaway, it controls the secondary power distribution unit to shut off the power supply to the body module unit (2) and records the fault information.

3. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, The intelligent power distribution box unit (3) has a preset shutdown temperature threshold, which is a configurable parameter. When the temperature data reported by any body module unit (2) continuously exceeds the shutdown temperature threshold, it is determined that the body module unit (2) has a thermal runaway fault.

4. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, The secondary power distribution unit of the intelligent power distribution box unit (3) integrates an EFUSE chip, which is used to replace the traditional one-time fuse to realize overvoltage, overcurrent and overtemperature protection of the vehicle body module unit (2) and monitor the working status of the power supply circuit in real time.

5. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, After the intelligent power distribution box unit (3) shuts down the power supply to a certain body module unit (2) due to thermal runaway, it automatically attempts to restore the power supply to the body module unit (2) after a configurable delay recovery time; if the temperature data still exceeds the shutdown temperature threshold after the power supply is restored, the shutdown operation is performed again.

6. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, Under normal operating conditions, the body module unit (2) periodically transmits its temperature data via the CAN bus in a first configurable period; when the internal temperature of the body module unit (2) reaches or exceeds a preset warning temperature threshold, it switches to transmitting temperature data in a second configurable period, wherein the second configurable period is shorter than the first configurable period.

7. A system for resolving thermal runaway in a vehicle body system according to claim 6, characterized in that: The first configurable period is 100ms, and the second configurable period is 20ms.

8. The system for resolving thermal runaway in a vehicle body system according to claim 1, characterized in that, The body module unit (2) is a body controller, whose control functions include at least one of the following: vehicle lights, wipers, windows, and central locking.

9. A system for resolving thermal runaway in a vehicle body system according to any one of claims 1-8, characterized in that, The fault information recorded by the intelligent power distribution box unit (3) includes at least the identifier of the vehicle body module unit (2) that malfunctioned, the time of the fault, the temperature data at the time of the fault, and the protection actions performed.

10. A control method for resolving thermal runaway in a vehicle body system based on any one of claims 1-9, characterized in that, Includes the following steps: S1: The intelligent power distribution box unit (3) receives the internal temperature data reported by each body module unit (2) in real time via the CAN bus; S2: Compare the received temperature data with the preset shutdown temperature threshold; S3: If the temperature data of any body module unit (2) continues to exceed the shutdown temperature threshold, it is determined that the body module unit (2) has experienced thermal runaway. S4: Control the intelligent power distribution box unit (3) to shut off the power supply to the body module unit (2) that has experienced thermal runaway, and record the relevant fault information.

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