New energy automobile driving motor control system fault diagnosis device

Abstract

The invention discloses a new energy automobile driving motor control system fault diagnosis device, which relates to the technical field of new energy automobile driving motor control, and comprises a data acquisition module, a data preprocessing module, a fault diagnosis module, an early warning and communication module, an installation and protection module and a local database, all operation state parameters and all signal interface physical state parameters of the driving motor are collected and converted into standardized digital signals through preprocessing, fault types are judged and graded, graded early warning is executed, response instructions are sent, meanwhile, fault recovery is monitored, related data are recorded, the device can be matched with multiple types of driving motors, integrated physical protection is provided, and the reliability of the device is improved. The problems of missed detection, poor adaptability and the like of a traditional scheme are solved, the diagnosis accuracy and the system stability are improved, and the driving safety of the new energy automobile is guaranteed.

Description

Technical Field

[0001] This invention relates to the field of new energy vehicle drive motor control technology, and specifically to a fault diagnosis device for a new energy vehicle drive motor control system. Background Technology

[0002] Currently, the drive motor control system is a core component of the power system of new energy vehicles. Its operational reliability directly determines the vehicle's power performance and driving safety performance. At present, the fault diagnosis technology of the drive motor control system of new energy vehicles relies on the continuous improvement of sensor perception accuracy, the deep optimization of artificial intelligence algorithms, and the mature application of multi-source data fusion technology. It has completed the upgrade from single parameter monitoring to multi-dimensional feature analysis, which can accurately capture subtle fault signs and effectively identify early potential faults. Moreover, it is continuously developing towards rapid response, adaptive adaptation, and integrated development, becoming an indispensable key component in the technological upgrade of drive motor control systems.

[0003] Existing technologies, such as the invention patent application with announcement number CN116605053A, disclose a fault diagnosis method, device, vehicle, and medium for active degradation of drive motors. The method includes: detecting whether the drive motor has entered an active degradation mode; if so, acquiring battery and motor operating parameters and diagnosing the fault, thus solving the relevant defects of the prior art. Existing technologies, such as the invention patent application with announcement number CN118672240B, disclose a fault-tolerant control system for fault diagnosis of drive motors in new energy mining dump trucks. The system includes: multi-source data prediction of abnormalities in the drive motors of mining dump trucks and classification, monitoring for severe shutdowns and return trips, and monitoring for minor load adjustments, thereby improving its safety and reliability.

[0004] As can be seen from the above solutions, although current fault diagnosis technologies have been upgraded to multi-dimensional feature analysis, there are still obvious shortcomings. Existing solutions mostly rely on single sensor data, neglecting fault monitoring of the signal interface, a critical transmission link. This can easily lead to misdiagnosis or missed detection of hidden faults such as loose connectors and electromagnetic interference. The signal acquisition stage lacks targeted electromagnetic shielding, waterproofing, and dustproofing measures. Data distortion caused by interface faults will directly reduce diagnostic accuracy and easily cause subsequent control logic disorder. Traditional diagnostic devices are mostly customized designs with poor integration and compatibility with different models of motor controllers. Furthermore, they have low fault location accuracy and slow response, making it difficult to meet the needs of real vehicles for rapid fault identification and early warning under complex operating conditions. Summary of the Invention

[0005] To address the aforementioned technical shortcomings, the present invention aims to provide a fault diagnosis device for the drive motor control system of new energy vehicles.

[0006] To solve the above technical problems, the present invention adopts the following technical solution: The present invention provides a fault diagnosis device for a new energy vehicle drive motor control system, including a data acquisition module: used to collect in real time various operating status parameters of the drive motor and physical status parameters of various signal interfaces. The various operating status parameters include the current and voltage of the power output harness and the temperature of key parts. The physical status parameters of various signal interfaces include the contact resistance of the interface pins, the intensity of ambient electromagnetic radiation, the vibration frequency of the interface pins, the signal amplitude, and the signal frequency distortion.

[0007] Data preprocessing module: Used to preprocess the acquired raw analog signals and convert them into standardized digital signals.

[0008] Preferably, the method for preprocessing the acquired raw analog signal and converting it into a standardized digital signal is as follows: A high-impedance filtering path constructed by the common-mode inductor inside the fault diagnosis device is used to filter out high-frequency common-mode electromagnetic interference generated by the high-voltage system of the drive motor during operation in the raw analog signal. A TVS transient suppression diode is used to clamp and absorb transient overvoltage spikes in the raw analog signal to obtain the preprocessed raw analog signal. An A / D conversion module is then used to convert the preprocessed raw analog signal into a discrete digital signal with a preset sampling accuracy. Based on the range coefficients and zero-point offset parameters calibrated by each sensor that acquired the raw analog signal, the discrete digital signal is proportionally converted and zero-point calibrated to obtain a standardized digital signal.

[0009] Fault diagnosis module: used to determine the type of drive motor fault and generate the drive motor fault level accordingly.

[0010] Preferably, the specific method for determining the fault type of the drive motor is as follows: obtaining the current and voltage of the power output harness and the temperature of key parts, the contact resistance of the interface pins, the intensity of surrounding electromagnetic radiation, the vibration frequency of the interface pins, the signal amplitude, and the signal frequency distortion in the preprocessed standardized digital signal.

[0011] If the current in the power output harness of the drive motor suddenly changes and exceeds the preset safe current threshold or the voltage exceeds the preset safe voltage threshold, it is determined that the drive motor has a short circuit fault.

[0012] When the temperature of critical components of the drive motor exceeds the preset safe temperature threshold, the drive motor is determined to have an overheating fault.

[0013] If the contact resistance of the drive motor interface pin is greater than the preset safe resistance threshold, and the vibration frequency of the interface pin is greater than the preset safe vibration frequency, then the drive motor is determined to have a loose plug fault.

[0014] When the electromagnetic radiation intensity around the drive motor exceeds the preset anti-interference tolerance, the drive motor is determined to have an electromagnetic interference fault.

[0015] If the amplitude of the drive motor signal is not within the preset safe amplitude range, the signal frequency distortion is greater than the preset safe signal frequency distortion, or the number of signal frame drops is greater than the preset safe number of frame drops threshold, then the drive motor is determined to have a signal transmission fault.

[0016] Preferably, the method for generating the drive motor fault level is as follows: classifying the drive motor fault level according to the fault type of the drive motor.

[0017] If a drive motor has a short circuit fault, overheating fault, loose plug fault, electromagnetic interference fault and signal transmission fault at the same time, the fault level of the drive motor is determined to be Level 1.

[0018] If a drive motor has any four of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be Level 2.

[0019] If a drive motor has any three of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be level three.

[0020] If a drive motor has any two of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be level four.

[0021] If a drive motor has any one of the following faults: short circuit, overheating, loose plug, electromagnetic interference, or signal transmission, then the fault level of the drive motor is determined to be level five.

[0022] Early warning and communication module: It is used to provide graded early warning based on the fault level of the drive motor, and send corresponding graded response strategy commands through the enhanced CAN bus interface. At the same time, it judges the recovery status of the drive motor fault and records the drive motor fault data and recovery process data.

[0023] Preferably, the method for providing graded early warning based on the fault level of the drive motor is as follows: When the fault level of the drive motor is level one, the red indicator light inside the fault diagnosis device will be triggered to flash at a high frequency, and the buzzer will be driven to emit a continuous, sharp alarm sound at the highest volume set by the factory.

[0024] When the fault level of the drive motor is level two, the red indicator light inside the fault diagnosis device will be immediately triggered to stay on, and the buzzer will be driven to emit intermittent sharp alarm sounds at the factory-set maximum volume.

[0025] When the fault level of the drive motor is level three, the yellow indicator light inside the fault diagnosis device will be triggered to flash rapidly at a high frequency, and at the same time the buzzer will be driven to emit a continuous sound at a level between the minimum and maximum volume to provide a warning.

[0026] When the fault level of the drive motor is level four, the yellow indicator light inside the fault diagnosis device will be constantly lit, and the buzzer will be driven to emit intermittent beeps at a level between the minimum and maximum volume to provide a warning.

[0027] When the fault level of the drive motor is level five, only the yellow indicator light inside the fault diagnosis device will be constantly lit as a warning.

[0028] Preferably, the method for sending the corresponding hierarchical response strategy command through the enhanced CAN bus interface is as follows: when the drive motor fault level is level one, a command is sent to the vehicle controller through the enhanced CAN bus interface to immediately execute the drive motor safety shutdown procedure and cut off the power output.

[0029] When the drive motor fault level is level two, an instruction is sent to the vehicle controller via the enhanced CAN bus interface to constrain the output power of the drive motor to below a preset safety threshold.

[0030] When the drive motor fault level is level three, the fault location information is sent to the vehicle controller through the enhanced CAN bus interface, and the drive motor output power is limited to a preset safety threshold to continue operation.

[0031] When the drive motor fault level is level four, an instruction is sent to the vehicle central control system through the enhanced CAN bus interface to strengthen the monitoring of the various operating status parameters of the drive motor and the physical status parameters of each signal interface.

[0032] When the drive motor fault level is level five, a prompt message indicating the drive motor fault type is sent to the vehicle's central control system via the enhanced CAN bus interface.

[0033] Preferably, the specific method for determining the recovery status of the drive motor fault is as follows: real-time acquisition of each operating status parameter and each signal interface physical status parameter of the faulty drive motor; when each operating status parameter and each signal interface physical status parameter of a faulty drive motor are all less than their corresponding fault determination threshold within a preset fault recovery determination sampling period, the drive motor fault is determined to have been recovered, and command information for warning cancellation and fault recovery is sent through the enhanced CAN bus interface.

[0034] If any one of the operating status parameters or the physical status parameters of each signal interface of a faulty drive motor exceeds its corresponding fault judgment threshold within a preset fault recovery judgment sampling period, then the drive motor fault is determined to be unrecovered.

[0035] Preferably, the method for recording drive motor fault data and recovery process data is as follows: when a drive motor fault is determined, the fault diagnosis device automatically generates a unique event identifier for the fault and creates a structured fault event record, synchronously recording the timestamp of the fault occurrence, real-time vehicle operating data, drive motor fault type and fault level, and sending corresponding hierarchical response strategy instructions through the enhanced CAN bus interface.

[0036] When a drive motor fault is determined to be resolved, the fault event record will be automatically appended with a timestamp confirming the recovery, the sequence of each operating status parameter and each signal interface physical status parameter of the faulty drive motor within the preset data recording sampling period before the fault recovery, and the command information for fault recovery sent through the enhanced CAN bus interface.

[0037] Installation and Protection Module: Used to install fault diagnosis devices and provide integrated physical protection.

[0038] Preferably, the method for installing the fault diagnosis device and providing integrated physical protection is as follows: the fault diagnosis device is installed on the vehicle body bracket next to the drive motor controller using an adjustable-spacing snap-on mounting base and an elastic buffer pad assembly; the current drive motor model of the new energy vehicle is obtained; the snap-on spacing corresponding to the drive motor model stored in the local database is matched with the snap-on spacing stored in the local database; the mounting base spacing is adjusted according to the snap-on spacing; the fault diagnosis device is encapsulated in an engineering plastic shell with dustproof and waterproof performance; and the side wall of the shell has evenly distributed heat dissipation holes; the external signal harness of the fault diagnosis device adopts a tin-plated copper core and a double-layer shielding structure design; and the external electrical interface of the fault diagnosis device adopts an automotive-grade connector with anti-pull-out snaps and sealing rings.

[0039] The beneficial effects of the present invention are as follows: (1) The first part of the present invention: Through the multi-dimensional and full-link parameter acquisition design, it breaks through the limitations of traditional single parameter monitoring, covering both the core operating status of the drive motor and focusing on the physical characteristics of the signal interface, accurately capturing hidden fault signs such as contact resistance and electromagnetic radiation that are easily overlooked. The targeted deployment of multiple types of professional sensors realizes the monitoring of key parts and transmission links without dead angles, providing a comprehensive and real data source for subsequent fault diagnosis, avoiding fault misjudgment or missed detection caused by monitoring blind spots from the source, and greatly improving the reliability of the diagnostic basis.

[0040] (2) The second part of the present invention not only solves the problems of weak anti-interference ability and data distortion in traditional preprocessing, but also ensures the accuracy of the physical meaning of the data through range coefficient and zero-point offset calibration, providing highly reliable data support for fault judgment and significantly improving the execution accuracy of subsequent diagnostic logic.

[0041] (3) The third part of the present invention: Through graded sound and light warning and enhanced CAN bus command transmission, the urgency of the fault is presented intuitively and responded to quickly. Combined with fault recovery judgment and data recording, it provides complete data support for operation and maintenance. The adjustable buckle design is compatible with multiple models of drive motors. Multiple protection measures resist interference and damage in complex vehicle environment. The two work together to solve the problems of poor adaptability and delayed warning of traditional devices, and ensure the long-term stable operation of the device, thus comprehensively improving the practicality and reliability of the system. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0043] Figure 1 This is a schematic diagram of the system modules of the present invention.

[0044] Figure 2 This is a block diagram of the device structure of the present invention.

[0045] Figure 3 This is a flowchart of the fault diagnosis and handling process of the present invention. Detailed Implementation

[0046] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0047] Reference Figure 1 As shown, the present invention provides a fault diagnosis device for a new energy vehicle drive motor control system, including a data acquisition module, a data preprocessing module, a fault diagnosis module, an early warning and communication module, an installation and protection module, and a local database.

[0048] It should be noted that the data acquisition module is connected to the data preprocessing module, the data preprocessing module is connected to the fault diagnosis module, the fault diagnosis module is connected to the early warning and communication module, the early warning and communication module is connected to the early warning and communication module, and the local database is connected to the data acquisition module, the data preprocessing module, the fault diagnosis module, the early warning and communication module, and the installation and protection module.

[0049] The data acquisition module is used to collect various operating status parameters of the drive motor and physical status parameters of various signal interfaces in real time. The operating status parameters include the current and voltage of the power output harness and the temperature of key parts. The physical status parameters of various signal interfaces include the contact resistance of the interface pins, the intensity of surrounding electromagnetic radiation, the vibration frequency of the interface pins, the signal amplitude, and the signal frequency distortion.

[0050] It should be noted that the current and voltage of the power output harness of the drive motor are collected through Hall current sensors and voltage detection terminals. A PT100 thermistor sensor is used, which is fixed to the motor housing, winding ends and controller heat dissipation surface with thermally conductive adhesive to monitor its temperature. The contact resistance detector built into the drive motor is used to monitor the contact resistance of the interface pins. An electromagnetic interference sensor is used to monitor the intensity of the surrounding electromagnetic radiation. A vibration sensor is used to detect the vibration frequency of the interface pins. The signal amplitude and signal frequency distortion are obtained through the signal conditioning and acquisition circuit connected to the signal pins.

[0051] The key components include the motor housing, the winding ends, and the controller heat dissipation surface.

[0052] The data preprocessing module is used to preprocess the acquired raw analog signals and convert them into standardized digital signals.

[0053] In a specific embodiment of the present invention, the method for preprocessing the acquired original analog signal and converting it into a standardized digital signal is as follows: A high-impedance filtering path constructed by the common-mode inductor inside the fault diagnosis device is used to filter out high-frequency common-mode electromagnetic interference generated by the high-voltage system of the drive motor during operation in the original analog signal. A TVS transient suppression diode is used to clamp and absorb transient overvoltage spikes in the original analog signal to obtain a preprocessed original analog signal. An A / D conversion module is then used to convert the preprocessed original analog signal into a discrete digital signal with a preset sampling accuracy. Based on the range coefficients and zero-point offset parameters calibrated by each sensor that acquired the original analog signal, the discrete digital signal is proportionally converted and zero-point calibrated to obtain a standardized digital signal.

[0054] It should be noted that the original analog signal is a continuous time-varying electrical signal directly acquired from the drive motor body and its signal interface by the on / off Hall current sensor, voltage detection terminal, PT100 thermistor, electromagnetic interference sensor, contact resistance detector and vibration sensor, etc., without any processing.

[0055] It should be noted that while filtering out the high-frequency common-mode electromagnetic interference generated by the high-voltage system of the drive motor during operation, the original analog signal is also protected against interference.

[0056] For example, the preset sampling precision is 16 bits, etc.

[0057] The clamping absorption refers to a protection mechanism that uses a TVS transient voltage suppressor diode to suppress and absorb the energy of transient overvoltage spikes in the original analog signal.

[0058] The zero-point offset coefficient refers to the original digital value of the sensor output signal after A / D conversion when the measured physical quantity is zero. It is used to eliminate the inherent zero-point error of the sensor and its signal conditioning circuit. For example, ideally, the original digital value of the current is 0, but in reality, due to hardware deviation, it may correspond to a value of 100. This value is the zero-point offset.

[0059] The range coefficient refers to the ratio between the maximum value of the physical quantity that the sensor can sense throughout its entire measurement range, i.e., the full-scale value, and the total effective change of the digital signal corresponding to the sensor output. The range coefficient is the digital value without a clear physical unit obtained after A / D conversion and zero-point calibration, which is proportionally scaled back to the real measurement value with a clear physical meaning and unit. Range coefficient = physical range / (full-scale original value - zero-point offset coefficient).

[0060] For example, discrete digital signals are proportionally converted and zero-point calibrated based on the range coefficients and zero-point offset parameters of each sensor that acquires the original analog signals. For instance, assuming the current sensor's measurement range is ±500A, the zero-point offset coefficient obtained during factory precision calibration is: when the current is 0A, the measured original digital value is 0; when the current is 500A, the measured full-scale original digital value is 32000. Therefore, the range coefficient = physical range / (full-scale original value - zero-point offset coefficient), and the range coefficient = 500A / (32000 - 0) ≈ 0.015. 625A means that for every unit increase or decrease in the digital signal after A / D conversion, the current change represents approximately 0.015625 amperes. If the original digital value acquired at a certain moment is 22400, the device will call the pre-stored parameters for calibration calculation. The final current value = (original digital value - zero-point bias coefficient) × range coefficient, and the final current value = (22400 - 0) × 0.015625A / unit = 350A. Through this calibration process, the device accurately converts the meaningless original digital value 22400 into a current value of 350A with a clear physical meaning.

[0061] The fault diagnosis module is used to determine the type of drive motor fault and generate the drive motor fault level accordingly.

[0062] Reference Figure 2 As shown in the specific embodiment of the present invention, the method for determining the fault type of the drive motor is as follows: obtaining the current and voltage of the power output harness and the temperature of key parts in the preprocessed standardized digital signal, as well as the contact resistance of the interface pins, the intensity of the surrounding electromagnetic radiation, the vibration frequency of the interface pins, the signal amplitude, and the signal frequency distortion.

[0063] If the current in the power output harness of the drive motor suddenly changes and exceeds the preset safe current threshold or the voltage exceeds the preset safe voltage threshold, it is determined that the drive motor has a short circuit fault.

[0064] When the temperature of critical components of the drive motor exceeds the preset safe temperature threshold, the drive motor is determined to have an overheating fault.

[0065] If the contact resistance of the drive motor interface pin is greater than the preset safe resistance threshold, and the vibration frequency of the interface pin is greater than the preset safe vibration frequency, then the drive motor is determined to have a loose plug fault.

[0066] When the electromagnetic radiation intensity around the drive motor exceeds the preset anti-interference tolerance, the drive motor is determined to have an electromagnetic interference fault.

[0067] If the amplitude of the drive motor signal is not within the preset safe amplitude range, the signal frequency distortion is greater than the preset safe signal frequency distortion, or the number of signal frame drops is greater than the preset safe number of frame drops threshold, then the drive motor is determined to have a signal transmission fault.

[0068] The signal frequency distortion refers to the percentage deviation of the actual frequency value of a signal from its theoretical standard frequency value, and is used to quantify the frequency stability and accuracy of a signal in real time.

[0069] In a specific embodiment of the present invention, the method for generating the drive motor fault level is as follows: the drive motor fault level is divided according to the fault type of the drive motor.

[0070] If a drive motor has a short circuit fault, overheating fault, loose plug fault, electromagnetic interference fault and signal transmission fault at the same time, the fault level of the drive motor is determined to be Level 1.

[0071] If a drive motor has any four of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be Level 2.

[0072] If a drive motor has any three of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be level three.

[0073] If a drive motor has any two of the following faults: short circuit, overheating, loose plug, electromagnetic interference, and signal transmission, then the fault level of the drive motor is determined to be level four.

[0074] If a drive motor has any one of the following faults: short circuit, overheating, loose plug, electromagnetic interference, or signal transmission, then the fault level of the drive motor is determined to be level five.

[0075] It should be noted that a level 1 fault is greater than a level 2 fault, a level 2 fault is greater than a level 3 fault, a level 3 fault is greater than a level 4 fault, and a level 4 fault is greater than a level 5 fault.

[0076] The early warning and communication module is used to provide graded early warnings based on the fault level of the drive motor, send corresponding graded response strategy instructions through the enhanced CAN bus interface, determine the recovery status of the drive motor fault, and record the drive motor fault data and recovery process data.

[0077] Reference Figure 3As shown in the specific embodiment of the present invention, the method for graded early warning based on the fault level of the drive motor is as follows: when the fault level of the drive motor is level one, the red indicator light inside the fault diagnosis device is immediately triggered to flash at a high frequency, and at the same time the buzzer is driven to emit a continuous sharp alarm sound at the highest volume set by the factory.

[0078] When the fault level of the drive motor is level two, the red indicator light inside the fault diagnosis device will be immediately triggered to stay on, and the buzzer will be driven to emit intermittent sharp alarm sounds at the factory-set maximum volume.

[0079] When the fault level of the drive motor is level three, the yellow indicator light inside the fault diagnosis device will be triggered to flash rapidly at a high frequency, and at the same time the buzzer will be driven to emit a continuous sound at a level between the minimum and maximum volume to provide a warning.

[0080] When the fault level of the drive motor is level four, the yellow indicator light inside the fault diagnosis device will be constantly lit, and the buzzer will be driven to emit intermittent beeps at a level between the minimum and maximum volume to provide a warning.

[0081] When the fault level of the drive motor is level five, only the yellow indicator light inside the fault diagnosis device will be constantly lit as a warning.

[0082] In a specific embodiment of the present invention, the method for sending the corresponding hierarchical response strategy command through the enhanced CAN bus interface is as follows: when the fault level of the drive motor is level one, a command to immediately execute the drive motor safety shutdown procedure and cut off the power output is sent to the vehicle controller through the enhanced CAN bus interface.

[0083] When the drive motor fault level is level two, an instruction is sent to the vehicle controller via the enhanced CAN bus interface to constrain the output power of the drive motor to below a preset safety threshold.

[0084] When the drive motor fault level is level three, the fault location information is sent to the vehicle controller through the enhanced CAN bus interface, and the drive motor output power is limited to a preset safety threshold to continue operation.

[0085] When the drive motor fault level is level four, an instruction is sent to the vehicle central control system through the enhanced CAN bus interface to strengthen the monitoring of the various operating status parameters of the drive motor and the physical status parameters of each signal interface.

[0086] When the drive motor fault level is level five, a prompt message indicating the drive motor fault type is sent to the vehicle's central control system via the enhanced CAN bus interface.

[0087] It should be noted that the enhanced CAN bus interface uses an automotive-grade CAN bus interface with a TVS transient suppression diode to communicate bidirectionally with the vehicle's central control system and the vehicle control unit (VCU).

[0088] In a specific embodiment of the present invention, the method for determining the recovery status of the drive motor fault is as follows: real-time acquisition of each operating status parameter and each signal interface physical status parameter of the faulty drive motor; when each operating status parameter and each signal interface physical status parameter of a faulty drive motor are all less than their corresponding fault judgment threshold within a preset fault recovery judgment sampling period, the drive motor fault is determined to have been recovered, and command information for warning cancellation and fault recovery is sent through the enhanced CAN bus interface.

[0089] If any one of the operating status parameters or the physical status parameters of each signal interface of a faulty drive motor exceeds its corresponding fault judgment threshold within a preset fault recovery judgment sampling period, then the drive motor fault is determined to be unrecovered.

[0090] For example, the preset fault recovery determination sampling period is 3 seconds, 4 seconds, etc.

[0091] The fault determination threshold refers to the safety standard or allowable range set for fault diagnosis, used to evaluate the various operating state parameters of the drive motor and the physical state parameters of the signal interface.

[0092] The instructions for warning cancellation and fault recovery include stopping the warning corresponding to the fault level, lifting the operation restrictions triggered by the fault, and updating the fault status flag from active to recovered.

[0093] In a specific embodiment of the present invention, the method for recording drive motor fault data and recovery process data is as follows: when it is determined that there is a fault in the drive motor, the fault diagnosis device automatically generates a unique event identifier for the fault and creates a structured fault event record, synchronously recording the timestamp of the fault occurrence, real-time vehicle operating data, drive motor fault type and fault level, and sending corresponding hierarchical response strategy instructions through the enhanced CAN bus interface.

[0094] When a drive motor fault is determined to be resolved, the fault event record will be automatically appended with a timestamp confirming the recovery, the sequence of each operating status parameter and each signal interface physical status parameter of the faulty drive motor within the preset data recording sampling period before the fault recovery, and the command information for fault recovery sent through the enhanced CAN bus interface.

[0095] It should be noted that creating a structured fault event record means persistently saving all information related to drive motor faults through the non-volatile storage unit built into the fault diagnosis device, managing the storage space with a cyclic update mechanism, and reserving a standard diagnostic interface to support data export and analysis. This structured recording method facilitates efficient computer-automated analysis, statistics, and mining of data exported through the diagnostic interface, providing a solid data foundation for drive motor fault type research, product quality improvement, and predictive maintenance.

[0096] The real-time operating data of the vehicle includes, but is not limited to, motor speed, output torque, and bus voltage.

[0097] It should be noted that the sequence of operating status data and signal interface physical status data of the faulty drive motor within the preset data recording sampling period before fault recovery is a dynamic process that records how the fault state gradually transitions to the normal state. This provides a key data foundation for subsequent root cause analysis of faults, improvement of drive motor system reliability, and optimization of predictive maintenance.

[0098] For example, the preset data recording sampling period is 30 seconds, 40 seconds, etc.

[0099] The installation and protection module is used to install fault diagnosis devices and provide integrated physical protection.

[0100] In a specific embodiment of the present invention, the method for installing the fault diagnosis device and providing integrated physical protection is as follows: the fault diagnosis device is installed on the vehicle body bracket next to the drive motor controller using an adjustable-spacing snap-on mounting base and an elastic buffer pad assembly; the current drive motor model of the new energy vehicle is obtained; the snap-on spacing corresponding to the drive motor model stored in the local database is matched with the snap-on spacing stored in the local database; the mounting base spacing is adjusted according to the snap-on spacing; the fault diagnosis device is encapsulated in an engineering plastic shell with dustproof and waterproof performance; and the side wall of the shell has evenly distributed heat dissipation holes; the external signal harness of the fault diagnosis device adopts a tin-plated copper core and a double-layer shielding structure design; and the external electrical interface of the fault diagnosis device adopts an automotive-grade connector with anti-pull-out snaps and sealing rings.

[0101] It should be noted that by matching the corresponding clip spacing of different drive motor models, the installation gap is controlled within the preset tolerance range, enabling quick disassembly and maintenance.

[0102] It should be noted that the evenly distributed array of heat dissipation holes on the side wall of the outer casing is to achieve efficient heat dissipation and protection in one.

[0103] It should be noted that the external signal harness of the fault diagnosis device is protected by corrugated pipes on key sections, and the wiring path actively avoids high-voltage harnesses and mechanical moving parts. This is the core guarantee for ensuring the reliability of signal transmission and the long-term stable operation of the device.

[0104] The critical line segment refers to a specific signal harness section that is highly susceptible to physical damage, electromagnetic interference, or environmental stress during the installation and long-term operation of the fault diagnosis device integrated into the new energy vehicle, due to its specific layout location, functional importance, or environmental exposure. Specifically, it includes, but is not limited to: the interface between the harness and the device body, the wiring section that needs to pass through or be adjacent to mechanical moving parts and high-voltage power harnesses, and the exposed section exposed to the harsh environment of the engine compartment.

[0105] For example, physical damage includes vibration friction, mechanical compression, scratching, etc.

[0106] For example, environmental stresses such as temperature shock, oil corrosion, and moisture intrusion.

[0107] It should be noted that the above-mentioned multi-dimensional measures work together to achieve reliable installation and integrated physical protection of the fault diagnosis device next to the drive motor controller, ensuring connection stability and environmental sealing, and providing comprehensive integrated physical protection and highly adaptable installation support for the fault diagnosis device in complex vehicle environments.

[0108] The examples described in this invention are not limited to the specific embodiments listed above. The examples are merely illustrative to facilitate understanding of the invention and do not constitute a limitation on the scope of protection of this invention. Any modifications, equivalent substitutions, etc., made within the spirit and principles of this invention should be included within the scope of protection.

[0109] The above description is merely an example and illustration of the concept of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described or use similar methods to replace them, as long as they do not deviate from the concept of the invention or exceed the scope defined in this specification, they should all fall within the protection scope of the present invention.

Claims

1. A new energy vehicle drive motor control system fault diagnosis device, characterized in that, The method comprises the following steps: A data acquisition module is configured to acquire real-time operation state parameters of the drive motor and physical state parameters of each signal interface, wherein the operation state parameters include current and voltage of the power output line bundle and temperature of key positions, and the physical state parameters of the signal interface include contact resistance of the interface pin, surrounding electromagnetic radiation intensity, vibration frequency of the interface pin, signal amplitude, and signal frequency distortion degree; A data preprocessing module is configured to preprocess the acquired original analog signals and convert them into standardized digital signals; A fault diagnosis module is configured to determine the fault type of the drive motor and generate a drive motor fault level accordingly; An early warning and communication module is configured to perform hierarchical early warning according to the drive motor fault level, send corresponding hierarchical response strategy instructions through an enhanced CAN bus interface, determine the recovery of the drive motor fault, and record drive motor fault data and recovery process data; An installation and protection module is configured to install the fault diagnosis device and provide integrated physical protection.

2. The new energy vehicle drive motor control system fault diagnosis device according to claim 1, characterized in that, The method of preprocessing the acquired original analog signals and converting them into standardized digital signals is as follows: A high-impedance filtering path constructed by a common-mode inductor inside the fault diagnosis device filters out high-frequency common-mode electromagnetic interference generated during operation of the high-voltage system of the drive motor, and a TVS transient voltage suppression diode clamps and absorbs transient overvoltage spikes in the original analog signals to obtain preprocessed original analog signals. The preprocessed original analog signals are converted into discrete digital signals by an A / D conversion module with a preset sampling precision. The discrete digital signals are proportionally scaled and zero-calibrated according to the range coefficient and zero-point bias parameters of each sensor that acquires the original analog signals to obtain standardized digital signals.

3. The new energy vehicle drive motor control system fault diagnosis device according to claim 2, characterized in that, The method of determining the fault type of the drive motor is as follows: The current and voltage of the power output line bundle and the temperature of key positions in the standardized digital signals obtained after preprocessing are acquired. When the current of the power output line bundle of the drive motor suddenly changes and is greater than a preset safe current threshold or the voltage is greater than a preset safe voltage threshold, it is determined that the drive motor has a circuit short circuit fault. When the temperature of the key positions of the drive motor is greater than a preset safe temperature threshold, it is determined that the drive motor has an overheating fault. When the contact resistance of the interface pin of the drive motor is greater than a preset safe resistance threshold and the vibration frequency of the interface pin is greater than a preset safe vibration frequency, it is determined that the drive motor has a plug-in loose fault. When the surrounding electromagnetic radiation intensity of the drive motor is greater than a preset anti-interference tolerance, it is determined that the drive motor has an electromagnetic interference fault. When the signal amplitude of the drive motor is not within a preset safe amplitude range, the signal frequency distortion degree is greater than a preset safe signal frequency distortion degree, or the signal frame loss number is greater than a preset safe frame loss threshold, it is determined that the drive motor has a signal transmission fault.

4. The new energy vehicle drive motor control system fault diagnosis device according to claim 3, characterized in that, The method of generating a drive motor fault level is as follows: According to the type of fault existing in the driving motor, the driving motor fault level is divided; If the driving motor simultaneously exists circuit short-circuit fault, overheat fault, plug-in loose fault, electromagnetic interference fault and signal transmission fault, it is determined that the driving motor fault level is level one; If the driving motor exists any four of the circuit short-circuit fault, overheat fault, plug-in loose fault, electromagnetic interference fault and signal transmission fault, it is determined that the driving motor fault level is level two; If the driving motor exists any three of the circuit short-circuit fault, overheat fault, plug-in loose fault, electromagnetic interference fault and signal transmission fault, it is determined that the driving motor fault level is level three; If the driving motor exists any two of the circuit short-circuit fault, overheat fault, plug-in loose fault, electromagnetic interference fault and signal transmission fault, it is determined that the driving motor fault level is level four; If the driving motor exists any one of the circuit short-circuit fault, overheat fault, plug-in loose fault, electromagnetic interference fault and signal transmission fault, it is determined that the driving motor fault level is level five.

5. The new energy vehicle drive motor control system fault diagnosis device according to claim 4, characterized in that, The specific method of the hierarchical early warning according to the driving motor fault level is: When the driving motor fault level is level one, the red indicator light inside the fault diagnosis device is triggered to high-frequency flicker, and the buzzer is driven to emit a continuous sharp alarm sound at the highest volume set at the factory; When the driving motor fault level is level two, the red indicator light inside the fault diagnosis device is triggered to constant light, and the buzzer is driven to emit an intermittent sharp alarm sound at the highest volume set at the factory; When the driving motor fault level is level three, the yellow indicator light inside the fault diagnosis device is triggered to high-frequency rapid flicker, and the buzzer is driven to emit a continuous ringing sound at an intermediate gear between the minimum volume and the maximum volume for early warning; When the driving motor fault level is level four, the yellow indicator light inside the fault diagnosis device is triggered to constant light, and the buzzer is driven to emit an intermittent ringing sound at an intermediate gear between the minimum volume and the maximum volume for early warning; When the driving motor fault level is level five, only the yellow indicator light inside the fault diagnosis device is triggered to constant light for early warning.

6. The new energy vehicle drive motor control system fault diagnosis device according to claim 5, characterized in that, The specific method of sending the corresponding hierarchical response strategy instruction through the enhanced CAN bus interface is: When the driving motor fault level is level one, the enhanced CAN bus interface sends the instruction of immediately executing the driving motor safety shutdown program and cutting off the power output to the vehicle controller; When the driving motor fault level is level two, the enhanced CAN bus interface sends the instruction of restricting the driving motor output power below the preset safety threshold to the vehicle controller; When the driving motor fault level is level three, the enhanced CAN bus interface sends the instruction of positioning the fault and limiting the driving motor output power within the preset safety threshold to continue running to the vehicle controller; When the driving motor fault level is level four, the enhanced CAN bus interface sends the instruction of strengthening the monitoring of the driving motor running state parameters and signal interface physical state parameters to the vehicle central control system; When the driving motor fault level is five, the enhanced CAN bus interface sends a prompt information instruction of the driving motor fault type to the vehicle central control system.

7. The new energy vehicle drive motor control system fault diagnosis device according to claim 6, characterized in that, The driving motor fault recovery condition is determined by the following method: Real-time acquisition of the driving motor fault state parameters and signal interface physical state parameters, when the driving motor fault state parameters and signal interface physical state parameters are less than the corresponding fault determination threshold within the preset fault recovery determination sampling period, the driving motor fault is determined to have recovered, and the pre-warning cancellation and fault recovery instruction information is sent through the enhanced CAN bus interface; When any one of the driving motor fault state parameters and signal interface physical state parameters is greater than the corresponding fault determination threshold within the preset fault recovery determination sampling period, the driving motor fault is determined to have not recovered.

8. The new energy vehicle drive motor control system fault diagnosis device according to claim 7, characterized in that, The driving motor fault data and recovery process data are recorded by the following method: When the driving motor fault is determined, the fault diagnosis device automatically generates a unique event identifier for the fault and creates a structured fault event record, simultaneously recording the timestamp of the fault occurrence, vehicle real-time operating condition data, driving motor fault type and fault level, and the corresponding hierarchical response strategy instruction sent through the enhanced CAN bus interface; When the driving motor fault is determined to have recovered, the recovery confirmation timestamp, sequence of the driving motor fault state parameters and signal interface physical state parameters within the preset data recording sampling period before fault recovery, and the fault recovery instruction information sent through the enhanced CAN bus interface are automatically recorded in the fault event record.

9. The new energy vehicle drive motor control system fault diagnosis device according to claim 1, characterized in that, The fault diagnosis device is installed and integrated physical protection is provided by the following method: The fault diagnosis device is installed on the vehicle body support beside the driving motor controller through an adjustable spacing buckle mounting seat and elastic buffer pad assembly, the current new energy vehicle driving motor model is obtained, the corresponding buckle spacing stored in the local database is matched according to the driving motor model corresponding to the buckle spacing stored in the local database, the mounting seat spacing is adjusted according to the buckle spacing, the fault diagnosis device is packaged in an engineering plastic shell with dustproof and waterproof performance, and the shell side wall is provided with evenly distributed heat dissipation holes, the external signal wire harness of the fault diagnosis device adopts a tinned copper core and double-layer shielding structure design, and the external electrical interface of the fault diagnosis device adopts a vehicle specification connector with a pull-resistant buckle and a sealing ring.

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