Insulation fault processing device and method and engineering machinery

Abstract

The invention relates to the field of engineering machinery, and discloses an insulation fault processing device and method and engineering machinery. The first relay is connected in series between the power supply and the high-voltage slip ring; the second relay is connected in series between the power supply and a loading high-voltage electrical element of the engineering machinery; the third relay is connected in series between the power supply and the chassis high-voltage electrical element; the controller is used for disconnecting the first relay and carrying out insulation fault detection on the high-voltage loop when an insulation fault exists in the operation process of the engineering machinery, disconnecting the second relay if the insulation fault exists, and closing the first relay and the second relay if the insulation fault does not exist; and the controller is also used for disconnecting the third relay and carrying out insulation fault detection on the high-voltage loop when an insulation fault exists in the driving process, and closing the third relay if the insulation fault does not exist. Insulation faults are accurately isolated, and high voltage is prevented from being applied to the whole vehicle.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of engineering machinery, in particular to an insulation fault handling device, method and engineering machinery. BACKGROUND

[0002] With the popularization of new energy technology in the field of engineering machinery, electric engineering machinery represented by new energy cranes has gradually become the mainstream choice in construction scenes. The high-voltage system of such equipment is the power source for realizing functions such as lifting operation and driving.

[0003] At present, when an insulation fault occurs in the high-voltage circuit of the engineering machinery, the protection mechanism of the whole vehicle under high voltage is triggered, and the power supply of the whole high-voltage system is cut off, which affects the normal work of the engineering machinery. SUMMARY

[0004] The present application provides an insulation fault handling device, method and engineering machinery to solve the problem that the insulation fault occurs in the high-voltage circuit of the engineering machinery, the power supply of the whole high-voltage system is cut off, and the normal work of the engineering machinery is affected.

[0005] In a first aspect, the present application provides an insulation fault handling device, comprising: a controller; a first relay connected in series between a power supply and a high-voltage slip ring; a second relay connected in series between the power supply and an upper vehicle high-voltage electrical element of the engineering machinery; a third relay connected in series between the power supply and a chassis high-voltage electrical element of the engineering machinery; wherein the upper vehicle high-voltage electrical element and the chassis high-voltage electrical element are arranged in the high-voltage circuit of the engineering machinery; and the power supply is a power supply for the high-voltage circuit of the engineering machinery; the controller is configured to, when an insulation fault exists during operation of the engineering machinery, open the first relay, and when the first relay is opened, perform insulation fault detection on the high-voltage circuit, if the high-voltage circuit has an insulation fault, open the second relay, and perform insulation fault detection on the high-voltage circuit again, if the high-voltage circuit has no insulation fault, close the first relay and the second relay to restore the high-voltage circuit to a powered state; the controller is further configured to, when an insulation fault exists during driving of the engineering machinery, open the third relay, and when the third relay is opened, perform insulation fault detection on the high-voltage circuit, if the high-voltage circuit has no insulation fault, close the third relay to restore the high-voltage circuit to a powered state.

[0006] In the embodiment, for the parts prone to insulation faults in the high-voltage circuit, the power supply-high-voltage slip ring, the power supply-vehicle high-voltage electrical element, and the power supply-chassis high-voltage electrical element are respectively configured with the first relay, the second relay, and the third relay to form a sub-area, independently controllable isolation architecture. When an insulation fault is detected during the operation process, the controller first disconnects the first relay to isolate the high-voltage slip ring. If the detection is still abnormal, the second relay is disconnected to isolate the vehicle high-voltage electrical element. When a fault is detected during driving, the third relay is directly disconnected to isolate the chassis high-voltage electrical element.

[0007] The drawbacks of traditional technology of cutting off the high voltage of the whole vehicle upon a fault are avoided. Even if there is an insulation fault in a loop, only the fault loop needs to be isolated, and the loop without fault can still maintain power supply. Especially in the hoisting operation scene, it can prevent the hoisted object from hovering due to the high voltage of the whole vehicle, fundamentally reduce the safety risk caused by object falling and equipment failure, and protect the safety of personnel and equipment in the construction site. Through the process of disconnection, detection, and qualified recovery, the fault troubleshooting time is shortened, unnecessary downtime is reduced, and the construction efficiency is improved. At the same time, the relay is closed to restore power supply only after it is confirmed that there is no fault, which can avoid secondary faults caused by power-on with faults, ensure the reliability of the high-voltage system operation, and the newly added relay does not need to reconstruct the original high-voltage architecture, the modification cost is low, the compatibility is strong, and it can quickly adapt to new and old construction machinery, taking into account safety, efficiency, and practicality.

[0008] In an optional implementation manner, the controller is further configured to disconnect the first relay when there is an insulation fault in the operation process of the construction machinery, and perform insulation fault detection on the high-voltage circuit in the case of disconnecting the first relay. If the high-voltage circuit does not have an insulation fault, the first relay is closed to restore the power-on state of the high-voltage circuit.

[0009] In the embodiment, the fault handling logic in the operation scene is further optimized. When the first relay is disconnected and no fault is detected, the first relay can be directly closed to restore power supply without additional operation, which is more efficient than the scene that needs multiple steps of troubleshooting. It can quickly exclude the fault suspicion of the high-voltage slip ring, avoid unnecessary extension of downtime due to subsequent operations, ensure that there is no abnormality in the loop before restoring power supply, prevent the risk of power-on with faults, and simplify part of the execution process of the controller, reduce the logic operation amount, improve the fault handling response speed, ensure that the crane can restore the high voltage faster during operation, and reduce the loss of hoisting efficiency and safety risks caused by high-voltage interruption.

[0010] In an optional implementation manner, the first relay includes a first sub-relay and a second sub-relay. The first sub-relay is connected in series between the negative electrode end of the high-voltage slip ring and the negative electrode end of the power supply. The second sub-relay is connected in series between the positive terminal of the high-voltage slip ring and the positive terminal of the power supply; The first sub-relay and the second sub-relay are disconnected when there is an insulation fault during the operation of the engineering machinery, so as to disconnect the electrical connection between the power supply and the high-voltage slip ring.

[0011] In this embodiment, through the design of positive and negative dual relays, compared with single relay only cutting off single-pole loop, the complete electrical isolation of the power supply and the high-voltage slip ring can be realized, the risk of leakage and high-voltage flow caused by single-pole disconnection can be avoided, and the safety of fault isolation is greatly improved. At the same time, the redundant design of dual relays can prevent the isolation from failing due to single relay failure, and ensure that the high-voltage slip ring loop can be reliably cut off when an insulation fault occurs, so as to exclude interference for subsequent precise detection of other loops; and the dual-pole disconnection can completely cut off the energy supply of the high-voltage slip ring, avoiding the damage of elements caused by residual high voltage, and further ensuring the stability and service life of the high-voltage system.

[0012] In an optional embodiment, the second relay comprises a third sub-relay, a fourth sub-relay and a fifth sub-relay; and the high-voltage electrical elements on the vehicle comprise a first heater and a first compressor. The third sub-relay is connected in series between the negative terminal of the power supply and the negative terminal of the high-voltage electrical elements on the vehicle; The fourth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the first heater; The fifth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the first compressor; The third sub-relay, the third sub-relay and the fifth sub-relay are disconnected if the high-voltage loop still has an insulation fault when the first relay is disconnected, so as to disconnect the electrical connection between the power supply and the high-voltage electrical elements on the vehicle.

[0013] In this embodiment, the second relay is split into sub-relays for different high-voltage electrical elements on the vehicle, realizing independent control and centralized isolation of the first heater and the first compressor. When the first relay is disconnected and there is still a fault, three sub-relays are disconnected at the same time, which can completely cut off the connection between the high-voltage electrical elements on the vehicle and the power supply, accurately isolate the fault loop on the vehicle, and avoid the influence of single element failure on other high-voltage electrical elements on the vehicle. Moreover, the design of positive and negative control ensures that there is no residual high voltage during isolation, reducing the risk of leakage. In addition, this subdivision design provides space for more accurate fault location in the future, such as disconnecting a certain sub-relay to check the specific element fault, further improving the refinement degree of fault handling, and reducing the impact of the overall shutdown of the high-voltage electrical elements on the vehicle.

[0014] In an alternative embodiment, the third relay comprises a sixth sub-relay, a seventh sub-relay and an eighth sub-relay; the chassis high-voltage electrical element comprises a second heater and a second compressor; The sixth sub-relay is connected in series between the negative terminal of the power supply and the negative terminal of the chassis high-voltage electrical element; The seventh sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the second heater; The eighth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the second compressor; The sixth sub-relay, the seventh sub-relay and the eighth sub-relay are disconnected when an insulation fault occurs during the travel of the engineering machinery, so as to disconnect the electrical connection between the power supply and the chassis high-voltage electrical element.

[0015] In this embodiment, for the chassis high-voltage electrical element in the travel scenario, a similar sub-relay subdivision design as on the car is adopted, which can realize precise isolation of the second heater and the second compressor. If an insulation fault occurs during travel, disconnecting the three sub-relays can quickly cut off the chassis high-voltage electrical element loop, avoid the fault spreading to the travel control system, and ensure the safety of the crane during travel. At the same time, the positive and negative pole double-pole cut-off design ensures complete isolation without high-voltage residue, preventing the chassis element from being damaged or causing a safety accident due to leakage. In addition, this design makes the fault isolation of the chassis high-voltage loop more targeted, without affecting the high-voltage loop on the car. If the travel fault only involves the chassis element, the car function can still operate normally, improving the functional retention capability of the equipment in the fault state and reducing the impact of the fault on the overall operation.

[0016] In an alternative embodiment, the insulation fault handling device further comprises a DC converter and a low-voltage power supply; The input end of the DC converter is connected with the power supply, and the output end of the DC converter is connected with the low-voltage power supply; The DC converter is used to convert the high-voltage direct current of the power supply into low-voltage direct current; The low-voltage power supply is used to supply power to the insulation fault handling device through the low-voltage direct current output by the DC converter.

[0017] In the embodiment, the configuration of the DC converter and the low-voltage power supply provides independent and stable low-voltage power supply for the insulation fault handling device. Even if the high-voltage circuit is isolated due to a fault, the DC converter can still take power from the power supply and convert it into low-voltage, ensuring that the low-voltage components such as the controller, relay coil, etc. continue to work, avoiding the interruption of the fault handling process due to the loss of low-voltage power. At the same time, the low-voltage power supply can store electrical energy to ensure stable power supply when the power supply is temporarily fluctuating, preventing voltage fluctuations from affecting the detection accuracy of the controller and the action reliability of the relay. The design ensures the continuity and stability of the fault handling logic from the power supply level, avoids the exacerbation of high-voltage faults due to low-voltage problems, further enhances the reliability of the entire insulation fault handling system, and ensures that fault isolation and recovery operations can be effectively performed under various working conditions.

[0018] In an alternative embodiment, the insulation fault handling device further comprises a fuse arranged between the DC converter and the power supply; The fuse is configured to disconnect the electrical connection between the DC converter and the power supply when overcurrent exists between the DC converter and the power supply.

[0019] In the embodiment, the addition of the fuse provides overcurrent protection for the connection circuit of the DC converter and the power supply. When a short circuit occurs in the circuit, such as overcurrent caused by internal faults of the DC converter or damaged lines, the fuse can quickly melt and cut off the circuit to prevent overcurrent damage to the DC converter, the low-voltage power supply and subsequent low-voltage components, and to prevent the spread of faults from the high-voltage side to the low-voltage side, ensuring the electrical safety of the entire device. At the same time, the protection function of the fuse can reduce the maintenance cost and downtime caused by component damage, ensure that the insulation fault handling device can still protect the core components when encountering overcurrent risk, maintain the basic safety of the low-voltage system, create conditions for subsequent fault troubleshooting and repair, and further improve the reliability and safety of the device.

[0020] In a second aspect, the application also provides an insulation fault handling method applied to the controller of the insulation fault handling device of the first aspect or any of the corresponding embodiments, and the method comprises: When an insulation fault occurs during the operation of the engineering machinery, the first relay is disconnected, and insulation fault detection is performed on the high-voltage circuit under the condition that the first relay is disconnected. If the high-voltage circuit has an insulation fault, the second relay is disconnected, and insulation fault detection is performed on the high-voltage circuit again. If the high-voltage circuit does not have an insulation fault, the first relay and the second relay are closed to restore the power-on state of the high-voltage circuit; When an insulation fault occurs during the operation of the construction machinery, the third relay is disconnected, and an insulation fault detection is performed on the high-voltage circuit while the third relay is disconnected. If there is no insulation fault in the high-voltage circuit, the third relay is closed to restore the high-voltage circuit to its powered state.

[0021] In one optional implementation, the method further includes: When an insulation fault occurs during the operation of the engineering machinery, the first relay is disconnected, and an insulation fault detection is performed on the high-voltage circuit while the first relay is disconnected. If there is no insulation fault in the high-voltage circuit, the first relay is closed to restore the high-voltage circuit to its powered state.

[0022] Thirdly, this application also provides an engineering machinery, including the insulation fault handling device of the first aspect or any corresponding embodiment described above. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 This is a schematic diagram of the structure of the insulation fault handling device according to an embodiment of this application; Figure 2 This is a schematic diagram of the insulation fault handling device in a high-voltage circuit according to an embodiment of this application; Figure 3 This is a schematic flowchart of an insulation fault handling method according to an embodiment of this application. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] In the description of this application, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0027] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection. They can refer to a mechanical connection or an electrical connection. They can refer to a direct connection or an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0028] Furthermore, the technical features involved in the different embodiments of this application described below can be combined with each other as long as they do not conflict with each other.

[0029] Figure 1 This is a schematic diagram of the insulation fault handling device according to an embodiment of this application.

[0030] like Figure 1 As shown in the figure, this application provides an insulation fault handling device, which includes: Controller.

[0031] The first relay K1 is connected in series between the power supply and the high-voltage slip ring.

[0032] The second relay K2 is connected in series between the power supply and the high-voltage electrical components on the construction machinery.

[0033] The third relay K3 is connected in series between the power supply and the high-voltage electrical components of the chassis of the engineering machinery.

[0034] The high-voltage electrical components on the vehicle and chassis are located in the high-voltage circuit of the construction machinery. The power supply is the power supply for the high-voltage circuit of the construction machinery.

[0035] The controller is used to disconnect the first relay K1 when an insulation fault occurs during the operation of the construction machinery. With the first relay K1 disconnected, the controller performs an insulation fault detection on the high-voltage circuit. If an insulation fault is found in the high-voltage circuit, the controller disconnects the second relay K2 and performs an insulation fault detection on the high-voltage circuit again. If no insulation fault is found in the high-voltage circuit, the controller closes the first relay K1 and the second relay K2 to restore the high-voltage circuit to the powered state.

[0036] The controller is also used to disconnect the third relay K3 when an insulation fault occurs during the operation of the construction machinery, and to perform insulation fault detection on the high-voltage circuit when the third relay K3 is disconnected. If there is no insulation fault in the high-voltage circuit, the third relay K3 is closed to restore the high-voltage circuit to the power-on state.

[0037] In this embodiment, the high-voltage circuit refers to the electrical circuit in construction machinery that uses high-voltage direct current as the core power component and high-voltage auxiliary components for power supply. It includes the power supply, high-voltage slip rings, upper-vehicle high-voltage electrical components, chassis high-voltage electrical components, and connecting lines. It is the foundation for realizing the operational actions (such as lifting and hoisting) and driving functions of the construction machinery. The high-voltage circuit includes the upper-vehicle high-voltage circuit and the chassis / undercarriage high-voltage circuit.

[0038] The power supply can be a high-voltage battery pack composed of multiple high-voltage lithium batteries connected in series, which typically outputs a DC voltage of 300V-800V to provide stable high-voltage power to the entire high-voltage circuit.

[0039] Construction machinery can be new energy cranes (such as truck cranes and crawler cranes), new energy excavators, new energy loaders, and other construction equipment that rely on high-voltage systems for driving. In this embodiment, new energy cranes are the core application scenario.

[0040] High-voltage electrical components on the upper structure refer to parts installed on the upper working mechanism of construction machinery that rely on high-voltage electricity to operate, primarily serving the operational functions. The upper working mechanism of construction machinery includes, for example, the boom and slewing platform of a crane. As an example, high-voltage electrical components on the upper structure may include: an upper-structure air conditioning compressor, an upper-structure PTC heater, a winch motor, and a slewing motor. Specifically, the upper-structure PTC heater provides low-temperature heating, the winch motor controls the lifting and lowering of the hook, and the slewing motor controls the rotation of the upper structure.

[0041] Chassis high-voltage electrical components refer to parts installed on the lower chassis structure of construction machinery that rely on high-voltage electricity to operate, primarily serving driving and chassis auxiliary functions. As an example, chassis high-voltage electrical components may include: chassis air conditioning compressor, chassis PTC heater, drive motor, and steering motor. The drive motor provides driving power, and the steering motor controls the driving direction.

[0042] In this embodiment of the application, insulation failure refers to the failure of the insulation layer in the high-voltage circuit, such as the insulation sheath of high-voltage cables or the insulation material of component shells, due to aging, damage, moisture, etc., resulting in abnormal conduction between high-voltage electricity and the machine body (grounding terminal) or low-voltage circuit. This is manifested as insulation resistance being lower than the safety threshold, which may cause leakage, short circuit or even electric shock risk.

[0043] This application first disconnects the suspected circuit relay in the corresponding scenario (disconnecting the first relay K1 during operation to isolate the high-voltage slip ring circuit, and disconnecting the third relay K3 during driving to isolate the chassis high-voltage electrical component circuit). After eliminating interference from the suspected faulty circuit, insulation testing is performed on the remaining high-voltage circuit. If the test still finds a fault, the associated relay is further disconnected (e.g., disconnecting the second relay K2 during operation to isolate the upper vehicle high-voltage electrical component circuit) for another test to locate the fault source. After the test confirms that there is no insulation fault in the high-voltage circuit, the previously disconnected relays are closed (e.g., closing K1 and K2 during operation, and closing K3 during driving) to restore the high-voltage circuit to the powered state. This avoids the drawbacks of traditional high-voltage circuits that require the entire vehicle to be powered down, and can efficiently locate and isolate faults, ensuring the safe and stable operation of the construction machinery after fault handling.

[0044] In this embodiment of the application, disconnecting and reclosing during a transient insulation fault can directly eliminate the cause of the fault: In actual operating conditions of construction machinery, some insulation faults are caused by non-permanent, transient interferences, rather than hard faults such as physical damage to the insulation layer. For example, during rainy weather, temporary moisture at high-voltage cable joints can cause the insulation resistance to temporarily fall below the safe threshold, triggering an insulation fault alarm. Alternatively, electromagnetic interference during the startup of high-voltage electrical components (such as compressors) can cause insulation detection sensors to misdiagnose a fault.

[0045] Disconnecting the relay at this point will cut off the high-voltage power supply to the circuit. After a brief power outage, the damp parts may recover their insulation due to the dry environment (such as wind or heat dissipation from the machine body), and the electromagnetic interference will also disappear as the components stabilize. When the relay is closed again to restore power, the circuit insulation has returned to normal, and the fault is naturally resolved. In this case, disconnecting and reclosing essentially eliminates the momentary interference by briefly cutting off power, allowing the circuit insulation to recover autonomously, thus resolving the fault without manual maintenance.

[0046] In this embodiment of the application, for permanent insulation faults: disconnecting and reclosing is the core means of locating the fault and isolating the risk, indirectly achieving system controllability. If the insulation fault is permanent, such as damage to the insulation of high-voltage cables or cracks in the casing of components, disconnecting and reclosing cannot repair the physical damage, but the impact of the fault can be controlled through the following logic to prevent system failure: By disconnecting relays to locate the faulty circuit: for example, during operation, first disconnect the first relay K1 to isolate the high-voltage slip ring circuit. If the remaining circuit insulation is found to be normal, it indicates that the fault is only in the high-voltage slip ring circuit. If it is still abnormal, then disconnect the second relay K2 to isolate the high-voltage electrical component circuit on the vehicle, until the test is normal. By gradually disconnecting different relays, the specific circuit where the fault is located can be accurately pinpointed, avoiding blind troubleshooting.

[0047] Partial functionality can be restored by closing only the normal circuit: After locating the faulty circuit, the relays in the faulty circuit can remain open. For example, if the high-voltage slip ring circuit is faulty, K1 will not be closed; only the relays in the normal circuit will be closed. Closing K2 will restore power supply to the high-voltage electrical components on the vehicle. Although the fault is not repaired at this time, the construction machinery can retain some functions, such as auxiliary functions on the vehicle, to avoid work interruptions or safety risks caused by the entire vehicle being placed under high voltage, such as suspending the hoisted object.

[0048] To create safe conditions for subsequent maintenance: After disconnecting the faulty circuit relay, the circuit is completely isolated from the power supply, with no high voltage residue. Maintenance personnel can safely disassemble faulty components, such as damaged cables or faulty parts, for replacement. After repair, the relay is closed to restore power to the entire circuit. Disconnection is a prerequisite for safe maintenance, while closure is the restoration of function after maintenance. The two work together to achieve a complete solution to the fault.

[0049] The core logic of disconnecting and reclosing to resolve insulation faults is that for transient faults, the cause is eliminated by cutting off power. For permanent faults, the risk is isolated by disconnecting and normal function is restored by closing, ultimately achieving maintenance without downtime or with controlled downtime, avoiding the drawback of traditional architectures where a single fault paralyzes the entire vehicle.

[0050] As an example, the controller can be a vehicle controller for construction machinery, a dedicated high-voltage control unit, or a battery management system (BMS), which has data acquisition, logic operation, and relay control capabilities, and can receive signals from insulation detection sensors and output relay on / off commands.

[0051] The controller is connected to the first relay K1, the second relay K2, and the third relay K3 via low-voltage control lines. The high and low level signals output by the controller control the energization of the relay coils, thereby closing and opening the relay contacts to control the on / off state of the high-voltage circuit. The first relay K1, the second relay K2, and the third relay K3 can be high-voltage DC relays, possessing the characteristics of withstanding high voltage (matching the power supply voltage), carrying large current (meeting the load requirements of the corresponding circuit), and supporting low-voltage signal control to ensure reliable operation in high-voltage environments.

[0052] In this embodiment of the application, when an insulation fault occurs during the operation of the construction machinery, the controller disconnects the first relay K1, which can cut off the electrical connection between the power supply and the high-voltage slip ring, isolate the high-voltage slip ring and the circuit of the associated on-board working components, and preliminarily investigate whether the insulation fault is caused by the core working circuit (related to the high-voltage slip ring), so as to prevent the fault from spreading to other high-voltage areas.

[0053] With the first relay K1 disconnected, insulation fault detection is performed on the high-voltage circuit. If an insulation fault is found in the high-voltage circuit, the second relay K2 is disconnected. This can further isolate the circuit of the high-voltage electrical components on the vehicle, narrow down the scope of fault investigation, and accurately locate whether the fault is located in the high-voltage electrical components on the vehicle (such as the hoist motor or the compressor on the vehicle). At the same time, it can prevent the faulty circuit on the vehicle from continuously affecting the safety of the high-voltage system.

[0054] When the first relay K1 is disconnected, insulation fault detection of the high-voltage circuit refers to the controller using insulation detection sensors, such as insulation resistance meters, to detect the insulation resistance value of other high-voltage circuits besides the high-voltage slip ring circuit, such as the chassis high-voltage electrical component circuit, after disconnecting the high-voltage slip ring circuit, to determine whether there is an insulation failure problem in that part of the circuit.

[0055] With the first relay K1 and the second relay K2 disconnected, the high-voltage circuit is re-tested for insulation faults. If there is no insulation fault in the high-voltage circuit, the first relay K1 and the second relay K2 are closed to restore the high-voltage circuit to its energized state.

[0056] When the first relay K1 and the second relay K2 are disconnected, the insulation fault detection of the high-voltage circuit is performed again. This means that after disconnecting the high-voltage slip ring circuit and the high-voltage electrical component circuit of the vehicle, only the connection between the chassis high-voltage electrical component circuit and the power supply is maintained (or all unnecessary circuits are completely disconnected), and the insulation status of the remaining circuit is checked again. If the test is qualified, it means that the fault exists only in the isolated vehicle-related circuit. If it is still not qualified, the chassis circuit or the power supply itself needs to be further investigated.

[0057] In this embodiment, when an insulation fault occurs during the operation of the construction machinery, disconnecting the third relay K3 can cut off the connection between the power supply and the high-voltage electrical components of the chassis, isolate the high-voltage circuits related to driving, such as the drive motor and steering motor circuits, prioritize driving safety, and avoid loss of driving control due to chassis high-voltage faults.

[0058] With the third relay K3 disconnected, an insulation fault detection is performed on the high-voltage circuit. If there is no insulation fault in the high-voltage circuit, the third relay K3 is closed to restore the high-voltage circuit to its energized state.

[0059] When the third relay K3 is disconnected, insulation fault detection of the high-voltage circuit refers to detecting the insulation status of other high-voltage circuits (such as high-voltage slip rings and upper vehicle high-voltage electrical component circuits) after disconnecting the chassis high-voltage electrical component circuit, in order to determine whether the fault is located in a high-voltage area that is not related to driving.

[0060] With the third relay K3 disconnected, insulation fault detection is performed on the high-voltage circuit. If an insulation fault is found in the high-voltage circuit, the controller can further trigger other protection mechanisms, such as disconnecting the main high-voltage relay of the power supply, cutting off the entire high-voltage circuit, and sending a fault alarm signal to the operator through the instrument panel, prompting the operator to stop the machine to troubleshoot the fault, so as to avoid safety accidents caused by operating with a fault.

[0061] The restoration of the high-voltage circuit to power means that the controller controls the disconnected relay to close again, so that the high-voltage power supply is reconnected to the corresponding high-voltage circuit, the high-voltage electrical components on and off the vehicle are restored to power supply, and the construction machinery can perform normal operation or driving actions.

[0062] In this embodiment, for the parts of the high-voltage circuit prone to insulation faults, the power supply-high-voltage slip ring (high-voltage slip ring circuit), the power supply-on-vehicle high-voltage electrical components (on-vehicle high-voltage electrical component circuit), and the power supply-chassis high-voltage electrical components (chassis high-voltage electrical component circuit) are respectively equipped with a first relay, a second relay, and a third relay, forming a regionally isolated architecture that can be independently controlled. When an insulation fault is detected during operation, the controller first disconnects the first relay to isolate the high-voltage slip ring. If the detection is still abnormal, it disconnects the second relay to isolate the on-vehicle high-voltage electrical components. When a fault is detected during driving, the third relay is directly disconnected to isolate the chassis high-voltage electrical components.

[0063] This design avoids the drawback of traditional technologies that cut off the entire vehicle's high voltage upon a fault. Even if an insulation fault exists in a circuit, only the faulty circuit needs to be isolated, while the unfaulty circuits can still maintain power supply. Especially in hoisting operations, it prevents the hoisted object from becoming suspended due to the entire vehicle being under high voltage, fundamentally reducing the safety risks caused by falling objects and equipment malfunction, and ensuring the safety of personnel and equipment at the construction site. Furthermore, the disconnection, testing, and successful restoration process shortens troubleshooting time and reduces unnecessary downtime, thus improving construction efficiency. Simultaneously, restoring power supply only after confirming there is no fault avoids secondary faults caused by powering on a faulty system, ensuring the reliability of the high-voltage system. Moreover, adding a new relay does not require reconstructing the original high-voltage architecture, resulting in low modification costs, strong compatibility, and rapid adaptation to both new and old construction machinery, balancing safety, efficiency, and practicality.

[0064] In an optional implementation, the controller is further configured to disconnect the first relay K1 when an insulation fault occurs during the operation of the construction machinery, and to perform insulation fault detection on the high-voltage circuit when the first relay K1 is disconnected. If there is no insulation fault in the high-voltage circuit, the first relay K1 is closed to restore the high-voltage circuit to the energized state.

[0065] In this embodiment, when the first relay K1 is disconnected, insulation fault detection is performed on the high-voltage circuit. If there is no insulation fault in the high-voltage circuit, closing the first relay K1 can quickly confirm that the insulation fault is not caused by the high-voltage slip ring circuit, but may be a false alarm or temporary abnormality caused by factors such as transient interference. At this time, closing the relay can immediately restore the power supply to the high-voltage slip ring circuit, allowing the on-vehicle operation function of the construction machinery to quickly return to normal without further disconnecting other relays or stopping the machine for troubleshooting. This minimizes the interruption time of the operation, ensures the continuity of core operations such as hoisting, and avoids the functional redundancy shutdown caused by unnecessary circuit isolation, thereby improving the efficiency of fault handling and the reliability of equipment operation.

[0066] In one alternative implementation, such as Figure 2 As shown, the first relay K1 includes: a first sub-relay K11 and a second sub-relay K12.

[0067] The first sub-relay K11 is connected in series between the negative terminal of the high-voltage slip ring and the negative terminal of the power supply. Specifically, the negative terminal of the first sub-relay K11 is connected to the negative terminal of the power supply, and the positive terminal of the first sub-relay K11 is connected to the negative terminal of the high-voltage slip ring.

[0068] The second sub-relay K12 is connected in series between the positive terminal of the high-voltage slip ring and the positive terminal of the power supply. Specifically, the negative terminal of the second sub-relay K12 is connected to the positive terminal of the high-voltage slip ring, and the positive terminal of the second sub-relay K12 is connected to the positive terminal of the power supply.

[0069] The first sub-relay K11 and the second sub-relay K12 disconnect when an insulation fault occurs during the operation of the construction machinery, thereby disconnecting the electrical connection between the power supply and the high-voltage slip ring.

[0070] like Figure 2 As shown, a dual-parallel high-voltage power supply architecture can be used to power the high-voltage slip ring circuit. This means the power supply includes two independent high-voltage output units, each with a positive and a negative output terminal. Therefore, there are two power supply outputs (+) and two power supply outputs (-). This dual-power supply design improves the power supply stability of the high-voltage slip ring circuit, meeting the high current requirements when the high-voltage slip ring drives the working components on the vehicle (such as the rotary motor and winch motor). Furthermore, it matches the dual-relay control logic, providing hardware support for independent isolation of the positive and negative terminals.

[0071] In this embodiment, the first sub-relay K11, connected in series between the negative terminal of the high-voltage slip ring and the negative terminal of the power supply, enables precise control of the negative circuit of the high-voltage slip ring. When an insulation fault occurs during operation, this relay disconnects promptly, cutting off the electrical connection between the high-voltage slip ring and the negative terminal of the power supply, thus preventing the spread of leakage risks in the negative circuit. Simultaneously, its coordinated operation with the second sub-relay K12 ensures that the negative and positive circuits disconnect synchronously, preventing safety hazards caused by residual charge on the high-voltage slip ring during single-pole disconnection and eliminating interference from the negative circuit for subsequent fault detection.

[0072] The second relay, K12, is connected in series between the positive terminal of the high-voltage slip ring and the positive terminal of the power supply, enabling independent control of the positive circuit of the high-voltage slip ring. As the main control element for high-voltage power input, its rapid disconnection in the event of an insulation fault directly cuts off the core energy supply to the high-voltage slip ring, preventing high-voltage conduction in the faulty circuit. Furthermore, in daily operation, this relay can work with the controller to control the start and stop of the high-voltage slip ring, meeting the operational requirements of the onboard components. Simultaneously, through the status feedback of the positive circuit, it provides the controller with a basis for determining whether the circuit is normal.

[0073] Compared to traditional high-voltage slip ring circuits that use only a single relay for unilateral positive or negative control, this application's embodiment achieves complete isolation between the high-voltage slip ring and the power supply through a combined control method using dual positive and negative relays. Traditional single-relay control can only disconnect one side of the circuit, potentially leaving residual high voltage due to parasitic capacitance or induced voltage, posing a risk of electric shock or component damage. In this application, however, K11 and K12 disconnect simultaneously, completely cutting off the positive and negative power supply to the high-voltage slip ring, eliminating residual high voltage, and significantly improving the safety of fault isolation. Simultaneously, the dual-relay design provides redundant protection; if one relay fails, the other can still limit the fault propagation to some extent, improving the reliability of the circuit control. Furthermore, the matching design of dual power supply and dual relays better adapts to the high-current operating requirements of the high-voltage slip ring, ensuring power supply stability during operation and preventing operational accuracy from being affected by fluctuations in a single power supply.

[0074] In one optional implementation, corresponding relays can be set for each independent functional component in the high-voltage electrical components of the vehicle to achieve more refined circuit control and fault isolation. For example, independent control relays can be configured for the first heater and the first compressor included in the high-voltage electrical components of the vehicle, and a unified control relay can be set for the common negative circuit of the high-voltage electrical components of the vehicle. In this case, as... Figure 2 As shown, the second relay K2 includes: a third sub-relay K21, a fourth sub-relay K22, and a fifth sub-relay K23.

[0075] The third sub-relay K21 is connected in series between the negative terminal of the power supply and the negative terminal of the onboard high-voltage electrical component. Specifically, the negative terminal of the third sub-relay K21 is connected to the negative terminal of the power supply, and the positive terminal of the third sub-relay K21 is connected to the negative terminal of the onboard high-voltage electrical component.

[0076] The fourth sub-relay K22 is connected in series between the positive terminal of the power supply and the positive terminal of the first heater.

[0077] The fifth sub-relay K23 is connected in series between the positive terminal of the power supply and the positive terminal of the first compressor.

[0078] If the first relay K1 is disconnected, the third sub-relay K21 and the fifth sub-relay K23 will disconnect if an insulation fault still exists in the high-voltage circuit, thereby disconnecting the power supply and the electrical connection between the power supply and the high-voltage electrical components on the vehicle.

[0079] In this embodiment, as an example, if an insulation fault is detected during operation and the first relay K1 (isolation high-voltage slip ring circuit) is disconnected, and if an insulation fault still exists in the high-voltage circuit, then the third sub-relay K21 (vehicle common negative terminal), the fourth sub-relay K22 (first heater positive terminal), and the fifth sub-relay K23 (first compressor positive terminal) are first disconnected. Then, the third sub-relay K21 is kept closed (connecting the vehicle common negative terminal), and the fourth sub-relay K22 is closed alone to perform insulation fault detection on the first heater circuit. If an insulation fault is detected, the first heater is determined to be the faulty component. If no fault is detected, the fourth sub-relay K22 is disconnected, and the fifth sub-relay K23 is closed alone to perform insulation fault detection on the first compressor circuit. If an insulation fault is detected, the first compressor is determined to be the faulty component, thereby accurately pinpointing the source of the fault on the vehicle side.

[0080] The first compressor circuit refers to an independent high-voltage power supply circuit consisting of the power supply, the third sub-relay K21 (the common negative relay of the vehicle), the fifth sub-relay K23 (the independent positive relay of the first compressor), the first compressor (such as the main air conditioning compressor of the vehicle), and the connection lines between the various components. It is a closed-loop electrical path in the high-voltage electrical system of the vehicle that is dedicated to supplying power to the first compressor and realizing its cooling or auxiliary heat dissipation functions.

[0081] After identifying and troubleshooting the faulty component (e.g., replacing the faulty first heater / compressor, repairing insulation damage in the circuit), the controller can close the relay corresponding to the high-voltage electrical component with insulation faults, while keeping the relays of other normal circuits (e.g., the fifth sub-relay K23 corresponding to the fault-free first compressor) closed. This restores full power supply to the high-voltage circuit, ensuring the normal operation of auxiliary functions such as cabin heating for the first heater and air conditioning cooling for the first compressor, thus guaranteeing comfort and operational continuity during the construction machinery's operation. If the fault persists, the controller keeps the relay corresponding to the faulty component open, closing only the relays of normal components to prevent the fault from spreading to the entire high-voltage circuit. Simultaneously, an equipment alarm alerts the operator to promptly perform maintenance, balancing operational safety and functional availability.

[0082] In this embodiment, the third sub-relay K21 is connected in series between the negative terminal of the power supply and the negative terminal of the onboard high-voltage electrical component to achieve centralized control of the negative circuit of the onboard high-voltage electrical component. When it is necessary to isolate the onboard high-voltage circuit, it is only necessary to disconnect the relay to cut off the negative power supply of all onboard high-voltage electrical components. With the sub-relay on the positive side, the onboard circuit is completely isolated, avoiding the leakage risk that may exist in traditional single-pole control. At the same time, it simplifies the control logic and eliminates the need to set up a control device for the negative terminal of each component.

[0083] In this embodiment, the fourth sub-relay K22, connected in series between the positive terminal of the power supply and the positive terminal of the first heater, enables independent on / off control of the first heater, allowing it to be managed independently of other onboard components. For example, when only the first heater circuit has an insulation fault, the relay can be disconnected to isolate the fault without affecting the normal operation of other onboard components such as the first compressor. This avoids the overall functional failure problem caused by traditional one-size-fits-all circuit control and improves the operational flexibility of the onboard system.

[0084] In this embodiment, the fifth sub-relay K23, connected in series between the positive terminal of the power supply and the positive terminal of the first compressor, enables precise and independent control of the first compressor, complementing the fourth sub-relay K22. During fault diagnosis, disconnecting this relay individually can determine whether the insulation fault originates from the first compressor circuit, providing a more accurate basis for fault location. In daily use, the compressor can also be started and stopped independently according to the vehicle's air conditioning needs, reducing energy consumption and preventing compressor failure from affecting the operation of other components such as the heater.

[0085] Compared to traditional technologies where high-voltage electrical components on the vehicle share a single relay for control and cannot be independently managed, this application's embodiment achieves centralized isolation of the high-voltage circuit (disconnecting K21 cuts off the negative pole of all on-board components when isolation is required) and independent control of each functional component (K22 and K23 manage the heater and compressor respectively). This design allows for more precise location of faulty components during insulation fault handling, reducing troubleshooting time. In non-faulty scenarios, individual components can be flexibly started and stopped according to actual needs, reducing energy consumption. Simultaneously, the bipolar control logic ensures more thorough circuit isolation, avoiding the risk of residual high voltage from single-pole disconnection, significantly improving the safety, reliability, and operating efficiency of the high-voltage circuit on the vehicle.

[0086] In one alternative implementation, corresponding relays can be set for each independent functional component in the chassis high-voltage electrical components to achieve more refined circuit control and fault isolation. For example, independent control relays can be configured for the second heater and the second compressor included in the chassis high-voltage electrical components, and a unified control relay can be set for the common negative circuit of the chassis high-voltage electrical components. In this case, such as... Figure 2 As shown, the third relay K3 includes: the sixth sub-relay K31, the seventh sub-relay K32, and the eighth sub-relay K33. The chassis high-voltage electrical components include the second heater and the second compressor.

[0087] The sixth sub-relay K31 is connected in series between the negative terminal of the power supply and the negative terminal of the chassis high-voltage electrical component. Specifically, the negative terminal of the sixth sub-relay K31 is connected to the negative terminal of the power supply, and the positive terminal of the sixth sub-relay K31 is connected to the negative terminal of the chassis high-voltage electrical component.

[0088] The seventh relay K32 is connected in series between the positive terminal of the power supply and the positive terminal of the second heater.

[0089] The eighth relay K33 is connected in series between the positive terminal of the power supply and the positive terminal of the second compressor.

[0090] The sixth sub-relay K31, the seventh sub-relay K32, and the eighth sub-relay K33 disconnect when an insulation fault occurs during the operation of the construction machinery, thereby disconnecting the power supply and the electrical connection between the chassis high-voltage electrical components.

[0091] In this embodiment, as an example, after an insulation fault is detected during driving and the sixth sub-relay K31 (common negative terminal), the seventh sub-relay K32 (second heater positive terminal), and the eighth sub-relay K33 (second compressor positive terminal) are disconnected, K31 is first kept closed (connecting the chassis common negative terminal), and then the seventh sub-relay K32 is closed alone to perform insulation fault detection on the second heater circuit. If an insulation fault is detected, the second heater is determined to be the faulty component. If no fault is detected, K32 is disconnected, and the eighth sub-relay K33 is closed alone to perform insulation fault detection on the second compressor circuit. If an insulation fault is detected, the second compressor is determined to be the faulty component, thereby accurately locating the source of the fault.

[0092] The second heater circuit refers to an independent high-voltage power supply circuit consisting of the power supply, the sixth sub-relay K31 (common negative relay), the seventh sub-relay K32 (second heater independent positive relay), the second heater (such as the chassis PTC heater), and connecting lines. It is a closed-loop electrical path in the chassis high-voltage electrical system specifically for powering the second heater and enabling its function.

[0093] After identifying and troubleshooting the faulty component (e.g., replacing the faulty second heater / compressor, repairing the corresponding circuit insulation), the controller can close the relay corresponding to the chassis high-voltage electrical component with insulation faults, while keeping the relays of other normal circuits closed. This restores complete power supply to the chassis high-voltage circuit, ensuring the normal operation of chassis auxiliary functions such as the cabin heating function of the second heater and the air conditioning cooling function of the second compressor, thus guaranteeing the comfort and handling stability of the construction machinery during operation. If the fault is not resolved, the controller keeps the relay corresponding to the faulty component open, closing only the relays of normal components to prevent the fault from spreading, and simultaneously alerts the operator to perform timely repairs via an alarm.

[0094] In this embodiment, the sixth sub-relay K31 is connected in series between the negative terminal of the power supply and the negative terminal of the chassis high-voltage electrical component to achieve centralized control of the negative circuit of the chassis high-voltage electrical component. When an insulation fault is detected during driving, disconnecting this relay can cut off the negative power supply of all chassis high-voltage electrical components. Together with the independent sub-relay on the positive side, it forms a bipolar isolation logic of centralized negative disconnection and separate positive disconnection, ensuring that the chassis high-voltage circuit is completely disconnected from the power supply, avoiding the leakage risk that may remain in single-pole control, and simplifying the control process, without the need to design a separate control unit for the negative terminal of each chassis component.

[0095] In this embodiment, the seventh sub-relay K32, connected in series between the positive terminal of the power supply and the positive terminal of the second heater, enables independent on / off control of the second heater. This allows for flexible start / stop of the heater during driving based on cabin temperature requirements, reducing energy consumption, and also isolates the heater circuit during troubleshooting. If only the heater has an insulation fault, disconnecting the relay will allow other high-voltage electrical components in the chassis (such as the second compressor) to continue operating normally, avoiding the problem of complete shutdown due to a single fault in traditional overall circuit control and ensuring the continuity of the chassis's core functions.

[0096] In this embodiment, the eighth sub-relay K33, connected in series between the positive terminal of the power supply and the positive terminal of the second compressor, enables precise and independent control of the second compressor, complementing the function of the seventh sub-relay K32. If an insulation fault occurs in the compressor circuit during operation, the fault source can be quickly isolated by independently disconnecting this relay, without affecting the normal operation of the heater. Simultaneously, the independent control design provides a clear basis for fault location; the controller can determine whether the fault originates from the compressor circuit by independently starting and stopping this relay, significantly shortening troubleshooting time and improving fault handling efficiency.

[0097] Compared to traditional technologies where chassis high-voltage electrical components share a single relay for control, resulting in the inability to achieve independent management and precise isolation, this application's embodiment utilizes a combination design of a common negative relay and independent positive relays for functional components. This achieves centralized isolation of the chassis high-voltage circuit (disconnecting K31 in case of a fault cuts off the negative terminals of all chassis components, and complete isolation is achieved by disconnecting K32 and K33). Simultaneously, it enables refined control of each functional component (heaters and compressors can be independently started / stopped and isolated from faults). This design not only accurately locates faulty components and prevents fault propagation during insulation faults, ensuring operational safety during driving, but also allows for flexible component operation control based on actual needs in daily use, reducing energy consumption. Furthermore, the bipolar isolation logic eliminates the high-voltage residual risk of traditional unipolar control, significantly improving the safety, reliability, and operational flexibility of the chassis high-voltage circuit.

[0098] This application considers the common practice of negative reference / common ground design in high-voltage systems of new energy engineering machinery. It aims to reduce costs and wiring complexity while ensuring safety redundancy and simplifying control logic, and to meet the core requirement of insulation detection using the machine body as a reference point. Therefore, it designs a common negative relay and an independent positive relay, rather than an independent negative relay and a common positive relay. The common negative relay utilizes the characteristic that the negative pole of the high-voltage system is at the same potential as the machine body to achieve centralized negative pole isolation of all high-voltage electrical components in a certain area (such as loading / unloading) with lower insulation requirements and electromagnetic interference. Combined with the independent positive relay, it enables precise start / stop and fault isolation of various functional components (such as heaters and compressors). This avoids the increased insulation costs and interference runaway problems caused by the high voltage difference between the positive pole and the machine body in the common positive design, and also solves the drawbacks of redundant control logic, messy wiring, and insufficient fault isolation safety in the independent negative design. Furthermore, it is highly compatible with insulation detection logic, enabling accurate fault location and rapid isolation, ensuring the safe and reliable operation of the system under complex working conditions. By adding relays to circuits with high failure rates, insulation abnormalities can be temporarily addressed and the risks associated with the operation of construction machinery can be reduced when a fault occurs.

[0099] In one alternative implementation, such as Figure 2 As shown, the insulation fault handling device also includes a DC converter and a low-voltage power supply.

[0100] The input terminal of the DC-DC converter is connected to the power supply, and the output terminal of the DC-DC converter is connected to the low-voltage power supply.

[0101] A DC-DC converter is used to convert high-voltage DC power from a power supply into low-voltage DC power.

[0102] A low-voltage power supply is used to power the insulation fault handling device with low-voltage DC power output from a DC-DC converter.

[0103] In this embodiment, a DC-DC converter is added to provide a low-voltage power supply even when the high-voltage circuit of the upper chassis is completely isolated (e.g., the first relay K1 is disconnected). The DC-DC converter and the low-voltage power supply are respectively located in the high-voltage circuit of the chassis and the high-voltage circuit of the upper vehicle.

[0104] In the embodiments of this application, the low-voltage power supply can be a low-voltage power supply built into the insulation fault handling device, or a low-voltage power supply installed in the engineering machinery, that is, the low-voltage power supply can be an external low-voltage power supply.

[0105] A DC-DC converter can convert high-voltage DC power from a power supply to low-voltage DC power. On one hand, it replenishes the low-voltage power supply, maintaining its energy storage state and ensuring continuous power supply even in the event of a temporary DC-DC converter malfunction. On the other hand, it provides a stable and continuous low-voltage power supply to the insulation fault handling device, ensuring the normal operation of critical functions such as insulation fault detection, relay on / off control, fault alarms, and status recording. Even when the high-voltage circuit is isolated due to a fault, it prevents the low-voltage power supply from interrupting the fault handling process, ensuring the continuity and reliability of the overall device operation.

[0106] In one alternative implementation, such as Figure 2 As shown, the insulation fault handling device also includes a fuse disposed between the DC converter and the power supply.

[0107] A fuse is used to disconnect the electrical connection between a DC-DC converter and its power supply when an overcurrent occurs between the DC-DC converter and the power supply.

[0108] In this embodiment, the converter can specifically be a high-voltage DC-to-low-voltage DC converter. The input voltage is adapted to the 300V-800V high-voltage DC power supply, and the output voltage is 12V or 24V low-voltage DC (matching the power supply requirements of the low-voltage components of the insulation fault handling device). It has the characteristics of high efficiency, wide input voltage range, and low ripple. It can stably convert the electrical energy of the high-voltage power supply into a low-voltage form and supports continuous operation mode. It ensures that even if the high-voltage circuit is partially isolated due to a fault, it can still provide stable energy input to the subsequent low-voltage power supply link, thus solving the problem of incompatibility between high and low voltage power supplies.

[0109] In this embodiment, the low-voltage power supply can specifically be a lead-acid battery or a low-voltage lithium battery, which has energy storage and voltage stabilization functions. It can store the low-voltage DC power output from the DC-DC converter, providing a continuous and stable low-voltage power supply to the core components of the insulation fault handling device (such as the controller, the coils of the first to third relays, and the insulation detection sensor), thus preventing malfunctions of the control components due to power supply voltage fluctuations. On the other hand, in the event of a brief abnormality in the DC-DC converter or a momentary power outage, it can maintain low-voltage power supply through its own energy storage, ensuring that the fault handling process is not interrupted and that the controller can normally perform critical operations such as relay switching and insulation detection.

[0110] In this embodiment, the fuse can specifically be a DC high-voltage fuse with a rated voltage matching the high-voltage level of the power supply (e.g., 300V-800V) and a rated current set according to the rated input current of the DC converter. It possesses fast-blowout characteristics and its core function is to act as an overcurrent protection barrier between the DC converter and the power supply. When a short circuit occurs in the circuit (e.g., internal breakdown of the DC converter, short circuit due to broken connecting lines) or abnormal overcurrent, the fuse can blow within milliseconds, quickly disconnecting the high-voltage power supply link. This prevents overcurrent damage to the DC converter, low-voltage power supply, and downstream low-voltage control components, avoiding the spread of faults from the high-voltage side to the low-voltage side. Simultaneously, it protects the power supply from short-circuit impacts, reducing equipment maintenance costs and safety risks.

[0111] This application also provides an embodiment of an aging test method for photovoltaic power electronic equipment. It should be noted that the steps shown in the flowchart in the accompanying drawings can be executed in a computer system such as a set of computer-executable instructions. Although a logical order is shown in the flowchart, in some cases, the steps shown or described may be executed in a different order than that shown here.

[0112] Figure 3 This is a schematic flowchart of an insulation fault handling method according to an embodiment of this application. This insulation fault handling method is applied to the controller in the insulation fault handling device described in the above example, such as... Figure 3 As shown, the process includes the following steps: S101: When an insulation fault occurs during the operation of the construction machinery, disconnect the first relay and perform an insulation fault detection on the high-voltage circuit while the first relay is disconnected. If an insulation fault is found in the high-voltage circuit, disconnect the second relay and perform an insulation fault detection on the high-voltage circuit again. If no insulation fault is found in the high-voltage circuit, close the first and second relays to restore the high-voltage circuit to the energized state.

[0113] In this embodiment of the application, if an insulation fault is detected in the high-voltage circuit during the re-insulation of the high-voltage circuit, an insulation fault alarm is triggered to accurately report the fault status to the operator and prompt timely troubleshooting or shutdown measures.

[0114] In this embodiment, the form of insulation fault alarm is not limited and can be flexibly configured according to the working scenario of the construction machinery (such as strong outdoor light or noisy environment) and operational needs. For example, it can be: light alarm: the red fault indicator light on the cockpit dashboard is constantly lit or flashing, and the external warning lights (such as the roof warning light) are lit to provide intuitive visual prompts, which can be quickly identified even in strong light or long-distance working scenarios. Voice alarm: preset voice prompts (such as high-voltage circuit insulation fault, please check immediately) are played through the cockpit built-in speaker, or a continuous buzzing sound or warning sound is emitted to ensure that the operator can perceive it in a timely manner in noisy working environments.

[0115] S102: When an insulation fault occurs during the operation of the construction machinery, disconnect the third relay and, with the third relay disconnected, perform an insulation fault detection on the high-voltage circuit. If there is no insulation fault in the high-voltage circuit, close the third relay to restore the high-voltage circuit to its energized state.

[0116] In this embodiment of the application, when an insulation fault occurs during the operation of the construction machinery, the third relay is disconnected, and with the third relay disconnected, an insulation fault detection is performed on the high-voltage circuit. If an insulation fault exists in the high-voltage circuit, an insulation fault alarm is triggered.

[0117] In one optional embodiment, the insulation fault handling method further includes: When an insulation fault occurs during the operation of construction machinery, the first relay is disconnected, and the insulation fault detection of the high-voltage circuit is performed while the first relay is disconnected. If there is no insulation fault in the high-voltage circuit, the first relay is closed to restore the high-voltage circuit to the energized state.

[0118] It should be noted that the contents not described in detail in this application specification are common knowledge to those skilled in the art.

[0119] This application also provides an engineering machinery, including the insulation fault handling device of the first aspect above or any corresponding embodiment thereof.

[0120] In this embodiment, the construction machinery can be common operating machinery, such as excavators, loaders, bulldozers, road rollers, concrete mixers, cranes, etc.

[0121] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this application.

Claims

1. An insulation fault handling device, characterized in that, include: Controller; The first relay is connected in series between the power supply and the high-voltage slip ring; A second relay connected in series between the power supply and the onboard high-voltage electrical components of the construction machinery; A third relay is connected in series between the power supply and the chassis high-voltage electrical components of the construction machinery; wherein the upper vehicle high-voltage electrical components and the chassis high-voltage electrical components are installed in the high-voltage circuit of the construction machinery; the power supply is the power supply for the high-voltage circuit of the construction machinery; The controller is configured to disconnect the first relay when an insulation fault occurs during the operation of the engineering machinery, and to perform insulation fault detection on the high-voltage circuit when the first relay is disconnected. If an insulation fault exists in the high-voltage circuit, the second relay is disconnected and the insulation fault detection on the high-voltage circuit is performed again. If no insulation fault exists in the high-voltage circuit, the first relay and the second relay are closed to restore the high-voltage circuit to its powered state. The controller is also used to disconnect the third relay when an insulation fault occurs during the operation of the construction machinery, and to perform insulation fault detection on the high-voltage circuit when the third relay is disconnected. If there is no insulation fault in the high-voltage circuit, the third relay is closed to restore the high-voltage circuit to the power-on state.

2. The insulation fault handling device according to claim 1, characterized in that, The controller is also configured to disconnect the first relay when an insulation fault occurs during the operation of the engineering machinery, and to perform insulation fault detection on the high-voltage circuit when the first relay is disconnected. If there is no insulation fault in the high-voltage circuit, the controller will close the first relay to restore the high-voltage circuit to its powered state.

3. The insulation fault handling device according to claim 1, characterized in that, The first relay includes: a first sub-relay and a second sub-relay; The first sub-relay is connected in series between the negative terminal of the high-voltage slip ring and the negative terminal of the power supply. The second sub-relay is connected in series between the positive terminal of the high-voltage slip ring and the positive terminal of the power supply. The first sub-relay and the second sub-relay disconnect when an insulation fault occurs during the operation of the engineering machinery, thereby disconnecting the electrical connection between the power supply and the high-voltage slip ring.

4. The insulation fault handling device according to claim 1, characterized in that, The second relay includes: a third sub-relay, a fourth sub-relay, and a fifth sub-relay; the upper vehicle high-voltage electrical components include a first heater and a first compressor; The third sub-relay is connected in series between the negative terminal of the power supply and the negative terminal of the onboard high-voltage electrical component; The fourth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the first heater; The fifth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the first compressor; If the first relay is disconnected, the third sub-relay, the third sub-relay, and the fifth sub-relay will disconnect if an insulation fault still exists in the high-voltage circuit, thereby disconnecting the power supply and the electrical connection between the vehicle's high-voltage electrical components.

5. The insulation fault handling device according to claim 1, characterized in that, The third relay includes: a sixth sub-relay, a seventh sub-relay, and an eighth sub-relay; the chassis high-voltage electrical components include a second heater and a second compressor; The sixth sub-relay is connected in series between the negative terminal of the power supply and the negative terminal of the chassis high-voltage electrical component; The seventh sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the second heater; The eighth sub-relay is connected in series between the positive terminal of the power supply and the positive terminal of the second compressor; The sixth, seventh, and eighth sub-relays disconnect when an insulation fault occurs during the operation of the construction machinery, thereby disconnecting the electrical connection between the power supply and the high-voltage electrical components of the chassis.

6. The insulation fault handling device according to claim 1, characterized in that, The insulation fault handling device further includes: a DC converter and a low-voltage power supply; The input terminal of the DC converter is connected to the power supply, and the output terminal of the DC converter is connected to the low-voltage power supply. The DC-DC converter is used to convert the high-voltage DC power from the power supply into low-voltage DC power. The low-voltage power supply is used to power the insulation fault handling device with low-voltage DC power output from the DC converter.

7. The insulation fault handling device according to claim 6, characterized in that, The insulation fault handling device further includes: a fuse disposed between the DC converter and the power supply; The fuse is used to disconnect the electrical connection between the DC converter and the power supply when an overcurrent exists between the DC converter and the power supply.

8. An insulation fault handling method, applied to the controller in the insulation fault handling device according to any one of claims 1 to 7, characterized in that, The method includes: When an insulation fault occurs during the operation of the construction machinery, the first relay is disconnected, and the high-voltage circuit is tested for insulation fault while the first relay is disconnected. If the high-voltage circuit has an insulation fault, the second relay is disconnected, and the high-voltage circuit is tested for insulation fault again. If the high-voltage circuit does not have an insulation fault, the first relay and the second relay are closed to restore the high-voltage circuit to the power-on state. When an insulation fault occurs during the operation of the construction machinery, the third relay is disconnected, and an insulation fault detection is performed on the high-voltage circuit while the third relay is disconnected. If there is no insulation fault in the high-voltage circuit, the third relay is closed to restore the high-voltage circuit to its powered state.

9. The insulation fault handling method according to claim 8, characterized in that, The method further includes: When an insulation fault occurs during the operation of the engineering machinery, the first relay is disconnected, and an insulation fault detection is performed on the high-voltage circuit while the first relay is disconnected. If there is no insulation fault in the high-voltage circuit, the first relay is closed to restore the high-voltage circuit to its powered state.

10. An engineering machinery, characterized in that, include: The insulation fault handling device according to any one of claims 1 to 7.

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