High-voltage storage battery cycle built-in self-detection system and method for high-altitude unmanned aerial vehicle

Abstract

The invention provides a high-voltage storage battery cycle built-in self-detection system and method for a high-altitude unmanned aerial vehicle, and the system comprises an analog signal sampling module, a discrete magnitude signal sampling module, a discrete magnitude signal output module, and a fault detection module. Detecting the working states of an analog quantity signal sampling module, a discrete magnitude signal sampling module and a discrete magnitude signal output module; the main control module is used for receiving information of the analog quantity signal sampling module and the discrete magnitude signal sampling module, controlling the discrete magnitude signal output module and carrying out fault diagnosis on the corresponding module according to the information transmitted by the fault detection module; and the fault storage module stores battery pack fault information and key parameter information. According to the invention, detection of various fault types is covered, the root of the problem can be quickly positioned, accurate maintenance is realized, and the maintenance efficiency is remarkably improved; the system has a function of storing fault information in real time, can record key parameters and operation data when a fault occurs, and improves the maintenance quality and efficiency.

Description

Technical Field

[0001] This invention belongs to the field of battery self-testing technology, and in particular relates to a built-in self-testing system and method for high-voltage batteries used in high-altitude unmanned aerial vehicles. Background Technology

[0002] With the continuous development of high-altitude unmanned aerial vehicle (UAV) technology, the reliability and safety of its power supply system have become crucial factors in ensuring the smooth operation of flight missions. 270V high-voltage batteries (hereinafter referred to as high-voltage batteries), as lithium-ion batteries that provide emergency power to critical 270V electrical equipment in emergency situations, are an important component of the high-altitude UAV power supply system. However, existing high-voltage batteries face numerous challenges during use, such as complex and diverse fault types, inaccurate fault location, and low maintenance efficiency. These problems seriously affect the overall performance and reliability of the UAV system.

[0003] To address these challenges, modern avionics equipment widely employs Built-in Test (BIT) technology. BIT is an automated diagnostic mechanism integrated within the equipment, enabling autonomous testing of hardware and software functionality. By periodically monitoring key equipment parameters, the BIT system can automatically identify abnormal operating conditions and perform fault isolation and alarm operations, thereby significantly improving the reliability and maintenance efficiency of aircraft systems.

[0004] However, existing high-voltage battery detection systems still fall short in terms of the comprehensiveness, accuracy, and real-time nature of fault diagnosis, lack an effective fault information storage mechanism, and cannot provide detailed data support for subsequent maintenance. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention aims to propose a built-in self-detection system and method for high-voltage batteries used in high-altitude unmanned aerial vehicles (UAVs) to monitor the operating status of the high-voltage battery in real time, quickly and accurately identify different types of fault information, and store the fault information in real time.

[0006] To achieve the above objectives, the technical solution of the present invention is implemented as follows: A self-testing system for the cycle of a high-voltage battery used in a high-altitude unmanned aerial vehicle (UAV) includes: Analog signal sampling module, used to acquire voltage and current signals of the battery; Discrete signal sampling module, used to acquire multiple discrete signals from the battery; Discrete signal output module, used to output multiple discrete signals to control the battery; The fault detection module is used to detect the working status of the analog signal sampling module, the discrete signal sampling module, and the discrete signal output module. The main control module is used to receive information from the analog signal sampling module and the discrete signal sampling module, control the discrete signal output module, and perform fault diagnosis on the corresponding module based on the information transmitted by the fault detection module. The fault storage module is used to store battery pack fault information and key parameter information.

[0007] Furthermore, the analog signal sampling module includes a voltage acquisition circuit and a current sampling circuit; the voltage acquisition circuit is used to acquire the power supply voltage, the total voltage of the battery pack, the voltage of each individual battery cell, the contactor output voltage, the output channel voltage, and the heating power supply voltage; the current sampling circuit is used to acquire the battery charging current and the discharging current.

[0008] Furthermore, the discrete signal sampling module includes a discrete input sampling unit for acquiring wheel load status signals, switch signals, and contactor status feedback signals.

[0009] Furthermore, the discrete signal output module is used to output a charging prohibition signal, a power supply indicator signal, an output channel overcurrent signal, a contactor status signal, a manufacturer identification signal, and a heating prohibition signal.

[0010] Furthermore, the fault detection module includes a discrete input BIT circuit, a discrete output BIT circuit, a heating signal BIT circuit, a secondary power supply BIT circuit, a watchdog BIT circuit, and a contactor control BIT circuit.

[0011] Furthermore, the discrete output BIT circuit includes a digital isolator, which is connected in parallel between the discrete signal output module and the main control module. The main control module performs BIT testing on the discrete output module by reading the BIT signal status transmitted by the digital isolator.

[0012] Furthermore, the heating signal BIT circuit detects the voltage on both sides of the heating band through an optocoupler and transmits it to the main control module; the heating signal BIT circuit collects the heating current through a sampling resistor, operational amplifier amplification, and hysteresis comparator circuit and transmits it to the main control module.

[0013] Furthermore, the contactor control BIT circuit collects contactor status information through an optocoupler isolation circuit and transmits it to the main control module; the main control module performs fault detection using wheel load signals, contactor status feedback signals, switch signals, and the collected contactor status information.

[0014] Furthermore, the main control module detects the following types of faults: battery fault, power supply fault, voltage fault, overcurrent fault, single cell open circuit fault, temperature open circuit fault, heating fault, fuse fault, and contactor fault.

[0015] A self-testing method for the cycle of a high-voltage battery used in a high-altitude unmanned aerial vehicle (UAV) includes the following steps: The voltage and current signals of the battery are acquired through an analog signal sampling module; Multiple discrete signals from the battery are acquired through a discrete signal sampling module; The discrete signal output module outputs multiple discrete signals to control the battery. The fault detection module detects the working status of the analog signal sampling module, discrete signal sampling module, and discrete signal output module. The main control module receives the collected signals, receives information from the analog signal sampling module and the discrete signal sampling module, controls the discrete signal output module, and performs fault diagnosis on the corresponding module based on the information transmitted by the fault detection module. The fault storage module saves relevant information when a fault occurs.

[0016] Compared with existing technologies, the high-voltage battery cycle self-testing system and method for high-altitude unmanned aerial vehicles described in this invention have the following advantages: This invention utilizes a periodic built-in self-testing function, enabling the system to monitor the operating status of the high-voltage battery in real time and immediately report any detected faults. This real-time capability ensures that ground maintenance personnel can obtain fault information immediately, thereby taking swift action to reduce the impact of faults on UAV operation and improve system reliability and safety.

[0017] This invention covers the detection of various fault types, including power supply faults, battery status faults, heating and output circuit faults, contactor faults, etc. This comprehensive fault diagnosis capability, combined with precise diagnostic logic, provides maintenance personnel with detailed fault information, helping them quickly locate the root cause of the problem, thereby achieving precise repairs, significantly improving maintenance efficiency, and reducing maintenance costs.

[0018] This invention features real-time fault information storage, enabling the recording of key parameters and operational data when a fault occurs. This stored data not only provides crucial reference for on-site maintenance but also offers comprehensive operational status information to R&D and maintenance personnel when high-voltage batteries are returned for factory repair. By analyzing this data, maintenance personnel can gain a deeper understanding of the fault's causes, develop more effective repair plans, and improve repair quality and efficiency.

[0019] This invention employs "false alarm prevention" measures during fault diagnosis, effectively avoiding false alarms caused by signal interference or transient fluctuations, significantly improving the stability and reliability of the system, ensuring that the true state of the battery can still be accurately reflected in complex working environments, reducing unnecessary maintenance work, and enhancing the overall performance of the system.

[0020] Through real-time monitoring, precise diagnostics, and efficient data storage, the self-monitoring system of this invention optimizes the maintenance and management processes of high-altitude unmanned aerial vehicles (UAVs). Maintenance personnel can develop reasonable maintenance plans based on the information provided by the system, proactively prevent potential faults, extend battery life, reduce downtime and repair costs caused by unexpected malfunctions, and improve the overall operational efficiency of the UAV system. Attached Figure Description

[0021] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an undue limitation of the invention. In the drawings: Figure 1 This is a schematic diagram of the control of the detection system provided in an embodiment of the present invention; Figure 2 This is a schematic diagram of a voltage acquisition circuit provided in an embodiment of the present invention; Figure 3 This is a schematic diagram of the discharge current acquisition circuit provided in an embodiment of the present invention; Figure 4 This is a schematic diagram of a charging current acquisition circuit provided in an embodiment of the present invention; Figure 5 This is a schematic diagram of a discrete input sampling circuit provided in an embodiment of the present invention; Figure 6 A schematic diagram of the heating-prohibiting output circuit provided in an embodiment of the present invention; Figure 7 This is a schematic diagram of the charge-disabled output circuit provided in an embodiment of the present invention; Figure 8 A schematic diagram of the power indicator output circuit provided in an embodiment of the present invention; Figure 9 This is a schematic diagram of the overcurrent output circuit for the output channel provided in an embodiment of the present invention; Figure 10 A schematic diagram of a contactor status output circuit provided in an embodiment of the present invention; Figure 11 A schematic diagram of the manufacturer identification output circuit provided in an embodiment of the present invention; Figure 12 A schematic diagram of a transistor-based main contactor control circuit provided in an embodiment of the present invention; Figure 13A schematic diagram of a main contactor control circuit based on relay feedback provided in an embodiment of the present invention; Figure 14 A schematic diagram of a main contactor control circuit based on relay feedback and total voltage dual self-locking provided in an embodiment of the present invention; Figure 15 This is a schematic diagram of an auxiliary contactor control circuit provided in an embodiment of the present invention; Figure 16 This is a schematic diagram of a discrete input bit circuit provided in an embodiment of the present invention; Figure 17 This is a schematic diagram of a discrete output bit circuit provided in an embodiment of the present invention; Figure 18 A schematic diagram of the heating signal BIT circuit provided in an embodiment of the present invention; Figure 19 This is a schematic diagram of a +15V / +5V power supply detection circuit provided in an embodiment of the present invention; Figure 20 This is a schematic diagram of a -15V power supply detection circuit provided in an embodiment of the present invention; Figure 21 This is a schematic diagram of a watchdog bit circuit provided in an embodiment of the present invention; Figure 22 This is a schematic diagram of a contactor control BIT circuit provided in an embodiment of the present invention. Detailed Implementation

[0022] It should be noted that, unless otherwise specified, the embodiments and features described in the present invention can be combined with each other.

[0023] In the description of this invention, it should be understood that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this invention, unless otherwise stated, "a plurality of" means two or more. The terms "installed," "connected," and "linked" 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; they can refer to the internal connection of two components. Those skilled in the art will understand the specific meaning of the above terms in this invention through the specific circumstances.

[0024] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.

[0025] like Figures 1 to 22As shown, a high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles includes: Analog signal sampling module, used to acquire voltage and current signals of the battery; Discrete signal sampling module, used to acquire multiple discrete signals related to the battery status; Discrete signal output module, used to output multiple discrete signals to control the state of the battery; The main control module is used to receive signals collected by the analog signal sampling module and the discrete signal sampling module, control the discrete signal output module, and perform fault diagnosis on the corresponding modules. The fault detection module is used to detect the working status of the analog signal sampling module, the discrete signal sampling module, and the discrete signal output module. The fault storage module is used to save relevant information when a fault occurs. It is used to save 5 seconds of data within the timeframe of the fault occurrence.

[0026] In a preferred embodiment of the present invention, the analog signal sampling module includes a voltage acquisition circuit and a current sampling circuit.

[0027] The voltage acquisition circuit is used to acquire the 28V / 5V / ±15V power supply voltage, total battery pack voltage, individual battery cell voltage, MSD output voltage, contactor output voltage, output channel voltage, heating power supply voltage, main power supply voltage of contactor coil (contactor coil + voltage), and backup power supply voltage of contactor coil (contactor coil + redundancy voltage). The output channel voltage includes the battery's output channel 1 voltage, output channel 2 voltage, and output channel 3 voltage. Multiple output channels are used to power different components of the UAV. The contactor output voltage includes the main contactor output voltage and the auxiliary contactor output voltage. The main contactor refers to the contactor of the main power distribution channel of the battery, and the auxiliary contactor refers to the contactor of the auxiliary power channel.

[0028] The voltage acquisition circuit includes a resistor R1. One end of the resistor R1 is connected to the voltage to be acquired, and the other end is connected to a resistor R2 and the positive input terminal of an operational amplifier N1. The resistor R2 and the negative power supply terminal of the operational amplifier N1 are both grounded, and the positive power supply terminal of the operational amplifier N1 is connected to a 5V power supply voltage. The negative input terminal of the operational amplifier N1 is connected to the output terminal of the operational amplifier N1. The output terminal of the operational amplifier N1 is connected to the input terminal of the linear optocoupler N2 through resistor R3. The output terminal of the linear optocoupler N2 is connected to the positive input terminal of the operational amplifier N3 through resistor R4. The negative input terminal of the operational amplifier N3 is connected to the output terminal of the operational amplifier N3, and the output terminal of the operational amplifier N3 is connected to the main control module through resistor R5; the negative power supply terminal of the operational amplifier N3 is grounded, and the positive power supply terminal is connected to the power supply VCC.

[0029] Specifically, the voltage to be acquired is divided by resistors R1 and R2, then output by operational amplifier N1 to follow the voltage, followed by linear optocoupler N2 for 1:1 voltage isolation, and finally processed by operational amplifier N3 before being sent to the main control module for voltage detection. The resistor divider circuit composed of resistors R1 and R2 corresponds to different acquired voltage parameters, some of which are shown in Table 1.

[0030] Table 1 Parameters of resistors R1 and R2

[0031] In a preferred embodiment of the present invention, the current signal sampling circuit includes a discharge current acquisition circuit and a charging current acquisition circuit.

[0032] The discharge current acquisition circuit includes a first Hall current sensor, which is powered by ±12V. The output terminal of the first Hall current sensor is connected to a diode TVS1 and two voltage amplification circuits, respectively. The output terminals of the two voltage amplification circuits are both connected to the main control module. One voltage amplification circuit A1 has an amplification factor of 1, and the other voltage amplification circuit A2 has an amplification factor of 2.

[0033] Specifically, the discharge current includes the current of output channel 1, the current of output channel 2, and the current of output channel 3. The discharge current sampling range is 0A to 800A. The first Hall current sensor model is CD-BH-1003-500A, quality grade is QJB, referring to grade J in standard GJB 8354, rated current detection range is ±500A, maximum current detection range is ±800A, and rated feedback voltage is 5V. When the discharge current range is 0A to 150A, the detection accuracy is ≤1%; when the discharge current range is 150A to 300A, the detection accuracy is ≤5%. Therefore, the voltage feedback signal of the first Hall current sensor is detected by two voltage amplification circuits, one with an amplification factor of 1 and the other with an amplification factor of 2.

[0034] The charging current acquisition circuit includes a second Hall current sensor, which is powered by ±12V. The output terminal of the second Hall current sensor, powered by ±12V, is connected to a diode TVS2 and a voltage amplifier circuit A3. The output terminal of the voltage amplifier circuit A3 is connected to the main control module. The amplification factor of the voltage amplifier circuit A3 is 1.

[0035] Specifically, the charging current range should be no less than 0A to 10A, the second Hall current sensor model is AR2V40H00, the rated current acquisition range is ±30A, the quality grade is QJB, referring to grade J in standard GJB 8354, and the voltage amplification circuit has an amplification voltage factor of 1.

[0036] The feedback terminal of the second Hall current sensor uses a TVS2 diode for transient suppression. The maximum feedback output voltage of the second Hall current sensor is 7.5V when the current detection range is at its limit. Therefore, a TVS2 diode with a reverse withstand voltage of 8.5V and a maximum clamping voltage of 600V is selected for transient suppression. During transient suppression, a voltage exceeding the limit threshold will not be generated at the input terminal of the back-end operational amplifier. Its model number is SY068V5CAMS2P, and its quality level is military grade.

[0037] In a preferred embodiment of the present invention, the discrete signal sampling module includes a discrete input sampling unit, which is used to collect wheel load status signals, switch signals, and contactor status feedback signals. The contactor status feedback signal is the contactor auxiliary contact ground open signal; the wheel load status signal refers to the signal indicating the current status of the landing gear (wheel load); the switch signals include a battery switch on signal, an FCCON1 signal, and an FCCON2 signal, which are switch signals used to control the battery.

[0038] The discrete input sampling unit includes a discrete input sampling circuit. Each discrete input sampling circuit receives a sampling signal at its input terminal and its output terminal is connected to a discrete input detection chip. The discrete input detection chip is connected to the main control module through a digital isolator.

[0039] Each discrete input sampling unit includes a filter circuit consisting of an inductor L1, a capacitor C1, and a capacitor C2. The output terminal of the inductor L1 is connected to the discrete input detection chip through a diode. The discrete input signal is input to the discrete input detection chip through the filter circuit and the diode TVS3 protection circuit. The discrete input detection chip is connected to the main control module.

[0040] Specifically, the discrete input detection chip model is HKA1300-PN / CQC. HKA1300-PN / CQC is a discrete input / output interface circuit that provides 8 channels of discrete-to-TTL level conversion and 4 channels of 200mA low-side current output. It supports SUPPLY / OPEN and GND / OPEN input modes. The discrete input port has lightning indirect effect protection level of AZ, BZ and ZZ of RTCA-DO-160G Section 22, and quality level of GJB597B-2012B.

[0041] The discrete input signal first passes through a diode TVS3 and a filter circuit. The TVS3 is a 3000W TVS diode with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, and the voltage will not exceed the withstand voltage of the 400V of the reverse series diode 2CZ140AFS1P of the discrete input channel. The LC filter composed of inductor L1, capacitor C1, and capacitor C2 has a cutoff frequency of 480.1KHz. Inductor L1 is model JMLPI2012G2R2M, with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, a DC impedance of 0.17Ω, and a quality grade of QJB, conforming to grade J in standard GJB 8354.

[0042] The output signal of the discrete input detection chip is isolated by a digital isolator and then enters the main control module for detection. The discrete input state is distinguished by the high and low levels of the detection logic: "high level" indicates that the discrete input is "grounded" and "low level" indicates that the discrete input is "on".

[0043] In a preferred embodiment of the present invention, the discrete signal output module is used to output a charging prohibition signal, a power supply indicator signal, an output channel overcurrent signal, a contactor status signal, a manufacturer identification signal, and a heating prohibition signal; wherein, the charging prohibition signal and the heating prohibition signal are discrete outputs controllable by the main control module; the output channel overcurrent signal, the contactor status signal, the manufacturer identification signal, and the power supply indicator signal are hardware-controlled discrete output signals. The output channel overcurrent signal includes the output channel 1 overcurrent signal, the output channel 2 overcurrent signal, and the output channel 3 overcurrent signal; the contactor status signal includes the contactor status 1 signal and the contactor status 2 signal; the manufacturer identification signal includes the manufacturer identification 1 signal and the manufacturer identification 2 signal.

[0044] The discrete signal output module includes a heating-prohibition output circuit, a charging-prohibition output circuit, a power indicator output circuit, an output channel overcurrent output circuit, a contactor status output circuit, a manufacturer identification output circuit, a main contactor control circuit, and an auxiliary contactor control circuit.

[0045] In a preferred embodiment of the present invention, the heating prohibition output circuit includes a temperature acquisition unit, which is connected to the temperature sensor of the battery pack and is used to acquire the battery pack temperature signal and transmit it to the main control module through the internal interconnection CAN communication circuit. The main control module is connected to the first pin of optocoupler N4 via resistor R6. The second pin of optocoupler N4 is grounded. The third pin of optocoupler N4 is connected to the gate of MOSFET Q1 via resistor R71. The source of MOSFET Q1 is grounded, and its drain is connected to inductor L2 and capacitor C3 respectively. The output of inductor L2 is used to output a heating disable signal. Capacitor C3 is connected to capacitor C4, and capacitor C4 is grounded. The output of inductor L2 is connected to the anode of diode TVS4, and the cathode of diode TVS4 is grounded. The fourth pin of optocoupler N4 is connected to power supply VCC1 via resistor R72.

[0046] Specifically, the logic for determining the heating prohibition signal output by the main control module is as follows: when both the highest and second-highest temperatures collected by the temperature acquisition unit are higher than 50℃, the heating prohibition output circuit is controlled to output a heating prohibition signal. The temperature acquisition unit includes acquisition unit 1 and acquisition unit 2. Acquisition unit 1 and acquisition unit 2 each detect 16 channels of temperature sensor data and report them via the CAN bus.

[0047] The MOSFET Q1 is model LYCS02N500S1P, with a drain-source withstand voltage of 500V, an on-resistance not exceeding 4.5Ω, meeting the requirement that the ground signal output impedance not exceed 5Ω, a continuous drain-source current of 200mA, meeting the requirement that the rated current carrying capacity not be less than 50mA, and a zero-gate-voltage drain current of 1uA. The test condition is 400V. Therefore, when MOSFET Q1 is turned off, the output drain-source resistance is approximately 400V / 1uA = 400MΩ, meeting the requirement that the on-signal output impedance not be less than 100kΩ when the output interface is on.

[0048] The TVS4 is a 3000W TVS transistor with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, ensuring the voltage does not exceed the drain-source withstand voltage of MOSFET Q1 (500V). The LC filter composed of inductor L2, capacitor C3, and capacitor C4 has a cutoff frequency of 480.1kHz. Inductor L2 is model JMLPI2012G2R2M, with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, and a DC impedance not exceeding 0.17Ω (meeting the requirement that the total impedance of the ground signal output should not exceed 5Ω). Its quality grade is QJB, conforming to Grade J in standard GJB 8354.

[0049] In a preferred embodiment of the present invention, the charge-disable output circuit includes an optocoupler N5. The first pin of the optocoupler N5 is connected to a 3.3V power supply through a resistor R8. The second pin of the optocoupler N5 is connected to the main control module. The third pin of the optocoupler N5 is connected to a 28V power supply through a resistor R9. The fourth pin of the optocoupler N5 is connected to the gate of a MOSFET Q2 through a resistor R10. The source of the MOSFET Q2 is grounded, and its drain is connected to an inductor L3 and a capacitor C5, respectively. The output terminal of the inductor L3 is used to output a charge-disable signal. The capacitors C5 and C6 are connected, and C6 is grounded; the output terminal of the inductor L3 is connected to the anode of the diode TVS5, and the cathode of the diode TVS5 is grounded.

[0050] The main control module outputs a charging disable signal when any of the following conditions are met: 1) When both the lowest and second-lowest temperatures of the battery pack are below -10℃; 2) When both the highest and second-highest temperatures of the battery pack are above 70℃; 3) When the total voltage of the battery pack exceeds 273V; 4) When the voltage of a single cell in the battery pack is higher than 3.65V.

[0051] Specifically, the MOSFET Q2 is model LYCS02N500S1P, with a drain-source withstand voltage of 500V and an on-resistance not exceeding 4.5Ω, meeting the requirement that the ground signal output impedance is not higher than 5Ω; the continuous drain-source current is 200mA, meeting the requirement that the rated current carrying capacity is not less than 50mA; the zero-gate-voltage drain current is 1uA, and the test condition is 400V. Therefore, when the MOSFET is turned off, the output drain-source resistance is approximately 400V / 1uA = 400MΩ, meeting the requirement that the on-signal output impedance is not less than 100kΩ when the output interface is on.

[0052] The TVS5 diode is a 3000W power TVS transistor with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, and the voltage will not exceed the drain-source withstand voltage of MOSFET Q1 of 500V.

[0053] The LC filter composed of inductor L3, capacitor C5, and capacitor C6 has a cutoff frequency of 480.1KHz. Inductor L3 is model JMLPI2012G2R2M with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, and a DC impedance not exceeding 0.17Ω (meeting the requirement that the total impedance of the ground signal output should not exceed 5Ω). Its quality level is QJB, referring to the J level in the standard GJB 8354.

[0054] In a preferred embodiment of the present invention, the power supply indicator output circuit includes a MOSFET Q3. The drain of the MOSFET Q3 is connected to a 28V power supply. The gate of the MOSFET Q3 is connected to a contactor status feedback signal through a resistor R11. A resistor R12 is connected in parallel between the drain and gate of the MOSFET Q3. The source of the MOSFET Q3 is connected to a resistor R13. The resistor R13 is connected to the gate of the MOSFET Q4. A resistor R14 is connected in parallel between the gate and source of the MOSFET Q4. The source of the MOSFET Q4 is grounded. The drain of the MOSFET Q4 is connected to an inductor L4 and a capacitor C7. The output terminal of the inductor L4 is used to output the power supply indicator signal. The output terminal of the inductor L4 is connected to the anode of a diode TVS6. The cathode of the diode TVS6 is grounded. The capacitor C7 and the capacitor C8 are connected in series. The other end of the capacitor C8 is grounded.

[0055] Specifically, MOSFET Q3 is a P-type MOSFET, and MOSFET Q4 is an N-type MOSFET. When the contactor status feedback signal (auxiliary contact) is "ground", that is, the contactor is on, MOSFETs Q3 and Q4 are turned on, and the discrete output of the power supply indicator light is "ground"; otherwise, it is "on".

[0056] The MOSFET Q4, model LYCS02N500S1P, has a drain-source withstand voltage of 500V and an on-resistance of ≤4.5Ω. The contactor auxiliary contact resistance is 50mΩ, meeting the requirement that the ground signal output impedance not exceed 5Ω. The continuous drain current of MOSFET Q4 is 200mA, and the rated current of the auxiliary contact is 3A. The zero-gate-voltage drain current of Q2 under 400V testing conditions is 1uA. When MOSFET Q4 is turned off, the output drain-source resistance is 400V / 1uA = 400MΩ, meeting the requirement that the signal output impedance not be less than 100kΩ when the output interface is open.

[0057] The TVS6 is a 3000W TVS transistor with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, and the voltage will not exceed the drain-source withstand voltage of MOSFET Q3 (500V). The LC filter composed of inductor L4, capacitor C7, and capacitor C8 has a cutoff frequency of 480.1kHz. Inductor L4 is model JMLPI2012G2R2M, with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, and a DC impedance not exceeding 0.17Ω (meeting the requirement that the total impedance of the ground signal output should not exceed 5Ω). Its quality grade is QJB, referring to Grade J in standard GJB 8354.

[0058] In a preferred embodiment of the present invention, the overcurrent output circuit of the output channel includes an optocoupler N6. The first pin of the optocoupler N6 is connected to a 5V power supply through a resistor R15, the second pin of the optocoupler N6 is connected to the main control module, the third pin of the optocoupler N6 is connected to a VCC1 power supply through a resistor R16, and the fourth pin of the optocoupler N6 is connected to the gate of a MOSFET Q5 through a resistor. The source of the MOSFET Q5 is grounded, and the drain is connected to an inductor L5 and a capacitor C9, respectively. The output terminal of the inductor L6 is used to output the overcurrent signal of the output channel. The capacitor C9 is connected in series with the capacitor C10, and the capacitor C10 is grounded; the output terminal of the inductor L6 is connected to the anode of the diode TVS7, and the cathode of the diode TVS7 is grounded.

[0059] The main control module collects the output channel current and the voltage before and after the fuse to determine the output channel overcurrent signal. When the following two conditions are triggered, the main control module controls the output channel overcurrent signal to "ground"; otherwise, it controls the output channel overcurrent signal to "open": 1) The fuse is open; 2) The current of the output channel is higher than 150A.

[0060] Specifically, each output channel corresponds to a fuse, namely fuse 1, fuse 2, and fuse 3; the MOSFET Q5 is model LYCS02N500S1P, with a drain-source withstand voltage of 500V, a conduction resistance of no more than 4.5Ω, meeting the requirement that the ground signal output impedance is no higher than 5Ω, a continuous drain-source current of 200mA, meeting the requirement that the rated current carrying capacity is no less than 50mA, and a zero-gate-voltage drain current of 1uA. Under test conditions of 400V, when the MOSFET Q5 is turned off, the output drain-source resistance is approximately 400V / 1uA = 400MΩ, meeting the requirement that the on-signal output impedance is no less than 100kΩ when the output interface is on.

[0061] The TVS7 diode is a 3000W power TVS diode with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, and the voltage will not exceed the drain-source withstand voltage of 500V of the TVS7 diode.

[0062] The LC filter composed of inductor L6, capacitor C9, and capacitor C10 has a cutoff frequency of 480.1KHz. Inductor L6 is model JMLPI2012G2R2M with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, and a DC impedance not exceeding 0.17Ω (meeting the requirement that the total impedance of the ground signal output should not exceed 5Ω). Its quality grade is QJB, referring to grade J in the standard GJB 8354.

[0063] In a preferred embodiment of the present invention, the contactor status output circuit is the same as the power supply indicator output circuit, and the component parameters can be selected according to the actual situation. The output terminal of the inductor L4 is used to output the contactor status signal.

[0064] Specifically, MOSFET Q3 is a P-type MOSFET, and MOSFET Q4 is an N-type MOSFET. When the contactor status feedback signal (auxiliary contact) is "ground", that is, the contactor is on, MOSFETs Q3 and Q4 are on, and the contactor status signal output is "ground"; otherwise, it is "open".

[0065] The MOSFET Q4, model LYCS02N500S1P, has a drain-source withstand voltage of 500V and an on-resistance of ≤4.5Ω. The contactor auxiliary contact resistance is 50mΩ, meeting the requirement that the ground signal output impedance not exceed 5Ω. The continuous drain current of MOSFET Q4 is 200mA, and the rated current of the auxiliary contact is 3A. The zero-gate-voltage drain current of Q2 under 400V testing conditions is 1uA. When MOSFET Q4 is turned off, the output drain-source resistance is 400V / 1uA = 400MΩ, meeting the requirement that the signal output impedance not be less than 100kΩ when the output interface is open.

[0066] TVS6 is a 3000W TVS transistor with a reverse withstand voltage of 58V, used to suppress transient voltages at the interface, and the voltage will not exceed the drain-source withstand voltage of MOSFET Q3 of 500V.

[0067] The LC filter composed of inductor L4, capacitor C7, and capacitor C8 has a cutoff frequency of 480.1 kHz. Inductor L4 is model JMLPI2012G2R2M with an inductance of 2.2 uH, a saturation current of 250 mA, a temperature rise current of 800 mA, and a DC impedance not exceeding 0.17 Ω (meeting the requirement that the total impedance of the ground signal output is not higher than 5 Ω). Its quality level is QJB, referring to the J level in the standard GJB 8354.

[0068] In a preferred embodiment of the present invention, the manufacturer identification output circuit includes an inductor L7, the input terminal of which is connected to the main control module, and the output terminal of which is used to output a manufacturer identification signal; the input terminal of the inductor L7 is connected to a capacitor C11, the capacitor C11 and the capacitor C12 are connected in series, and the capacitor C12 is grounded; the output terminal of the inductor L7 is connected to the anode of a diode TVS8, and the cathode of the diode TVS8 is grounded.

[0069] Specifically, manufacturer identification 1 is "open" and manufacturer identification 2 is "ground".

[0070] The TVS8 uses a 3000W TVS diode with a reverse withstand voltage of 58V to suppress transient voltages at the interface. Capacitors C11 and C12 are connected in series, with C12 grounded. The inductor L7, capacitors C11 and C12 form an LC filter. Inductor L7 is a JMLPI2012G2R2M with an inductance of 2.2uH, a saturation current of 250mA, a temperature rise current of 800mA, and a DC impedance not exceeding 0.17Ω (meeting the requirement that the total impedance of the ground signal output should not exceed 5Ω).

[0071] In a preferred embodiment of the present invention, the control logic of the main contactor control circuit is as follows: when any one of the battery switch on signal, FCCON1 signal, and FCCON2 signal is "grounded", the main contactor is turned on; when both the wheel load signal and the contactor auxiliary contact signal are "grounded", i.e., the contactor is turned on and "in the air", the main contactor self-locks. The power supply of this circuit is independent of the working power supply, and it can still work when the working power supply fails; the control of the main contactor is independent of the control signal of the main control module.

[0072] Based on the different control methods of the self-locking circuit, three main contactor control circuits were designed.

[0073] (1) A transistor-based main contactor control circuit, wherein the contactor power supply + bus is connected to the anode of diode V1, the contactor power supply + redundancy bus is connected to the anode of diode V2, the cathode of diode V1 and the cathode of diode V2 are connected to form a power supply bus, the power supply bus is connected to one end of the contactor coil, and the other end of the contactor coil is connected to the battery switch turn-on signal, FCCON1 signal and FCCON2 signal respectively through diodes; the two ends of the contactor coil are connected in parallel with diode V3 and diode V4 respectively; The contactor self-locking circuit includes a transistor Q6. The base of transistor Q6 is connected to a resistor R17. The other end of the resistor R17 is connected to the cathodes of diodes V5 and V6, respectively. The anode of diode V5 is connected to the anode of diode V7 and a resistor R18, respectively. The cathode of diode V7 is connected to the wheel load signal, and the other end of the resistor R18 is connected to the power supply bus. The anode of diode V6 is connected to the anode of diode V8 and a resistor R19, respectively. The cathode is connected to the contactor status feedback signal, and the other end of the resistor R19 is connected to the power supply bus. The collector of transistor Q6 is connected to the power supply bus through a resistor R20. The collector of transistor Q6 is connected to the gate of MOSFET Q7 and the gate of MOSFET Q8, respectively. The drain of MOSFET Q7 is connected to the source of MOSFET Q8, and the drain of MOSFET Q8 is connected to the contactor coil. The emitter of transistor Q6 is grounded, the gates of MOSFET Q7 and MOSFET Q8 are grounded through resistors, and the source of MOSFET Q7 is grounded.

[0074] Specifically, the wheel load signal and the contactor status feedback signal are used to form an AND control signal to control the grounding of the contactor auxiliary coil in the subsequent stage. Diodes V3 and V4 are freewheeling diodes. The MOSFET in the main contactor self-locking circuit has dual redundancy backup. Transistor Q6 uses two NPN transistors connected in parallel to ensure the reliability of the control circuit.

[0075] (2) The main contactor control circuit based on relay feedback is as follows: the contactor power supply + bus is connected to the anode of diode V9, the contactor power supply + redundancy bus is connected to the anode of diode V10, and the cathode of diode V9 is connected to the cathode of diode V10 to form the power supply bus. The power supply bus is connected to the positive terminal of the self-locking relay coil and the positive terminal of the contactor coil respectively. The negative terminal of the contactor coil is connected to one end of the self-locking relay contact through diode V11, and the negative terminal of the contactor coil is connected to the battery switch connection signal, FCCON1 signal and FCCON2 signal through diodes respectively. The negative terminal of the self-locking relay coil is connected to the wheel load signal through diode V12. Diode V13 is connected in parallel between the positive and negative terminals of the self-locking relay coil. Diode V14 and diode V15 are connected in parallel between the positive and negative terminals of the contactor coil respectively. The contactor status feedback signal is connected to the other end of the self-locking relay contact and one end of the contactor auxiliary contact via diodes, and the other end of the contactor auxiliary contact is grounded.

[0076] Specifically, a wheel-mounted signal controls a self-locking relay to incorporate the contactor status feedback signal into the contactor coil control signal, enabling the auxiliary contacts to lock the contactor state when the contactor is closed. When in the "air" state, FCCON1, FCCON2, and the battery connection switch signals are disconnected, and the contactor coil current flows through the auxiliary contacts. Prolonged use can lead to increased contact resistance in the auxiliary contacts, causing intermittent connections and resulting in abnormalities in contactor feedback status, power indicator output, and other signals.

[0077] (3) A main contactor control circuit based on relay feedback and total voltage double self-locking. In (2), a self-locking control circuit based on total voltage feedback is set on the main contactor control circuit based on relay feedback. The self-locking control circuit based on total voltage feedback includes an optocoupler N7. The first pin of the optocoupler N7 is connected to the positive terminal of the total voltage at the rear end of the contactor through a resistor. The second pin of the optocoupler relay N7 is connected to the negative terminal of the total voltage at the rear end of the contactor through a resistor. The third pin of the optocoupler N7 is connected to the power supply bus through a resistor R21. The fourth pin of the optocoupler N7 is connected to the gate of the MOS transistor Q9. The drain of the MOS transistor Q9 is connected to the negative terminal of the contactor coil. The source of the MOS transistor Q9 is connected to the wheel load signal through a diode V16. A resistor is connected in parallel between the source and the gate of the MOS transistor Q9.

[0078] Specifically, the contactor control circuit based on relay feedback and total voltage dual self-locking achieves control of the contactor coil by introducing the total voltage of the battery at the back end of the contactor, which makes up for the problem of reduced service life caused by large overcurrent of auxiliary contacts and realizes dual locking based on contactor status feedback signal and total voltage output.

[0079] A comparative analysis of the three circuits was conducted, considering their complexity, cost, and potential failure points, as shown in Table 2. Based on this analysis, the transistor-based contactor control circuit, which balances cost and reliability, is preferred in this embodiment.

[0080] Table 2 Main Contactor Control Circuit

[0081] In a preferred embodiment of the present invention, the auxiliary contactor control circuit includes an independent power supply. The positive terminal of the independent power supply is connected to the auxiliary coil + terminal, and the negative terminal of the independent power supply is connected to the auxiliary coil - terminal. The auxiliary coil + terminal is connected to transistor Q10 through diode D1. The emitter of transistor Q10 is connected to the negative terminal of the auxiliary coil, and the base of transistor Q10 is connected to the base of transistor Q11. The emitter of transistor Q11 is connected to the negative terminal of the auxiliary coil, and the collector of transistor Q11 is connected to the auxiliary coil + terminal through diode D1. The collector of transistor Q11 is connected to the drain and gate of MOSFET Q12 through a resistor. The drain of MOSFET Q12 is connected to the auxiliary coil + terminal, and the source of MOSFET Q12 is connected to the auxiliary coil + terminal through diode D3. The negative terminal of the auxiliary contactor coil is connected to the auxiliary coil - terminal. The collector of transistor Q10 is connected to the drain and gate of MOSFET Q13 through a resistor, and the source of MOSFET Q13 is connected to the positive terminal of the auxiliary contactor coil through diode D4.

[0082] The control logic of the auxiliary contactor control circuit is as follows: when the auxiliary coil is at a low level, the auxiliary contactor is turned on; when the auxiliary coil is open, the auxiliary contactor is turned off.

[0083] In a preferred embodiment of the present invention, the fault detection module includes a discrete input BIT circuit, a discrete output BIT circuit, a heating signal BIT circuit, a secondary power supply BIT circuit, a watchdog BIT circuit, and a contactor control BIT circuit.

[0084] The discrete input (BIT) circuit includes an optocoupler N8 whose first pin is connected to a 3.3V power supply via resistor R22, an optocoupler N8 whose third pin is grounded, an optocoupler N8 whose fourth pin is connected to the discrete signal input terminal of the discrete input sampling circuit via diode V17, and an optocoupler N8 whose second pin is connected to the main control module to transmit the BIT control signal to the main control module.

[0085] Specifically, when the discrete input signal is on and the BIT control signal is low, the input and output terminals of the optocoupler N8 are turned on, and its output terminal is a ground signal. At this time, the discrete input detection chip will detect "ground". When the BIT control signal outputs a high level, the input and output terminals of the optocoupler N8 are turned off, and its output terminal is on. The discrete input detection chip will detect "on". The BIT test of the discrete input circuit is realized by controlling the high and low levels of the BIT control signal.

[0086] The discrete output bit circuit is connected in parallel between the discrete signal output module and the main control module. The discrete output bit circuit includes a digital isolator. Taking the charge-disable output circuit as an example, the input terminal of the digital isolator is connected to the drain of the MOSFET Q2 of the charge-disable output circuit through a diode. The input terminal of the digital isolator is connected to the 5V power supply through a resistor. The output terminal of the digital isolator is connected to the main control module to transmit the bit signal.

[0087] Specifically, when the discrete output signal is "ground", the digital isolator input is low and the output BIT signal is low; when the discrete output signal is "on", the digital isolator input is high and the output BIT signal is high. Therefore, the main control module can perform BIT testing on the discrete output by reading the state of the BIT signal.

[0088] The heating signal BIT circuit includes a heating band R23. The two ends of the heating band R23 are connected to the first and second pins of the optocoupler N9 through resistors R24 and R25, respectively. The third pin of the optocoupler N9 is grounded, and the fourth pin of the optocoupler N9 is connected to the main control module to transmit the heating voltage BIT signal. The output terminal of the heating band R23 is connected to the drain of MOSFET Q14 and MOSFET Q15 respectively. The source of MOSFET Q14 and MOSFET Q15 is grounded through sampling resistor R26 respectively. The two ends of sampling resistor R26 are connected to the operational amplifier and hysteresis comparator circuit respectively. The output terminal of the operational amplifier and hysteresis comparator circuit is connected to the main control module to transmit the heating current BIT signal. The gates of MOSFETs Q14 and Q15 are connected to the temperature relays of battery module 1 and battery module 2 through resistors and diodes, respectively. The output terminals of the temperature relays of battery module 1 and battery module 2 are grounded.

[0089] Specifically, the voltage across the heating band R23 is fed into optocoupler N9 for BIT detection via current-limiting resistor R24 ​​and resistor R25. When the heating band R23 is heating, the voltage across it is the heating voltage of 270V. At this time, the input and output terminals of optocoupler N9 are conducting, and the heating voltage BIT signal detected by the main control module is low. When the heating current of the heating band R23 is disconnected, the voltage across it is at the same potential, the input and output terminals of optocoupler N9 are closed, and the heating voltage BIT signal detected by the main control module is high. The heating band status is obtained by judging the BIT signal.

[0090] Among them, resistors R24 and R25 are composed of four 10kΩ / 1206 resistors connected in series. Ignoring the forward voltage drop at the input of the optocoupler, the 270V heating voltage is divided into 27V across each resistor, with a power of 72.9mW, which does not exceed the resistor's 200V withstand voltage and 250mW rated power.

[0091] The main control module can determine the presence of heating current through sampling resistors, operational amplifiers, and hysteresis comparator circuits, thus indicating whether there is an open circuit fault in the heating circuit. When the heating current is greater than 2.5A, the heating current feedback signal is "high level"; otherwise, it is "low level," thereby realizing the heating current BIT function.

[0092] The secondary power supply BIT circuit includes a +15V / +5V power detection circuit. The input voltage is connected to the main control module through a voltage divider circuit composed of resistors R27 and R28 and a diode V18 protection circuit.

[0093] Specifically, the +15V and +5V power supplies are divided by resistors R27 and R28 and then connected to the ADC interface of the main control module for analog signal acquisition. V18 is a 3.6V Zener diode, model 2CW5914CMS1P, with a military-grade quality level. Some parameters of resistors R27 and R28 are shown in Table 3.

[0094] Table 3 Parameters of resistors R27 and R28

[0095] The secondary power supply BIT circuit also includes a -15V power supply detection circuit. The input voltage is connected to the inverting input terminal of the operational amplifier through resistor R29. The output terminal of the operational amplifier is connected to the main control module. The output terminal of the operational amplifier is connected to diode V19. Resistor R30 is connected in parallel between the inverting input terminal and the output terminal of the operational amplifier.

[0096] Specifically, the -15V power supply detection circuit uses an inverse proportional voltage amplifier circuit for detection, where R29 is a 100kΩ / 0603 resistor, R30 is a 10kΩ / 0603 resistor, the operational amplifier output signal is connected to the ADC interface of the main control module for analog signal acquisition, and V19 is a 3.6V Zener diode, model 2CW5914CMS1P, with a quality grade of military grade.

[0097] The watchdog BIT circuit includes a hardware watchdog module. The input of the hardware watchdog module is connected to the main control module, and the output is connected to a normally open switch and the main control module respectively. The normally open switch outputs a watchdog signal to the main control module, and the normally open switch receives a watchdog disable signal from the main control module.

[0098] Specifically, during the BIT test, the main control module sends a watchdog disable signal to keep the normally open switch in the open state. At this time, the hardware watchdog barking signal will not trigger the main control module to reset. The main control module detects the watchdog BIT signal through the GPIO to determine whether the hardware watchdog outputs a barking signal, thereby realizing the BIT function of the hardware watchdog circuit.

[0099] The contactor control BIT circuit includes an optocoupler isolation circuit. The input terminal of the optocoupler isolation circuit is connected to the collector of transistor Q6 in the transistor-based main contactor control circuit, and the input terminal of the optocoupler isolation circuit is connected to the main control module.

[0100] Specifically, the main control module uses the detected wheel load signal, contactor status feedback signal (contactor auxiliary contact signal), battery switch on signal, FCCON1 signal, FCCON2 signal, and BIT signal 1 to perform contactor self-locking circuit and contactor status BIT. The BIT principle is as follows: Contactor Status BIT: If any of the battery switch on signal, FCCON1 signal, or FCCON2 signal is "ground", the contactor should be closed, and the contactor status feedback signal should be "ground". Otherwise, the BIT result is that the contactor is closed or the contactor status feedback is abnormal. Contactor self-locking circuit BIT: If both the wheel load signal and the contactor status feedback signal are "grounded" (i.e., in the air) and the contactor is in the closed state, then BIT signal 1 is "high level"; otherwise, it is "low level". If this logic is not met, then the contactor self-locking circuit is abnormal or the contactor status feedback signal is abnormal. Other: If the wheel load signal, battery switch on signal, FCCON1 signal, and FCCON2 signal are all in the "on" state, and BIT signal 1 is at a low level, but the contactor status feedback signal is "grounded", that is, the contactor is on, then the contactor is stuck or the MOSFETs Q7 and Q8 are short-circuited at the same time.

[0101] In a preferred embodiment of the present invention, as shown in Table 4, the fault types involved in this embodiment include, but are not limited to, the following categories: Power supply failure: including but not limited to 5V power supply failure, 15V power supply failure, 28V power supply failure, etc., involving abnormal or failed power supply voltage.

[0102] Battery status faults include, but are not limited to, battery failure faults, single cell disconnection faults, temperature disconnection faults, total voltage sampling faults, battery over-temperature faults, low temperature faults, single cell over-voltage faults, single cell under-voltage faults, single cell voltage imbalance faults, battery pack over-voltage faults, and battery pack under-voltage faults, involving issues related to battery voltage, temperature, and status sampling.

[0103] Heating and output circuit faults: including but not limited to heating faults, overcurrent circuit faults in output channels 1 / 2 / 3, and overheating output circuit faults, involving abnormal current and voltage in the heating system and output channels.

[0104] Contactor faults include, but are not limited to, contactor status feedback circuit faults, main contactor not working faults, main contactor not opening faults, auxiliary contactor not working faults, and auxiliary contactor not opening faults, which involve abnormalities in the contactor's status, on / off control, and feedback signals.

[0105] Fuse-related faults: including but not limited to output channel 1 / 2 / 3 fuse faults, battery fuse faults, etc., involving open circuits or abnormal states of fuses.

[0106] Other faults: including but not limited to other fault types that are not explicitly classified but are related to system operation.

[0107] Table 4 Fault Handling Table

[0108] In a preferred embodiment of the present invention, a fault storage module is used to store battery pack fault information and key parameter information. The main control module is equipped with a 4Mbit MRAM for fault information storage, model HKZ4M-PSC. Additionally, a 1Gbit NOR FLASH is configured to store key parameter information, model SM25QH01GMP.

[0109] The fault storage module records key parameter information at the time of a fault to pinpoint the cause. Several fault modes are combined to form a fault code (16 bits), and multiple parameter information are combined to form a fault data packet according to a convention. When the fault code is not 0, it indicates that a fault has occurred and the fault information needs to be stored.

[0110] The fault storage module is based on fault information in the periodic BIT, with a fault storage period of 1 second. When a fault occurs, a delay is applied; if a fault is detected continuously for 5 seconds, the fault is saved. Information from 1 second before the fault occurs, 5 seconds during the fault assessment process, and 3 seconds after the fault assessment is completed are saved.

[0111] The fault information storage address allocation is shown in Table 5; the fault code table is shown in Table 6; and the fault data packet is shown in Table 7.

[0112] Table 5 Fault Information Storage Address Allocation

[0113] Table 6 Fault Codes

[0114] Table 7 Fault Data Packet

[0115] The key parameter storage is used to periodically store key information about the battery's operating parameters. The storage cycle is 3 seconds. The storage address allocation and storage content are shown in the table below.

[0116] Table 8 Data Storage Address Allocation

[0117] Table 9 Key Parameter Information Data Packet

[0118] In a preferred embodiment of the present invention, the main control module is centered on a CPU circuit, and the peripheral circuits include a watchdog circuit, an EEPROM circuit, and a power supply circuit. For power conversion, the 28V power input is first converted to 5V and ±15V by a power conversion circuit, and the 5V is then converted to 3.3V. The RS485 circuit implements RS485 bus communication functionality, the internal interconnect CAN communication circuit is used for interconnection with the sampling board, and the program download CAN communication circuit is used for CAN bus program upgrades.

[0119] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A self-testing system for the cycle of a high-voltage battery used in a high-altitude unmanned aerial vehicle (UAV), characterized in that, include: Analog signal sampling module, used to acquire voltage and current signals of the battery; Discrete signal sampling module, used to acquire multiple discrete signals from the battery; Discrete signal output module, used to output multiple discrete signals from the battery; The fault detection module is used to detect the working status of the analog signal sampling module, the discrete signal sampling module, and the discrete signal output module. The main control module is used to receive information from the analog signal sampling module and the discrete signal sampling module, control the discrete signal output module, and perform fault diagnosis on the corresponding module based on the information transmitted by the fault detection module. The fault storage module is used to store battery pack fault information and key parameter information.

2. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The analog signal sampling module includes a voltage acquisition circuit and a current sampling circuit; the voltage acquisition circuit is used to acquire the power supply voltage, the total voltage of the battery pack, the voltage of each individual battery cell, the contactor output voltage, the output channel voltage, and the heating power supply voltage; the current sampling circuit is used to acquire the battery charging current and the discharging current.

3. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The discrete signal sampling module includes a discrete input sampling unit for acquiring wheel load status signals, switch signals, and contactor status feedback signals.

4. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The discrete signal output module is used to output charging prohibition signal, power supply indicator signal, output channel overcurrent signal, contactor status signal, manufacturer identification signal and heating prohibition signal.

5. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The fault detection module includes a discrete input BIT circuit, a discrete output BIT circuit, a heating signal BIT circuit, a secondary power supply BIT circuit, a watchdog BIT circuit, and a contactor control BIT circuit.

6. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The discrete output BIT circuit includes a digital isolator connected in parallel between the discrete signal output module and the main control module. The main control module performs BIT testing on the discrete output module by reading the BIT signal status transmitted by the digital isolator.

7. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The heating signal BIT circuit detects the voltage on both sides of the heating band through an optocoupler and transmits it to the main control module; the heating signal BIT circuit collects the heating current through a sampling resistor, operational amplifier amplification, and hysteresis comparator circuit and transmits it to the main control module.

8. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The contactor control BIT circuit collects contactor status information through an optocoupler isolation circuit and transmits it to the main control module; the main control module performs fault detection using wheel load signals, contactor status feedback signals, switch signals, and the collected contactor status information.

9. The high-voltage battery cycle self-testing system for high-altitude unmanned aerial vehicles according to claim 1, characterized in that: The main control module detects the following types of faults: battery fault, power supply fault, voltage fault, overcurrent fault, single cell open circuit fault, temperature open circuit fault, heating fault, fuse fault, and contactor fault.

10. A self-testing method for the cycle of a high-voltage battery for a high-altitude unmanned aerial vehicle (UAV), employing the self-testing system for the cycle of a high-voltage battery for a high-altitude UAV as described in any one of claims 1-9, characterized in that, Includes the following steps: The voltage and current signals of the battery are acquired through an analog signal sampling module; Multiple discrete signals from the battery are acquired through a discrete signal sampling module; The discrete signal output module outputs multiple discrete signals to control the battery. The fault detection module detects the working status of the analog signal sampling module, discrete signal sampling module, and discrete signal output module. The main control module receives information from the analog signal sampling module and the discrete signal sampling module, controls the discrete signal output module, and performs fault diagnosis on the corresponding module based on the information transmitted by the fault detection module. The fault storage module saves relevant information when a fault occurs.

Images