High-voltage distribution box current detection system and method and storage medium

Abstract

The invention discloses a high-voltage distribution box current detection system and method and a storage medium, and relates to the technical field of vehicle high-voltage system current detection. The system comprises a high-voltage distribution box and a processing assembly, the high-voltage distribution box is arranged to distribute high-voltage electric energy to at least one high-voltage electric appliance assembly in the vehicle, a Hall effect sensing assembly is arranged in the high-voltage distribution box, and the Hall effect sensing assembly is arranged to conduct Hall sensing on a high-voltage discharge loop in the high-voltage distribution box to obtain output voltage; and the processing assembly is connected with the Hall effect sensing assembly and is used for carrying out current conversion on the output voltage to obtain a current detection result. According to the invention, the technical problems of low current detection precision and high cost of the automobile high-voltage distribution box in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of vehicle high-voltage system current detection technology, and more specifically, to a high-voltage distribution box current detection system, method, and storage medium. Background Technology

[0002] With the rapid development of electric vehicle technology, the high-voltage distribution box in automobiles, as a key component of high-voltage power management, directly affects the vehicle's operational safety and efficiency. In the high-voltage systems of modern electric vehicles, accurate current detection is crucial, as it not only relates to the effective distribution of energy but also involves fault diagnosis, the triggering of protection mechanisms, and the safe operation of the entire system.

[0003] Traditional current detection methods typically employ a shunt combined with precision circuitry. This involves connecting a low-resistance resistor (shunt) in series in the current path and calculating the current flow by detecting the voltage drop across the resistor. However, this approach suffers from several technical drawbacks. The shunt's resistance is affected by temperature variations, causing it to drift at different operating temperatures and thus impacting the accuracy of current detection. Furthermore, the shunt solution requires a complete peripheral circuitry, including precision operational amplifiers, isolation devices, analog-to-digital converters, and microcontrollers. Integrating these components increases material costs and complicates circuit board design and layout. Therefore, improving the accuracy of current detection in automotive high-voltage distribution boxes while reducing detection costs is a crucial technical challenge in this field.

[0004] There is currently no effective solution to the above problems. Summary of the Invention

[0005] This invention provides a high-voltage distribution box current detection system, method, and storage medium to at least solve the technical problems of low accuracy and high cost in automotive high-voltage distribution box current detection in related technologies.

[0006] According to one aspect of the present invention, a high-voltage distribution box current detection system is provided, comprising: a high-voltage distribution box and a processing component; the high-voltage distribution box is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in a vehicle, wherein a Hall effect sensing component is disposed in the high-voltage distribution box, the Hall effect sensing component is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; the processing component is connected to the Hall effect sensing component and is configured to perform current conversion on the output voltage to obtain a current detection result.

[0007] Optionally, the Hall effect sensing component includes: a Hall element and a signal conditioning circuit; the Hall element is configured to perform Hall sensing on the high-voltage discharge circuit to obtain an induced voltage; the signal conditioning circuit is configured to amplify and filter the induced voltage to obtain an output voltage.

[0008] Optionally, the Hall effect sensing component further includes: a temperature compensation circuit, an isolation circuit, and an output circuit; the temperature compensation circuit is configured to adjust the induced voltage based on the current operating ambient temperature of the Hall effect sensing component to obtain the adjusted induced voltage; the isolation circuit is configured to electrically isolate the high-voltage discharge circuit from the output circuit; and the output circuit is configured to output the output voltage to the processing component.

[0009] Optionally, the processing component includes: a calculation module; the calculation module is configured to determine the effective current corresponding to the output voltage based on a predefined voltage-current mapping relationship, and obtain the current detection result.

[0010] Optionally, the processing component further includes: an early warning module; the early warning module is configured to perform a risk assessment on the current detection result, obtain the risk assessment result, and determine whether to trigger the overcurrent protection mechanism based on the risk assessment result.

[0011] Optionally, the high-voltage distribution box current detection system also includes: a low-voltage power supply; the low-voltage power supply is configured to supply power to the Hall effect sensing component.

[0012] Optionally, the high-voltage distribution box current detection system further includes: a test component; the test component is configured to perform a durability test on the high-voltage distribution box current detection system and obtain test results.

[0013] According to another aspect of the present invention, a high-voltage distribution box current detection method is also provided. The high-voltage distribution box current detection method is applied to the high-voltage distribution box current detection system in any of the above-mentioned embodiments. The high-voltage distribution box current detection method includes: responding to the distribution of high-voltage electrical energy from the high-voltage distribution box of the vehicle to at least one high-voltage electrical component in the vehicle, performing Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; and performing current conversion on the output voltage to obtain a current detection result.

[0014] According to another aspect of the present invention, a vehicle is also provided, including: the high-voltage distribution box current detection system of any one of the above.

[0015] According to another aspect of the present invention, a computer-readable storage medium is also provided, the computer-readable storage medium including a stored executable program, wherein, when the executable program is running, it controls the device where the computer-readable storage medium is located to perform the above-described high-voltage distribution box current detection method.

[0016] This invention provides a high-voltage distribution box current detection system, comprising: a high-voltage distribution box and a processing component; the high-voltage distribution box is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in a vehicle, wherein a Hall effect sensing component is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; the processing component is connected to the Hall effect sensing component and configured to perform current conversion on the output voltage to obtain a current detection result. This invention utilizes the relationship between magnetic field and current in the high-voltage distribution box, which, compared to traditional shunt solutions, avoids resistance drift caused by temperature changes and improves the accuracy of current detection. Furthermore, the processing component, connected to the Hall effect sensing component, performs current conversion on the output voltage to obtain a current detection result. This step employs a software algorithm instead of hardware compensation, reducing reliance on external precision components, lowering material costs, simplifying circuit design, and thus reducing overall cost. It also makes current detection more flexible and efficient. In summary, this invention achieves the technical effect of improving the current detection accuracy of automotive high-voltage distribution boxes and reducing detection costs, thereby solving the technical problems of low accuracy and high cost of automotive high-voltage distribution box current detection in related technologies. Attached Figure Description

[0017] The accompanying drawings, which are included to provide a further understanding of the invention and form part of this application, illustrate exemplary embodiments of the invention and, together with their description, serve to explain the invention and do not constitute an undue limitation thereof. In the drawings:

[0018] Figure 1 This is a structural block diagram of a high-voltage distribution box current detection system according to one embodiment of the present invention;

[0019] Figure 2 This is a system architecture diagram of a high-voltage distribution box current detection system according to one embodiment of the present invention;

[0020] Figure 3 This is a structural diagram of a high-voltage distribution box according to one embodiment of the present invention;

[0021] Figure 4 This is a flowchart of a high-voltage distribution box current detection method according to one embodiment of the present invention. Detailed Implementation

[0022] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present invention.

[0023] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this invention are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of the invention described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover a non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0024] This invention provides a high-voltage distribution box current detection system. Figure 1 This is a structural block diagram of a high-voltage distribution box current detection system according to one embodiment of the present invention, such as... Figure 1 As shown, the high-voltage distribution box current detection system 100 includes: a high-voltage distribution box 101 and a processing component 102; the high-voltage distribution box 101 is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in the vehicle, wherein the high-voltage distribution box 101 is equipped with a Hall effect sensing component, which is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; the processing component 102 is connected to the Hall effect sensing component and is configured to perform current conversion on the output voltage to obtain a current detection result.

[0025] The core function of a high-voltage distribution box is to distribute the high-voltage electrical energy from the power battery to the high-voltage electrical components in the vehicle, such as the motor controller, air conditioning compressor, and charger. This requires the high-voltage distribution box to have good power distribution capabilities and safety protection mechanisms to ensure that electrical energy is transmitted along the correct path, while preventing risks such as overload and short circuit.

[0026] A Hall effect sensing component is installed inside the high-voltage distribution box to perform Hall effect sensing on the high-voltage discharge circuit in the high-voltage distribution box.

[0027] The Hall effect refers to the phenomenon where, when an electric current flows through a conductor or semiconductor perpendicular to a magnetic field, a transverse voltage proportional to the magnetic field strength is generated on the side of the conductor; this voltage is called the Hall voltage. The current detection result is determined by detecting the Hall voltage.

[0028] Optionally, when using a Hall effect sensing component, the primary lead (i.e., the wire or busbar through which the current flows) needs to be connected in series with the current being measured. When current flows, according to the electromagnetism part of Maxwell's equations, a magnetic field proportional to the current is generated around the conductor or busbar. The Hall element in the Hall effect sensing component senses this magnetic field and generates a Hall voltage. Other components in the Hall effect sensing component process this Hall voltage to obtain the output voltage.

[0029] Optionally, the processing component is directly connected to the Hall effect sensing component via an electrical interface to collect and process the voltage signal output by the Hall effect sensing component.

[0030] In one optional embodiment, the processing component includes an analog-to-digital converter (ADC) and a microcontroller. The ADC is responsible for converting the analog voltage signal received from the Hall effect sensing component into a digital signal for processing by the microcontroller. The microcontroller is the core of the processing component; it receives the digital signal converted by the ADC, calculates the effective value of the current using a preset software algorithm, and obtains the current detection result. Optionally, the current detection result is sent to the vehicle controller or battery management system via a communication method such as a CAN bus.

[0031] Optionally, after receiving the voltage signal converted by the analog-to-digital converter, the microcontroller in the processing component calculates the actual value of the current based on the known sensitivity of the Hall element and the relationship between current and magnetic field strength. This process includes signal filtering, data processing, current calculation, and result output.

[0032] Optionally, the processing component also includes a comparator circuit for current threshold detection, which can monitor in real time whether the current exceeds the safe range and trigger safety mechanisms, such as warnings, power reduction, or hard shutdown, when necessary.

[0033] This invention provides a high-voltage distribution box current detection system, comprising: a high-voltage distribution box and a processing component; the high-voltage distribution box is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in a vehicle, wherein a Hall effect sensing component is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; the processing component is connected to the Hall effect sensing component and configured to perform current conversion on the output voltage to obtain a current detection result. This invention utilizes the relationship between magnetic field and current in the high-voltage distribution box, which, compared to traditional shunt solutions, avoids resistance drift caused by temperature changes and improves the accuracy of current detection. Furthermore, the processing component, connected to the Hall effect sensing component, performs current conversion on the output voltage to obtain a current detection result. This step employs a software algorithm instead of hardware compensation, reducing reliance on external precision components, lowering material costs, simplifying circuit design, and thus reducing overall cost. It also makes current detection more flexible and efficient. In summary, this invention achieves the technical effect of improving the current detection accuracy of automotive high-voltage distribution boxes and reducing detection costs, thereby solving the technical problems of low accuracy and high cost of automotive high-voltage distribution box current detection in related technologies.

[0034] Optionally, the Hall effect sensing component includes: a Hall element and a signal conditioning circuit; the Hall element is configured to perform Hall sensing on the high-voltage discharge circuit to obtain an induced voltage; the signal conditioning circuit is configured to amplify and filter the induced voltage to obtain an output voltage.

[0035] The Hall element described above is a solid-state sensor that operates based on the Hall effect. Under the influence of an external magnetic field, the flow of electrons is deflected, creating a voltage difference perpendicular to both the current and the magnetic field. The Hall element can sense the magnetic field strength in the surrounding environment and convert this information into a voltage signal.

[0036] Optionally, the Hall element is placed close to or around the conductor or copper busbar of the high-voltage discharge circuit to minimize the magnetic circuit length, thereby reducing interference from external magnetic fields. When selecting the placement location of the Hall element, it should be avoided near contactor coils, fuses, or other components that generate strong transient magnetic fields to ensure a clean magnetic field environment, which is beneficial for the Hall element to accurately detect the magnetic field generated by the current.

[0037] The aforementioned signal conditioning circuit refers to a circuit that amplifies, filters, and performs other preprocessing on the signal (i.e., induced voltage) output by the Hall element, with the aim of ensuring that the signal meets the requirements of subsequent processing.

[0038] The signal conditioning circuit amplifies and filters the induced voltage to obtain the output voltage. Since the voltage signal generated by the Hall element is very weak, the amplifier (such as an operational amplifier) ​​in the signal conditioning circuit is responsible for amplifying the signal to a level suitable for processing. Signal filtering is used to remove noise and interference from the signal, ensuring that the amplified voltage signal is clear and stable, thereby improving the accuracy of current detection.

[0039] By working together with Hall elements and signal conditioning circuits, high-precision and high-reliability current detection can be achieved, while reducing system complexity and improving anti-interference capabilities.

[0040] Optionally, the Hall effect sensing component further includes: a temperature compensation circuit, an isolation circuit, and an output circuit; the temperature compensation circuit is configured to adjust the induced voltage based on the current operating ambient temperature of the Hall effect sensing component to obtain the adjusted induced voltage; the isolation circuit is configured to electrically isolate the high-voltage discharge circuit from the output circuit; and the output circuit is configured to output the output voltage to the processing component.

[0041] A temperature compensation circuit is a circuit used to automatically adjust the induced voltage to compensate for measurement errors caused by temperature changes. In Hall effect sensing, temperature variations affect the Hall voltage, i.e., the magnitude of the induced voltage, thus affecting the accuracy of current detection. The temperature compensation circuit monitors the temperature of the Hall element and adjusts the Hall voltage according to a pre-set temperature-voltage compensation curve, ensuring consistent and accurate measurement results over a wide temperature range.

[0042] In one alternative embodiment, when the temperature changes, the temperature compensation circuit dynamically compensates based on the temperature of the Hall element, adjusting the Hall voltage to ensure that the measurement results are not affected by temperature. This process is implemented based on an algorithm within the microcontroller or application-specific integrated circuit (ASIC), which automatically adjusts the voltage amplification factor according to temperature changes, thereby compensating for the effect of temperature on the Hall voltage.

[0043] Isolation circuits are used to electrically isolate high-voltage discharge circuits from output circuits, preventing high-voltage circuits from causing electrical interference or damage to low-voltage circuits. Isolation circuits are particularly important in electric vehicles because a significant voltage difference exists between the high-voltage system and the low-voltage control system, requiring effective isolation measures.

[0044] In one alternative embodiment, electrical isolation is achieved using an optocoupler, a magnetic coupler, or a digital isolator. Exemplarily, digital isolation technology is employed, utilizing capacitive or magnetic isolation, to ensure electrical isolation between the high-voltage discharge circuit and the output circuit.

[0045] The output circuit is responsible for outputting the output voltage signal collected by the Hall effect sensing component to the processing component.

[0046] By using temperature compensation circuit, isolation circuit, and output circuit, efficient detection of current in the high-voltage distribution box of electric vehicles is achieved.

[0047] Optionally, the processing component includes: a calculation module; the calculation module is configured to determine the effective current corresponding to the output voltage based on a predefined voltage-current mapping relationship, and obtain the current detection result.

[0048] The processing component is responsible for converting the voltage signal output by the Hall effect sensing component into a valid current detection result.

[0049] The calculation module is the core of the processing components. Based on a predefined voltage-current mapping relationship, it converts the voltage signal output by the Hall effect sensing component into a corresponding current value. This process mainly involves signal processing and mathematical operations, the most crucial of which are establishing the mapping relationship, acquiring and converting the voltage signal, and calculating the effective value of the current.

[0050] The voltage-current mapping relationship is used to describe the quantitative relationship between the output voltage and the detected current of a Hall effect sensing component. Ideally, this relationship is linear, but in practical applications, it may exhibit nonlinear characteristics due to sensor properties and environmental factors. Accurately establishing this mapping relationship is crucial for the precision of current detection.

[0051] In AC circuits, effective current refers to a form of equivalent DC current where the average of the squares of the instantaneous current is considered. It reflects the actual power consumption level of the AC current. Optionally, the calculation module can process not only DC signals but also AC signals, converting them into effective current so that the detection results can accurately reflect the current state under actual operating conditions.

[0052] In one alternative embodiment, a series of voltage and current data points are obtained through experiments or simulations. These data points reflect the output voltage of the Hall effect sensing component under different current intensities. Next, curve fitting or other mathematical tools, such as polynomial regression, are used to construct a mapping function between the voltage and current.

[0053] The calculation module converts continuous analog voltage signals into digital signals using an analog-to-digital converter (ADC) for subsequent digital signal processing. The converted digital signals are stored in a buffer or register, awaiting further processing. The calculation module calculates the effective current value based on a pre-established voltage-current mapping relationship. This process involves mathematical algorithms such as the Fast Fourier Transform (FFT) to accurately extract frequency information from the signal and calculate the effective value.

[0054] Optionally, the calculated effective current value is converted and packaged, and then sent to the central processing unit or control unit via a communication protocol for further processing or display by the system.

[0055] The calculation module can calculate the effective current by establishing an accurate voltage-current mapping relationship, thereby obtaining accurate current detection results.

[0056] Optionally, the processing component further includes: an early warning module; the early warning module is configured to perform a risk assessment on the current detection result, obtain the risk assessment result, and determine whether to trigger the overcurrent protection mechanism based on the risk assessment result.

[0057] Risk assessment is the core function of the early warning module. It determines whether the current system operation exceeds safety boundaries through real-time analysis of current detection results. This process involves real-time monitoring of current values, comparison and analysis with preset thresholds, and prediction of current change trends.

[0058] In one optional embodiment, the current detection result is compared with a warning current threshold, a power reduction current threshold, and a hard shutdown current threshold to obtain a risk assessment result. The warning current threshold, power reduction current threshold, and hard shutdown current threshold are set based on a comprehensive consideration of system safety and vehicle operating performance.

[0059] Optionally, the sliding window averaging method or other time series analysis techniques can be used to predict current change trends, especially to focus on monitoring current trends that suddenly increase or decrease, in order to identify overload or short circuit risks in advance.

[0060] Overcurrent protection mechanisms are emergency safety measures implemented when the system current exceeds the safe operating range. These measures include cutting off high-voltage circuits or limiting the current to prevent damage to electrical equipment or accidents. Once the current value exceeds a set threshold, the warning module immediately triggers the corresponding protection mechanism, such as cutting off the circuit by controlling a relay or adjusting the output of the power converter to limit the current.

[0061] Optionally, after the protection mechanism is activated, the warning module will feed back information such as the protection action, current value and cause to the vehicle control unit or battery management system via the CAN bus for overall system adjustment and fault diagnosis.

[0062] It is easy to understand that the early warning module can accurately assess the risk of current changes, promptly activate the overcurrent protection mechanism, effectively prevent system overload and short circuit, and ensure the driving safety of electric vehicles and the stable operation of electrical equipment.

[0063] Optionally, the high-voltage distribution box current detection system also includes: a low-voltage power supply; the low-voltage power supply is configured to supply power to the Hall effect sensing component.

[0064] The aforementioned low-voltage power supply refers to a power supply with a lower operating voltage compared to a high-voltage power distribution system. Its voltage level is usually below 48V, and more commonly 5V or 3.3V. This type of power supply is mainly used for power supply control systems, sensors, and other low-voltage electronic equipment.

[0065] In one alternative embodiment, a stable low-voltage power supply, such as a 5V or 3.3V DC power supply, is selected to provide a clean and uninterrupted power supply to the Hall effect sensing components. Optionally, a power adapter or power management chip with voltage regulation function is used to ensure that the Hall effect sensing components can still obtain a constant voltage in the event of battery voltage fluctuations or instability in the vehicle's electrical grid.

[0066] By introducing a low-voltage power supply to power the Hall effect sensing components, a high degree of integration and safety of the high-voltage distribution box current detection system is achieved. A stable low-voltage power supply ensures the long-term stability and measurement accuracy of the Hall effect sensing components, providing continuous and accurate measurement data even in extreme environments or under sudden conditions. This is crucial for energy management and fault diagnosis of electric vehicles.

[0067] Optionally, the high-voltage distribution box current detection system further includes: a test component; the test component is configured to perform a durability test on the high-voltage distribution box current detection system and obtain test results.

[0068] The test suite is used to evaluate the performance of the high-voltage switch box current sensing system under various preset conditions, ensuring that it can continuously provide accurate current sensing data in the actual operating environment of electric vehicles.

[0069] Durability testing covers the system's performance under extreme temperature, humidity, vibration, and long-term operating conditions to identify any potential failure modes and mechanisms. Test components can simulate common current fluctuations in high-voltage systems, including different states such as standby, startup, normal operation, and peak operation, thereby comprehensively examining the system's response characteristics.

[0070] After durability testing, the test component generates a series of data, including but not limited to key performance indicators such as test accuracy, response time, false alarm rate, and failure rate.

[0071] In an alternative embodiment, to comprehensively evaluate the system's fault handling capabilities, the test component can inject artificial faults, such as overcurrent, short circuit, or open circuit, into the current sensing loop and observe whether the system can correctly trigger protection mechanisms, such as warning signals, power reduction control, or hard shutdown.

[0072] By introducing testing components to conduct durability tests on the high-voltage switch box current detection system, a comprehensive assessment of the system's long-term stability and reliability was achieved. Detailed testing ensures that the system maintains high-precision current detection throughout its lifecycle, enhancing the overall safety of electric vehicles and the user's driving experience.

[0073] Optionally, Figure 2 This is a system architecture diagram of a high-voltage distribution box current detection system according to one embodiment of the present invention, such as... Figure 2 As shown, the high-voltage distribution box includes a 5V LDO (Low Dropout) power supply, which, after filtering, powers the next-generation Hall sensor. The main advantages of LDO power supplies are their simplicity, low noise, and high accuracy, making them suitable for electronic devices or circuits that require stable voltage and are sensitive to noise, such as audio equipment and sensor power supplies.

[0074] The new generation Hall effect sensor generates magnetic induction based on a high-voltage copper busbar, and then outputs SENT (Single Edge Near-zero Transition) / PWM (Pulse Width Modulation) digital signals, fault flag signals, and real-time current data to the main control MCU (Microcontroller Unit). The main control MCU generates drive signals to control the contactor's on / off state based on the contactor drive circuit. Furthermore, the main control MCU reports current values ​​and faults to the VCU (Vehicle Control Unit) / BMS (Battery Management System) via CAN communication. The VCU / BMS issues protection commands to the main control MCU. A multi-level protection algorithm is employed. The protection logic includes both normal range protection and sensor fault protection.

[0075] Optionally, Figure 3 This is a structural diagram of a high-voltage distribution box according to one embodiment of the present invention. Figure 3 This is a structural diagram of an optional high-voltage distribution box. In this structure, a Hall effect sensing component is integrated into the drive PCB (Printed Circuit Board) section shown in the diagram, thereby enabling current detection of the high-voltage distribution box. The OBC (On-board Charger) converts the AC power supplied by the battery pack into DC power. The high-voltage distribution box distributes the electrical energy supplied by the battery pack, allocating the high-voltage energy from the battery to the high-voltage electrical components in the vehicle. A 6W signal connector is used for connection, compatible with both single-phase and three-phase sockets, or a single-phase socket.

[0076] According to an embodiment of the present invention, an embodiment of a high-voltage distribution box current detection method is provided. 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. Furthermore, 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.

[0077] According to another aspect of the present invention, a method for detecting current in a high-voltage distribution box is also provided. This method is applied to the high-voltage distribution box current detection system described in any of the above embodiments. Figure 4 This is a flowchart of a high-voltage distribution box current detection method according to one embodiment of the present invention, as follows: Figure 4 As shown, the current detection method for high-voltage distribution boxes includes the following steps:

[0078] Step S401: In response to the high-voltage distribution box of the vehicle distributing high-voltage electrical energy to at least one high-voltage electrical component in the vehicle, Hall effect sensing is performed on the high-voltage discharge circuit in the high-voltage distribution box to obtain the output voltage.

[0079] Step S402: Convert the output voltage to current to obtain the current detection result.

[0080] When an electric vehicle starts or runs, the high-voltage distribution box, acting as the distribution center for high-voltage electrical energy, distributes the high-voltage electrical energy from the power battery to multiple high-voltage electrical components in the vehicle, such as the motor controller and air conditioning system. During this process, a magnetic field is generated when current flows through the high-voltage discharge circuit. This magnetic field is sensed by a Hall effect sensor component in the high-voltage distribution box. The Hall effect sensor component can directly sense the magnetic field generated by the current in the current loop and convert the magnetic field into an output voltage signal proportional to the current magnitude.

[0081] The Hall effect sensing component includes: Hall element, signal conditioning circuit, temperature compensation circuit, isolation circuit, and output circuit.

[0082] Specifically, the Hall element senses the high-voltage discharge circuit, obtaining an induced voltage. The signal conditioning circuit amplifies and filters the induced voltage to obtain the output voltage. The temperature compensation circuit monitors the temperature of the Hall element and adjusts the Hall voltage (i.e., the induced voltage) according to a pre-set temperature-voltage compensation curve to ensure the consistency and accuracy of measurement results over a wide temperature range. The isolation circuit provides electrical isolation between the high-voltage discharge circuit and the output circuit, preventing electrical interference or damage from the high-voltage circuit to the low-voltage circuit. The output circuit is responsible for outputting the output voltage signal acquired by the Hall effect sensing component to the processing component.

[0083] The processing component converts the output voltage into a current to obtain the current detection result.

[0084] Specifically, the processing component converts the continuous analog voltage signal (i.e., the output voltage) into a digital signal using an analog-to-digital converter (ADC) for subsequent digital signal processing. The converted digital signal is stored in a buffer or register, awaiting further processing. The calculation module calculates the effective current value based on a pre-established voltage-current mapping relationship. This process involves mathematical algorithms such as the Fast Fourier Transform to accurately extract frequency information from the signal and calculate the effective value.

[0085] In addition, in an optional embodiment, a risk assessment is performed on the current detection results to obtain the risk assessment results, and based on the risk assessment results, it is determined whether an overcurrent protection mechanism is triggered.

[0086] For example, the current detection result is compared with the warning current threshold, the power reduction current threshold, and the hard shutdown current threshold to obtain the risk assessment result. Based on the risk assessment result, it is determined whether to trigger a specific overcurrent protection mechanism.

[0087] This invention provides a method for current detection in a high-voltage distribution box, comprising: responding to the distribution of high-voltage electrical energy from the high-voltage distribution box of a vehicle to at least one high-voltage electrical component in the vehicle; performing Hall effect sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; and performing current conversion on the output voltage to obtain a current detection result. This invention uses a Hall effect sensing component configured in the high-voltage distribution box to perform Hall effect sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage. This process utilizes the relationship between magnetic field and current, avoiding resistance drift caused by temperature changes compared to traditional shunt solutions, thus improving the accuracy of current detection. Secondly, a processing component performs current conversion on the output voltage to obtain a current detection result. This step uses a software algorithm instead of hardware compensation, reducing reliance on external precision components, lowering material costs, simplifying circuit design, and thus reducing overall costs. It also makes current detection more flexible and efficient. In summary, this invention achieves the technical effect of improving the accuracy of current detection in automotive high-voltage distribution boxes and reducing detection costs, thereby solving the technical problems of low accuracy and high cost in related technologies for current detection in automotive high-voltage distribution boxes.

[0088] In one optional embodiment, this invention proposes a high-voltage distribution box current detection scheme based on a new generation of Hall effect current sensors. This method achieves the purpose of monitoring and detecting the current in the distribution box by utilizing a new generation of Hall effect current sensors in the high-voltage distribution box. This method integrates signal conditioning, temperature compensation, isolation, ADC, and other functions into a single chip at the chip level, solving various problems inherent in traditional shunts at the chip level, thereby achieving accurate detection of the current in the high-voltage distribution box. First, a requirements analysis and sensor selection are required. Firstly, the electrical properties are defined to determine the continuous current, peak current, and minimum measurable current of the circuit to be monitored; the entire temperature range is determined to be between -40℃ and 125℃. Based on these parameters, a linear isolated Hall sensor integrating isolation, amplification, compensation, and diagnostic functions is selected. Furthermore, a PWM digital output protocol is chosen to enhance anti-interference capabilities and simplify interface communication with the main control MCU. Secondly, the sensor is placed close to (or directly sleeved) the high-voltage copper busbar / wire to be monitored, ensuring the shortest possible magnetic path and reducing external magnetic field interference. Plan the installation location and method of the sensor PCB board to ensure that it meets the creepage distance and clearance requirements with the high-voltage busbar. At the same time, software algorithm and logic development is required, including writing driver programs to read the sensor's digital output or ADC sampling value in real time, setting multiple threshold levels (such as warning, power reduction, hard shutdown), and adopting inverse time protection characteristics: the more the current exceeds the threshold, the shorter the protection action time.

[0089] Furthermore, the high-voltage distribution box current detection system needs to be calibrated and verified. A full-scale test of the system's accuracy is required, validating the accuracy across the entire temperature and measurement range. Secondly, a simulated fault injection is necessary to verify whether the diagnostic functions correctly trigger the expected safety mechanisms. Additionally, EMC (Electromagnetic Compatibility) testing is required to ensure system stability and consistent output signal characteristics under electromagnetic interference. Finally, long-term durability testing is essential to verify the system's long-term stability.

[0090] According to another aspect of the present invention, a vehicle is also provided, including: the high-voltage distribution box current detection system of any one of the above.

[0091] Optionally, the high-voltage distribution box current detection system includes: a high-voltage distribution box and a processing component; the high-voltage distribution box is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in the vehicle, wherein the high-voltage distribution box is equipped with a Hall effect sensing component, the Hall effect sensing component is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain an output voltage; the processing component is connected to the Hall effect sensing component and is configured to perform current conversion on the output voltage to obtain a current detection result.

[0092] Optionally, the Hall effect sensing component includes: a Hall element and a signal conditioning circuit; the Hall element is configured to perform Hall sensing on the high-voltage discharge circuit to obtain an induced voltage; the signal conditioning circuit is configured to amplify and filter the induced voltage to obtain an output voltage.

[0093] Optionally, the Hall effect sensing component further includes: a temperature compensation circuit, an isolation circuit, and an output circuit; the temperature compensation circuit is configured to adjust the induced voltage based on the current operating ambient temperature of the Hall effect sensing component to obtain the adjusted induced voltage; the isolation circuit is configured to electrically isolate the high-voltage discharge circuit from the output circuit; and the output circuit is configured to output the output voltage to the processing component.

[0094] Optionally, the processing component includes: a calculation module; the calculation module is configured to determine the effective current corresponding to the output voltage based on a predefined voltage-current mapping relationship, and obtain the current detection result.

[0095] Optionally, the processing component further includes: an early warning module; the early warning module is configured to perform a risk assessment on the current detection result, obtain the risk assessment result, and determine whether to trigger the overcurrent protection mechanism based on the risk assessment result.

[0096] Optionally, the high-voltage distribution box current detection system also includes: a low-voltage power supply; the low-voltage power supply is configured to supply power to the Hall effect sensing component.

[0097] Optionally, the high-voltage distribution box current detection system further includes: a test component; the test component is configured to perform a durability test on the high-voltage distribution box current detection system and obtain test results.

[0098] According to another aspect of the present invention, a computer-readable storage medium is also provided, the computer-readable storage medium including a stored executable program, wherein, when the executable program is running, it controls the device where the computer-readable storage medium is located to perform the above-described high-voltage distribution box current detection method.

[0099] Optionally, in this embodiment, the executable program can be configured to store an executable program for performing the following steps:

[0100] Step S401: In response to the high-voltage distribution box of the vehicle distributing high-voltage electrical energy to at least one high-voltage electrical component in the vehicle, Hall effect sensing is performed on the high-voltage discharge circuit in the high-voltage distribution box to obtain the output voltage.

[0101] Step S402: Convert the output voltage to current to obtain the current detection result.

[0102] Optionally, specific examples in this embodiment can refer to the examples described in the above embodiments and optional implementations, and will not be repeated here.

[0103] In the above embodiments of the present invention, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0104] In the embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The system embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection of units or modules may be electrical or other forms.

[0105] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0106] Furthermore, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0107] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present invention, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of the present invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, read-only memory (ROM), random access memory (RAM), portable hard drives, magnetic disks, or optical disks.

[0108] The above description is only a preferred embodiment of the present invention. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A high-voltage distribution box current detection system, characterized in that, include: High-voltage distribution box and processing components; The high-voltage distribution box is configured to distribute high-voltage electrical energy to at least one high-voltage electrical component in the vehicle. The high-voltage distribution box is equipped with a Hall effect sensing component, which is configured to perform Hall sensing on the high-voltage discharge circuit in the high-voltage distribution box to obtain the output voltage. The processing component is connected to the Hall effect sensing component and is configured to perform current conversion on the output voltage to obtain a current detection result.

2. The high-voltage distribution box current detection system according to claim 1, characterized in that, The Hall effect sensing component includes: a Hall element and a signal conditioning circuit; The Hall element is configured to perform Hall sensing on the high-voltage discharge circuit to obtain the induced voltage; The signal conditioning circuit is configured to amplify and filter the induced voltage to obtain the output voltage.

3. The high-voltage distribution box current detection system according to claim 2, characterized in that, The Hall effect sensing component also includes: a temperature compensation circuit, an isolation circuit, and an output circuit; The temperature compensation circuit is configured to adjust the sensing voltage based on the current operating ambient temperature of the Hall effect sensing component to obtain the adjusted sensing voltage. The isolation circuit is configured to electrically isolate the high-voltage discharge circuit from the output circuit; The output circuit is configured to output the output voltage to the processing component.

4. The high-voltage distribution box current detection system according to claim 1, characterized in that, The processing component includes: a computing module; The calculation module is configured to determine the effective current corresponding to the output voltage based on a predefined voltage-current mapping relationship, and obtain the current detection result.

5. The high-voltage distribution box current detection system according to claim 4, characterized in that, The processing components also include: an early warning module; The early warning module is configured to perform a risk assessment on the current detection result, obtain a risk assessment result, and determine whether to trigger an overcurrent protection mechanism based on the risk assessment result.

6. The high-voltage distribution box current detection system according to claim 1, characterized in that, The high-voltage distribution box current detection system also includes: a low-voltage power supply; The low-voltage power supply is configured to supply power to the Hall effect sensing component.

7. The high-voltage distribution box current detection system according to claim 1, characterized in that, The high-voltage distribution box current detection system also includes: a testing component; The test component is configured to perform a durability test on the current detection system of the high-voltage distribution box and obtain the test results.

8. A method for detecting current in a high-voltage distribution box, characterized in that, The high-voltage distribution box current detection method is applied to the high-voltage distribution box current detection system according to any one of claims 1 to 7, and the high-voltage distribution box current detection method includes: In response to the high-voltage distribution box of the vehicle distributing high-voltage electrical energy to at least one high-voltage electrical component in the vehicle, Hall effect sensing is performed on the high-voltage discharge circuit in the high-voltage distribution box to obtain the output voltage; The output voltage is converted to current to obtain the current detection result.

9. A vehicle, characterized in that, include: The high-voltage distribution box current detection system according to any one of claims 1 to 7.

10. A computer-readable storage medium, characterized in that, The computer-readable storage medium includes a stored executable program, wherein, when the executable program is executed, it controls the device containing the computer-readable storage medium to perform the high-voltage distribution box current detection method of claim 8.

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