Battery system of vehicle and control method thereof
By introducing displacement and humidity sensors into the high-voltage connector, the problem of not being able to detect the connection status and sealing of the high-voltage connector in the existing technology is solved, thereby improving the reliability and safety of the high-voltage circuit connection and ensuring the safety of the vehicle.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- SHANGHAI XUANYI NEW ENERGY DEV CO LTD
- Filing Date
- 2026-03-09
- Publication Date
- 2026-05-08
AI Technical Summary
Existing technology cannot detect the connection status and sealing of high-voltage connectors in segments, and cannot provide timely alarms or execute safety protection actions, resulting in risks of loose connections and water ingress, thus posing safety hazards.
Displacement sensor and humidity sensor components are introduced into the high-voltage connector to detect the connection status and sealing status, respectively, and are monitored and controlled in real time through the detection module and control module of the battery management system.
It enables accurate detection of the connection status and sealing of high-voltage connectors, improving the reliability and safety of high-voltage circuit connections and ensuring vehicle driving safety.
Smart Images
Figure CN121989697A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electrical engineering, and in particular to a battery system for a vehicle and a control method thereof. Background Technology
[0002] With the rapid development of high-voltage electrical platforms such as new energy vehicles and energy storage systems, the reliability and safety of high-voltage connectors, as key components for power transmission and circuit connection, are of paramount importance. High-voltage connectors typically carry hundreds of volts and hundreds of amperes of current; a connection failure could lead to overheating, arcing, or even safety accidents.
[0003] To ensure high-voltage interlock safety, the industry standard currently employs a high-voltage interlock loop (HVIL) built into the high-voltage connector for status monitoring. This loop typically consists of a pair of independent low-voltage signal terminals arranged in parallel with the high-voltage power terminals. When the connector is fully engaged, the HVIL loop is on; when the connector is not engaged or is loose, the HVIL loop is off. This on / off signal is transmitted to the Battery Management System (BMS) or vehicle controller, which uses this signal to determine whether the connector is physically connected and accordingly decides whether to power on or off the high-voltage main circuit.
[0004] However, the above-mentioned solution that relies solely on the BMS or vehicle controller to detect the continuity of the HVIL circuit has the following drawbacks: First, it cannot detect in sections, that is, it cannot determine whether there is a loose connection in the connector; second, it cannot detect whether there is water inside the connector, that is, it cannot determine the sealing status of the connector; third, because it cannot detect in sections and detect water ingress, it is also impossible to promptly issue fault alarms and execute corresponding safety protection actions when a fault occurs. Summary of the Invention
[0005] In a first aspect, embodiments of this application provide a battery system for a vehicle, comprising:
[0006] A high-voltage connector includes a connector plug and a connector socket. The connector plug is equipped with a displacement sensor assembly and a humidity sensor assembly. When the connector plug and the connector socket are mated, the high-voltage power terminal and the interlock signal terminal can be mated. The displacement sensor assembly is used to determine the electrical signal corresponding to the displacement change caused by mating, and the humidity sensor assembly is used to determine the humidity value inside the high-voltage connector.
[0007] Battery management system, including:
[0008] The detection module includes:
[0009] Interlock detection unit, which is connected to the interlock signal terminal, is used to determine whether the high-voltage connector is properly connected;
[0010] The water ingress detection unit is connected to the humidity sensor assembly and is used to determine the sealing status of the high-voltage connector based on the humidity value determined by the humidity sensor assembly.
[0011] The terminal detection unit is connected to the displacement sensor assembly and is used to determine the connection status of the high-voltage connector based on the electrical signal determined by the displacement sensor assembly. The connection status includes full insertion, loose connection and no connection.
[0012] The control module is used to issue corresponding control commands based on the detection results of the interlock detection unit, the water inlet detection unit, and the terminal detection unit.
[0013] In some embodiments, the control commands include one or more of the following: audible and visual alarm, power reduction, prohibition of high voltage power-on, and disconnection of high voltage relay; and / or, the electrical signals include voltage signals.
[0014] Secondly, embodiments of this application provide a control method for a vehicle battery system as described in the first aspect, comprising:
[0015] Verify that the high-voltage connector is properly connected.
[0016] After confirming that the high-voltage connector is connected normally, determine whether the humidity value is greater than the preset humidity threshold.
[0017] If the humidity value is determined to be no greater than the preset humidity threshold, the connection status of the high-voltage connector is determined, and corresponding control commands are executed based on different connection statuses.
[0018] If the humidity value is greater than the preset humidity threshold, determine whether the vehicle is in a stopped state;
[0019] If the vehicle is not stationary, reduce the power to the preset power value.
[0020] In some embodiments, the control method further includes:
[0021] When it is certain that the vehicle is stationary and no high voltage is applied, high voltage is prohibited; when it is certain that the vehicle is stationary and high voltage is applied, the high voltage relay should be disconnected.
[0022] In some embodiments, when it is determined that the vehicle is stationary and no high voltage is applied, the high voltage application is prohibited; when it is determined that the vehicle is stationary and high voltage is applied, the step of disconnecting the high voltage relay further includes:
[0023] A red audible and visual alarm light indicates the corresponding fault.
[0024] In some embodiments, the steps of determining the connection status of the high-voltage connector and executing corresponding control commands based on different connection statuses when the humidity value is determined to be no greater than a preset humidity threshold include:
[0025] If it is determined that the high-voltage connector is not connected, proceed to determine whether the vehicle is stopped.
[0026] If it is determined that the high-voltage connector is loosely connected, proceed to determine whether the vehicle is stopped.
[0027] If the high-voltage connector is confirmed to be fully engaged, proceed with the steps to determine if the high-voltage connector is properly connected.
[0028] In some embodiments, the step of determining whether the vehicle is in a stopped state when the humidity value is determined to be greater than a preset humidity threshold includes:
[0029] If the humidity value is determined to be greater than the preset humidity threshold, determine whether it continues for more than the preset time.
[0030] If the time exceeds the preset time, determine whether the vehicle is in a stopped state;
[0031] If the duration does not exceed the preset time, the yellow alarm light indicates that the short-term humidity abnormality no longer exists, and the process proceeds to determine the connection status of the high-voltage connector and execute corresponding control commands based on different connection statuses.
[0032] In some embodiments, the interlock detection unit includes a PWM signal source, a voltage divider resistor, a signal transmitting end, and a signal receiving end. The steps for determining whether the high-voltage connector is properly connected include:
[0033] Determine whether the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end;
[0034] If the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end, it is determined that the high-voltage connector is connected normally.
[0035] If the waveform at the signal receiving end of the interlock detection unit is inconsistent with that at the signal transmitting end, it is determined that the high-voltage connector connection is abnormal.
[0036] In some embodiments, when it is determined that the vehicle is not stationary, the step of reducing the power to a preset power value includes:
[0037] Determine the additional impedance caused by different faults, including interlock open circuits, varying degrees of water ingress, and loose or unconnected high-pressure connectors.
[0038] Based on the additional impedance caused by different faults, a preset relationship between different faults and power loss under different currents is determined.
[0039] Based on the preset relationship between different faults and power loss under different currents, the maximum allowable power loss threshold for different faults is determined, thereby determining the maximum allowable current;
[0040] The maximum allowable output power is determined based on the maximum allowable current for different faults and the voltage of the battery system when the corresponding fault occurs, and the preset power value does not exceed the maximum allowable output power.
[0041] In some embodiments, the steps of determining the connection status of the high-voltage connector and executing corresponding control commands based on different connection statuses when the humidity value is determined to be no greater than a preset humidity threshold include:
[0042] Determine the voltage signal corresponding to the displacement change caused by the mating of the connector plug and connector socket;
[0043] The connection status of the high-voltage connector is determined based on the voltage signal.
[0044] Thirdly, embodiments of this application provide a high-voltage connector, comprising:
[0045] Connector plug, the connector plug includes:
[0046] The outer housing includes a receiving cavity, and at least two symmetrically arranged cavity walls are respectively provided with first elastic protrusions;
[0047] The internal component has a first recess on its first outer wall corresponding to the cavity wall with the first elastic protrusion. After the first elastic protrusion and the first recess are engaged, the internal component is fixed inside the outer shell.
[0048] The connector socket and connector plug are inserted into each other in the insertion direction to achieve the mating of high-voltage power terminals and interlocking signal terminals;
[0049] The displacement sensor assembly is mounted on the outer housing of the connector plug and is used to determine the electrical signal corresponding to the displacement change caused by the mating of the connector plug and connector socket. The electrical signal is used to determine the connection status of the high-voltage connector.
[0050] A humidity sensor assembly is located on an internal component of the connector plug and is used to determine the humidity value inside the high-voltage connector. The humidity value is used to determine the sealing condition of the high-voltage connector.
[0051] In some embodiments, each cavity wall of the receiving cavity is provided with two first elastic protrusions; each first outer wall of the internal component is provided with two first recesses.
[0052] In some embodiments, the internal component has a square cross-section perpendicular to the insertion direction, and the internal component has a first extension extending in the radial direction at the four apex corners away from the insertion direction, and the outer housing has a first stop portion adapted to the first extension portion on the cavity wall near the insertion direction.
[0053] In some embodiments, the outer housing includes a first card interface for attaching a displacement sensor assembly; and / or, the internal assembly includes a second card interface disposed at its bottom for attaching a humidity sensor assembly.
[0054] In some embodiments, the displacement sensor assembly includes a second housing and a displacement sensor, the displacement sensor being encapsulated within the second housing, and at least a portion of the contacts of the displacement sensor being located outside the second housing.
[0055] In some embodiments, the second outer wall of the second housing of the displacement sensor assembly is provided with a second groove, and the first inner wall of the first card interface of the outer housing is provided with a first elastic buckle. After the displacement sensor assembly is inserted into the first card interface, the first elastic buckle engages with the second groove, and the displacement sensor assembly is fixed to the outer housing.
[0056] In some embodiments, the second outer wall of the displacement sensor assembly, which does not have a second groove, is provided with a second extension extending in the radial direction on two symmetrically arranged second outer walls, and the first inner wall of the outer housing, which does not have a first elastic buckle, is provided with a second stop portion adapted to the second extension portion.
[0057] In some embodiments, the humidity sensor assembly includes a third housing and a humidity sensor, the humidity sensor being encapsulated within the third housing, and the humidity sensing portion of the displacement sensor being located outside the third housing.
[0058] In some embodiments, the third outer wall of the third housing of the humidity sensor assembly is provided with a third groove on two symmetrically arranged third outer walls, and the second inner wall of the second card interface of the internal component is provided with a second elastic buckle. After the humidity sensor assembly is inserted into the second card interface, the second elastic buckle engages with the third groove, and the humidity sensor assembly is fixed to the internal component.
[0059] In some embodiments, after the front wall of the humidity sensing part of the humidity sensor assembly near the insertion direction abuts against the inner wall of the second card interface near the insertion direction, the movement of the humidity sensor assembly along the insertion direction is stopped. Attached Figure Description
[0060] Figure 1 A schematic diagram of a connector plug provided according to some embodiments of this application is shown;
[0061] Figure 2 A schematic diagram of a connector socket provided according to some embodiments of this application is shown;
[0062] Figure 3 This shows a cross-sectional view of a connector plug and connector socket after mating, according to some embodiments of this application;
[0063] Figure 4 A schematic diagram of an external housing provided according to some embodiments of this application is shown. Figure 1 ;
[0064] Figure 5 A schematic diagram of an external housing provided according to some embodiments of this application is shown. Figure 2 ;
[0065] Figure 6 A schematic diagram illustrating internal components provided according to some embodiments of this application. Figure 1 ;
[0066] Figure 7 A schematic diagram illustrating internal components provided according to some embodiments of this application. Figure 2 ;
[0067] Figure 8 This diagram illustrates the insertion of an outer housing and internal components according to some embodiments of this application.
[0068] Figure 9 Show Figure 8 A magnified view of part A in the image;
[0069] Figure 10 Show Figure 8 A magnified view of part B in the image;
[0070] Figure 11 A schematic diagram of a displacement sensor assembly provided according to some embodiments of this application is shown;
[0071] Figure 12 A schematic diagram of an external housing provided according to some embodiments of this application is shown. Figure 3 ;
[0072] Figure 13 This shows a top cross-sectional view of a displacement sensor assembly and its outer housing after installation according to some embodiments of this application;
[0073] Figure 14 Show Figure 13 A magnified view of part C;
[0074] Figure 15This shows a side sectional view of the displacement sensor assembly after it has been installed with the outer housing;
[0075] Figure 16 Show Figure 15 A magnified view of part D;
[0076] Figure 17 A schematic diagram of a humidity sensor assembly provided according to some embodiments of this application is shown;
[0077] Figure 18 A schematic diagram illustrating internal components provided according to some embodiments of this application. Figure 3 ;
[0078] Figure 19 A cross-sectional view of a second card interface of an internal component provided according to some embodiments of this application is shown;
[0079] Figure 20 A side sectional view of the humidity sensor assembly and its internal components after installation is shown.
[0080] Figure 21 Show Figure 20 A magnified view of part E in the image;
[0081] Figure 22 This shows a top cross-sectional view of a humidity sensor assembly and its internal components after installation, according to some embodiments of this application;
[0082] Figure 23 Show Figure 22 A magnified view of part of F;
[0083] Figure 24 The flowchart illustrates a control method for a vehicle battery system according to some embodiments of this application. Figure 1 ;
[0084] Figure 25 The flowchart illustrates a control method for a vehicle battery system according to some embodiments of this application. Figure 2 . Detailed Implementation
[0085] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention will be presented in conjunction with preferred embodiments, this does not mean that the features of the invention are limited to this embodiment. On the contrary, the purpose of describing the invention in conjunction with embodiments is to cover other options or modifications that may be derived based on the claims of the present invention. To provide a deep understanding of the present invention, many specific details will be included in the following description. The present invention may also be implemented without using these details. Furthermore, to avoid confusion or obscuring the focus of the present invention, some specific details will be omitted in the description. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present invention can be combined with each other.
[0086] It should be noted that in this specification, similar reference numerals and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0087] The terms “first”, “second”, etc., are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.
[0088] In the description of this embodiment, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set up," "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; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this embodiment based on the specific circumstances.
[0089] To make the objectives, technical solutions, and advantages of the present invention clearer, the embodiments of the present invention will be described in further detail below with reference to the accompanying drawings.
[0090] Firstly, reference Figures 1 to 3 This application provides a vehicle battery system, including a high-voltage connector and a battery management system (not shown in the figure). The high-voltage connector includes a connector plug 1 and a connector socket 2. The connector plug 1 is provided with a displacement sensor assembly 5 and a humidity sensor assembly 6. After the connector plug 1 and the connector socket 2 are mated, the high-voltage power terminal 3 and the interlock signal terminal 4 can be connected. The displacement sensor assembly 5 is used to determine the electrical signal corresponding to the displacement change caused by mating, and the humidity sensor assembly 6 is used to determine the humidity value within the high-voltage connector. The specific structure of the high-voltage connector will be described in detail in the third aspect below.
[0091] The battery management system includes a detection module and a control module. The detection module includes an interlock detection unit, a water ingress detection unit, and a terminal detection unit. The interlock detection unit is connected to interlock signal terminal 4 to determine whether the high-voltage connector is properly connected. The water ingress detection unit is connected to humidity sensor assembly 6 to determine the sealing status of the high-voltage connector based on the humidity value determined by humidity sensor assembly 6. The terminal detection unit is connected to displacement sensor assembly 5 to determine the connection status of the high-voltage connector based on the electrical signal (e.g., voltage signal) determined by displacement sensor assembly 5. Connection status includes fully inserted, loosely connected, and not connected. The control module issues corresponding control commands based on the detection results from the interlock detection unit, water ingress detection unit, and terminal detection unit.
[0092] According to the battery system of the vehicle of this application, by additionally providing a displacement sensor assembly 5 and a humidity sensor assembly 6, the connection status (e.g., fully plugged, loosely plugged, not connected) and sealing status of the high-voltage connector can be determined respectively. Thus, the control module can issue corresponding control commands based on the detection results of the interlock detection unit, the water ingress detection unit, and the terminal detection unit, improving the reliability and safety of the high-voltage circuit connection. The second aspect below will specifically describe how the control module issues corresponding control commands based on the detection results of the above three detection units.
[0093] In some embodiments, the control commands include one or more of the following: audible and visual alarm, power reduction, prohibition of high voltage power-on, and disconnection of high voltage relay.
[0094] Secondly, this application provides a control method for a vehicle battery system as described in the first aspect. Figure 24 The flowchart illustrates a control method for a vehicle battery system according to some embodiments of this application. Figure 1 . refer to Figure 24 The control method includes the following steps:
[0095] Step S1: Determine if the high-voltage connector is properly connected;
[0096] If the high-voltage connector is confirmed to be connected normally, proceed to step S2 to determine whether the humidity value is greater than the preset humidity threshold.
[0097] If the humidity value is determined to be no greater than the preset humidity threshold, step S3 is executed to determine the connection status of the high-voltage connector and execute corresponding control commands based on different connection statuses.
[0098] If the humidity value is determined to be greater than the preset humidity threshold, step S4 is executed to determine whether the vehicle is in a stopped state.
[0099] If it is determined that the vehicle is not stationary, step S5 is executed to reduce the power to a preset power value.
[0100] According to the control method of the vehicle battery system of this application, when the humidity value in the high-voltage connector is determined to be greater than the preset humidity threshold (i.e., water enters the high-voltage connector) and the vehicle is not in a stopped state (i.e., still in motion), a control strategy of reducing power (i.e., reducing vehicle speed) is adopted instead of immediately cutting off the high voltage, thus ensuring driving safety; and can execute corresponding control commands based on different connection states (e.g., fully connected, loosely connected, not connected), thereby improving the reliability and safety of the high-voltage circuit connection.
[0101] The following sections will provide a detailed description of the steps described above.
[0102] Step S1: Determine if the high-voltage connector is properly connected.
[0103] In some embodiments, the interlock detection unit is connected to the interlock signal terminal 4 to determine whether the high-voltage connector is properly connected. The interlock detection unit includes a PWM signal source, a voltage divider resistor, a signal transmitter, and a signal receiver. The PWM signal source generates a PWM signal, and the signal transmitter sends the generated PWM signal to the high-voltage connector and transmits it back to the signal receiver via a high-voltage circuit. The interlock detection unit determines whether the high-voltage connector is properly connected based on whether the waveform at the signal receiver matches that at the signal transmitter. If the waveform at the signal receiver matches that at the signal transmitter, the high-voltage connector is properly connected. If the waveform at the signal receiver does not match that at the signal transmitter, the high-voltage connector is improperly connected.
[0104] In some embodiments, step S1, before determining whether the high-voltage connector is properly connected, may further include the following steps:
[0105] The battery management system is powered on;
[0106] Initialize self-test.
[0107] In other words, after the battery management system is powered on, it performs an initial self-test. If the self-test is normal, step S1 is executed to determine whether the high-voltage connector is properly connected.
[0108] If the high-voltage connector is confirmed to be connected normally, proceed to step S2 to determine whether the humidity value is greater than the preset humidity threshold.
[0109] In some embodiments, the water ingress detection unit is connected to the humidity sensor assembly 6 and is used to determine the sealing state of the high-voltage connector based on the humidity value determined by the humidity sensor assembly 6. For example, the preset humidity threshold can be 85%RH, but this is not specifically limited. Those skilled in the art can dynamically adjust the preset humidity threshold based on actual conditions (e.g., ambient temperature and humidity), for example, reducing the humidity threshold by 5% in high-temperature (above 45°C) environments (i.e., it can be 80%RH). Different humidity values, such as 85%RH, 90%RH, and 95%RH, can correspond to different water ingress conditions (i.e., sealing states).
[0110] If the humidity value is determined to be no greater than the preset humidity threshold, step S3 is executed to determine the connection status of the high-voltage connector and execute corresponding control commands based on different connection statuses.
[0111] In some embodiments, the terminal detection unit is connected to the displacement sensor assembly 5 and is used to determine the connection state of the high-voltage connector based on the electrical signal (e.g., voltage signal) determined by the displacement sensor assembly 5. The connection state includes full insertion, partial connection, and no connection. For example, when the voltage value is 0 V, the high-voltage connector is determined to be in a non-connected state; when the voltage value is 2.5 V, the high-voltage connector is determined to be in a partial connection state; and when the voltage value is 5 V, the high-voltage connector is determined to be in a fully inserted state.
[0112] If the humidity value is determined to be greater than the preset humidity threshold, step S4 is executed to determine whether the vehicle is in a stopped state.
[0113] In other words, when the humidity value is determined to be greater than the preset humidity threshold (i.e., water enters the high-voltage connector), by determining whether the vehicle is in a stopped state (i.e., whether it is stopped or in motion), different safety control commands can be executed based on the different conditions of the vehicle (such as reducing power, prohibiting high-voltage power supply, and disconnecting the high-voltage relay), thereby improving safety.
[0114] If it is determined that the vehicle is not stationary, step S5 is executed to reduce the power to a preset power value.
[0115] In some embodiments, the preset power value can be determined through the following specific steps:
[0116] Determine the additional impedance ΔR caused by different faults, including interlock open circuit, different degrees of water ingress (e.g., 85%RH, 90%RH, 95%RH), and loose or unconnected high-voltage connectors.
[0117] Based on the additional impedance caused by different faults, a preset relationship between different faults and power loss P_loss under different currents is determined.
[0118] Based on the preset relationship between different faults and power loss under different currents, the maximum allowable power loss threshold P_loss_max for different faults is determined, thereby determining the maximum allowable current I_max_allowed, i.e., I_max_allowed=sqrt(P_loss_max / △R).
[0119] Based on the maximum allowable current I_max_allowed for different faults and the voltage value U of the battery system when the corresponding fault occurs, the maximum allowable output power P_available is determined, and the preset power value does not exceed the maximum allowable output power.
[0120] In some embodiments, the control method further includes the following steps:
[0121] Step S6: If it is determined that the vehicle is stationary and no high voltage is applied, prohibit the application of high voltage; if it is determined that the vehicle is stationary and high voltage is applied, disconnect the high voltage relay. In some embodiments, this step may further include: a red audible and visual alarm light indicating the corresponding fault (e.g., loose connection or no connection, water ingress).
[0122] In some embodiments, the control method further includes the following steps:
[0123] If it is determined that the high-voltage connector is not properly connected, proceed to step S4 to determine whether the vehicle is in a stopped state.
[0124] In some embodiments, step S3, determining the connection status of the high-voltage connector and executing corresponding control commands based on different connection statuses, specifically includes the following steps:
[0125] If it is determined that the high-voltage connector is not connected, proceed to step S4 to determine whether the vehicle is in a stopped state.
[0126] If it is determined that the high-voltage connector is loosely connected, proceed to step S4 to determine whether the vehicle is in a stopped state.
[0127] If the high-voltage connector is confirmed to be fully plugged in, proceed to step S1 to determine whether the high-voltage connector is properly connected.
[0128] In some embodiments, if the humidity value is determined to be greater than a preset humidity threshold, step S4 is executed to determine whether the vehicle is in a stopped state, specifically including the following steps:
[0129] If the humidity value is determined to be greater than the preset humidity threshold, determine whether this situation (i.e., the humidity value being greater than the preset humidity threshold) continues for more than the preset time.
[0130] If the time exceeds the preset time, determine whether the vehicle is in a stopped state;
[0131] If the duration does not exceed the preset time, the yellow alarm light indicates that the short-term humidity abnormality no longer exists, and step S3 is executed to determine the connection status of the high-voltage connector and execute the corresponding control command based on the different connection statuses.
[0132] In other words, if the humidity value is greater than the preset humidity threshold (e.g., 85%RH), water ingress is detected. By determining whether this situation lasts for more than a preset time, fluctuations in the humidity value inside the high-voltage connector caused by external factors such as environmental factors can be ruled out, thus improving the accuracy of water ingress detection.
[0133] In some embodiments, the control method further includes: if it is determined that the high-voltage connector connection is abnormal, performing step S4 to determine whether the vehicle is in a stopped state.
[0134] Figure 25 The flowchart illustrates a control method for a vehicle battery system according to some embodiments of this application. Figure 2 . refer to Figure 25 The control method includes the following steps:
[0135] Step S11: Determine whether the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end;
[0136] If the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end, step S12 is executed to determine whether the humidity value is greater than the preset humidity threshold.
[0137] If the humidity value is determined to be greater than the preset humidity threshold, step S13 is executed to determine whether it continues for more than the preset time.
[0138] If it is determined that the time exceeds the preset time, step S16 is executed to determine whether the vehicle is in a stopped state.
[0139] If it is determined that the vehicle is not stopped, step S19 is executed to reduce the power to a preset ratio;
[0140] If the vehicle is confirmed to be stationary, proceed to step S17: if no high voltage is applied, prohibit high voltage application; if high voltage is applied, disconnect the high voltage relay. Then proceed to step S18, where a red audible and visual alarm light indicates the corresponding fault.
[0141] If the humidity value is determined to be no greater than the preset humidity threshold, step S14 is executed to determine whether the connection status of the high-voltage connector is not connected, loosely connected, or fully plugged in based on the voltage value output by the terminal detection unit.
[0142] If it is determined that the high-voltage connector is not connected, proceed to step S16 to determine whether the vehicle is in a stopped state.
[0143] If it is determined that the connection status of the high-voltage connector is loose, proceed to step S16 to determine whether the vehicle is in a stopped state.
[0144] If it is determined that the high-voltage connector is fully plugged in, proceed to step S11 to determine whether the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end.
[0145] If the duration does not exceed the preset time, step S15 is executed, the yellow alarm light indicates that the short-term humidity abnormality no longer exists, and step S14 is executed to determine the connection status of the high-voltage connector as unconnected, loosely connected, or fully plugged in based on the voltage value output by the terminal detection unit.
[0146] According to the control method of the vehicle battery system provided in this application, the accuracy of the high-voltage connector connection status detection is ensured by dual detection of the interlock detection unit and the terminal detection unit; and different safety control commands (such as reducing power, prohibiting high voltage power-on, and disconnecting high voltage relay) can be executed based on different vehicle conditions, thereby improving the safety and reliability of the vehicle.
[0147] Please refer to the preceding description for a detailed explanation of each step; it will not be repeated here.
[0148] In other embodiments, the control method may not include step S11, which determines whether the waveform of the signal receiving end of the interlock detection unit is consistent with that of the signal transmitting end, and the connection status of the high-voltage connector is detected only by the terminal detection unit; or, the control method may not include step S14, which determines whether the connection status of the high-voltage connector is not connected, loosely connected or fully plugged in based on the voltage value output by the terminal detection unit, and the connection status of the high-voltage connector is detected only by the interlock detection unit.
[0149] The following is for reference Figures 1 to 23 A detailed introduction to high-voltage connectors.
[0150] Thirdly, refer to Figures 1 to 3 This application provides a high-voltage connector, including: a connector plug 1, a connector socket 2, a displacement sensor assembly 5, and a humidity sensor assembly 6. Combined with... Figures 4 to 10The connector plug 1 includes an outer housing 11 and an internal component 12. Exemplarily, both can be made of high-performance engineering plastics (e.g., PA6 GF30). The outer housing 11 includes a receiving cavity 13, and at least two symmetrically arranged cavity walls 131 are respectively provided with first elastic protrusions 1311. The internal component 12 has first recesses 121 on its first outer wall 121 corresponding to the cavity walls 131 of the receiving cavity 13 with the first elastic protrusions 1311. After the first elastic protrusions 1311 and the first recesses 1211 engage, the internal component 12 is fixed inside the outer housing 11. After the connector plug 1 and the connector socket 2 are inserted along the insertion direction X, the high-voltage power terminal 3 and the interlocking signal terminal 4 are engaged.
[0151] In other words, during the insertion of the internal component 12 into the outer housing 11 along the insertion direction X, the first elastic protrusion 1311 provided on the outer housing 11 is pushed up and undergoes elastic deformation. When the internal component 12 continues to be inserted until the first elastic protrusion 1311 and the first recess 1211 engage, the internal component 12 and the outer housing 11 are fixed, preventing the internal component 12 from coming out in the opposite direction of the insertion direction X. After the connector plug 1 and the connector socket 2 are inserted into each other along the insertion direction X, a portion of the high-voltage power terminal 3 provided on the connector plug 1 and another portion of the high-voltage power terminal 3 provided on the connector socket 2 are engaged, as are a portion of the interlock signal terminal 4 provided on the connector plug 1 and another portion of the interlock signal terminal 4 provided on the connector socket 2.
[0152] The displacement sensor assembly 5 is disposed on the outer housing 11 of the connector plug 1 and is used to determine the electrical signal corresponding to the displacement change caused by the mating of the connector plug 1 and the connector socket 2. The electrical signal is used to determine the connection status of the high-voltage connector. The humidity sensor assembly 6 is disposed on the inner component 12 of the connector plug 1 and is used to determine the humidity value inside the high-voltage connector. The humidity value is used to determine the sealing status of the high-voltage connector.
[0153] According to the high-voltage connector of this application, the connector plug 1 is snapped into the inner component 12 by the outer housing 11, which facilitates assembly, disassembly and replacement. It is also equipped with a displacement sensor component 5 and a humidity sensor component 6, which can determine the connection status (e.g., fully inserted, loosely connected, not connected) and sealing status of the high-voltage connector respectively.
[0154] In some embodiments, such as Figure 4 As shown, the cross-section of the receiving cavity 13 of the outer shell 11 is square, meaning the receiving cavity 13 includes four cavity walls 131, each cavity wall 131 having two first elastic protrusions 1311. Correspondingly, as... Figure 7As shown, the internal component 12 includes four first outer walls 121, and each first outer wall 121 has two first recesses 1211. This arrangement allows the internal component 12 to be securely engaged within the outer housing 11.
[0155] In some embodiments, such as Figure 6 As shown, the internal component 12 has a square cross-section perpendicular to the insertion direction X, and the internal component 12 has a first extension 1212 extending radially at its four apex corners away from the insertion direction X. Figure 5 As shown, the outer housing 11 has a first stop portion 1312 on the cavity wall 131 near the insertion direction X, which is adapted to the first extension portion 1212. After the first extension portion 1212 abuts against the first stop portion 1312, the internal component 12 moves along the insertion direction X, thereby preventing over-insertion of the internal component 12.
[0156] In some embodiments, reference Figures 11 to 16 The outer casing 11 includes a first card interface 14 (e.g., Figure 12 As shown, the first card interface 14 is used to snap onto the displacement sensor assembly 5. The displacement sensor assembly 5 includes a second housing 51 and a displacement sensor, which is encapsulated within the second housing 51 for easy installation. Exemplarily, the displacement sensor can be encapsulated within the second housing 51 using PC plastic and resin. At least a portion of the contacts 521 of the displacement sensor are located outside the second housing 51. The displacement sensor assembly 5 also includes a first wiring harness 53, at least a portion of which is located outside the second housing 51. Exemplarily, when the connector plug 1 and connector socket 2 are mated, the contacts 521 of the displacement sensor can be displaced, causing a change in resistance and consequently a change in voltage. For example, when the voltage is 0 V, the high-voltage connector is not connected; when the voltage is 2.5 V, the high-voltage connector is partially connected; and when the voltage is 5 V, the high-voltage connector is fully connected.
[0157] In some embodiments, the second outer walls 511 of the second housing 51 of the displacement sensor assembly 5 are provided with second grooves 5111. The first inner wall 141 of the first card interface 14 of the outer housing 11 is correspondingly provided with a first elastic buckle 1411 (e.g., ...). Figure 14(As shown). After the displacement sensor assembly 5 is inserted into the first card interface 14, the first elastic buckle 1411 engages with the second groove 5111, thus fixing the displacement sensor assembly 5 to the outer housing 11. In other words, during the insertion of the displacement sensor assembly 5 into the first card interface 14 of the outer housing 11, the first elastic buckle 1411 is pushed up and undergoes elastic deformation. When the displacement sensor assembly 5 continues to be inserted until the first elastic buckle 1411 engages with the second groove 5111, the displacement sensor assembly 5 is fixed to the outer housing 11, preventing the displacement sensor assembly 5 from coming out in the opposite direction of the insertion direction X.
[0158] In some embodiments, the second outer wall 51 of the displacement sensor assembly 5, which does not have a second groove 5111, has a second extension portion 5112 extending in the radial direction on two symmetrically arranged second outer walls 511 (e.g., ...). Figure 11 (As shown). The first card interface 14 of the outer housing 11 does not have a first elastic buckle 1411. The two symmetrically arranged first inner walls are provided with second stop portions 1412 that are adapted to the second extension portion 5112 (as shown). Figure 16 (As shown). In other words, when the displacement sensor assembly 5 is inserted into the second extension 5112 and abuts against the second stop 1412, the movement of the displacement sensor assembly 5 along the insertion direction X is stopped to prevent over-insertion of the displacement sensor assembly 5.
[0159] refer to Figures 17 to 23 In some embodiments, the internal component 12 includes a second card interface 15 disposed at its bottom (e.g., Figure 18 and Figure 19 As shown), the second card interface 15 is used to attach the humidity sensor assembly 6. By placing the humidity sensor assembly 6 within the internal assembly 12, the sealing status of the high-voltage connector can be detected more promptly. Figure 17 As shown, the humidity sensor assembly 6 includes a third housing 61 and a humidity sensor, which is encapsulated within the third housing 61 for easy mounting. Exemplarily, the humidity sensor can be encapsulated within the third housing 61 using PC plastic and resin. The humidity sensing portion 621 of the displacement sensor is located outside the third housing 61. The humidity sensor assembly 6 also includes a second wiring harness 63, at least a portion of which is located outside the third housing 61.
[0160] In some embodiments, combined with Figure 1 and Figure 3 As shown, a sealing ring 7 (e.g., a rubber sealing ring) is nested on the cavity wall 131 of the outer housing 11 of the connector plug 1. The humidity sensor can detect the humidity change caused by water entering the high-voltage connector due to the failure of the sealing ring, which in turn causes the resistance value of the humidity sensor to change.
[0161] In some embodiments, the third outer wall 611 of the third housing 61 of the humidity sensor assembly 6 is provided with a third groove 6111 (e.g., Figure 17 (As shown). A second elastic buckle 1511 is correspondingly provided on the second inner wall 151 of the second card interface 15 of the internal component 12 (as shown). Figure 21 (As shown). After the humidity sensor assembly 6 is inserted into the second card interface 15, the second elastic buckle 1511 engages with the third groove 6111, thus fixing the humidity sensor assembly 6 to the internal assembly 12. In other words, during the process of inserting the humidity sensor assembly 6 into the second card interface 15 of the internal assembly 12, the second elastic buckle 1511 is pushed up and undergoes elastic deformation. When the humidity sensor assembly 6 continues to be inserted until the second elastic buckle 1511 engages with the third groove 6111, the humidity sensor assembly 6 is fixed to the internal assembly 12, preventing the humidity sensor assembly 6 from coming out in the opposite direction of the insertion direction X.
[0162] In some embodiments, combined with Figure 22 and Figure 23 As shown, after the front wall 6211 of the humidity sensing part 621 of the humidity sensor assembly 6 near the insertion direction X abuts against the inner wall of the second card interface 15 near the insertion direction X, it stops the movement of the humidity sensor assembly 6 along the insertion direction X, thereby preventing the humidity sensor assembly 6 from being over-inserted.
[0163] While the present invention has been illustrated and described with reference to certain preferred embodiments, those skilled in the art should understand that the above description is a further detailed explanation of the invention in conjunction with specific embodiments, and should not be construed as limiting the specific implementation of the invention to these descriptions. Various changes in form and detail can be made by those skilled in the art, including several simple deductions or substitutions, without departing from the spirit and scope of the invention.
Claims
1. A battery system for a vehicle, characterized in that, include: A high-voltage connector includes a connector plug and a connector socket. The connector plug is provided with a displacement sensor assembly and a humidity sensor assembly. When the connector plug and the connector socket are mated, the high-voltage power terminal and the interlocking signal terminal can be mated. The displacement sensor assembly is used to determine the electrical signal corresponding to the displacement change caused by the mating. The humidity sensor assembly is used to determine the humidity value inside the high-voltage connector. Battery management system, including: The detection module includes: An interlock detection unit is connected to the interlock signal terminal and is used to determine whether the high-voltage connector is properly connected. A water inlet detection unit is connected to the humidity sensor assembly and is used to determine the sealing status of the high-voltage connector based on the humidity value determined by the humidity sensor assembly. A terminal detection unit, connected to the displacement sensor assembly, is used to determine the connection status of the high-voltage connector based on the electrical signal determined by the displacement sensor assembly. The connection status includes full insertion, loose connection, and no connection. The control module is used to issue corresponding control commands based on the detection results of the interlock detection unit, the water inlet detection unit, and the terminal detection unit.
2. The battery system of the vehicle as claimed in claim 1, characterized in that, The control commands include one or more of the following: audible and visual alarm, power reduction, prohibition of high-voltage power supply, and disconnection of high-voltage relay; and / or, the electrical signals include voltage signals.
3. A control method for a vehicle battery system as described in claim 1 or 2, characterized in that, include: Determine whether the high-voltage connector is properly connected; If the high-voltage connector is confirmed to be connected normally, determine whether the humidity value is greater than a preset humidity threshold. If the humidity value is determined to be no greater than a preset humidity threshold, the connection status of the high-voltage connector is determined, and corresponding control commands are executed based on different connection statuses. If the humidity value is greater than a preset humidity threshold, determine whether the vehicle is in a stopped state; If it is determined that the vehicle is not in the stopped state, the power is reduced to a preset power value.
4. The control method for the vehicle's battery system as described in claim 3, characterized in that, Also includes: When it is determined that the vehicle is in the stopped state and is not powered by high voltage, high voltage power is prohibited; when it is determined that the vehicle is in the stopped state and is powered by high voltage, the high voltage relay is disconnected.
5. The control method for the vehicle's battery system as described in claim 4, characterized in that, The steps of prohibiting high-voltage power supply when it is determined that the vehicle is in the stopped state and no high-voltage power is applied, and disconnecting the high-voltage relay when it is determined that the vehicle is in the stopped state and high-voltage power is applied, further include: A red audible and visual alarm light indicates the corresponding fault.
6. The control method for the vehicle's battery system as described in claim 3, characterized in that, The step of determining the connection status of the high-voltage connector when the humidity value is determined to be no greater than a preset humidity threshold, and executing corresponding control commands based on different connection statuses, includes: If it is determined that the high-voltage connector is not connected, then the step of determining whether the vehicle is in a stopped state is performed. If it is determined that the connection status of the high-voltage connector is loose, then the step of determining whether the vehicle is in a stopped state is performed. If it is determined that the high-voltage connector is fully plugged in, then the step of determining whether the high-voltage connector is properly connected is performed.
7. The control method for the vehicle's battery system as described in claim 3, characterized in that, The step of determining whether the vehicle is in a stopped state when the humidity value is greater than a preset humidity threshold includes: If the humidity value is determined to be greater than a preset humidity threshold, it is determined whether the condition continues for a preset time. If the time exceeds the preset time, determine whether the vehicle is in a stopped state; If the duration does not exceed the preset time, the yellow alarm light indicates that the short-term humidity abnormality no longer exists, and the steps of determining the connection status of the high-voltage connector and executing corresponding control commands based on different connection statuses are performed.
8. The control method for the vehicle's battery system as described in claim 3, characterized in that, The interlock detection unit includes a PWM signal source, a voltage divider resistor, a signal transmitting end, and a signal receiving end. The step of determining whether the high-voltage connector is properly connected includes: Determine whether the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end; If the waveform at the signal receiving end of the interlock detection unit is consistent with that at the signal transmitting end, it is determined that the high-voltage connector is connected normally. If the waveform at the signal receiving end of the interlock detection unit is inconsistent with that at the signal transmitting end, it is determined that the high-voltage connector is not properly connected.
9. The control method for the vehicle's battery system as described in claim 3, characterized in that, The step of reducing the power to a preset power value when it is determined that the vehicle is not in the stopped state includes: Determine the additional impedance caused by different faults, including interlock open circuit, varying degrees of water ingress, and the high-voltage connector being loose or not connected. Based on the additional impedance caused by different faults, a preset relationship between different faults and power loss under different currents is determined; Based on the preset relationship between different faults and power loss under different currents, the maximum allowable power loss threshold for different faults is determined, thereby determining the maximum allowable current; The maximum allowable output power is determined based on the maximum allowable current for different faults and the voltage value of the battery system when the corresponding fault occurs, and the preset power value does not exceed the maximum allowable output power.
10. The control method for the battery system of a vehicle as described in claim 3, characterized in that, The step of determining the connection status of the high-voltage connector when the humidity value is determined to be no greater than a preset humidity threshold, and executing corresponding control commands based on different connection statuses, includes: Determine the voltage signal corresponding to the displacement change caused by the mating of the connector plug and the connector socket; Based on the voltage signal, the connection status of the high-voltage connector is determined.