Cross-validation and retest fault diagnosis method and system for military vehicle-mounted integrated power supply system
By employing cross-validation and retesting fault diagnosis methods, combined with multi-timescale retesting and dynamic reconfiguration, the problem of misjudgment in military vehicle-mounted power supply systems under complex environments was solved, achieving accurate fault location and reliable power supply, and reducing the false alarm rate.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHANGZHOU WUJIN HGPOWER
- Filing Date
- 2026-04-21
- Publication Date
- 2026-07-10
AI Technical Summary
Existing military vehicle-mounted integrated power supply systems are prone to misjudging faults in complex battlefield environments and are difficult to accurately identify fault sources without interrupting power, resulting in a high false alarm rate and impacting combat missions.
The cross-validation and retesting fault diagnosis method is adopted. Through real-time detection, retesting, cross-comparison and dynamic reconstruction, combined with retesting at multiple time scales, the fault can be accurately located and the false alarm rate can be reduced.
It significantly reduces false alarm rate and improves fault location accuracy without power interruption, ensuring the continuity and reliability of power supply to critical loads.
Smart Images
Figure CN122063496B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of vehicle power system fault diagnosis technology, and more specifically, to a cross-validation and retesting fault diagnosis method, system, and vehicle for a military vehicle-mounted integrated power system. Background Technology
[0002] Modern military and high-reliability special vehicles typically employ modular integrated power systems to provide independent and stable power supplies for different mission loads such as radar, communication, fire control, and navigation. Each power module generally contains parameter detection circuits to monitor key operating parameters such as output voltage, output current, and module temperature in real time, ensuring the reliable operation of the power system.
[0003] In existing technologies, most power modules rely on a simple threshold comparison method for fault diagnosis. This means that if any detected parameter exceeds a preset normal range, the module is immediately identified as faulty and reported to the vehicle control system. However, in the complex operational environment of a real battlefield, factors such as sudden load changes, strong electromagnetic interference, or fluctuations in grid bus voltage can cause transient, non-continuous anomalies in module parameters. This single-point, single-detection-based judgment method is highly susceptible to generating numerous false alarms, increasing the burden of battlefield maintenance and impacting the execution of combat missions.
[0004] Furthermore, when upstream power sources such as vehicle-mounted generators or battery packs fail, multiple power modules within the same power supply area often exhibit abnormal parameters simultaneously. Existing single-module self-diagnostic technologies struggle to effectively distinguish between module-specific faults and upstream systemic power supply anomalies. To address this issue, some solutions employ power-off testing, which involves disconnecting modules sequentially to pinpoint the fault source. However, this is impractical in operational or mission-critical scenarios where uninterrupted power supply is paramount, as power-off testing could lead to critical load failures and severe consequences.
[0005] Therefore, there is an urgent need for a fault diagnosis solution for military power modules that can accurately confirm the authenticity of a fault and precisely locate the source of the fault under uninterrupted power conditions. Summary of the Invention
[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a cross-validation and retesting fault diagnosis method, system and vehicle for a military vehicle-mounted integrated power supply system, so as to effectively reduce the false alarm rate and improve the accuracy of fault location without interrupting power supply, and meet the high reliability requirements of military vehicles for power supply systems.
[0007] To achieve the above objectives, this invention provides a cross-validation and retesting fault diagnosis method for a military vehicle-mounted integrated power supply system, applicable to a military vehicle power supply system comprising multiple power modules, characterized by comprising the following steps:
[0008] The target power module monitors its own operating parameters in real time, and generates an abnormal signal when the detected parameters exceed a preset threshold.
[0009] After the abnormal signal is generated, the detection parameters are retested after a preset time interval. If the retest result still exceeds the preset threshold, the cross-validation step is triggered.
[0010] The corresponding operating parameters of at least one adjacent power module located in the same area as the target power module are obtained through the vehicle communication bus. The same area refers to a power supply area composed of multiple power modules powered by the same upstream bus.
[0011] The detection parameters of the target power module are compared with the corresponding operating parameters of the adjacent power modules;
[0012] When the target power module is abnormal and the adjacent power module is normal, it is determined that the target power module itself is faulty.
[0013] When the corresponding operating parameters of multiple power modules in the same area are abnormal within a preset time period, it is determined to be an upstream power supply abnormality or a systemic power supply abnormality.
[0014] Furthermore, the operating parameters include at least one of output voltage, output current, and module temperature.
[0015] Furthermore, the preset time interval is between 10 milliseconds and 500 milliseconds.
[0016] Furthermore, the vehicle communication bus is a CAN bus.
[0017] Furthermore, the retesting includes multi-timescale retesting, with continuous testing performed at at least two time points within 10 milliseconds, 200 milliseconds, and 2 seconds, and anomaly pattern pre-classification based on the changing trends of the test values:
[0018] If the test values quickly return to the normal range after multiple tests, it is determined to be a transient interference, and only the log is recorded without reporting a fault.
[0019] If the test value shows a slow downward trend, it is judged as performance degradation, and an early warning message is reported;
[0020] If the test value drops sharply and shows no signs of recovery, it is considered a suspected hardware failure, triggering the cross-validation step.
[0021] Furthermore, after completing the determination step, a dynamic reconfiguration step is also included, which executes corresponding processing measures according to different fault types:
[0022] When the target power module itself is determined to be faulty, and a decrease in voltage and an increase in current are detected in the module, it is further identified as a load short circuit fault, and current limiting protection is automatically activated.
[0023] When the target power module is determined to be faulty and the parameters are detected to be slowly decreasing during the test, it is further identified as module performance degradation, and the module output power is automatically reduced to enter derating operation mode.
[0024] When the target power module itself is determined to be faulty, and further testing does not improve the situation, and cross-verification shows that only this module is abnormal, it is further identified as an internal hardware fault of the module, and the load is automatically switched to a backup module in the same area.
[0025] When an upstream power supply anomaly is detected, the load will be automatically switched to the backup bus.
[0026] The load switching, current limiting protection, and derating operation steps are all completed without power interruption, and the switching process is completed within 5 milliseconds.
[0027] A cross-validation and retesting fault diagnosis system for a military vehicle-mounted integrated power supply system includes multiple power modules and a communication bus connecting the multiple power modules, wherein each power module includes:
[0028] The parameter acquisition unit is used to collect the operating parameters of this module in real time.
[0029] An anomaly detection unit, connected to the parameter acquisition unit, is used to determine whether the operating parameters exceed a preset threshold, and to generate an anomaly trigger signal when they do.
[0030] The retest control unit is connected to the anomaly detection unit and is used to control the parameter acquisition unit to re-acquire parameters after a preset delay in response to the anomaly trigger signal, so as to obtain retest parameters.
[0031] A cross-validation unit, connected to the retest control unit, is used to request corresponding operating parameters from other power modules in the same area via the communication bus when the retest parameters still exceed a preset threshold. The same area refers to a power supply area composed of multiple power modules powered by the same upstream bus.
[0032] The fault determination unit, connected to the cross-validation unit, is used to perform a horizontal comparison between the abnormal parameters of this module and the operating parameters of other modules received, and output the final fault type based on the comparison results.
[0033] Furthermore, the fault types include local faults of this module and systemic faults of the upstream power supply system.
[0034] Compared with the prior art, the present invention has the following beneficial effects:
[0035] The retesting mechanism effectively eliminates transient interference and significantly reduces the false alarm rate;
[0036] Accurate fault location is achieved without power interruption through a regional-level cross-validation mechanism;
[0037] Performance degradation trend identification and predictive maintenance are achieved through multi-timescale retesting;
[0038] The system achieves self-recovery after a fault through a dynamic reconfiguration mechanism, ensuring continuous power supply to critical loads. Attached Figure Description
[0039] Figure 1 This is a flowchart illustrating the cross-validation and retesting fault diagnosis method for a military vehicle-mounted integrated power supply system provided in an embodiment of the present invention.
[0040] Figure 2 This is a structural block diagram of a cross-validation and retesting fault diagnosis system for a military vehicle-mounted integrated power supply system provided in an embodiment of the present invention. Detailed Implementation
[0041] To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.
[0042] Example 1: Basic Method Example
[0043] This embodiment provides a cross-validation and retesting fault diagnosis method for a military vehicle-mounted integrated power system, applied to the integrated power system of a military armored vehicle. The system comprises multiple power modules, divided into multiple logical regions according to the areas they supply power to different loads such as radar, communication, and fire control. The same region refers to a group of power modules powered by the same upstream bus.
[0044] Reference Figure 1 The method includes the following steps:
[0045] The first step is real-time detection and anomaly triggering. Module A, which powers the radar, monitors its output voltage, output current, and module temperature in real time through its internal parameter acquisition unit. When the output voltage drops below the preset undervoltage threshold of 24V, the anomaly detection unit of module A generates an undervoltage anomaly signal.
[0046] The second step is to check if the parameters exceed a preset threshold. The anomaly detection unit compares the real-time detected parameters with the preset threshold. If the parameters do not exceed the threshold, it returns to continue monitoring; if the parameters exceed the threshold, it proceeds to the next step.
[0047] The third step is to generate an abnormal signal. After confirming that the parameter exceeds the limit, the abnormal detection unit generates an abnormal signal and sends it to the retest control unit.
[0048] The fourth step is to retest after a preset time interval following the generation of the abnormal signal. Upon receiving the abnormal signal, the retest control unit starts a timer preset to 200 milliseconds. After the timer expires, the control parameter acquisition unit re-acquires the output voltage.
[0049] Step 5: Determine if the anomaly persists. If the voltage returns to the normal range after 200 milliseconds, the anomaly is determined to be a transient interference, and the process ends. If the voltage remains below the 24V threshold after 200 milliseconds, the anomaly is confirmed to persist, and the process proceeds to the next step.
[0050] Step 6: Trigger cross-validation. The cross-validation unit of module A sends data requests to adjacent modules B and C in the same area via the CAN bus to obtain their current output voltage values.
[0051] Step 7: Obtain the corresponding operating parameters from adjacent modules. The cross-validation unit of module A receives the operating parameter data returned by modules B and C.
[0052] Step 8: Parameter Comparison and Judgment. The fault diagnosis unit of module A compares its own abnormal voltage of 23.5V with the voltages of module B (27.5V) and module C (27.0V). Analysis reveals that the voltage of module A is too low, while the voltages of modules B and C are normal.
[0053] Step 9: Determine if the fault is within this module itself. Based on the comparison results showing only this module is faulty, it is determined that the target power module A itself has malfunctioned.
[0054] Conversely, if the voltages of both modules B and C are found to be abnormal within 100 milliseconds in step eight, for example, 23.0V and 22.8V respectively, then it is determined that the upstream power supply is abnormal.
[0055] Step 10: Fault Reporting. After the fault determination is completed, module A reports the fault type to the vehicle controller via the CAN bus.
[0056] Example 2: System Example
[0057] This embodiment provides a cross-validation and retesting fault diagnosis system for a military vehicle-mounted integrated power supply system. The system uses the method described in Embodiment 1 for fault diagnosis.
[0058] Reference Figure 2 The system includes multiple power modules and a communication bus connecting the multiple power modules. The communication bus is preferably a CAN bus.
[0059] Each power module includes the following units:
[0060] The parameter acquisition unit consists of a voltage sensor, a current sensor, a temperature sensor, and a signal conditioning circuit. It is used to acquire the output voltage, output current, and module temperature of this module in real time, and then convert them into digital quantities and output them to the anomaly detection unit.
[0061] The anomaly detection unit is connected to the parameter acquisition unit and internally stores the normal threshold ranges for each parameter, such as a normal voltage range of 24V to 29V. It receives real-time digital parameter values and compares them with the thresholds. Once a parameter is found to be outside the limit, an anomaly trigger signal is generated and sent to the retest control unit.
[0062] The core of the retest control unit is a programmable timer. Upon receiving an abnormal trigger signal, a timer with a preset delay of 200 milliseconds is started. After the timer expires, a retest command is sent to the parameter acquisition unit, and new parameters are received. If the new parameters return to normal, the process terminates; if the new parameters are still abnormal, the cross-validation unit is activated.
[0063] The cross-validation unit is responsible for interacting with other modules via the communication bus. Once activated, it sends data requests to other modules within the same area, receives response data, and then sends its own abnormal parameters along with those of other modules to the fault determination unit.
[0064] The fault determination unit collects abnormal parameters from this module and compares them with those from other modules. If only this module is abnormal while other modules are normal, a partial fault in this module is output. If multiple modules are abnormal within a preset time period, a systemic fault in the upstream power supply system is output. The final conclusion is reported to the vehicle controller via the bus.
[0065] The communication bus uses the CAN bus, which features strong anti-interference capability and good real-time performance. The structures of other modules are exactly the same as those mentioned above, forming a distributed intelligent diagnostic architecture.
[0066] Example 3: Example of Enhanced Diagnostic Method
[0067] Based on Embodiment 1, this embodiment provides an enhanced fault diagnosis method that further improves the diagnostic accuracy and survivability of the system through multi-timescale retesting and dynamic reconstruction mechanisms.
[0068] Multi-timescale retesting
[0069] Once the target power module detects an abnormal parameter for the first time, the control unit is tested again at at least two time points: 10 milliseconds, 200 milliseconds, and 2 seconds, and the test values are recorded each time. The selection criteria for these three time points are: 10 milliseconds to eliminate high-frequency electromagnetic interference, 200 milliseconds to eliminate transient load fluctuations, and 2 seconds to detect persistent faults.
[0070] The fault determination unit pre-classifies abnormal modes based on the changing trends of test values:
[0071] If the test values quickly return to the normal range after multiple tests, it is determined to be transient electromagnetic interference, and only the log is recorded without reporting a fault.
[0072] If the test value shows a slow downward trend, such as 23.8V, 23.5V, 23.2V, it is determined that the module performance is degraded and an early warning message is reported.
[0073] If the test value drops sharply and shows no signs of recovery, such as 23.5V, 23.4V, 23.4V, it is determined to be a suspected hardware failure and triggers the cross-validation step.
[0074] Dynamic Reconfiguration Mechanism
[0075] After completing the basic assessment, the system automatically performs dynamic reconfiguration based on the subdivided fault types:
[0076] When the target power module itself is determined to be faulty and a voltage drop is detected while the current increases, it is identified as a load short circuit fault and the current limiting protection is automatically activated to limit the current to within 120% of the rated value.
[0077] When the target power module itself is determined to be faulty and the parameters show a slow downward trend during testing, it is identified as module performance degradation, and the output power is automatically reduced to 70% of the rated value to enter the derating operation mode.
[0078] When the target power module itself is determined to be faulty and further testing does not improve the situation, and cross-validation shows that only this module is abnormal, it is identified as an internal hardware fault of the module, and the load is automatically switched to a backup module in the same area. The switching is completed within 5 milliseconds.
[0079] When an upstream power supply anomaly is detected, the load will be automatically switched to the backup bus.
[0080] All reconfiguration steps were completed without power interruption.
[0081] This invention employs a two-level verification mechanism combining time-based retesting and spatial-based cross-validation to achieve accurate fault location under uninterrupted power conditions, significantly reducing false alarm rates. This method and system can be widely applied to mobile platforms with high reliability requirements, such as military vehicles and special-purpose vehicles.
[0082] The above description is merely a preferred embodiment of the present invention and is not intended to limit the scope of protection of the present invention.
Claims
1. A cross-validation and retesting fault diagnosis method for a military vehicle-mounted integrated power supply system, applied to a military vehicle power supply system comprising multiple power modules, characterized in that... Includes the following steps: The target power module monitors its own operating parameters in real time. When the detected parameters exceed a preset threshold, an abnormal signal is generated. The operating parameters include at least one of output voltage, output current, and module temperature. After the abnormal signal is generated, the detection parameters are retested after a preset time interval. If the retest result still exceeds the preset threshold, the cross-validation step is triggered. The preset time interval is from 10 milliseconds to 500 milliseconds. The retesting includes multi-timescale retesting, with continuous testing at at least two time points within 10 milliseconds, 200 milliseconds, and 2 seconds, and pre-classification of abnormal patterns based on the changing trends of the test values. If the test values quickly return to the normal range after multiple tests, it is determined to be a transient interference, and only the log is recorded without reporting a fault. If the test value shows a slow downward trend, it is judged as performance degradation, and an early warning message is reported; If the test value drops sharply and shows no signs of recovery, it is considered a suspected hardware failure, triggering the cross-validation step. The corresponding operating parameters of at least one adjacent power module located in the same area as the target power module are obtained through the vehicle communication bus. The same area refers to a power supply area composed of multiple power modules powered by the same upstream bus. The detection parameters of the target power module are compared with the corresponding operating parameters of the adjacent power modules; When the target power module is abnormal and the adjacent power module is normal, it is determined that the target power module itself is faulty. When the corresponding operating parameters of multiple power modules in the same area are abnormal within a preset time period, it is determined to be an upstream power supply abnormality or a systemic power supply abnormality. It also includes a dynamic reconfiguration step, which executes corresponding handling measures based on different fault types: When the target power module itself is determined to be faulty, and a decrease in voltage and an increase in current are detected in the module, it is further identified as a load short circuit fault, and current limiting protection is automatically activated. When the target power module is determined to be faulty and the parameters are detected to be slowly decreasing during the test, it is further identified as module performance degradation, and the module output power is automatically reduced to enter derating operation mode. When the target power module itself is determined to be faulty, and further testing does not improve the situation, and cross-verification shows that only this module is abnormal, it is further identified as an internal hardware fault of the module, and the load is automatically switched to a backup module in the same area. When an upstream power supply anomaly is detected, the load will be automatically switched to the backup bus. The load switching, current limiting protection, and derating operation steps are all completed without power interruption, and the switching process is completed within 5 milliseconds.
2. The cross-validation and retesting fault diagnosis method for a military vehicle-mounted integrated power supply system according to claim 1, characterized in that, The vehicle communication bus is a CAN bus.
3. A system for implementing the cross-validation and retesting fault diagnosis method for the military vehicle-mounted integrated power supply system according to any one of claims 1-2, characterized in that, It includes multiple power modules and a communication bus connecting the multiple power modules, wherein each power module includes: The parameter acquisition unit is used to collect the operating parameters of this module in real time. An anomaly detection unit, connected to the parameter acquisition unit, is used to determine whether the operating parameters exceed a preset threshold, and to generate an anomaly trigger signal when they do. The retest control unit is connected to the anomaly detection unit and is used to control the parameter acquisition unit to re-acquire parameters after a preset delay in response to the anomaly trigger signal, so as to obtain retest parameters. A cross-validation unit, connected to the retest control unit, is used to request corresponding operating parameters from other power modules in the same area via the communication bus when the retest parameters still exceed a preset threshold. The same area refers to a power supply area composed of multiple power modules powered by the same upstream bus. The fault determination unit, connected to the cross-validation unit, is used to perform a horizontal comparison between the abnormal parameters of this module and the operating parameters of other modules received, and output the final fault type based on the comparison results.
4. The system according to claim 3, characterized in that, The fault types include local faults in this module and systemic faults in the upstream power supply system.