Method and device for preventing condensation of a motor controller

Abstract

The application discloses a motor controller anti-condensation method and device, and belongs to the technical field of motor controllers. The method comprises the following steps: collecting controller data according to a vehicle state; determining a dew point temperature according to the controller data; determining a condensation risk state according to the controller data and the dew point temperature; and starting a heating system to heat the inside of the motor controller to prevent internal condensation of the motor controller in the case where the condensation risk state indicates that there is a condensation risk. The dew point temperature is determined by collecting current controller data, the condensation risk of the motor controller in the current environment is judged according to the dew point temperature change, and heating is only performed in the case where there is a condensation risk, thereby avoiding continuous heating and causing the controller to age quickly, and the accuracy of the condensation risk judgment is ensured.

Description

Technical Field

[0001] This application relates to the field of motor controller technology, specifically to a method and apparatus for preventing condensation in a motor controller. Background Technology

[0002] In environments with high humidity and significant internal temperature variations, condensation can occur in the motor controller of electric vehicles. Without appropriate protective measures, this can lead to electrical short circuits, component corrosion, reduced insulation performance, and malfunctions within the controller, significantly impacting the product's functional safety.

[0003] In related technologies, condensation prevention is achieved by actively maintaining the controller housing temperature above the ambient dew point. However, continuous heating leads to high energy consumption, rapid component aging, and an inability to adapt to dynamic environments. Heating is triggered based solely on a single temperature parameter, ignoring dynamic changes in the dew point and making it easy to misjudge the risk of condensation. Summary of the Invention

[0004] This application provides a method and apparatus for preventing condensation in a motor controller, aiming to solve the problem that it cannot adapt to dynamic environments, triggers heating based solely on a single temperature parameter, ignores dynamic changes in dew point, and is prone to misjudging the risk of condensation.

[0005] In a first aspect, embodiments of this application provide a method for preventing condensation in a motor controller, comprising the following steps: Data is collected from the controller based on the vehicle status. Determine the dew point temperature based on controller data; Determine the condensation risk status based on controller data and dew point temperature; When the condensation risk status is indicated as having a condensation risk, the heating system is activated to heat the inside of the motor controller to prevent condensation inside the motor controller.

[0006] In some embodiments, the vehicle status includes an operating status and a stopped status; Based on data from the vehicle status acquisition controller, including: When the vehicle is in operation, controller data is collected in the first cycle. When the vehicle is in a stopped state, controller data is collected in the second cycle until the duration of controller data collection reaches the duration of the stopped operation.

[0007] In some embodiments, the controller data includes the relative humidity at the first preset detection location and the air temperature inside the housing of the motor controller; Determine the dew point temperature based on controller data, including: Dew point temperature is determined based on relative humidity and air temperature.

[0008] In some embodiments, multiple humidity ranges are preset, each humidity range corresponding to a safety margin, and the anti-condensation method further includes: Determine the safety margin based on the humidity range in which the relative humidity falls.

[0009] In some embodiments, the controller data also includes the surface temperature at a second preset detection location; The condensation risk status is determined based on controller data and dew point temperature, including: If the first triggering condition is met, the condensation risk status is determined to be condensation risk. The first triggering condition includes at least one of the following: the surface temperature is less than or equal to the sum of the dew point temperature and the safety margin; the air temperature is less than or equal to the sum of the dew point temperature and the safety margin.

[0010] In some embodiments, activating the heating system to heat the interior of the motor controller includes: The parameter set for the PID algorithm is determined based on relative humidity; The power of the heating element in the heating system is adjusted according to the parameter set of the PID algorithm to control the temperature at which the motor controller is heated.

[0011] In some embodiments, the condensation risk status also includes no condensation risk; Anti-condensation methods also include: When the heating system heats the inside of the motor controller, the condensation risk status indication is determined to be no condensation risk when the second trigger condition is met. The second triggering condition includes: The surface temperature is greater than or equal to the sum of the dew point temperature, safety margin, and preset temperature parameters, and the air temperature is greater than or equal to the sum of the dew point temperature, safety margin, and preset temperature parameters.

[0012] In some embodiments, the anti-condensation method further includes: If the third triggering condition is met, a sealing alarm will be triggered; The third triggering condition includes: the heating system heats the inside of the motor controller for a period of time exceeding a preset alarm time threshold, and the second triggering condition is not triggered within the range of the alarm time threshold.

[0013] In some embodiments, the anti-condensation method further includes: When the fourth triggering condition is met, the conservative heating temperature is determined based on the dew point temperature and the preset conservative heating margin. The heating system is then started to heat the inside of the motor controller using the conservative heating temperature as the target temperature. The fourth trigger condition includes at least one of the following: relative humidity cannot be obtained; air temperature cannot be obtained; surface temperature cannot be obtained.

[0014] Secondly, this application provides an anti-condensation device for a motor controller, the anti-condensation device comprising: The data acquisition module is used to collect controller data based on vehicle status. The dew point temperature determination module is used to determine the dew point temperature based on controller data. The condensation risk status judgment module is used to determine the condensation risk status based on controller data and dew point temperature; The execution module is used to activate the heating system to heat the inside of the motor controller when the condensation risk status is indicated as having a condensation risk, in order to prevent condensation inside the motor controller.

[0015] This application determines the dew point temperature by collecting current controller data, judges the condensation risk of the motor controller under the current environment based on the change of dew point temperature, and only heats the controller when there is a condensation risk, so as to avoid continuous heating that will cause the controller to age quickly and ensure the accuracy of the condensation risk judgment. Attached Figure Description

[0016] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0017] Figure 1 This is a schematic flowchart of an anti-condensation method for a motor controller provided by an exemplary embodiment of this disclosure; Figure 2 This is another schematic flowchart of an anti-condensation method for a motor controller provided by an exemplary embodiment of this disclosure; Figure 3 This is a flowchart of an anti-condensation method for a motor controller provided by an exemplary embodiment of this disclosure; Figure 4 This is a schematic diagram of the structure of an anti-condensation device for a motor controller provided in an exemplary embodiment of this disclosure.

[0018] Explanation of icon numbers: 100. Anti-condensation device; 101. Data acquisition module; 102. Control unit; 1021. Dew point determination module; 1022. Condensation risk status judgment module; 103. Execution module; 104. Communication module; 200. Motor controller housing; 201. Vent valve; 300. Vehicle system. Detailed Implementation

[0019] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0020] In the description of this application, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicating orientation or positional relationships based on the orientation or positional relationships shown in the accompanying drawings, are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first" and "second" may explicitly or implicitly include one or more of the stated features. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0021] "A and / or B" includes the following three combinations: A only, B only, and a combination of A and B.

[0022] The use of "applies to" or "configured to" in this application implies open and inclusive language, which does not exclude the applicability to or configuration to devices performing additional tasks or steps. Additionally, the use of "based on" implies openness and inclusivity, because processes, steps, calculations, or other actions "based on" one or more of the stated conditions or values ​​may in practice be based on additional conditions or values ​​beyond those stated.

[0023] In this application, the term "exemplary" is used to mean "used as an example, illustration, or description." Any embodiment described as "exemplary" in this application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use this application. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that this application can be made without using these specific details. In other instances, well-known structures and processes are not described in detail to avoid obscuring the description of this application with unnecessary detail. Therefore, this application is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed in this application.

[0024] In a first aspect, embodiments of this application provide a method for preventing condensation in a motor controller, such as... Figure 1 As shown, it includes the following steps: S101. Collect controller data based on vehicle status.

[0025] Specifically, vehicle status includes both running and stopped states. The operating conditions for collecting controller data are determined based on the vehicle status, such as the data collection cycle or duration. Controller data consists of detection data from inside the motor controller housing, such as temperature or humidity.

[0026] By collecting controller data based on vehicle status, and collecting controller data under different operating conditions according to different vehicle statuses, a data foundation is provided for subsequent steps.

[0027] S102. Determine the dew point temperature based on the controller data.

[0028] Specifically, the dew point temperature is the temperature at which air reaches saturation when cooled under constant water vapor content and air pressure. When the surface temperature of an object is less than or equal to the dew point temperature, water vapor in the air will condense into dew on its surface. It is a critical parameter used to determine whether condensation has occurred.

[0029] By calculating the dew point temperature under the current operating conditions in real time using controller data, and dynamically adapting to different environments, the accuracy of subsequent steps in judging the risk of condensation is guaranteed, avoiding the limitations of using a single temperature for judgment in traditional methods.

[0030] S103. Determine the condensation risk status based on controller data and dew point temperature.

[0031] Specifically, the condensation risk status is used to determine whether the current motor controller has a condensation risk. The condensation risk status includes having a condensation risk and not having a condensation risk.

[0032] In related technologies, active and continuous heating is used, which cannot adapt to different environments. In this embodiment, the criterion for judging condensation risk is adjusted by adjusting the dew point temperature, thereby improving the accuracy of condensation risk assessment.

[0033] S104. When the condensation risk status is indicated as having a condensation risk, the heating system is activated to heat the inside of the motor controller to prevent condensation inside the motor controller.

[0034] Specifically, the heating system is activated to heat the internal components of the motor controller only when the condensation risk status indicates a condensation risk. When the condensation risk status indicates no condensation risk, the heating system is not activated. Continuous heating of the motor controller is unnecessary and prevents rapid aging of components.

[0035] This embodiment determines the dew point temperature by collecting current controller data, judges the condensation risk of the motor controller under the current environment based on the change of dew point temperature, and only heats the controller when there is a condensation risk, so as to avoid continuous heating that will cause the controller to age quickly and ensure the accuracy of the condensation risk judgment.

[0036] This application also provides another method for preventing condensation in a motor controller, such as... Figure 2 As shown, it includes the following steps: S201. Collect controller data based on vehicle status.

[0037] Specifically, the vehicle status includes both running and stopped states. Controller data includes the relative humidity at a first preset detection location, the air temperature inside the motor controller housing, and the surface temperature at a second preset detection location. The first preset detection location is the area between a heat-prone location inside the motor controller housing and the corresponding metal component above it, such as the area between the circuit board and the top cover. A temperature and humidity sensor is installed at the first preset detection location to detect the relative humidity at that location. and the air temperature inside the motor controller housing The second preset detection location is the surface of a metal component above a heat-prone area inside the motor controller housing, such as the top cover surface above the circuit board or the top cover surface above the copper busbar. A surface-mount temperature sensor is installed at this second preset detection location to monitor the surface temperature in real time. .

[0038] When the vehicle is in the running state, controller data is collected in the first cycle. In some examples, the first cycle is 10 seconds, meaning controller data is collected once every 10 seconds. There is no limit to the collection duration when the vehicle is in the running state.

[0039] When the vehicle is in a stopped state, controller data is collected in a second cycle until the duration of controller data collection reaches the stop operation duration. In some instances, the second cycle is shorter than the first cycle, with the second cycle being 1 second, meaning controller data is collected once every 1 second. The stop operation duration is not a fixed value and is adjusted in real time according to the environment when the vehicle is stopped. Specifically, it can be 0.5 hours to 2 hours, for example, 0.5 hours in a dry, low-humidity environment and 2 hours in a rainy, high-humidity environment.

[0040] After acquiring the controller data, it is preprocessed by filtering to eliminate noise interference, for example, by using a Kalman filter to filter the controller data.

[0041] When the vehicle is running, the controller generates continuous heat due to its operation, and the internal temperature and humidity change relatively slowly. By collecting controller data in the first cycle at a lower frequency, environmental changes can be captured in a timely manner, while reducing the energy consumption of sensors and control units. After the vehicle stops, the temperature and humidity of the controller change drastically, and the risk of condensation increases sharply. By collecting controller data in the second cycle at a higher frequency, the temperature changes inside the motor controller can be tracked in real time, avoiding the failure to detect the risk of condensation.

[0042] The first and second preset detection positions correspond to the overall environment and condensation-prone areas inside the motor controller housing. By using multi-dimensional data, the limitations of single parameters in traditional methods are avoided, providing a stable and accurate data foundation for subsequent steps.

[0043] S202. Determine the dew point temperature based on the controller data.

[0044] Specifically, the dew point temperature is determined based on relative humidity and air temperature, and the calculation formula is as follows: ; in, Dew point temperature, The relative humidity at the first preset detection location. A represents the air temperature inside the motor controller housing, and B represents coefficients.

[0045] In some examples, A=17.625 and B=243.04℃, which is applicable when the air temperature T1>0℃. When the controller is running, the air temperature inside the housing is usually not lower than 0℃.

[0046] Related technologies typically use fixed temperature values ​​as anti-condensation thresholds, which cannot adapt to dynamic changes in different temperature and humidity environments. In this embodiment, the dew point temperature is calculated based on relative humidity and air temperature to determine the specific threshold for condensation generation under actual operating conditions, providing a data basis for subsequent condensation risk assessment and adapting to different environments.

[0047] S203. Determine the safety margin based on the humidity range in which the relative humidity is located.

[0048] Specifically, there are multiple preset humidity ranges, each with a corresponding safety margin. The safety margin is determined based on the humidity range in which the relative humidity is located.

[0049] By setting a humidity range, a mapping relationship between relative humidity and safety margin is achieved.

[0050] In some examples, there are two humidity ranges: a low humidity range and a high humidity range. A relative humidity of 60% or less is considered a low humidity range, and a relative humidity greater than 60% is considered a high humidity range. The safety margin for the low humidity range is 2°C, and the safety margin for the high humidity range is 6°C. ; ; in, Relative humidity, For safety margin.

[0051] Higher relative humidity means higher water vapor saturation in the air, making condensation conditions more likely and requiring a larger safety margin. Conversely, lower relative humidity means lower water vapor saturation, a lower probability of condensation, and a smaller safety margin. By classifying humidity ranges, the safety margin can be dynamically adjusted based on relative humidity to adapt to different environments.

[0052] S204. Determine the condensation risk status based on controller data and dew point temperature.

[0053] Specifically, the condensation risk status is used to determine whether the current motor controller has a condensation risk. The condensation risk status includes having a condensation risk and not having a condensation risk.

[0054] If the first triggering condition is met, the condensation risk status is determined to be condensation risk.

[0055] The first triggering condition includes at least one of the following conditions: At that time, i.e., surface temperature Less than or equal to dew point temperature and safety margin The sum of these values ​​indicates that the surface temperature of the controller has reached the critical threshold for condensation, which can easily lead to condensation risk.

[0056] At that time, i.e., air temperature Less than or equal to dew point temperature and safety margin At this point, the overall air environment inside the controller housing has reached the critical threshold for condensation, which can easily lead to condensation risks.

[0057] The risk of condensation is assessed by measuring both surface temperature and air temperature. Heating is triggered before condensation forms, thereby preventing condensation.

[0058] S205. When the condensation risk status is indicated as having a condensation risk, the heating system is activated to heat the inside of the motor controller to prevent condensation inside the motor controller.

[0059] In some embodiments, the parameter set of the PID (Proportional-Integral-Derivative) algorithm is determined based on the relative humidity; the power of the heating element of the heating system is adjusted according to the parameter set of the PID algorithm to control the temperature at which the motor controller is heated.

[0060] When the controller internally determines that heating is triggered, a PID algorithm is used to control the power of the PTC heating element. The formula is as follows: ; The error e(t) is: ; PID parameter assignment needs to be combined with the thermal characteristics of the motor controller system. The balanced response speed (Kp), steady-state accuracy (Ki), and anti-interference capability (Kd) should be initially determined through experiments or classical methods. After laboratory simulation verification under different operating conditions, the optimal parameters under different temperatures and humidity are determined and pre-stored in the control unit. Finally, in actual application, the system can switch the pre-stored PID parameter group in advance according to real-time environmental parameters (humidity, temperature).

[0061] The parameter groups of the PID algorithm are grouped according to relative humidity. In some examples, the parameter groups can be divided into high humidity mode and low humidity mode, where the relative humidity is greater than 60% and the relative humidity is less than or equal to 60% and the relative humidity is less than or equal to 60% and the relative humidity is less than or equal to 60%.

[0062] In high humidity mode, the parameter set of the PID algorithm can be set to ( ), ( ), ( At this time, the humidity is high, requiring a rapid response to suppress condensation.

[0063] In low humidity mode, the parameter set of the PID algorithm can be set to ( ), ( ), ( At this time, the humidity is low, so energy saving should be prioritized to reduce overshoot.

[0064] When relative humidity is detected When crossing the 60% threshold between high humidity mode and low humidity mode, select a smooth transition to the corresponding parameter group.

[0065] When heating is started, the surface of the area prone to condensation is heated first, followed by the area of ​​the vent valve and other areas inside the chamber.

[0066] In other embodiments, a stepped power regulation algorithm is used to adjust the power of the heating element in the heating system in order to control the temperature at which the motor controller is heated.

[0067] Based on the surface temperature of the location prone to condensation With real-time calculated dew point temperature The difference between Combined with the current relative humidity inside the box This is used to determine the required level of heating power. The goal is to ensure... Always higher Dynamic safety margin However, avoid overheating.

[0068] The stepped power regulation algorithm includes low power level, medium power level and high power level.

[0069] The trigger condition for low power mode is: , i.e., surface temperature With dew point temperature The difference between Greater than or equal to dynamic safety margin The sum of the preset temperature parameters, or the surface temperature With dew point temperature The difference between Within the first safety range, for example At this point, the risk of condensation is very low. It is only necessary to maintain or slightly supplement the heat to prevent the temperature from slowly dropping to the danger zone. Therefore, only use the lowest heating power setting, such as 20% of the rated power.

[0070] The trigger condition for the medium power setting is: , i.e., surface temperature With dew point temperature The difference between Greater than or equal to dynamic safety margin Less than or equal to dynamic safety margin The sum of the preset temperature parameters, or the surface temperature With dew point temperature The difference between Within the second safety range, for example There is a certain risk of condensation at this point, so it is necessary to actively heat the water to bring it back to a safer range. Use a medium setting for heating, such as 50% of the rated power.

[0071] The trigger condition for high power mode is: , i.e., surface temperature With dew point temperature The difference between Less than dynamic safety margin or surface temperature With dew point temperature The difference between Less than the emergency safety threshold, for example At this point, condensation is about to occur or is already in a high-risk state, requiring rapid heating at maximum power. Use a high setting for heating, such as 100% of the rated power.

[0072] In other embodiments, the temperature of each region is independently controlled by multiple different heating elements, and the dew point change trend is predicted over a future time range based on a predictive model.

[0073] Specifically, the prediction model is an LSTM (Long Short Term Memory) neural network.

[0074] The input data for the prediction model includes historical air temperature, historical relative humidity, historical surface temperature, historical heating power, historical heating status, external environmental parameters, external environmental temperature, external environmental relative humidity, and weather forecast data.

[0075] Historical air temperature is a record of the air temperature at the first preset detection location inside the chamber over a period of time. It is used to reflect the thermal state inside the chamber, such as the air temperature over the past 6 hours, with a sampling interval of 5-15 minutes.

[0076] Historical relative humidity is a record of the relative humidity inside the chamber at a time corresponding to the historical air temperature, used to reflect the moisture content inside the chamber.

[0077] The historical surface temperature is a record of the historical temperature at the second preset detection location. It reflects the temperature changes at key locations.

[0078] Historical heating power and historical heating status are records of past applied heating power levels or PTC duty cycles, used to reflect the history of system intervention.

[0079] External environmental parameters are those that affect temperature. These data can significantly improve prediction accuracy, but require additional sensors or data interfaces.

[0080] The external ambient temperature refers to the temperature of the environment in which the enclosure is located, such as the temperature of the computer room or the temperature outside the vehicle compartment, and is used to influence the temperature change trend of the enclosure.

[0081] The external relative humidity is the humidity of the environment in which the chamber is located, and is used to influence the long-term changes in humidity inside the chamber.

[0082] Weather forecast data includes predicted temperature, humidity, and precipitation probability for the next few hours, providing valuable clues about the future environment.

[0083] By predicting the dew point change trend over the next two hours based on input data, the heating system can be started in advance to improve control accuracy.

[0084] S206. When the heating system heats the inside of the motor controller, and the second trigger condition is met, the condensation risk status indication is determined to be no condensation risk.

[0085] Specifically, the second triggering condition includes: the surface temperature being greater than or equal to the sum of the dew point temperature, the safety margin, and the preset temperature parameter, and the air temperature being greater than or equal to the sum of the dew point temperature, the safety margin, and the preset temperature parameter. The preset temperature parameter is a pre-set temperature value to prevent fluctuation redundancy, used to avoid frequent start-ups and shutdowns of the heating system due to small fluctuations in temperature and humidity. In some examples, the preset temperature parameter is set to 2°C.

[0086] When the heating system heats the inside of the motor controller, it satisfies... , i.e., surface temperature Greater than or equal to dew point temperature Safety margin The sum of the preset temperature parameters and the air temperature Greater than or equal to dew point temperature Safety margin If the sum of the preset temperature parameters does not meet the conditions for condensation, the heating can be turned off.

[0087] S207. If the third triggering condition is met, trigger the sealing alarm.

[0088] The third triggering condition includes: the heating system heats the inside of the motor controller for a period of time exceeding a preset alarm time threshold, and the second triggering condition is not triggered within the range of the alarm time threshold.

[0089] Specifically, if the heating system heats the inside of the motor controller for a period exceeding the preset alarm time threshold and fails to meet the condition to stop heating, it indicates that there may be a sealing problem inside the motor controller, triggering a cavity sealing alarm.

[0090] The alarm time threshold can be set based on the power of the heating element and the same internal space size. In some examples, the alarm time threshold can be 1 hour.

[0091] S208. When the fourth triggering condition is met, the conservative heating temperature is determined based on the dew point temperature and the preset conservative heating margin. The heating system is started to heat the inside of the motor controller using the conservative heating temperature as the target temperature. The fourth trigger condition includes at least one of the following: relative humidity cannot be obtained; air temperature cannot be obtained; surface temperature cannot be obtained.

[0092] Specifically, abnormal situations such as no sensor output, abnormal data, or communication interruption may prevent the acquisition of controller data, such as relative humidity, air temperature, or surface temperature. In this case, a conservative heating mode is activated, using the conservative heating temperature as the target temperature to start the heating system and heat the inside of the motor controller.

[0093] The conservative heating temperature is the sum of the dew point temperature and the preset conservative heating margin. In some examples, the preset conservative heating margin can be set to 6°C, etc.

[0094] like Figure 3 The diagram shown is a flowchart of the anti-condensation method in this embodiment. The current vehicle status is determined to establish the data acquisition mode for the controller. In the running state, data is continuously collected at a period of 10 seconds; in the stopped state, data is collected at a period of 1 second for 0.5-2 hours. Data acquisition and preprocessing are performed according to the controller data acquisition mode, including collecting air temperature data. relative humidity Surface temperature The controller data is obtained by preprocessing the data using Kalman filtering or median filtering. The dew point temperature is then dynamically calculated using this controller data. According to relative humidity and dew point temperature Dynamically adjust safety margin Determine the condensation risk, and based on the condensation risk assessment, determine whether condensation risk exists. If there is no condensation risk, return to continued monitoring. If there is a condensation risk, activate heating control and monitor the air temperature. and surface temperature The smaller of the two components is heated, and the heating power is adjusted using a PID algorithm. The system determines whether the temperature meets the target based on real-time temperature monitoring; if the temperature does not meet the target, PID adjustment continues; if the temperature meets the target, heating stops.

[0095] Secondly, this application provides an anti-condensation device for a motor controller, such as... Figure 4As shown, the anti-condensation device 100 is installed inside the motor controller housing 200, which includes a data acquisition module 101, a control unit 102, an execution module 103, and a communication module 104.

[0096] The data acquisition module 101 is used to collect controller data based on the vehicle status. Specifically, the data acquisition module 101 collects controller data by setting up a sensor module inside the motor controller housing 200. The sensor module can be a temperature and humidity sensor or a surface temperature sensor. By collecting controller data based on the vehicle status and under different operating conditions according to different vehicle states, the module provides a data foundation for subsequent steps.

[0097] The control unit 102 can be a microcontroller unit (MCU) used to determine the condensation risk based on controller data. The control unit 102 includes a dew point determination module 1021 and a condensation risk status judgment module 1022.

[0098] The dew point temperature determination module is used to determine the dew point temperature based on controller data. It calculates the dew point temperature in real time under the current operating conditions using controller data, dynamically adapting to different environments. This ensures the accuracy of subsequent steps in assessing condensation risk and avoids the limitations of traditional methods that rely on a single temperature for determination.

[0099] The condensation risk assessment module 1022 is used to determine the condensation risk status based on controller data and dew point temperature. Related technologies involve active and continuous heating, which cannot adapt to different environments. In this embodiment, the condensation risk assessment criterion is adjusted by changing the dew point temperature, thereby improving the accuracy of condensation risk assessment.

[0100] The execution module 103 is used to activate the heating system to heat the interior of the motor controller when the condensation risk indicator shows a condensation risk, in order to prevent condensation inside the motor controller. The heating system can heat the interior of the controller housing using positive temperature coefficient (PTC) heating elements. The PTC heating elements can be positioned on the surface of the controller housing where condensation is likely to occur, such as in the central area inside the housing, to increase the internal air temperature. For housings with a vent valve 201, they can be positioned near the vent valve 201. When the condensation risk indicator shows no condensation risk, the heating system is not activated to heat the interior of the motor controller. Continuous heating of the motor controller is unnecessary, preventing rapid aging of components.

[0101] The communication module 104 can be a Controller Area Network (CAN) bus for data interaction with the vehicle system.

[0102] This embodiment determines the dew point temperature by collecting current controller data, judges the condensation risk of the motor controller under the current environment based on the change of dew point temperature, and only heats the controller when there is a condensation risk, so as to avoid continuous heating that will cause the controller to age quickly and ensure the accuracy of the condensation risk judgment.

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

[0104] The above provides a detailed description of the anti-condensation method and apparatus for a motor controller provided in the embodiments of this application. Specific examples have been used to illustrate the principles and implementation methods of this application. The description of the above embodiments is only for the purpose of helping to understand the method and core ideas of this application. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this application. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A method for preventing condensation in a motor controller, characterized in that, The method for preventing condensation includes the following steps: Data is collected from the controller based on the vehicle status. Determine the dew point temperature based on the controller data; The condensation risk status is determined based on the controller data and the dew point temperature. When the condensation risk status is indicated as having a condensation risk, the heating system is activated to heat the interior of the motor controller to prevent condensation inside the motor controller.

2. The anti-condensation method according to claim 1, characterized in that, The vehicle status includes both operating status and shutdown status; Based on data from the vehicle status acquisition controller, including: When the vehicle is in a running state, the controller data is collected in a first cycle. When the vehicle is in a stopped state, the controller data is collected in a second cycle until the duration of collecting the controller data reaches the duration of the stopped operation.

3. The anti-condensation method according to claim 1, characterized in that, The controller data includes the relative humidity at the first preset detection location and the air temperature inside the housing of the motor controller; Determining the dew point temperature based on the controller data includes: The dew point temperature is determined based on the relative humidity and the air temperature.

4. The anti-condensation method according to claim 3, characterized in that, The method includes multiple preset humidity ranges, each with a corresponding safety margin, and further includes: The safety margin is determined based on the humidity range in which the relative humidity falls.

5. The anti-condensation method according to claim 4, characterized in that, The controller data also includes the surface temperature at a second preset detection location; Determining the condensation risk status based on the controller data and the dew point temperature includes: If the first triggering condition is met, the condensation risk status is determined to be that there is a condensation risk. The first triggering condition includes at least one of the following conditions: the surface temperature is less than or equal to the sum of the dew point temperature and the safety margin; the air temperature is less than or equal to the sum of the dew point temperature and the safety margin.

6. The anti-condensation method according to claim 5, characterized in that, The heating system is activated to heat the interior of the motor controller, including: The parameter set for the PID algorithm is determined based on the relative humidity. The power of the heating element of the heating system is adjusted according to the parameter set of the PID algorithm to control the temperature at which the motor controller is heated.

7. The anti-condensation method according to claim 6, characterized in that, The condensation risk status also includes no condensation risk; The method for preventing condensation also includes: When the heating system heats the interior of the motor controller, and the second trigger condition is met, the condensation risk status indication is determined to be no condensation risk. The second triggering condition includes: The surface temperature is greater than or equal to the sum of the dew point temperature, the safety margin, and the preset temperature parameter, and the air temperature is greater than or equal to the sum of the dew point temperature, the safety margin, and the preset temperature parameter.

8. The anti-condensation method according to claim 7, characterized in that, The method for preventing condensation also includes: If the third triggering condition is met, a sealing alarm will be triggered; The third triggering condition includes: the heating system heating the inside of the motor controller for a period of time exceeding a preset alarm time threshold, and the second triggering condition not being triggered within the range of the alarm time threshold.

9. The anti-condensation method according to claim 5, characterized in that, The method for preventing condensation also includes: When the fourth triggering condition is met, the conservative heating temperature is determined based on the dew point temperature and the preset conservative heating margin, and the heating system is started to heat the inside of the motor controller with the conservative heating temperature as the target temperature. The fourth triggering condition includes at least one of the following conditions: the relative humidity cannot be obtained; the air temperature cannot be obtained; the surface temperature cannot be obtained.

10. An anti-condensation device for a motor controller, characterized in that, The anti-condensation device includes: The data acquisition module is used to collect controller data based on vehicle status. A dew point temperature determination module is used to determine the dew point temperature based on the controller data; A condensation risk status determination module is used to determine the condensation risk status based on the controller data and the dew point temperature. An execution module is configured to activate a heating system to heat the interior of the motor controller when the condensation risk status is indicated as having a condensation risk, in order to prevent condensation inside the motor controller.

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