New energy vehicle high-voltage insulation detection method and device, vehicle and equipment

Abstract

The new energy vehicle high-voltage insulation detection method, device, vehicle and equipment can monitor the organic matter leakage value of the electrolyte in the power battery system in real time, and simultaneously detect the insulation resistance of the high-voltage system to the positive ground and the negative ground. The insulation resistance detection value is compared with a preset insulation threshold value for judgment, and the detection period of the insulation resistance is dynamically adjusted based on the judgment result. The organic matter leakage monitoring value is compared with a preset diagnosis threshold value for judgment, and whether to trigger the fast detection period of the insulation resistance is determined based on the judgment result. Based on the insulation resistance detection result and the organic matter leakage monitoring value, a fault reporting strategy is executed. The fault reporting strategy includes insulation resistance fault reporting and high organic matter concentration independent fault reporting. The problem that the slight electrolyte leakage in the early stage of battery monomer structure damage cannot be identified early, leading to missed detection of high-voltage insulation safety hazards and easy ignition accidents can be solved.

Description

Technical Field

[0001] This application relates to the field of high-voltage electrical safety in the power system of new energy commercial vehicles, specifically to a high-voltage insulation testing method, device, vehicle, and equipment for new energy vehicles. Background Technology

[0002] Currently, the application scenarios for new energy commercial vehicles are becoming increasingly diversified, and the market's requirements for their range are continuously increasing. The industry generally improves energy storage capacity by increasing the total voltage of the power battery or adopting a multi-branch parallel connection to meet range demands. Therefore, high-voltage electrical safety has become a core focus in the design and application of power battery systems for new energy commercial vehicles. Related data shows that over 65% of fire accidents occurring during the charging or use of new energy vehicles are related to prior battery pack insulation damage or electrolyte leakage. The timeliness of high-voltage insulation detection in the power battery system directly determines the vehicle's high-voltage electrical safety protection level.

[0003] Among related technologies, the mainstream methods for insulation testing of power battery systems are the DC injection method and the balance bridge method. The battery management system (BMS) sequentially checks the insulation values ​​of the positive terminal to ground and the negative terminal to ground, and uses the smaller of the two values ​​as the insulation value of the high-voltage system for monitoring. At the same time, some related technologies are trying to link electrolyte leakage with insulation resistance reporting strategies, or dynamically adjust the insulation self-test cycle based on the voltage, temperature and other status information of individual battery cells, in order to improve the effectiveness of battery safety monitoring.

[0004] However, the abnormal state of the battery pack can only be identified when the electrolyte leakage reaches a preset threshold and the insulation resistance drops below the threshold. It cannot detect minor electrolyte leakage in the early stages of battery cell structural damage. Furthermore, the solution that triggers insulation detection through battery cell voltage and temperature parameters cannot identify the potential risk of battery structural damage when electrolyte leakage does not cause a drop in cell voltage or an increase in temperature. Summary of the Invention

[0005] This application provides a method, device, vehicle, and equipment for high-voltage insulation testing of new energy vehicles, which can solve the problem in related technologies that cannot identify minor electrolyte leakage in the early stage of structural damage to battery cells, leading to missed detection of high-voltage insulation safety hazards and potentially causing fire accidents.

[0006] In a first aspect, embodiments of this application provide a high-voltage insulation testing method for new energy vehicles, the high-voltage insulation testing method for new energy vehicles comprising: Real-time monitoring of organic matter leakage value in the electrolyte of the power battery system, and simultaneous detection of insulation resistance of the high voltage system to ground and negative ground; The insulation resistance test value is compared with the preset insulation threshold for judgment, and the detection cycle of insulation resistance is dynamically adjusted based on the judgment result; The organic matter leakage monitoring value is compared with the preset diagnostic threshold, and the judgment result determines whether to trigger the rapid detection cycle of insulation resistance. Based on the insulation resistance test results and organic matter leakage monitoring values, a fault reporting strategy is implemented; the fault reporting strategy includes insulation resistance fault reporting and independent fault reporting of high organic matter concentration.

[0007] In conjunction with the first aspect, in one embodiment, the step of comparing the insulation resistance detection value with a preset insulation threshold and dynamically adjusting the insulation resistance detection cycle based on the judgment result includes: Determine whether the detected insulation resistance exceeds the preset insulation threshold. If the insulation resistance exceeds the preset insulation threshold, the insulation resistance should be tested using a regular testing cycle. If the insulation resistance does not exceed the preset insulation threshold, a rapid testing cycle is used to test the insulation resistance; the testing frequency of the rapid testing cycle is higher than that of the conventional testing cycle.

[0008] In conjunction with the first aspect, in one embodiment, the step of comparing the organic leakage monitoring value with a preset diagnostic threshold and determining whether to trigger a rapid detection cycle for insulation resistance based on the judgment result includes: Determine whether the real-time acquired organic matter leakage value reaches the preset diagnostic threshold; If the organic matter leakage value reaches the preset diagnostic threshold and the insulation resistance test does not trigger the rapid detection cycle, then the counting test will begin. If the insulation resistance test has not triggered the fast test cycle after the count test has reached the preset number of times, the fast test cycle of insulation resistance will be triggered directly. If the organic matter leakage value reaches the preset diagnostic threshold, and the insulation resistance detection has triggered the rapid detection cycle, then the current rapid detection cycle will continue to be executed without any additional adjustment to the insulation resistance detection cycle.

[0009] In conjunction with the first aspect, in one implementation, the insulation resistance fault reporting in the fault reporting strategy includes: Compare the positive-to-ground insulation resistance test data and the negative-to-ground insulation resistance test data, and select the smaller value as the representative insulation resistance value of the high-voltage system. Determine whether the representative insulation resistance value reaches the preset insulation failure threshold; If the representative insulation resistance value reaches the preset insulation failure threshold and this state continues for a preset duration, the battery management system will perform an insulation resistance fault reporting operation.

[0010] In conjunction with the first aspect, in one implementation, the high organic matter concentration independent fault reporting in the fault reporting strategy includes: Determine whether the organic matter leakage value has reached the preset leakage failure threshold, and at the same time determine whether the insulation resistance detection has failed to identify the insulation failure of the high-voltage system; If the organic matter leakage value reaches the preset leakage failure threshold and the high-voltage system insulation has not been identified as failing, the organic matter leakage value will continue to be monitored and updated in real time. When the organic matter leakage value reaches the preset leakage alarm threshold, the battery management system directly executes the high organic matter concentration fault reporting operation, which is independent of the insulation resistance fault reporting process.

[0011] In conjunction with the first aspect, in one embodiment, the insulation resistance detection of the high-voltage system to ground and to ground includes: The battery management system sequentially detects the positive-to-ground insulation resistance and negative-to-ground insulation resistance of the high-voltage system according to the preset inspection logic. Acquire real-time detection data of insulation resistance between positive and negative ground; The insulation resistance detection data from both circuits are stored in real time and used as the basis for judging the insulation status of the high-voltage system.

[0012] In conjunction with the first aspect, in one embodiment, the real-time monitoring of organic matter leakage value of the electrolyte in the power battery system includes: The concentration signal of organic solvent generated by electrolyte leakage is collected in the sealed space of the power battery system, and the organic solvent concentration signal is converted into a quantified organic leakage value. The organic matter leakage value is transmitted to the battery management system in real time and stored synchronously with the insulation resistance detection data.

[0013] Secondly, embodiments of this application provide a high-voltage insulation testing device for new energy vehicles, the high-voltage insulation testing device for new energy vehicles comprising: The dual-parameter monitoring module is used to monitor the leakage value of organic matter in the electrolyte of the power battery system in real time, and at the same time to detect the insulation resistance of the high voltage system to ground and to ground. The detection cycle adaptive adjustment module is used to compare the insulation resistance detection value with the preset insulation threshold and dynamically adjust the insulation resistance detection cycle based on the judgment result. The rapid detection trigger module is used to compare the organic matter leakage monitoring value with the preset diagnostic threshold and determine whether to trigger the rapid detection cycle of insulation resistance based on the judgment result. The integrated fault reporting module is used to execute fault reporting strategies based on insulation resistance detection results and organic matter leakage monitoring values; the fault reporting strategies include insulation resistance fault reporting and independent fault reporting of high organic matter concentration.

[0014] Thirdly, embodiments of this application provide a vehicle that includes the high-voltage insulation detection device for new energy vehicles as described above.

[0015] Fourthly, this application provides a high-voltage insulation testing device for new energy vehicles. The high-voltage insulation testing device for new energy vehicles includes a processor, a memory, and a high-voltage insulation testing program for new energy vehicles stored in the memory and executable by the processor. When the high-voltage insulation testing program for new energy vehicles is executed by the processor, it implements the steps of the high-voltage insulation testing method for new energy vehicles as described in any of the above embodiments.

[0016] The beneficial effects of the technical solutions provided in this application include: Using real-time insulation resistance detection values ​​as the core criterion, logical judgments are made in conjunction with preset thresholds corresponding to the insulation resistance. The detection cycle is dynamically adjusted based on the judgment results, ensuring the detection frequency matches the actual insulation state of the high-voltage system, thus achieving on-demand control of the detection cycle. Similarly, using real-time organic matter leakage monitoring values ​​as the core criterion, logical judgments are made in conjunction with preset diagnostic thresholds corresponding to the organic matter leakage values. Based on the judgment results, a rapid detection cycle for insulation resistance is triggered specifically, enabling timely detection and response to potential safety risks caused by electrolyte leakage. Combining the aforementioned insulation resistance detection results and organic matter leakage monitoring values, a preset fault reporting strategy is executed. This differentiated fault reporting method allows for the separate identification and independent reporting of insulation failure faults and potential safety faults caused by electrolyte leakage in the high-voltage system. This ensures that all types of insulation-related safety risks in the high-voltage system are accurately fed back based on real-time detection data, achieving all-time, multi-dimensional monitoring of the high-voltage system's insulation status. Attached Figure Description

[0017] Figure 1 This is a flowchart illustrating an embodiment of the high-voltage insulation testing method for new energy vehicles according to this application; Figure 2 This is a flowchart illustrating another embodiment of the high-voltage insulation testing method for new energy vehicles according to this application; Figure 3 This is a schematic diagram of the hardware structure of the high-voltage insulation testing equipment for new energy vehicles involved in the embodiments of this application. Detailed Implementation

[0018] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present application.

[0019] To make the objectives, technical solutions, and advantages of this application clearer, the embodiments of this application will be described in further detail below with reference to the accompanying drawings.

[0020] In one aspect, embodiments of this application provide a method for high-voltage insulation testing of new energy vehicles.

[0021] In one embodiment, reference is made to Figure 1 , Figure 1 This is a flowchart illustrating the first embodiment of the high-voltage insulation testing method for new energy vehicles according to this application. Figure 1 As shown, the high-voltage insulation testing method for new energy vehicles includes: S100: Real-time monitoring of organic matter leakage value in the electrolyte of the power battery system, and simultaneous detection of insulation resistance of the high voltage system to ground and negative ground. S200: Compare the insulation resistance detection value with the preset insulation threshold to make a judgment, and dynamically adjust the insulation resistance detection cycle based on the judgment result; S300: Compare the organic leakage monitoring value with the preset diagnostic threshold and determine whether to trigger the rapid detection cycle of insulation resistance based on the judgment result; S400: Based on the insulation resistance test results and organic matter leakage monitoring values, execute the fault reporting strategy; the fault reporting strategy includes insulation resistance fault reporting and high organic matter concentration independent fault reporting.

[0022] In this embodiment, the organic matter leakage value of the electrolyte in the power battery system is monitored in real time. Simultaneously, insulation resistance tests are performed on the high-voltage system's positive and negative ground connections. The organic matter leakage monitoring values ​​and insulation resistance test values ​​are acquired concurrently, providing real-time and effective data support for subsequent adjustment of the insulation resistance test cycle, triggering of rapid test cycles, and fault status assessment. The real-time insulation resistance test value is used as the core judgment criterion, compared with a preset insulation threshold. Based on the judgment result, the insulation resistance test cycle is dynamically adjusted to adapt the test frequency to the actual insulation state of the high-voltage system, achieving on-demand control of the test cycle. The real-time organic matter leakage monitoring value is also used as the core judgment criterion, compared with a preset diagnostic threshold. Based on the judgment result, it is determined whether to trigger a rapid insulation resistance test cycle, enabling timely detection and response to potential safety risks caused by electrolyte leakage. Based on the aforementioned insulation resistance test results and organic matter leakage monitoring values, a preset fault reporting strategy is executed. This fault reporting strategy includes two differentiated reporting forms: insulation resistance fault reporting and independent fault reporting for high organic matter concentration. Through these differentiated fault reporting forms, the insulation failure faults and potential safety faults caused by electrolyte leakage in the high-voltage system can be identified and reported independently. This ensures that all kinds of insulation-related safety risks in the high-voltage system can be accurately fed back based on real-time detection data, achieving all-time, multi-dimensional monitoring of the insulation status of the high-voltage system.

[0023] Furthermore, in one embodiment, S100 includes the following steps: S101: The battery management system sequentially detects the positive-to-ground insulation resistance and negative-to-ground insulation resistance of the high-voltage system according to the preset inspection logic. S102: Acquire real-time detection data of insulation resistance between positive and negative ground; S103: Store the insulation resistance detection data of the two channels in real time as the basis for judging the insulation status of the high-voltage system.

[0024] In this embodiment, for the insulation resistance testing of the high-voltage system's positive to ground and negative to ground, the testing process is systematically advanced based on the preset inspection logic of the battery management system, simultaneously acquiring and storing the test data. This provides effective data support for subsequent determinations of the high-voltage system's insulation status. Relying on the preset inspection logic of the battery management system, the positive to ground and negative to ground insulation resistance of the high-voltage system are tested sequentially, ensuring the standardization and orderliness of the insulation resistance testing operation. Real-time acquisition of the test data for both positive and negative to ground insulation resistance ensures that the test data accurately reflects the current insulation status of the high-voltage system. The real-time test data for both insulation resistances is stored immediately, forming a basic data reserve for judging the insulation status of the high-voltage system, providing direct and effective data basis for subsequent operations such as adjusting the insulation testing cycle and determining fault status.

[0025] Furthermore, in one embodiment, S100 includes the following steps: S104: Collect the organic solvent concentration signal generated by electrolyte leakage in the sealed space of the power battery system, and convert the organic solvent concentration signal into a quantified organic leakage value. S105: The organic leakage value is transmitted to the battery management system in real time and stored synchronously with the insulation resistance detection data.

[0026] In this embodiment, for real-time monitoring of organic matter leakage values ​​in the electrolyte within the power battery system, continuous operations of signal acquisition, quantification conversion, and data transmission and storage are employed to effectively acquire and collaboratively retain organic matter leakage values. This provides quantified and synchronous leakage monitoring data for subsequent monitoring cycle adjustments and fault status determination. The system accurately acquires organic solvent concentration signals generated by electrolyte leakage within the sealed space of the power battery system, effectively capturing physical signals related to electrolyte leakage. The acquired organic solvent concentration signals are converted into quantified organic matter leakage values, achieving a digital characterization of the electrolyte leakage degree. This allows for subsequent logical determination of the electrolyte leakage status of the power battery system based on specific numerical values. The quantified organic matter leakage values ​​are transmitted to the battery management system in real time and simultaneously stored synchronously with the insulation resistance detection data of the high-voltage system. This forms a collaborative basic data reserve between the organic matter leakage monitoring data and the insulation resistance detection data, ensuring the synchronous retrieval and comprehensive analysis of both types of data in subsequent determination stages.

[0027] Furthermore, in one embodiment, step S200 includes the following steps: S201: Determine whether the detected insulation resistance exceeds the preset insulation threshold; S202: If the insulation resistance exceeds the preset insulation threshold, the insulation resistance shall be tested using the regular testing cycle. S203: If the insulation resistance does not exceed the preset insulation threshold, the insulation resistance shall be tested using a rapid testing cycle; wherein, the testing frequency of the rapid testing cycle is higher than that of the conventional testing cycle.

[0028] In this embodiment, the detection cycle is hierarchically adapted and controlled by comparing the real-time insulation resistance detection value with the preset insulation threshold. Based on the insulation status of the high-voltage system reflected by the insulation resistance detection value, different detection frequencies are matched to the detection cycle. When the insulation resistance detection value exceeds the preset insulation threshold, insulation resistance detection is carried out using a regular detection cycle, adapting to the current normal insulation status of the high-voltage system. This ensures insulation status monitoring while maintaining the normal execution rhythm of the detection process. When the insulation resistance detection value does not exceed the preset insulation threshold, a faster detection cycle with a higher detection frequency is switched to acquire insulation resistance detection data with a more intensive detection frequency. This allows for timely capture of dynamic changes in the insulation status of the high-voltage system, ensuring that the frequency of insulation resistance detection matches the actual insulation status of the high-voltage system. This matches the execution intensity of insulation detection with the insulation risk level of the high-voltage system, achieving flexible control of the detection cycle based on the actual insulation status.

[0029] Furthermore, in one embodiment, step S300 includes the following steps: S301: Determine whether the real-time acquired organic matter leakage value reaches the preset diagnostic threshold; S302: If the organic matter leakage value reaches the preset diagnostic threshold and the insulation resistance detection does not trigger the rapid detection cycle, then the counting detection will begin. S303: If the insulation resistance detection has not triggered the fast detection cycle after the count detection has reached the preset number of times, the insulation resistance fast detection cycle will be triggered directly. S304: If the organic leakage value reaches the preset diagnostic threshold and the insulation resistance detection has triggered the fast detection cycle, the current fast detection cycle will continue to be executed without any additional adjustment to the insulation resistance detection cycle.

[0030] In this embodiment, based on the comparison results of the real-time acquired organic leakage value and the preset diagnostic threshold, and combined with the current triggering state of the insulation resistance rapid detection cycle, a layered logic judgment is carried out to achieve targeted linkage triggering of the insulation resistance rapid detection cycle. When the organic leakage value reaches the preset diagnostic threshold, it is first determined whether the insulation resistance rapid detection cycle has been triggered. If the rapid detection cycle has not been triggered, a counting detection is started and the number of times is accumulated. When the counting detection reaches the preset number and the insulation resistance rapid detection cycle is still not triggered, the rapid detection cycle is directly triggered, so that the potential risk of organic leakage can be directly linked to the increase of insulation detection frequency. If the insulation resistance rapid detection cycle is already in the triggered state at the time of judgment, the original insulation resistance detection logic is directly continued to perform the detection, ensuring the continuity of the insulation resistance detection process, avoiding detection logic disorder caused by repeated adjustment, and making the organic leakage monitoring data an important basis for the control of the insulation resistance detection cycle, realizing the effective linkage between the potential risk of electrolyte leakage and the insulation detection response.

[0031] Furthermore, in one embodiment, S400 includes the following steps: S401: Compare the positive-to-ground insulation resistance test data and the negative-to-ground insulation resistance test data, and select the smaller value as the representative insulation resistance value of the high-voltage system. S402: Determine whether the representative insulation resistance value reaches the preset insulation failure threshold; S403: If the representative insulation resistance value reaches the preset insulation failure threshold and this state continues for a preset duration, the battery management system will perform an insulation resistance fault reporting operation.

[0032] In this embodiment, the characteristic detection value of the insulation resistance of the high-voltage system is selected as the core judgment criterion. Combined with threshold comparison and state continuity verification, the determination and reporting of insulation resistance faults are completed, thereby ensuring the accuracy of insulation resistance fault reporting. By comparing the insulation resistance detection data of the positive-to-ground and negative-to-ground paths, the smaller value is selected as the representative insulation resistance value of the high-voltage system. This value can accurately reflect the weak point of the insulation state of the high-voltage system and becomes the core reference for insulation failure judgment. Based on this representative insulation resistance value, it is compared with a preset insulation failure threshold to determine whether the high-voltage system is in a potential state of insulation failure. Simultaneously, a state continuity verification condition is set. Only when the representative insulation resistance value reaches the preset insulation failure threshold and the state remains stable for the preset duration will the battery management system perform the insulation resistance fault reporting operation. Through the duration verification design, false alarms caused by instantaneous fluctuations in detection data are effectively avoided, ensuring that the insulation resistance fault reporting results match the actual insulation failure state of the high-voltage system, thus ensuring the rigor and effectiveness of insulation resistance fault reporting.

[0033] Furthermore, in one embodiment, S400 includes the following steps: S404: Determine whether the organic leakage value has reached the preset leakage failure threshold, and at the same time determine whether the insulation resistance detection has failed to identify the insulation failure of the high-voltage system; S405: If the organic matter leakage value reaches the preset leakage failure threshold and the high-voltage system insulation has not been identified as failing, continue to monitor and update the organic matter leakage value in real time. S406: When the organic matter leakage value reaches the preset leakage alarm threshold, the battery management system directly executes the high organic matter concentration fault reporting operation, which is independent of the insulation resistance fault reporting process.

[0034] In this embodiment, a dual-condition parallel judgment method is used to define the preliminary scope of fault judgment, and the risk level is verified by continuous leakage value monitoring. Finally, a special feedback on electrolyte leakage risk is achieved through an independent reporting process. First, the comparison and judgment of organic matter leakage value with the preset leakage failure threshold are completed simultaneously, and the identification status of insulation failure of high-voltage system by insulation resistance detection is judged. Only the case where the organic matter leakage value reaches the preset leakage failure threshold and the insulation resistance detection does not identify the insulation failure is included in the judgment category of high organic matter concentration fault, so as to distinguish it from the scenario of insulation resistance fault reporting and avoid the cross-confusion of the two types of fault judgment. When the above two preconditions are met, the organic matter leakage value is continuously monitored and updated in real time to dynamically track the risk development trend of electrolyte leakage and provide continuous numerical basis for subsequent fault reporting. When the organic matter leakage value further reaches the preset leakage alarm threshold, the battery management system directly executes the high organic matter concentration fault reporting operation. This reporting operation is independent of the insulation resistance fault reporting process. When the insulation status of the high-voltage system is not abnormal, it realizes the special reporting of potential safety risks caused by electrolyte leakage, fills the reporting gap of the initial risk of electrolyte leakage when the insulation resistance detection is not triggered, and allows the safety risks related to electrolyte leakage to be identified and fed back separately from the insulation resistance failure state.

[0035] On the other hand, the embodiments of this application present an integrated solution of "detection system + detection strategy". By adding an electrolyte leakage value monitoring system and cooperating with the BMS to execute an optimized high-voltage insulation detection strategy, it can achieve risk identification in the early stage of battery cell structural damage / electrolyte leakage. The core includes an electrolyte leakage value monitoring system and three major high-voltage insulation detection sub-strategies. Figure 2 The complete execution logic of this strategy corresponds one-to-one with the following technical solutions.

[0036] (a) Electrolyte Leakage Monitoring System Structural design: The addition of an organic leakage sensor (liquid leakage sensor) within the sealed space of the power battery system (battery pack) is a core hardware improvement point; Working principle: When a minor electrolyte leak occurs due to structural damage to a battery cell, the concentration of organic solvents (esters) in the electrolyte increases within the sealed space of the battery pack. After the sensor absorbs the organic matter, it can detect the leakage value of organic matter in real time, realizing the acquisition and quantification of physical signals in the early stage of leakage, and providing a data basis for subsequent strategy execution.

[0037] (II) High-voltage insulation testing strategy for new energy vehicles This strategy is executed by the BMS and adds monitoring, diagnosis, and fault reporting of organic matter leakage values ​​to the original insulation detection logic. It includes three sub-strategies: insulation resistance inspection strategy, organic matter leakage value monitoring and diagnosis strategy, and high organic matter concentration fault reporting strategy. The three strategies are executed synchronously and data is interconnected, realizing full-process control of "periodic dynamic adjustment + early risk triggering + independent fault reporting".

[0038] 1. Insulation resistance testing strategy Basic testing: The BMS sequentially checks the insulation resistance values ​​of the positive to ground and negative to ground of the power battery system according to the original logic, and takes the smaller value as the representative insulation resistance value of the high voltage system. Period determination logic: When the detected insulation resistance value is > M (1~20MΩ), the insulation resistance is checked using a normal cycle t (10~20s) to match the normal insulation condition. When the detected insulation resistance value is ≤M (1~20MΩ), switch to fast cycle t1 (≤10s) to check the insulation resistance and quickly report the insulation resistance value; Strategy features: Although t1 has low insulation accuracy and may produce false alarms, it can remind the driver to check the cause of the fault in time and avoid fire caused by failure to identify the electrolyte leakage in the early stage.

[0039] 2. Organic matter leakage monitoring and diagnostic strategies This strategy is Figure 2 The core link between "organic leakage value and insulation cycle" enables proactive increases in insulation detection frequency in the early stages of leakage. The specific logic is as follows: Data synchronization: While performing insulation resistance detection, the BMS receives the organic leakage value transmitted by the organic leakage sensor in real time; Threshold determination and periodic triggering: When the detected organic leakage value is > N1 (500~5000ppm) and the BMS insulation test does not trigger the fast cycle t1, the counting check is started, and the cumulative check is W (10~50) cycles. If the BMS still does not trigger the fast cycle t1 after counting to W cycles, then t1 is triggered directly to check the insulation resistance. If the organic matter leakage value is greater than N1, the BMS has already triggered the fast cycle t1, and the original BMS insulation detection logic will be executed without additional control.

[0040] 3. High Organic Matter Concentration Fault Reporting Strategy This strategy is Figure 2 The "supplementary step in fault reporting" is independent of traditional insulation resistance fault reporting, filling the reporting gap when insulation failure is not triggered in the early stages of leakage. The specific logic is as follows: Dual-condition pre-judgment: In addition to the original positive to ground / negative to ground insulation resistance comparison, an organic matter leakage value judgment is added; when the organic matter leakage value reaches the failure threshold (between N1 and N2), but the BMS insulation resistance detection does not identify insulation failure, the organic matter leakage value continues to be monitored and updated in real time. Independent reporting trigger: When the organic matter leakage value further reaches the alarm threshold N2 (5000~10000ppm), the BMS directly reports a high organic matter concentration fault; Key features: This fault reporting operation is completely independent of the traditional insulation resistance fault reporting process and does not rely on insulation resistance test results.

[0041] This technical solution solves the problem of missed detection in existing technologies, enabling early identification and reporting of high-voltage insulation risks in power batteries. Compared with traditional detection methods, it can detect structural damage / electrolyte leakage problems in advance during reliability testing. Traditional testing: In a 70-hour reliability test, insulation abnormalities are reported only after 15 to 50 hours; in an 800,000-cycle simulated torsion test, insulation abnormalities are reported only after 199,000 cycles, indicating that the structural components are already severely damaged when the package is unpacked. After the implementation of this solution: In the 70-hour reliability test, insulation abnormalities can be reported within 15-30 hours; in the 800,000 simulated torsion test, insulation abnormalities can be reported within 150,000-300,000 cycles; upon unpacking, only initial structural damage / minor leakage of the battery cells is observed, effectively avoiding fire accidents caused by electrolyte leakage.

[0042] This application embodiment adds an organic matter leakage sensor to the power battery system to monitor the concentration of organic matter generated by electrolyte leakage in real time. It also achieves linkage with the insulation detection cycle through multi-threshold logic judgment, which can promptly detect the initial structural damage / minor electrolyte leakage of battery cells. In contrast, existing technologies can only identify risks when leakage / structural damage reaches a certain level (triggering insulation threshold / abnormal battery cell voltage / temperature), and cannot detect the initial state at all.

[0043] The effectiveness of the technical solution of this application's embodiments is fully verified here through three sets of comparative / verification examples. All embodiments are power battery reliability tests, with unified test items and methods, and only differences in sample configuration. Specific details are summarized below without omission: Example 1: Uniaxial mechanical reliability test of sample A without an organic leakage monitoring sensor Sample characteristics: Sample A, without an organic matter leakage monitoring sensor installed (traditional solution control group); Full range of testing items: total battery pack voltage, maximum / minimum voltage of individual cells, maximum / minimum temperature of individual cells, thermal runaway, instantaneous interruption of total voltage, and insulation resistance to ground / negative ground. Test conditions: First, complete random vibration of 1.44g in the Z direction for 42 hours → then complete random vibration of 1.33g in the X direction for 12 hours → finally complete random vibration of 1.33g in the X direction for 12 hours; Test results: No abnormalities were triggered by the monitoring signal throughout the test. After the test, the insulation resistance values ​​measured by the insulation meter to ground and to ground both met the design requirements. Disassembly results: Cracks were found on the top cover of 3 battery cells, and there was obvious electrolyte leakage (in the early stage of leakage, traditional detection would completely miss it).

[0044] Example 2: Uniaxial mechanical reliability test of sample B with organic matter leakage monitoring sensor installed Sample characteristics: Sample B, equipped with an organic matter leakage monitoring sensor (experimental group of this scheme); All testing items: completely consistent with Example 1; Test conditions: 1.44g random vibration in the Z direction (full cycle test not completed); Test results: After 27 hours of vibration, the BMS reported an insulation abnormality. After the test bench was disassembled, the insulation resistance values ​​of the positive to ground and negative to ground measured by the insulation meter still met the design requirements. Disassembly results: A crack was found in the weld of the top cover of one battery cell, and there was obvious electrolyte leakage (in the early stage of leakage, this solution successfully identified and reported it).

[0045] Example 3: Simulated Torsional Reliability Test of C / D / E Samples Equipped with Organic Leakage Monitoring Sensors Sample characteristics: Samples C, D, and E are all equipped with organic matter leakage monitoring sensors (batch verification group of this solution); The testing items throughout the entire process are completely consistent with those in Example 1, with each of the three samples being tested independently throughout the entire process. Test conditions: Simulated torsional reliability test, with a cumulative test run of 200,000 times; Test results: When the test reached 200,000 cycles, the BMS of sample C reported an insulation abnormality, while samples D and E did not report any abnormalities; after the bench was disassembled, the insulation resistance of sample C failed, while the insulation resistance values ​​of samples D and E met the design requirements. Disassembly results: Sample C was found to have one battery cell torn and a large amount of electrolyte spilled out (this solution reported the insulation failure stage in a timely manner, verifying the stability and effectiveness of the strategy).

[0046] Secondly, this application also provides a high-voltage insulation detection device for new energy vehicles. The high-voltage insulation detection device includes: a dual-parameter monitoring module, used to monitor the organic matter leakage value of the electrolyte in the power battery system in real time, and simultaneously perform insulation resistance detection on the high-voltage system to ground and negative ground; a detection cycle adaptive adjustment module, used to compare the insulation resistance detection value with a preset insulation threshold and dynamically adjust the insulation resistance detection cycle based on the judgment result; a rapid detection trigger module, used to compare the organic matter leakage monitoring value with a preset diagnostic threshold and determine whether to trigger the rapid detection cycle of insulation resistance based on the judgment result; and a comprehensive fault reporting module, used to execute a fault reporting strategy based on the insulation resistance detection result and the organic matter leakage monitoring value; wherein the fault reporting strategy includes insulation resistance fault reporting and independent fault reporting for high organic matter concentration.

[0047] The functions of each module in the above-mentioned high-voltage insulation testing device for new energy vehicles correspond to the steps in the above-mentioned high-voltage insulation testing method embodiment for new energy vehicles, and their functions and implementation processes will not be described in detail here.

[0048] Thirdly, embodiments of this application provide a vehicle that includes the new energy vehicle high-voltage insulation detection device as described above.

[0049] Fourthly, this application provides a high-voltage insulation testing device for new energy vehicles. The high-voltage insulation testing device for new energy vehicles can be a personal computer (PC), laptop computer, server, or other device with data processing capabilities.

[0050] Reference Figure 3 , Figure 3 This is a schematic diagram of the hardware structure of the high-voltage insulation testing equipment for new energy vehicles involved in the embodiments of this application. In this embodiment, the high-voltage insulation testing equipment for new energy vehicles may include a processor, a memory, a communication interface, and a communication bus.

[0051] The communication bus can be of any type and is used to interconnect the processor, memory, and communication interface.

[0052] The communication interface includes input / output (I / O) interfaces, physical interfaces, and logical interfaces used for interconnecting internal components of the high-voltage insulation testing equipment for new energy vehicles, as well as interfaces used for interconnecting the high-voltage insulation testing equipment for new energy vehicles with other devices (such as other computing devices or user equipment). Physical interfaces can be Ethernet interfaces, fiber optic interfaces, ATM interfaces, etc.; user equipment can be displays, keyboards, etc.

[0053] Memory can be various types of storage media, such as random access memory (RAM), read-only memory (ROM), non-volatile RAM (NVRAM), flash memory, optical storage, hard disk, programmable ROM (PROM), erasable PROM (EPROM), electrically erasable PROM (EEPROM), etc.

[0054] The processor can be a general-purpose processor, which can call the high-voltage insulation detection program for new energy vehicles stored in the memory and execute the high-voltage insulation detection method for new energy vehicles provided in the embodiments of this application. For example, the general-purpose processor can be a central processing unit (CPU). The method executed when the high-voltage insulation detection program for new energy vehicles is called can be referred to in the various embodiments of the high-voltage insulation detection method for new energy vehicles in this application, and will not be repeated here.

[0055] Those skilled in the art will understand that Figure 3 The hardware structure shown does not constitute a limitation of this application and may include more or fewer components than shown, or combine certain components, or have different component arrangements.

[0056] Fifthly, embodiments of this application also provide a readable storage medium.

[0057] The present application has a storage medium storing a high-voltage insulation testing program for new energy vehicles, wherein when the high-voltage insulation testing program for new energy vehicles is executed by a processor, the steps of the high-voltage insulation testing method for new energy vehicles described above are implemented.

[0058] The method implemented when the high-voltage insulation testing procedure for new energy vehicles is executed can be referred to in the various embodiments of the high-voltage insulation testing method for new energy vehicles in this application, and will not be repeated here.

[0059] It should be noted that the sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0060] The terms "comprising" and "having," and any variations thereof, in the specification, claims, and accompanying drawings of this application are intended to cover a non-exclusive inclusion. For example, a process, method, system, product, or apparatus that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to such process, method, product, or apparatus. The terms "first," "second," and "third," etc., are used to distinguish different objects, etc., and do not indicate a sequence, nor do they limit "first," "second," and "third" to different types.

[0061] In the description of the embodiments of this application, terms such as "exemplary," "for example," or "for instance" are used to indicate examples, illustrations, or explanations. Any embodiment or design described as "exemplary," "for example," or "for instance" in the embodiments of this application should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of terms such as "exemplary," "for example," or "for instance" is intended to present the relevant concepts in a concrete manner.

[0062] In the description of the embodiments of this application, unless otherwise stated, " / " means "or". For example, A / B can mean A or B. The "and / or" in the text is merely a description of the relationship between related objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, A and B exist simultaneously, and B exists alone. In addition, in the description of the embodiments of this application, "multiple" means two or more.

[0063] In some processes described in the embodiments of this application, multiple operations or steps are included in a specific order. However, it should be understood that these operations or steps may not be executed in the order they appear in the embodiments of this application, or they may be executed in parallel. The sequence number of the operation is only used to distinguish different operations, and the sequence number itself does not represent any execution order. In addition, these processes may include more or fewer operations, and these operations or steps may be executed sequentially or in parallel, and these operations or steps may be combined.

[0064] Through the above description of the embodiments, those skilled in the art can clearly understand that the methods of the above embodiments can be implemented by means of software plus necessary general-purpose hardware platforms. Of course, they can also be implemented by hardware, but in many cases the former is a better implementation method. Based on this understanding, the technical solution of this application, in essence, or the part that contributes to the prior art, can be embodied in the form of a software product. This computer software product is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk) as described above, and includes several instructions to cause a terminal device to execute the methods described in the various embodiments of this application.

[0065] The above are merely preferred embodiments of this application and do not limit the patent scope of this application. Any equivalent structural or procedural transformations made using the content of this application's specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of this application.

Claims

1. A method for testing high-voltage insulation in new energy vehicles, characterized in that, The high-voltage insulation testing method for new energy vehicles includes: Real-time monitoring of organic matter leakage value in the electrolyte of the power battery system, and simultaneous detection of insulation resistance of the high voltage system to ground and negative ground; The insulation resistance test value is compared with the preset insulation threshold for judgment, and the detection cycle of insulation resistance is dynamically adjusted based on the judgment result; The organic matter leakage monitoring value is compared with the preset diagnostic threshold, and the judgment result determines whether to trigger the rapid detection cycle of insulation resistance. Based on the insulation resistance test results and organic matter leakage monitoring values, a fault reporting strategy is implemented; the fault reporting strategy includes insulation resistance fault reporting and independent fault reporting of high organic matter concentration.

2. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The step of comparing the insulation resistance detection value with a preset insulation threshold and dynamically adjusting the insulation resistance detection cycle based on the judgment result includes: Determine whether the detected insulation resistance exceeds the preset insulation threshold. If the insulation resistance exceeds the preset insulation threshold, the insulation resistance should be tested using a regular testing cycle. If the insulation resistance does not exceed the preset insulation threshold, a rapid testing cycle is used to test the insulation resistance; the testing frequency of the rapid testing cycle is higher than that of the conventional testing cycle.

3. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The step of comparing the organic leakage monitoring value with a preset diagnostic threshold and determining whether to trigger a rapid insulation resistance detection cycle based on the judgment result includes: Determine whether the real-time acquired organic matter leakage value reaches the preset diagnostic threshold; If the organic matter leakage value reaches the preset diagnostic threshold and the insulation resistance test does not trigger the rapid detection cycle, then the counting test will begin. When the count detection reaches the preset number of times, the insulation resistance detection still does not trigger the fast detection cycle, and the insulation resistance fast detection cycle is directly triggered. If the organic matter leakage value reaches the preset diagnostic threshold, and the insulation resistance detection has triggered the rapid detection cycle, then the current rapid detection cycle will continue to be executed without any additional adjustment to the insulation resistance detection cycle.

4. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The insulation resistance fault reporting in the fault reporting strategy includes: Compare the positive-to-ground insulation resistance test data and the negative-to-ground insulation resistance test data, and select the smaller value as the representative insulation resistance value of the high-voltage system. Determine whether the representative insulation resistance value reaches the preset insulation failure threshold; If the representative insulation resistance value reaches the preset insulation failure threshold and this state continues for a preset duration, the battery management system will perform an insulation resistance fault reporting operation.

5. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The fault reporting strategy includes independent fault reporting for high organic matter concentration, which includes: Determine whether the organic matter leakage value has reached the preset leakage failure threshold, and at the same time determine whether the insulation resistance detection has failed to identify the insulation failure of the high-voltage system; If the organic matter leakage value reaches the preset leakage failure threshold and the high-voltage system insulation has not been identified as failing, the organic matter leakage value will continue to be monitored and updated in real time. When the organic matter leakage value reaches the preset leakage alarm threshold, the battery management system directly executes the high organic matter concentration fault reporting operation, which is independent of the insulation resistance fault reporting process.

6. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The insulation resistance test of the high-voltage system to ground and to ground includes: The battery management system sequentially detects the positive-to-ground insulation resistance and negative-to-ground insulation resistance of the high-voltage system according to the preset inspection logic. Acquire real-time detection data of insulation resistance between positive and negative ground; The insulation resistance detection data from both circuits are stored in real time and used as the basis for judging the insulation status of the high-voltage system.

7. The high-voltage insulation testing method for new energy vehicles as described in claim 1, characterized in that, The real-time monitoring of organic matter leakage values ​​in the electrolyte within the power battery system includes: The concentration signal of organic solvent generated by electrolyte leakage is collected in the sealed space of the power battery system, and the organic solvent concentration signal is converted into a quantified organic leakage value. The organic matter leakage value is transmitted to the battery management system in real time and stored synchronously with the insulation resistance detection data.

8. A high-voltage insulation testing device for new energy vehicles, characterized in that, The high-voltage insulation testing device for new energy vehicles includes: The dual-parameter monitoring module is used to monitor the leakage value of organic matter in the electrolyte of the power battery system in real time, and at the same time to detect the insulation resistance of the high voltage system to ground and to ground. The detection cycle adaptive adjustment module is used to compare the insulation resistance detection value with the preset insulation threshold and dynamically adjust the insulation resistance detection cycle based on the judgment result. The rapid detection trigger module is used to compare the organic matter leakage monitoring value with the preset diagnostic threshold and determine whether to trigger the rapid detection cycle of insulation resistance based on the judgment result. The integrated fault reporting module is used to execute fault reporting strategies based on insulation resistance detection results and organic matter leakage monitoring values; the fault reporting strategies include insulation resistance fault reporting and independent fault reporting of high organic matter concentration.

9. A vehicle, characterized in that, It includes the high-voltage insulation testing device for new energy vehicles as described in claim 8.

10. A high-voltage insulation testing device for new energy vehicles, characterized in that, The new energy vehicle high-voltage insulation testing equipment includes a processor, a memory, and a new energy vehicle high-voltage insulation testing program stored in the memory and executable by the processor. When the new energy vehicle high-voltage insulation testing program is executed by the processor, it implements the steps of the new energy vehicle high-voltage insulation testing method as described in any one of claims 1 to 7.

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