Electric wide-body vehicle fault reporting system

Abstract

The utility model discloses an electric wide-body vehicle fault reporting system which comprises a VCU control module, an exterior control module, a power control module, a T-BOX terminal, an instrument and a signal receiving terminal, the whole VCU control module comprises a VCU controller and a controlled assembly which are in signal connection with each other, and the exterior control module comprises an exterior controller and an exterior assembly which are in signal connection with each other. The VCU controller, the external controller and the power control module respectively feed back fault signals to the CAN bus, the T-BOX terminal and the instrument respectively read the fault signals on the CAN bus, the T-BOX terminal feeds back the fault signals to the signal receiving terminal to inform the fault information, and the instrument displays the fault information. According to the utility model, fault coverage and accurate positioning of the whole vehicle are realized, dynamic reliability optimization is carried out, the anti-interference capability is improved, efficient communication is realized, and data collaborative analysis is realized.

Description

Technical Field

[0001] This utility model relates to a fault reporting system for electric wide-body vehicles, belonging to the technical field of electric wide-body vehicles. Background Technology

[0002] Electric wide-body mining trucks are a new generation of engineering transportation equipment designed specifically for heavy-duty scenarios such as mines and large open-pit mines. Their core features lie in optimizing load capacity and driving stability through a widened body structure, and integrating electrification technology to achieve high efficiency and energy saving. However, they have significant technical deficiencies in fault diagnosis and operational stability.

[0003] The existing mining truck control system suffers from limited fault coverage and low diagnostic efficiency. Its intelligence level is insufficient; the controller cannot effectively identify potential fault types in core components, and the lack of an embedded fault feedback mechanism limits the number of faults that can be reported. When complex faults occur, manual on-site troubleshooting is required, which is time-consuming, labor-intensive, and makes it difficult to quickly locate the fault source, severely impacting equipment uptime.

[0004] The fault reporting system lacks reliability. Traditional fault diagnosis logic uses a single threshold trigger mechanism, which has two core problems: First, when actual operating conditions meet the fault triggering conditions, the system is prone to missed reports due to signal interference or algorithm defects; second, slight environmental disturbances can easily trigger false alarms. These two problems directly affect the accuracy of fault diagnosis, resulting in a lack of data support for the overall machine's operational stability.

[0005] The adaptability deficiencies of complex system communication architectures. With the expansion of functional modules in electric mining trucks, the amount of communication data generated by the collaboration of multiple components is growing exponentially. Existing communication protocols struggle to meet the demands of high-concurrency data transmission, leading to problems such as delayed fault information transmission and data packet loss, further exacerbating the diagnostic difficulties when multiple faults overlap. Simultaneously, the lack of a unified fault information integration platform makes real-time collaborative analysis of multi-source heterogeneous data impossible. Summary of the Invention

[0006] Purpose of the invention: To address the shortcomings of existing technologies, this invention provides a fault reporting system for electric wide-body vehicles. This invention uses a CAN bus to collect fault signals from various components of the vehicle, accurately locates faults, and enables targeted repairs, thereby improving the coverage of fault monitoring. At the same time, it sets up an anti-interference time mechanism to improve the stability of fault reporting.

[0007] Technical solution: A kind of electric wide-body vehicle fault reporting system, including VCU control module, external control module, power control module, T-BOX terminal, instrument, signal receiving terminal, the VCU control module includes VCU controller and controlled component connected by mutual signal, the external control module includes external controller and external component connected by mutual signal, the VCU controller, external controller, power control module respectively feedback fault signal to CAN bus, the T-BOX terminal and instrument respectively read fault signal on CAN bus, T-BOX terminal feedback fault signal to signal receiving terminal to inform fault information, the instrument displays fault information.

[0008] By connecting VCU controller, external controller and power control module for responsible low-voltage power distribution, monitor whether low-voltage wire harness fault respectively with CAN bus signal, cover all vehicle fault type, independent transmission fault signal, again by T-BOX terminal and instrument to fault signal reading, T-BOX terminal feedback signal read to signal receiving terminal, signal receiving terminal is divided into online platform and app terminal, can provide online remote master machine fault information for manufacturer, app terminal informs simple fault, user can independently repair according to fault prompt, realize unmanned online service and multiple data real-time collaborative analysis.

[0009] Preferred, to realize the comprehensiveness of VCU controller fault feedback, the controlled component includes controlled controller, whole machine sensor, controlled subsystem, controlled parts, the controlled controller, whole machine sensor, controlled subsystem, controlled parts are connected with VCU controller signal, and the real-time state of each is sent to VCU controller, and VCU controller obtains the fault condition and feedback fault signal to CAN bus.

[0010] Preferred, to realize the fault detection of low-voltage wire harness, the power control module includes power controller and whole machine electric connection wire harness, and the power controller obtains current value to judge fault condition through whole machine electric connection wire harness, and feedback fault signal to CAN bus.

[0011] Beneficial effect: the utility model discloses an integrated VCU controller, external controller and power control module to CAN bus architecture, independent acquisition and feedback core parts, whole machine sensor, low-voltage wire harness and the real-time state of external component, constructs the global fault detection network.Detects low-voltage wire harness fault when power on, ensures system initial safety;Start controller and component detection after 3 seconds, avoid misjudgment interference.Determine short-circuit / open-circuit fault by differentiating current threshold, and improve the accuracy of fault identification by combining pin voltage monitoring, cover mechanical, electrical and communication composite fault, realize whole vehicle fault coverage and accurate positioning;

[0012] The fault judgment logic adopts three consecutive frame packet loss as the communication fault judgment standard, combines with the 1.5 second continuous abnormal detection threshold, effectively filters transient signal interference, the power controller monitors the current anomaly under different working conditions in real time, dynamically adjusts the judgment condition, ensures the diagnosis robustness under complex working conditions, realizes dynamic reliability optimization and anti-interference ability;

[0013] Based on the high concurrency data transmission capability of the CAN bus, the system realizes the millisecond level response of the fault signal, combines the double channel feedback of the online platform and the APP terminal, supports the remote real-time analysis of the fault data packet, realizes the collaborative analysis of the multi-source heterogeneous data, realizes efficient communication and data collaborative analysis;

[0014] Through the double warning mechanism of instrument display and T-BOX terminal remote reporting, the user can quickly locate the fault and independently handle simple problems, reduce the on-site manual troubleshooting time. The system automatic recovery mechanism, i.e. the next power cycle resets the fault state and fault removal confirmation process, i.e. the 1.5 second normal state judgment, reduces the false maintenance frequency and improves the equipment attendance rate. In addition, the instantaneous cut-off protection function of the low-voltage wire harness fault can avoid the expansion of the fault and prolong the service life of the components. BRIEF DESCRIPTION OF DRAWINGS

[0015] In order to more clearly illustrate the technical schemes in the embodiments of the present application or the prior art, the drawings needed to be used in the embodiment or prior art description will be briefly introduced as follows. Obviously, the drawings in the following description are only a part of the embodiments of the present application, and for those skilled in the art, other drawings can be obtained without creative labor on the basis of the provided drawings.

[0016] Figure 1 It is a system structure schematic diagram of the present application. DETAILED DESCRIPTION

[0017] The technical schemes in the embodiments of the present application will be described clearly and completely in combination with the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0018] In the description of the utility model, it is understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the utility model.

[0019] In the utility model, unless otherwise expressly specified and limited, the "upper" or "lower" of the first feature in the second feature can include that the first and second features are in direct contact, or can include that the first and second features are not in direct contact but are in contact through another feature between them. Moreover, the "upper", "upper" and "upper" of the first feature in the second feature include that the first feature is directly above and obliquely above the second feature, or only indicates that the horizontal height of the first feature is higher than that of the second feature. The "below", "below" and "below" of the first feature in the second feature include that the first feature is directly below and obliquely below the second feature, or only indicates that the horizontal height of the first feature is less than that of the second feature.

[0020] As shown in Figure 1 A kind of electric wide-body vehicle fault reporting system, including VCU control module 1, outer control module 2, power control module 3, T-BOX terminal 4, instrument 5, signal receiving terminal 6, the VCU control module 1 includes VCU controller 11 and controlled component of mutual signal connection, the outer control module 2 includes outer controller 21 and outer component 22 of mutual signal connection, the VCU controller 11, outer controller 21, power control module 3 respectively feedback fault signal to CAN bus, the T-BOX terminal 4 and instrument 5 respectively read fault signal on CAN bus, T-BOX terminal 4 feedback fault signal to signal receiving terminal 6 to inform fault information, the instrument 5 shows fault information.

[0021] By VCU controller 11, outer controller 21 and power control module 3 for being responsible for low-voltage power distribution, monitoring whether low-voltage wire harness appears fault are respectively connected with CAN bus signal, cover whole vehicle fault type, independently send fault signal, then by T-BOX terminal 4 and instrument 5 to fault signal reading, T-BOX terminal 4 feedback signal read to signal receiving terminal 6, signal receiving terminal 6 is divided into online platform and app terminal, can provide online remote whole machine fault information for manufacturer, app terminal informs simple fault, user can independently maintain according to fault prompt, realize unmanned online service and multiple data real-time collaborative analysis.

[0022] In order to realize the comprehensiveness of the fault feedback of the VCU controller 11, the controlled components include the controlled controller 12, the whole machine sensor 13, the controlled subsystem 14, and the controlled parts 15, which are respectively connected with the VCU controller 11 in signal and send the real-time state of each to the VCU controller 11, so that the VCU controller 11 knows the fault condition and feeds back the fault signal to the CAN bus.

[0023] In order to realize the fault detection of the low-voltage wire harness, the power control module 3 includes the power controller 31 and the whole machine electrical connection wire harness 32, the power controller 31 obtains the current value through the whole machine electrical connection wire harness 32 to judge the fault condition, and feeds back the fault signal to the CAN bus.

[0024] The control method for realizing the fault reporting system of the electric wide-body vehicle includes:

[0025] After the whole machine is powered on, the power controller 31 detects whether the electrical connection wire harness has a fault, and if there is a fault, it is fed back to the CAN bus, and the machine is stopped for maintenance, and after the maintenance is completed, the whole machine electrical connection wire harness 32 is detected again whether there is a fault; if there is no fault, after being powered on for 3s, the VCU controller 11 detects the fault condition of the controlled controller 12 communication, the whole machine sensor 13, the controlled subsystem 14, and the controlled parts 15, and if any fault occurs, it is fed back to the CAN bus; the external controller 21 detects the fault condition of the external component 22, and if there is a fault, it is fed back to the CAN bus;

[0026] At the same time, after being powered on for 3s, the T-BOX terminal 4 and the instrument 5 read the heartbeat message and the key information message of the VCU controller 11 or the power controller 31 or the external controller 21 from the CAN bus, and if any message is not read for three frames in a row, it is determined that the VCU controller 11 or the power controller 31 or the external controller 21 has a communication fault, Embodiment one

[0027] The key information message of the VCU controller 11 is the low-voltage system voltage, and the key information message of the power controller 31 is the input voltage;

[0028] The instrument 5 displays the fault information to the staff, and the T-BOX terminal 4 sends the fault signal to the signal receiving terminal 6 to inform the manufacturer or the user of the current fault condition;

[0029] If the fault reporting is completed, the VCU controller 11, the power controller 31, and the external controller 21 detect that the reported fault condition has returned to normal, then stop sending the fault signal to the CAN bus, and send the normal signal to it;

[0030] Or T-BOX terminal 4 and instrument 5 continuously read three frames from CAN bus simultaneously to the heartbeat message and key information message of VCU controller 11 or power controller 31 or external controller 21, then T-BOX terminal 4 stops sending fault signals to signal receiving terminal 6, and instrument 5 displays that the state of VCU controller 11 or power controller 31 or external controller 21 is normal.

[0031] The utility model discloses a low voltage wire harness fault detection system, including VCU controller 11, power controller 31, external controller 21, T-BOX terminal 4 and instrument 5, the CAN bus of VCU controller 11, power controller 31 and external controller 21 are connected, and T-BOX terminal 4 and instrument 5 are connected to CAN bus.

[0032] The power controller 31 detects the fault condition of the electric connection wire harness, and specifically is:

[0033] When there is a power output request greater than 3w, the power controller 31 monitors the current value of any electric connection wire harness greater than 2 times the set current maximum value, and the power controller 31 determines that the branch has a short circuit fault, and immediately disconnects the branch electromagnetic coil and reports a short circuit fault to the CAN bus;

[0034] The power controller 31 monitors the current value of any electric connection wire harness less than 0.5 times the set current maximum value, and the power controller 31 determines that the branch has an open circuit fault, and immediately disconnects the branch electromagnetic coil and reports an open circuit fault to the CAN bus;

[0035] When there is no power request, the power controller 31 monitors the output pin voltage value in real time, and if the voltage value exceeds 3.3V, it is determined that the pin has a short circuit fault with the power supply;

[0036] After the above fault condition is triggered, the current power-on period stops responding to the power output request, and automatically recovers in the next power-on period;

[0037] When there is a power output request less than or equal to 3w, the power controller 31 monitors the current value of any electric connection wire harness greater than 3 times the set current maximum value, and the power controller 31 determines that the branch has a short circuit fault, and immediately disconnects the branch electromagnetic coil and reports a short circuit fault to the CAN bus;

[0038] When the power controller 31 monitors that the current value of any electrical connection bundle is less than 0.25 times of the set maximum current value, the power controller 31 determines that an open circuit fault occurs in the branch, and then disconnects the branch electromagnetic coil and immediately reports the open circuit fault to the CAN bus;

[0039] When there is no power request, the power controller 31 monitors the output pin voltage value in real time, and if the voltage value exceeds 1.5V, it is determined that the pin has a short circuit fault with the power supply;

[0040] After the above fault conditions are triggered, the current power-on period stops responding to power output requests, and automatically recovers in the next power-on period.

[0041] The VCU controller 11 detects the communication fault conditions of the controlled controller 12, which are as follows:

[0042] If the VCU controller 11 cannot detect any of the heartbeat messages and key information messages of the controlled controller 12 within 1.5s in three consecutive frames, i.e. within 500ms of the heartbeat message period, it is determined that the controlled controller 12 has a fault, and the VCU controller 11 sends a fault signal to the CAN bus; after the reporting is completed, the VCU controller 11 detects the heartbeat message and key information message of the controlled controller 12 in three consecutive frames, and determines that the controlled controller 12 is normal, stops sending the fault signal to the CAN bus, and sends a normal signal to it. Example two

[0043] The controlled controller is a TCU controller, which needs to obtain its heartbeat message and key information message, i.e. output shaft speed message.

[0044] The VCU controller 11 detects the fault conditions of the whole machine sensor 13, which are as follows:

[0045] If the VCU controller 11 detects that the feedback value of the whole machine sensor 13 exceeds its set rated range, and the duration is greater than or equal to 1.5s, it is determined that the whole machine sensor 13 has a fault, and the VCU controller 11 sends a whole machine sensor 13 fault signal to the CAN bus; after the reporting is completed, the VCU controller 11 detects that the feedback value of the whole machine sensor 13 component returns to normal, i.e. within the rated range, and the duration is greater than or equal to 1.5s, it is determined that the whole machine sensor 13 component returns to normal, stops sending the fault signal to the CAN bus, and sends a normal signal to it. Example three

[0046] The pressure / hydraulic sensor has a feedback value of current signal, and its rated range is 4-20mA. If it exceeds the rated range, and the duration is greater than or equal to 1.5s, it is determined that the pressure / hydraulic sensor has a fault.

[0047] The VCU controller 11 detects the fault condition of the controlled subsystem 14, the controlled component 15, and the external controller 21 detects the fault condition of the external component 22. Specifically, the VCU controller 11 detects the fault condition of the controlled subsystem 14, the controlled component 15, and the external controller 21 detects the fault condition of the external component 22.

[0048] If the VCU controller 11 detects that the controlled subsystem 14 sends a fault signal to it or the controlled component 15 sends a valid fault feedback pin signal, and the duration is greater than or equal to 1.5s, the VCU controller 11 determines that the controlled subsystem 14 or the controlled component 15 has a fault, and sends a fault signal of the whole machine sensor 13 to the CAN bus; after the report is completed, the VCU controller 11 detects that the controlled subsystem 14 or the controlled component 15 has no fault condition, and the duration is greater than or equal to 1.5s, then it is determined that the controlled subsystem 14 or the controlled component 15 has returned to normal, and stops sending a fault signal to the CAN bus, and sends a normal signal to it. Example Four

[0049] The controlled subsystem is the steering system, the 360 ring / around view system, the controlled component is the motor cooling water pump, the emergency steering motor,

[0050] If the external controller 21 detects that the external component 22 sends a fault signal to it and the duration is greater than or equal to 1.5s, the external controller 21 determines that the external component 22 has a fault, and sends a fault signal of the external component 22 to the CAN bus; after the report is completed, the external controller 21 detects that the external component 22 has no fault condition, and the duration is greater than or equal to 1.5s, then it is determined that the external component 22 has returned to normal, and stops sending a fault signal to the CAN bus, and sends a normal signal to it. Example Five

[0051] The external component is the weighing system, the tire pressure system, the external controller is the weighing system controller, the tire pressure system controller, the key information message of the weighing system controller is the weight, and the key information message of the tire pressure system controller is the tire pressure value;

[0052] The T-BOX terminal 4 obtains the fault signal from the CAN bus, specifically:

[0053] The T-BOX monitors in real time, if it detects a fault signal on the CAN bus, it immediately reads the fault signal and reports the fault message data to the signal receiving terminal 6, the minimum reading period of the CAN bus is 100ms, the fault signal reporting period is 500ms, when a fault signal is detected, the reading and reporting is started, if the fault signal reporting period is less than 500ms, the T-BOX terminal 4 ignores the fault signal and does not report the fault.

[0054] The various embodiments described in this specification are presented by way of example, and each embodiment is presented for the purpose of conveying the novelty and inventive aspects of the present patent application. Each embodiment is presented in a progressive and explanatory manner, and each embodiment highlights differences from other embodiments. The same or similar parts and / or functions between embodiments are to be understood as mutual references among the embodiments.

[0055] The above description of disclosed embodiments is intended to be illustrative and not restrictive. Many modifications of these embodiments by one having ordinary skill in the art are intended to be within the scope of the following claims. Thus, the present patent application is not to be limited to the embodiments described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A fault reporting system for an electric wide-body vehicle, characterized in that: The system includes a VCU control module (1), an external control module (2), a power control module (3), a T-BOX terminal (4), an instrument (5), and a signal receiving terminal (6). The VCU control module (1) includes a VCU controller (11) and a controlled component that are interconnected by signals. The external control module (2) includes an external controller (21) and an external component (22) that are interconnected by signals. The VCU controller (11), the external controller (21), and the power control module (3) respectively feed back fault signals to the CAN bus. The T-BOX terminal (4) and the instrument (5) respectively read the fault signals on the CAN bus. The T-BOX terminal (4) feeds back the fault signals to the signal receiving terminal (6) to inform of the fault information. The instrument (5) displays the fault information.

2. The electric wide-body vehicle fault reporting system according to claim 1, characterized in that: The controlled components include a controlled controller (12), a whole machine sensor (13), a controlled subsystem (14), and a controlled component (15). The controlled controller (12), the whole machine sensor (13), the controlled subsystem (14), and the controlled component (15) are respectively connected to the VCU controller (11) and send their real-time status to the VCU controller (11). The VCU controller (11) learns of the fault and feeds back the fault signal to the CAN bus.

3. The electric wide-body vehicle fault reporting system according to claim 2, characterized in that: The power control module (3) includes a power controller (31) and a whole machine electrical connection harness (32). The power controller (31) obtains the current value through the whole machine electrical connection harness (32) to determine the fault condition and feeds back the fault signal to the CAN bus.

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