Redundant control and failure protection circuit in high-voltage battery system
By employing a dual-redundant control and failure detection circuit using relays and bidirectional thyristors in the high-voltage battery system, the problems of contact adhesion and single-device failure under high-current conditions are solved, achieving high-reliability and safe battery system control.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- SHANGHAI PYTES ENERGY CO LTD
- Filing Date
- 2025-06-25
- Publication Date
- 2026-06-23
AI Technical Summary
Existing high-voltage battery systems face risks of contact adhesion and single-component failure under high-current conditions. They lack dual-path collaborative control and fault redundancy mechanisms, thus failing to meet functional safety requirements.
Dual redundancy control is achieved by using relays and bidirectional thyristors, combined with failure detection circuits and air switch protection. The relays are turned on and off with zero current, which extends the service life of the relays. In case of a fault, the air switch is disconnected through the shunt trip unit, realizing dual-path synchronous judgment and fault isolation.
It improves the safety and reliability of high-voltage battery systems, reduces the probability of circuit failure, ensures timely disconnection of power supply in case of failure, and provides multiple safety guarantees.
Smart Images
Figure CN224401185U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of battery system management technology, specifically a redundancy control and failure protection circuit in a high-voltage battery system. Background Technology
[0002] With the rapid development of electric vehicles, energy storage systems, and other fields, the safety and reliability of high-voltage battery systems have attracted much attention. Existing circuits typically use a single relay to control the heating pad's on / off state, but especially under high-current conditions, there is a risk of contact sticking, which can easily lead to heating pad malfunction and battery thermal runaway. Meanwhile, while using a single thyristor solution avoids mechanical wear, it carries the risk of breakdown failure. A single device cannot meet functional safety requirements, and there is a lack of dual-path collaborative control and fault redundancy mechanisms specifically for high-voltage battery heating scenarios. Utility Model Content
[0003] To address the problems mentioned in the background section, this utility model provides a redundancy control and failure protection circuit for a high-voltage battery system, including a power supply, a heating pad, an MCU chip, a relay control circuit, a bidirectional thyristor control circuit, a failure detection circuit, a shunt trip unit, and an air switch. The relay control circuit has a HEAT_CTRL_H port and a Vheat+ port; the bidirectional thyristor control circuit has a HEAT_CTRL_L port and a Vheat- port; the failure detection circuit has a Vheat+ port and a Vheat- port; the heating pad has a Vheat+ port and a Vheat- port; the power supply has a neutral wire and a live wire, and the live wire of the power supply is connected to the relay control circuit via the air switch. The neutral wire of the power supply is connected to the bidirectional thyristor control circuit via an air switch. The Vheat+ port of the heating pad is connected to the Vheat+ port of the failure detection circuit and the Vheat+ port of the relay control circuit. The Vheat- port of the heating pad is connected to the Vheat- port of the failure detection circuit and the Vheat- port of the bidirectional thyristor control circuit. One output pin of the MCU chip is connected to the shunt trip control terminal, and the shunt trip is connected to the air switch. One analog input pin of the MCU chip is connected to the MCU_REF_HEAT port. One control pin of the MCU chip is connected to the HEAT_CTRL_H port, and the other control pin of the MCU chip is connected to the HEAT_CTRL_L port.
[0004] The relay control circuit includes a relay U1, which is model HF32F-G / 005-HT. Pin 1 of relay U1 is connected to a 5V voltage and the negative terminal of diode D1. Pin 2 of relay U1 is connected to the positive terminal of diode D1 and the collector of transistor Q1. The base of transistor Q1 is connected to one end of capacitor C1, one end of resistor R1, and one end of resistor R2. The other end of resistor R1 is connected to the HEAT_CTRL_H port. The emitter of transistor Q1, the other end of capacitor C1, and the other end of resistor R2 are grounded together. Pin 3 of relay U1 is connected to the Vheat+ port, and pin 4 of relay U1 is connected to the live wire.
[0005] The bidirectional thyristor control circuit includes a bidirectional thyristor Q2 and a thyristor output optocoupler U6. The bidirectional thyristor Q2 is a T810-600B-TR or T810-600B-ST model. Pin 1 of the thyristor output optocoupler U6 is connected to one end of resistor R18, and the other end of resistor R18 is connected to a 3.3V voltage. Pin 2 of the thyristor output optocoupler U6 is connected to the collector of transistor Q3. The base of transistor Q3 is connected to one end of capacitor C10, one end of resistor R24, and one end of resistor R23. The other end of resistor R23 is connected to the HEAT_CTRL_L port. The emitter of transistor Q3 and the other end of capacitor C10... One end of the resistor R24 and the other end of the resistor R24 are grounded together. Pin 4 of the thyristor output optocoupler U6 is connected to one end of the resistor R21 and pin 3 of the triac Q2. The other end of the resistor R21 is connected to pin 1 of the triac Q2, one end of the resistor R22 and the neutral line. Pin 6 of the thyristor output optocoupler U6 is connected to one end of the resistor R19. The other end of the resistor R19 is connected to one end of the resistor R20. The other end of the resistor R20 is connected to pin 2 of the triac Q2, one end of the capacitor C8 and the Vheat-port. The other end of the capacitor C8 is connected to one end of the capacitor C9. The other end of the capacitor C9 is connected to the other end of the resistor R22.
[0006] The failure detection circuit includes operational amplifier U3, which is an LM358BIDR model. Pin 4 of operational amplifier U3 is grounded. Pin 5 of operational amplifier U3 is connected to one end of resistor R13. The other end of resistor R13 is connected to one end of resistor R14 and one end of capacitor C3. The other end of capacitor C3 is grounded. The other end of resistor R14 is connected to one end of resistor R15 and one end of capacitor C4. The other end of capacitor C4 is grounded. The other end of resistor R15 is connected to... One end of the optocoupler U4 is connected to the emitter, and the other end of resistor R11 is grounded. The collector of optocoupler U4 is connected to one end of capacitor C6 and a 3.3V voltage, while the other end of capacitor C6 is grounded. The negative terminal of optocoupler U4 is connected to one end of capacitor C5 and grounded. The positive terminal of optocoupler U4 is connected to the other end of capacitor C5 and one end of resistor R16. The other end of resistor R16 is connected to one end of resistor R17, one end of capacitor C7, and the emitter of optocoupler U5. The other end of resistor R17 and capacitor C7... The other end is grounded. The collector of optocoupler U5 is connected to one end of resistor R12, and the other end of resistor R12 is connected to a 3.3V voltage. The negative terminal of optocoupler U5 is connected to the positive terminal of diode D3, and the negative terminal of diode D3 is connected to the Vheat- port. The positive terminal of optocoupler U5 is connected to the negative terminal of diode D2. The positive terminal of diode D2 is connected to one end of resistor R7, one end of resistor R8, one end of resistor R9, and one end of resistor R10. The other end of resistor R10 is connected to the other end of resistor R7 and resistor R8. The other end of resistor R9, one end of resistor R3, one end of resistor R4, one end of resistor R5, one end of resistor R6, the other ends of resistor R3, R4, R5, and R6 are connected together to the Vheat+ port. Pins 6 and 7 of operational amplifier U3 are connected together to the MCU_REF_HEAT port. Pin 8 of operational amplifier U3 is connected to the 3.3V voltage and one end of capacitor C2. The other end of capacitor C2 is grounded.
[0007] The MCU chip mentioned is an STM32 series model.
[0008] Compared with the prior art, this utility model extends the service life of the relay by using zero-current switching on and off, reduces the probability of circuit failure by using relays and bidirectional thyristors for dual redundancy control, and adds a failure detection circuit that can determine the specific short-circuit point and air switch protection to further enhance the safety of the system. Attached Figure Description
[0009] Figure 1 This is a schematic diagram of a redundancy control and fail-safe circuit.
[0010] Figure 2 Circuit diagram of relay control circuit;
[0011] Figure 3 Circuit diagram of a bidirectional thyristor control circuit;
[0012] Figure 4 Circuit diagram of the failure detection circuit. Detailed Implementation
[0013] The present invention will be further described below with reference to the accompanying drawings.
[0014] like Figure 1 A redundancy control and failure protection circuit for a high-voltage battery system includes a power supply, a heating pad, an MCU chip, a relay control circuit, a bidirectional thyristor control circuit, a failure detection circuit, a shunt trip unit, and an air switch. The relay control circuit has a HEAT_CTRL_H port and a Vheat+ port; the bidirectional thyristor control circuit has a HEAT_CTRL_L port and a Vheat- port; the failure detection circuit has a Vheat+ port and a Vheat- port; the heating pad has a Vheat+ port and a Vheat- port; the power supply has a neutral wire and a live wire; the live wire of the power supply is connected to the relay control circuit via the air switch; the neutral wire of the power supply is connected to the relay control circuit via the air switch. Connect the bidirectional thyristor control circuit. The Vheat+ port of the heating pad is connected to the Vheat+ port of the failure detection circuit and the Vheat+ port of the relay control circuit. The Vheat- port of the heating pad is connected to the Vheat- port of the failure detection circuit and the Vheat- port of the bidirectional thyristor control circuit. One output pin of the MCU chip is connected to the shunt trip control terminal. The shunt trip is connected to the air switch. One analog input pin of the MCU chip is connected to the MCU_REF_HEAT port. One control pin of the MCU chip is connected to the HEAT_CTRL_H port. The other control pin of the MCU chip is connected to the HEAT_CTRL_L port.
[0015] like Figure 2 The relay control circuit includes relay U1, which is model HF32F-G / 005-HT. Pin 1 of relay U1 is connected to the 5V voltage and the negative terminal of diode D1. Pin 2 of relay U1 is connected to the positive terminal of diode D1 and the collector of transistor Q1. The base of transistor Q1 is connected to one end of capacitor C1, one end of resistor R1, and one end of resistor R2. The other end of resistor R1 is connected to the HEAT_CTRL_H port. The emitter of transistor Q1, the other end of capacitor C1, and the other end of resistor R2 are grounded together. Pin 3 of relay U1 is connected to the Vheat+ port, and pin 4 of relay U1 is connected to the live wire.
[0016] like Figure 3The bidirectional thyristor control circuit includes a bidirectional thyristor Q2 and a thyristor output optocoupler U6. The bidirectional thyristor Q2 is either a T810-600B-TR or T810-600B-ST model. Pin 1 of the thyristor output optocoupler U6 is connected to one end of resistor R18, and the other end of resistor R18 is connected to a 3.3V voltage. Pin 2 of the thyristor output optocoupler U6 is connected to the collector of transistor Q3. The base of transistor Q3 is connected to one end of capacitor C10, one end of resistor R24, and one end of resistor R23. The other end of resistor R23 is connected to the HEAT_CTRL_L port. The emitter of transistor Q3 and the other end of capacitor C10... The other end of resistor R24 is grounded. Pin 4 of the SCR output optocoupler U6 is connected to one end of resistor R21 and pin 3 of the bidirectional SCR Q2. The other end of resistor R21 is connected to pin 1 of the bidirectional SCR Q2, one end of resistor R22, and the neutral line. Pin 6 of the SCR output optocoupler U6 is connected to one end of resistor R19. The other end of resistor R19 is connected to one end of resistor R20. The other end of resistor R20 is connected to pin 2 of the bidirectional SCR Q2, one end of capacitor C8, and the Vheat-port. The other end of capacitor C8 is connected to one end of capacitor C9. The other end of capacitor C9 is connected to the other end of resistor R22.
[0017] like Figure 4The failure detection circuit includes operational amplifier U3, which is an LM358BIDR model. Pin 4 of operational amplifier U3 is grounded. Pin 5 of operational amplifier U3 is connected to one end of resistor R13. The other end of resistor R13 is connected to one end of resistor R14 and one end of capacitor C3. The other end of capacitor C3 is grounded. The other end of resistor R14 is connected to one end of resistor R15 and one end of capacitor C4. The other end of capacitor C4 is grounded. The other end of resistor R15 is connected to one end of resistor R11. The emitter of optocoupler U4 is connected to the other end of resistor R11, which is grounded. The collector of optocoupler U4 is connected to one end of capacitor C6 and a 3.3V voltage source, with the other end of capacitor C6 grounded. The negative terminal of optocoupler U4 is connected to one end of capacitor C5 and grounded. The positive terminal of optocoupler U4 is connected to the other end of capacitor C5 and one end of resistor R16. The other end of resistor R16 is connected to one end of resistor R17, one end of capacitor C7, and the emitter of optocoupler U5. The other end of resistor R17 and the other end of capacitor C7 are also connected to the emitter of optocoupler U5. One end of the optocoupler is grounded. The collector of optocoupler U5 is connected to one end of resistor R12, and the other end of resistor R12 is connected to a 3.3V voltage. The negative terminal of optocoupler U5 is connected to the positive terminal of diode D3, and the negative terminal of diode D3 is connected to the Vheat-port. The positive terminal of optocoupler U5 is connected to the negative terminal of diode D2. The positive terminal of diode D2 is connected to one end of resistors R7, R8, R9, and R10, respectively. The other end of resistor R10 is connected to the other end of resistor R7 and resistor R8, respectively. The other end of resistor R9, one end of resistor R3, one end of resistor R4, one end of resistor R5, one end of resistor R6, the other ends of resistor R3, R4, R5, and R6 are connected together to the Vheat+ port. Pins 6 and 7 of operational amplifier U3 are connected together to the MCU_REF_HEAT port. Pin 8 of operational amplifier U3 is connected to the 3.3V voltage and one end of capacitor C2. The other end of capacitor C2 is grounded.
[0018] The MCU chip uses the STM32 series.
[0019] A control method for a redundancy control and failure protection circuit in a high-voltage battery system includes a redundancy control and failure protection circuit in a high-voltage battery system. The control method includes the following steps: S1, Start heating: The MCU chip first controls the HEAT_CTRL_H port output signal to a high level, transistor Q1 is turned on, relay U1 is closed, and the Vheat+ port of the heating pad is statically connected to the live wire. Then, the MCU chip controls the HEAT_CTRL_L port output signal to a high level, transistor Q3 is turned on, optocoupler-triggered bidirectional thyristor Q2 is turned on, and the Vheat- port of the heating pad is connected to the neutral wire; S2, Stop heating: The MCU chip first controls the HEAT_CTRL_L port output signal to a low level, and transistor Q3 is turned off. S1. The bidirectional thyristor Q2 is turned off, cutting off the Vheat- port and neutral wire path of the heating pad. Then, the MCU chip controls the HEAT_CTRL_H port output signal to a low level, turning off transistor Q1 and relay U1, cutting off the Vheat+ port and live wire path of the heating pad. S2. The MCU continuously monitors the voltage of the MCU_REF_HEAT port. If the detected voltage is 0.6-2V, the control circuit is considered normal; if the detected voltage is 0-0.4V, the control circuit is considered to have failed. S3. Upon determining that the control circuit has failed, the MCU chip initiates failure diagnosis. S4. Upon confirming the control circuit failure, the MCU chip responds to the protection mechanism, triggering the shunt trip to cut off the air switch, thus completely de-energizing the control circuit.
[0020] The failure diagnosis method in step S4 specifically includes the following steps: S41, keep the Vheat+ port of the failure detection circuit connected to the live wire of the power supply and the Vheat- port disconnected from the neutral wire of the power supply. If the MCU_REF_HEAT port can detect a DC voltage of 0.6-2V, then it is determined that the bidirectional thyristor control circuit has a short circuit failure; S42, keep the Vheat+ port of the failure detection circuit disconnected from the live wire of the power supply and the Vheat- port connected to the neutral wire of the power supply. If the MCU_REF_HEAT port can detect a DC voltage of 0.6-2V, then it is determined that the relay control circuit has a short circuit failure.
[0021] The use of relays enables static opening, extending relay lifespan. Active control of bidirectional thyristors and relays powers the heating pad, thus heating the battery system. In case of failure of any component, the power supply circuit is disconnected. It supports active shutdown and fault isolation, dual-path synchronous judgment, and in case of failure, the AC high-voltage power supply is forcibly disconnected by controlling the shunt trip unit to disconnect the air switch. This provides multiple safety guarantees for the high-voltage battery system, effectively reducing the failure risk of the battery system and improving its reliability and safety.
Claims
1. A redundancy control and failure protection circuit in a high-voltage battery system, comprising a power supply, a heating pad, an MCU chip, a relay control circuit, a bidirectional thyristor control circuit, a failure detection circuit, a shunt trip unit, and an air switch, characterized in that: The relay control circuit has a HEAT_CTRL_H port and a Vheat+ port; the bidirectional thyristor control circuit has a HEAT_CTRL_L port and a Vheat- port; the failure detection circuit has a Vheat+ port and a Vheat- port; the heating pad has a Vheat+ port and a Vheat- port; the power supply has a neutral wire and a live wire; the live wire of the power supply is connected to the relay control circuit via an air switch; the neutral wire of the power supply is connected to the bidirectional thyristor control circuit via an air switch; the Vheat+ port of the heating pad is connected to the Vheat+ port of the failure detection circuit and the Vheat+ port of the relay control circuit; the Vheat- port of the heating pad is connected to the Vheat- port of the failure detection circuit and the Vheat- port of the bidirectional thyristor control circuit; one output pin of the MCU chip is connected to the shunt trip control terminal; the shunt trip is connected to the air switch; one analog input pin of the MCU chip is connected to the MCU_REF_HEAT port; one control pin of the MCU chip is connected to the HEAT_CTRL_H port; and the other control pin of the MCU chip is connected to the HEAT_CTRL_L port.
2. The redundancy control and failure protection circuit in a high-voltage battery system according to claim 1, characterized in that: The relay control circuit includes a relay U1, which is model HF32F-G / 005-HT. Pin 1 of relay U1 is connected to a 5V voltage and the negative terminal of diode D1. Pin 2 of relay U1 is connected to the positive terminal of diode D1 and the collector of transistor Q1. The base of transistor Q1 is connected to one end of capacitor C1, one end of resistor R1, and one end of resistor R2. The other end of resistor R1 is connected to the HEAT_CTRL_H port. The emitter of transistor Q1, the other end of capacitor C1, and the other end of resistor R2 are grounded together. Pin 3 of relay U1 is connected to the Vheat+ port, and pin 4 of relay U1 is connected to the live wire.
3. The redundancy control and failure protection circuit in a high-voltage battery system according to claim 1, characterized in that: The bidirectional thyristor control circuit includes a bidirectional thyristor Q2 and a thyristor output optocoupler U6. The bidirectional thyristor Q2 is a T810-600B-TR or T810-600B-ST model. Pin 1 of the thyristor output optocoupler U6 is connected to one end of resistor R18, and the other end of resistor R18 is connected to a 3.3V voltage. Pin 2 of the thyristor output optocoupler U6 is connected to the collector of transistor Q3. The base of transistor Q3 is connected to one end of capacitor C10, one end of resistor R24, and one end of resistor R23. The other end of resistor R23 is connected to the HEAT_CTRL_L port. The emitter of transistor Q3 and the other end of capacitor C10... One end of the resistor R24 and the other end of the resistor R24 are grounded together. Pin 4 of the thyristor output optocoupler U6 is connected to one end of the resistor R21 and pin 3 of the triac Q2. The other end of the resistor R21 is connected to pin 1 of the triac Q2, one end of the resistor R22 and the neutral line. Pin 6 of the thyristor output optocoupler U6 is connected to one end of the resistor R19. The other end of the resistor R19 is connected to one end of the resistor R20. The other end of the resistor R20 is connected to pin 2 of the triac Q2, one end of the capacitor C8 and the Vheat-port. The other end of the capacitor C8 is connected to one end of the capacitor C9. The other end of the capacitor C9 is connected to the other end of the resistor R22.
4. The redundancy control and failure protection circuit in a high-voltage battery system according to claim 1, characterized in that: The failure detection circuit includes operational amplifier U3, which is an LM358BIDR model. Pin 4 of operational amplifier U3 is grounded. Pin 5 of operational amplifier U3 is connected to one end of resistor R13. The other end of resistor R13 is connected to one end of resistor R14 and one end of capacitor C3. The other end of capacitor C3 is grounded. The other end of resistor R14 is connected to one end of resistor R15 and one end of capacitor C4. The other end of capacitor C4 is grounded. The other end of resistor R15 is connected to... One end of the optocoupler U4 is connected to the emitter, and the other end of resistor R11 is grounded. The collector of optocoupler U4 is connected to one end of capacitor C6 and a 3.3V voltage, while the other end of capacitor C6 is grounded. The negative terminal of optocoupler U4 is connected to one end of capacitor C5 and grounded. The positive terminal of optocoupler U4 is connected to the other end of capacitor C5 and one end of resistor R16. The other end of resistor R16 is connected to one end of resistor R17, one end of capacitor C7, and the emitter of optocoupler U5. The other end of resistor R17 and capacitor C7... The other end is grounded. The collector of optocoupler U5 is connected to one end of resistor R12, and the other end of resistor R12 is connected to a 3.3V voltage. The negative terminal of optocoupler U5 is connected to the positive terminal of diode D3, and the negative terminal of diode D3 is connected to the Vheat- port. The positive terminal of optocoupler U5 is connected to the negative terminal of diode D2. The positive terminal of diode D2 is connected to one end of resistor R7, one end of resistor R8, one end of resistor R9, and one end of resistor R10. The other end of resistor R10 is connected to the other end of resistor R7 and resistor R8. The other end of resistor R9, one end of resistor R3, one end of resistor R4, one end of resistor R5, one end of resistor R6, the other ends of resistor R3, R4, R5, and R6 are connected together to the Vheat+ port. Pins 6 and 7 of operational amplifier U3 are connected together to the MCU_REF_HEAT port. Pin 8 of operational amplifier U3 is connected to the 3.3V voltage and one end of capacitor C2. The other end of capacitor C2 is grounded.
5. The redundancy control and failure protection circuit in a high-voltage battery system according to claim 1, characterized in that: The MCU chip mentioned is an STM32 series model.