Vehicle controller with insulation breakdwon detection function and insulation breakdown detection method thereof

Abstract

A vehicle controller having an insulation breakdown detection function according to a preferred embodiment of the present invention includes a printed circuit board having an input terminal located at a predetermined distance from an output terminal of a high-voltage battery system to maintain an insulation state, and a control unit that detects a voltage applied to the printed circuit board and determines whether the insulation state is broken using the detected voltage.

Description

Technology Field

[0001] The present invention relates to a vehicle controller equipped with an insulation breakdown detection function and a method for detecting insulation breakdown thereof. Background Technology

[0002] Electric vehicles or hybrid vehicles are equipped with a high-voltage battery system that supplies voltage for vehicle propulsion.

[0003] The high-voltage battery system is managed by a vehicle controller comprising a printed circuit composed of electrical conductors, a printed circuit board including a board formed of electrical insulating material, and electrical components or electronic modules connected through the printed circuit.

[0004] During operation, the temperature of electrical components or electronic modules in these vehicle controllers can rise due to the resistance and current of the printed circuits. If the temperature of these electrical components or electronic modules rises excessively, there is a problem of damage or malfunction. Furthermore, there is a problem where the elevated temperature is transferred to surrounding systems, causing adverse effects.

[0005] Vehicle controllers form insulation patterns to maintain insulation between systems when high temperatures occur. While these insulation patterns can withstand high temperatures, the insulation state may be compromised depending on the surrounding environment. Inducing factors that cause insulation breakdown in controllers include altitude, humidity, atmospheric conditions, pollution levels, and material groups.

[0006] However, there is a problem in that follow-up measures due to insulation breakdown are difficult because there is no technology to detect insulation breakdown inside the vehicle controller. Prior art literature

[0007] Republic of Korea Published Patent No. 10-2022-0045558 The problem to be solved

[0008] Accordingly, the present invention has been devised in consideration of the above circumstances and aims to provide a vehicle controller equipped with an insulation breakdown detection function that eliminates potential risks and prevents human and material accidents in advance by configuring a PCB circuit pattern that detects insulation breakdown of a vehicle's high-voltage system at an early stage, and a method for detecting insulation breakdown thereof. means of solving the problem

[0009] A vehicle controller having an insulation breakdown detection function according to a preferred embodiment of the present invention for achieving the above objective comprises: a printed circuit board having an input terminal located at a predetermined distance from the output terminal of a high-voltage battery system to maintain an insulation state; and a control unit that detects a voltage applied to the printed circuit board and determines whether the insulation state is broken using the detected voltage.

[0010] The printed circuit board may include: an input terminal located at a predetermined distance from the output terminal of the high-voltage battery system; a plurality of voltage divider resistors connected to the input terminal; a shunt resistor connected between one of the voltage divider resistors and ground; and an amplifier that amplifies the voltage across the shunt resistor and transmits it to the control unit.

[0011] The above separation distance can be determined based on the surrounding environmental factors of the vehicle and the voltage of the high-voltage battery system.

[0012] The control unit above can calculate a shunt current value using the amplification voltage received from the amplifier, the resistance values ​​of the plurality of divider resistors and the shunt resistor.

[0013] The control unit compares the shunt current value with a preset reference current, and based on the comparison result, if the shunt current value is greater than or equal to the reference current, it can determine that the insulation state has been destroyed.

[0014] The above control unit can perform danger alerting and vehicle output limiting control when it determines that the insulation state has been destroyed.

[0015] A method for detecting insulation breakdown of a vehicle controller according to a preferred embodiment of the present invention for achieving the above objective comprises: a power sensing step in which a control unit detects a voltage applied to the printed circuit board, wherein the control unit determines whether the insulation state is broken using the detected voltage; and a determination step in which the control unit determines whether the insulation state is broken using the detected voltage.

[0016] After the power sensing step above, the control unit may further include a current calculation step in which it calculates a shunt current value using the voltage applied to the printed circuit board.

[0017] In the above judgment step, the control unit compares the shunt current value with a preset reference current, and if the shunt current value is greater than or equal to the reference current based on the comparison result, it can determine that the insulation state has been destroyed.

[0018] After the above judgment step, if the control unit determines that the insulation state has been destroyed, it may further include a notification step of performing a danger notification and vehicle output limit control. Effects of the invention

[0019] According to a preferred embodiment of the present invention, a vehicle controller equipped with an insulation breakdown detection function and an insulation breakdown detection method have the effect of eliminating potential risks and preventing human and material accidents in advance by configuring a PCB circuit pattern that detects insulation breakdown of a vehicle's high-voltage system at an early stage. Brief explanation of the drawing

[0020] FIG. 1 is a drawing showing a part of the configuration of a vehicle controller equipped with an insulation breakdown detection function according to a preferred embodiment of the present invention. FIG. 2 is a circuit diagram showing a part of the configuration of a vehicle controller equipped with an insulation breakdown detection function according to a preferred embodiment of the present invention. Figure 3 is a diagram illustrating a method for setting the separation distance between a printed circuit board and a high-voltage battery system. FIG. 4 is a flowchart of a method for detecting insulation breakdown of a vehicle controller according to a preferred embodiment of the present invention. Specific details for implementing the invention

[0021] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. First, it should be noted that in assigning reference numerals to the components of each drawing, the same components are given the same reference numeral whenever possible, even if they are shown in different drawings. Furthermore, while preferred embodiments of the present invention will be described below, the technical concept of the present invention is not limited thereto and can be modified and implemented in various ways by those skilled in the art.

[0022] FIG. 1 is a drawing showing a part of the configuration of a vehicle controller equipped with an insulation breakdown detection function according to a preferred embodiment of the present invention.

[0023] FIG. 2 is a circuit diagram showing a part of the configuration of a vehicle controller equipped with an insulation breakdown detection function according to a preferred embodiment of the present invention.

[0024] Referring to FIGS. 1 and 2, a vehicle controller (100) equipped with an insulation breakdown detection function according to a preferred embodiment of the present invention is characterized by forming an insulation breakdown-inducing copper foil structure and an insulation breakdown detection circuit on a printed circuit board to detect the possibility of insulation breakdown of the copper foil structure due to changes in the surrounding environment, thereby enabling rapid follow-up action.

[0025] A vehicle controller (100) having an insulation breakdown detection function according to a preferred embodiment of the present invention includes a printed circuit board (110) and a control unit (120).

[0026] The printed circuit board (110) may be configured to include an insulating board and an electrically conductive circuit pattern for electrical connection with a high-voltage battery system (200).

[0027] A printed circuit board (110) may include an input terminal (CF1) for maintaining an insulated state from a high-voltage battery system (200), a plurality of voltage divider resistors (R_Divide1, R_Divide2, R_Divide3) electrically connected to the input terminal (CF1), a shunt resistor (R_Shunt) for measuring the voltage of the high-voltage battery system (200), a first circuit pattern (PN1) connected to the shunt resistor (R_Shunt), a second circuit pattern (PN2) connected to a connector (CN), and an amplifier (POWAMP) connected between the first circuit pattern (PN1) and the second circuit pattern (PN2). Here, the connector (CN) may be connected to an input / output terminal of a control unit (120).

[0028] The input terminal (CF1) may be made of copper foil material. The input terminal (CF1) may be formed at a position having a predetermined separation distance from the output terminal (CF2) of the high-voltage battery system (200). The separation distance may be appropriately set to induce insulation breakdown between the printed circuit board (110) and the high-voltage battery system (200). Insulation breakdown refers to the state in which the input terminal (CF1) or the output terminal (CF2) is destroyed, so that the insulation state between the input terminal (CF1) and the output terminal (CF2) is not maintained.

[0029] Additionally, the separation distance can be appropriately set according to the usage environment of the vehicle controller (100) or the voltage of the high-voltage battery system (200).

[0030] A plurality of voltage divider resistors (R_Divide1, R_Divide2, R_Divide3) may be provided on a printed circuit board (110) to lower the voltage input to the input terminal (CF1) to a voltage level that various electrical components can withstand.

[0031] A plurality of voltage divider resistors (R_Divide1, R_Divide2, R_Divide3) may include a first voltage divider resistor (R_Divide1) connected to an input terminal (CF1), a second voltage divider resistor (R_Divide2) connected to the first voltage divider resistor (R_Divide1), and a third voltage divider resistor (R_Divide3) connected to the second voltage divider resistor (R_Divide2).

[0032] The shunt resistor (R_Shunt) can be connected between the second voltage divider resistor (R_Divide3) and ground.

[0033] The amplifier (POWAMP) can amplify the voltage of the high-voltage battery system (200) applied to the shunt resistor (R_Shunt) and transmit it to the control unit (120). One end of the shunt resistor (R_Shunt) may be connected to the first input terminal of the amplifier (POWAMP). A first resistor (R1) and a second resistor (R2) may be connected to the second input terminal of the amplifier (POWAMP). One end of the first resistor (R1) may be connected to the node between the third voltage divider resistor and the shunt resistor, and the other end may be connected to the second input terminal of the amplifier. One end of the second resistor (R1) may be connected to the second input terminal of the amplifier (POWAMP), and the other end may be connected to the output terminal of the amplifier (POWAMP).

[0034] When insulation breakdown occurs between the input terminal (CF1) and the output terminal (CF2), current is generated through multiple voltage divider resistors (R_Divide1, R_Divide2, R_Divide3), and this current flows to ground through a shunt resistor (R_Shunt).

[0035] At this time, the voltage across the shunt resistor (R_Shunt) is amplified through the amplifier (POWAMP) and transmitted to the control unit (120).

[0036] The control unit (120) can calculate the current of the shunt resistor (R_Shunt) using the amplified voltage received from the amplifier (POWAMP). That is, the control unit (120) can calculate the shunt current value using the resistance values ​​of the multiple voltage divider resistors (R_Divide1, R_Divide2, R_Divide3), the resistance value of the shunt resistor (R_Shunt), and the amplified voltage value. Therefore, it is possible to determine that insulation breakdown has occurred when a current value above a certain level is applied.

[0037] The control unit (120) can determine that insulation breakdown between the printed circuit board (110) and the high-voltage battery system (200) has occurred if a shunt current value greater than a preset reference current is measured.

[0038] The control unit (120) can measure various voltage levels depending on the distance between the input terminal (CF1) of the printed circuit board (110) and the output terminal (CF2) of the high-voltage battery system (200). The control unit (120) can detect insulation breakdown phenomena using the various voltage levels measured. That is, the control unit (120) can detect unexpected insulation breakdown phenomena between the printed circuit board (110) and the high-voltage battery system (200) when the printed circuit board (110) is affected by a rapid change in humidity and altitude of the environment around the vehicle.

[0039] The control unit (120) can notify the user of the danger in an alarm manner when insulation breakdown is detected. The control unit (120) can limit the vehicle output when insulation breakdown is detected.

[0040] Figure 3 is a diagram illustrating a method for setting the separation distance between a printed circuit board and a high-voltage battery system.

[0041] Referring to FIG. 3, various separation distances between the input terminal (CF1) of the printed circuit board (110) and the output terminal (CF2) of the high-voltage battery system (200) can be observed.

[0042] In one embodiment, the separation distance may be set according to the altitude of the environment surrounding the vehicle. When the altitude of the environment surrounding the vehicle is 3000m, a separation distance of 2.6mm may be applied. When the altitude of the environment surrounding the vehicle is 2000m, a separation distance of 5.2mm may be applied. When the altitude of the environment surrounding the vehicle is 1000m, a separation distance of 7.8mm may be applied.

[0043] That is, as the altitude of the environment surrounding the vehicle increases, the atmospheric pressure decreases, so the separation distance can be set larger as the altitude increases. In one embodiment, for an altitude of 3000m, a separation distance approximately 14% larger than that for an altitude of 2000m can be applied.

[0044] In another embodiment, the separation distance may be set according to the voltage of the high-voltage battery system (200). When the voltage of the high-voltage battery system (200) is 200V, a separation distance of 2.6mm may be applied. When the voltage of the high-voltage battery system (200) is 400V, a separation distance of 5.2mm may be applied. When the voltage of the high-voltage battery system (200) is 800V, a separation distance of 7.8mm may be applied.

[0045] That is, as the voltage of the high-voltage battery system (200) increases, the separation distance can be set to be larger.

[0046] FIG. 4 is a flowchart of a method for detecting insulation breakdown of a vehicle controller according to a preferred embodiment of the present invention.

[0047] Referring to FIG. 4, a method for detecting insulation breakdown of a vehicle controller according to a preferred embodiment of the present invention is characterized by forming an insulation breakdown-inducing copper foil structure and an insulation breakdown detection circuit on a printed circuit board to detect the possibility of insulation breakdown of the copper foil structure due to changes in the surrounding environment, thereby enabling rapid follow-up action.

[0048] In the power sensing step (S410), the control unit (120) senses the power of the high-voltage battery system (200). At this time, the control unit (120) can receive the voltage across the shunt resistor (R_Shunt) from the amplifier (POWAMP). The amplifier (POWAMP) can amplify the voltage of the high-voltage battery system (200) applied to the shunt resistor (R_Shunt) and transmit it to the control unit (120).

[0049] In the current calculation step (S420), the control unit (120) can calculate the current of the shunt resistor (R_Shunt) using the amplified voltage received from the amplifier (POWAMP). At this time, the control unit (120) can calculate the shunt current value using the resistance values ​​of a plurality of voltage divider resistors (R_Divide1, R_Divide2, R_Divide3), the resistance value of the shunt resistor (R_Shunt), and the amplified voltage value.

[0050] In the judgment step (S430), the control unit (120) can determine whether insulation breakdown has occurred between the printed circuit board (110) and the high-voltage battery system (200) by comparing the shunt current value with a preset reference current. If the control unit (120) measures a shunt current value greater than the preset reference current, it can determine that insulation breakdown has occurred between the printed circuit board (110) and the high-voltage battery system (200).

[0051] In the notification step (S440), the control unit (120) can notify the user of the danger in an alarm manner when insulation breakdown is detected. The control unit (120) can limit the vehicle output when insulation breakdown is detected.

[0052] The foregoing description is merely an illustrative explanation of the technical concept of the present invention, and those skilled in the art to which the present invention pertains will be able to make various modifications, changes, and substitutions within the scope of the essential characteristics of the present invention. Accordingly, the embodiments disclosed in the present invention and the accompanying drawings are intended to explain, not limit, the technical concept of the present invention, and the scope of the technical concept of the present invention is not limited by such embodiments and accompanying drawings.

[0053] The steps and / or operations according to the present invention may occur in a different order, in parallel, or simultaneously in different embodiments for different epochs, as can be understood by a person skilled in the art.

[0054] Depending on the embodiment, some or all of the steps and / or operations may be implemented or performed in some or all of the way using instructions, programs, interactive data structures, and one or more processors running clients and / or servers stored on one or more non-transient computer-readable media. One or more non-transient computer-readable media may be, for example, software, firmware, hardware, and / or any combination thereof. Additionally, the functions of the “module” discussed herein may be implemented in software, firmware, hardware, and / or any combination thereof. Explanation of the symbols

[0055] 100: Vehicle controller 110: Printed circuit board CF1: Input terminal R_Divide1, R_Divide2, R_Divide3: 1st, 2nd, and 3rd voltage dividers R_Shunt: Shunt resistor POWAMP: Amplifier 120: Control unit 200: High-voltage battery system CF2: Output terminal

Claims

Claim 1 A vehicle controller having an insulation breakdown detection function, comprising: a printed circuit board having an input terminal located at a predetermined distance from an output terminal of a high-voltage battery system to detect a breakdown of the insulation state; and a control unit that detects a voltage applied from the output terminal of the high-voltage battery system to the input terminal of the printed circuit board and determines whether the insulation state is broken using the detected voltage; wherein the input terminal is composed of a copper foil material, and the printed circuit board comprises: a plurality of voltage divider resistors connected to the input terminal to distribute a voltage caused by a current flowing into the input terminal; a shunt resistor connected between one of the voltage divider resistors and ground to provide a path for the current; and an amplifier that amplifies the voltage across the shunt resistor and transmits it to the control unit; wherein the control unit calculates a shunt current value flowing through the shunt resistor using the amplified voltage received from the amplifier and preset resistance values ​​of the plurality of voltage divider resistors and the shunt resistor, and determines that the insulation state is broken if the calculated shunt current value is greater than or equal to a preset reference current. Claim 2 delete Claim 3 A vehicle controller having an insulation breakdown detection function, characterized in that, in claim 1, the separation distance is determined according to the surrounding environmental factors of the vehicle and the voltage of the high-voltage battery system. Claim 4 delete Claim 5 delete Claim 6 A vehicle controller having an insulation breakdown detection function, wherein, in claim 1, the control unit performs a danger alert and vehicle output limit control when it is determined that the insulation state has been broken. Claim 7 A method for detecting insulation breakdown of a vehicle controller comprising a printed circuit board having an input terminal located at a predetermined separation distance from an output terminal of a high-voltage battery system to detect insulation breakdown, the method comprising: a power sensing step in which a control unit detects a voltage applied from the output terminal of the high-voltage battery system to the input terminal of the printed circuit board; and a determination step in which the control unit determines whether insulation breakdown has occurred using the detected voltage; wherein the input terminal is composed of a copper foil material, and the printed circuit board comprises: a plurality of voltage divider resistors connected to the input terminal to distribute voltage caused by a current flowing into the input terminal; and a shunt resistor connected between one of the voltage divider resistors and ground to provide a path for the current. A method for detecting insulation breakdown of a vehicle controller, comprising: an amplifier that amplifies the voltage across the terminals of the shunt resistor and transmits it to the control unit; and, after the power sensing step, further comprising a current calculation step in which the control unit calculates a shunt current value flowing through the shunt resistor using the amplified voltage received from the amplifier and preset resistance values ​​of the plurality of voltage dividers and the shunt resistor; wherein the judgment step is characterized in that the control unit compares the shunt current value with a preset reference current, and if the shunt current value is greater than or equal to the reference current according to the comparison result, determines that the insulation state has been broken. Claim 8 delete Claim 9 delete Claim 10 A method for detecting insulation breakdown of a vehicle controller according to claim 7, further comprising a notification step in which, after the judgment step, the control unit performs a danger notification and vehicle output limit control when it determines that the insulation state has been broken.

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