Vehicle APM Contactor Control for Switching Cycle Wear
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Solution Overview
Problem
Current vehicle power storage and distribution systems fail to adequately mitigate wear and tear on power electronics system components due to frequent power requests from vehicle accessories, necessitating a new system for controlling auxiliary power module (APM) contactors.
Innovation Solution
A method and system for controlling APM contactors by logging actuations, comparing them to predetermined thresholds, and restricting future actuations to prevent excessive wear, including predicting high actuation frequencies and adjusting the contactor's state accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the APM contactor is actuated frequently to meet accessory power requests, then vehicle accessory functionality is improved, but wear and tear on the APM contactor increases
Solution Approach 1:
The controller performs preliminary actions by logging and tracking contactor actuation counts before wear becomes critical. By monitoring the actuation history in advance and comparing against predetermined thresholds, the system proactively identifies when the contactor is approaching its wear limit, allowing preventive measures to be taken before failure occurs.
Solution Approach 2:
The system implements feedback by continuously monitoring the actuation count of the APM contactor and using this information to control future actuations. When the logged actuation count exceeds the predetermined threshold, the controller provides feedback by restricting further actuations, creating a closed-loop control system that balances functionality with component protection.
2Duration of action of stationary object
If the APM contactor actuation is restricted to reduce wear, then contactor lifespan is extended, but vehicle accessory power availability is reduced
Solution Approach 1:
The system applies partial action by restricting APM contactor actuations only when the predetermined threshold is exceeded, rather than continuously restricting all actuations. This allows the contactor to operate freely within acceptable limits while imposing restrictions only when necessary to prevent excessive wear, thereby maintaining accessory power availability during normal operation.
Solution Approach 2:
The controller changes the operational parameter of the APM contactor by dynamically adjusting actuation permissions based on the logged actuation count. When the count is below the threshold, full actuation freedom is permitted; when the threshold is exceeded, actuation is restricted. This parameter-based control allows flexible balancing of lifespan extension with functionality maintenance.
Data Source
AI summary
According to several aspects, a method for controlling an auxiliary power module (APM) contactor for a vehicle may include logging a plurality of actuations of the APM contactor within a time step. The plurality of actuations includes a plurality of auxiliary battery charging actuations and a plurality of accessory actuations. The method further may include comparing a quantity of the plurality of accessory actuations to a predetermined accessory actuation threshold. The method further may include restricting future actuations of the APM contactor in response to determining that the quantity of the plurality of accessory actuations is greater than or equal to the predetermined accessory actuation threshold.