Battery Diagnostic System Using Redundant Microcontroller Flags
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Solution Overview
Problem
Existing diagnostic systems for battery modules often fail to properly open a contactor when a single hardware device malfunctions, as they rely on a single diagnostic flag set to a fault value based on a single signal, leading to incomplete or incorrect diagnostic operations.
Innovation Solution
A diagnostic system that uses first and second diagnostic indicator flags determined by first and second hardware devices, such as an analog-to-digital converter and a fault line, to perform tests and open a contactor, and also employs third and fourth diagnostic indicator flags from voltage comparators and a serial bus to further assess the battery system, ensuring reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single diagnostic flag based on a single hardware device is used to control contactor opening, then the system complexity is reduced, but the reliability of diagnostic operation deteriorates because malfunction of the single hardware device may prevent desired opening operation
Solution Approach 1:
The diagnostic system is segmented into multiple independent diagnostic flags (first diagnostic flag from first hardware device, second diagnostic flag from second hardware device) that independently monitor different aspects of battery cell voltage. Each flag can independently trigger contactor opening, ensuring that failure of one hardware device does not compromise overall diagnostic reliability.
Solution Approach 2:
The system implements redundant diagnostic flags and hardware devices as a protective measure against potential hardware failures. By having multiple independent diagnostic paths established beforehand, the system cushions against the risk of single-point failures, ensuring that at least one diagnostic path remains functional to trigger safety operations.
2Reliability
If multiple diagnostic flags from multiple hardware devices are used to control contactor opening, then the reliability of diagnostic operation is improved, but the device complexity increases
Solution Approach 1:
The diagnostic system divides monitoring functions into separate segments with dedicated hardware devices (first voltage comparator, second voltage comparator, first ADC, second ADC) and corresponding diagnostic flags. Each segment independently evaluates specific voltage conditions, and the control logic simply checks if any flag is set, avoiding complex integrated analysis while maintaining high reliability through distributed monitoring.
Data Source
AI summary
A diagnostic system for a battery system in accordance with an exemplary embodiment is provided. The battery system includes a battery module electrically coupled to a contactor. The diagnostic system includes a first microcontroller and a second microcontroller operably communicating with the first microcontroller. The second microcontroller is programmed to open the contactor electrically coupled to the battery module if either a first diagnostic indicator flag is equal to a first fault value or a second diagnostic indicator flag is equal to a second fault value. The second microcontroller is further programmed to open the contactor if either a third diagnostic indicator flag is equal to a third fault value or a fourth diagnostic indicator flag is equal to a fourth fault value.