Charging Relay Fusion Detection in High-Voltage Battery Junction Boxes
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Solution Overview
Problem
Existing vehicle battery charging systems fail to accurately determine the fusion status of relays before and after charging, leading to safety hazards such as arcing and explosion, and impair vehicle functionality.
Innovation Solution
A system and method for detecting and controlling relay fusion in vehicle battery charging systems, including a high-voltage battery, junction box, and charge controller, which performs fusion checks before and after charging, using voltage comparisons and memory storage to ensure accurate fusion detection and condition-specific high-voltage control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fusion diagnosis is performed only before charging starts, then the charging operation can begin quickly, but safety hazards such as arcing and explosion may occur after charging due to undetected relay fusion
Solution Approach 1:
The system performs fusion diagnosis before charging starts (pre-charging diagnosis) to detect relay fusion in advance. This preliminary detection prevents safety hazards during charging while allowing the charging process to proceed without unnecessary delays when no fusion is detected.
Solution Approach 2:
The system performs post-charging fusion diagnosis to detect relay fusion that may have occurred during charging. This feedback mechanism ensures safety by identifying fusion after charging completes, preventing hazards such as arcing and explosion while maintaining efficient charging operation.
2Reliability
If fusion diagnosis is performed continuously before and after charging, then safety is ensured, but vehicle functionality may be impaired due to inability to start or use radio/air conditioner
Solution Approach 1:
The system dynamically controls the high-voltage battery relay based on fusion diagnosis results. When no fusion is detected, the relay remains on allowing full vehicle functionality. When fusion is detected, the relay is switched off to prevent safety hazards, enabling conditional operation rather than complete system shutdown.
Solution Approach 2:
The system applies different control strategies based on the specific charging port flap status. When the flap is open, the high-voltage relay is switched off to prevent hazards. When the flap is closed, the relay remains on to maintain vehicle functionality. This localized control based on port status resolves the contradiction between safety and functionality.
3Object-affected harmful factors
If high-voltage relay is switched off upon fusion detection, then safety hazards are prevented, but vehicle productivity is reduced due to inability to start or use essential functions
Solution Approach 1:
The system applies different control strategies based on the specific charging port flap status. When the flap is open, the high-voltage relay is switched off to prevent hazards. When the flap is closed, the relay remains on to maintain vehicle functionality. This localized control based on port status resolves the contradiction between safety and productivity.
Solution Approach 2:
The system dynamically adjusts relay control based on real-time conditions (charging port flap status and fusion diagnosis results). This dynamic approach allows the system to maintain productivity when safe (flap closed) and prevent hazards when necessary (flap open), rather than using a static shutdown approach.
Data Source
AI summary
In a fusion detection control system for a vehicle battery charging relay, the system can include a high-voltage battery, a high-voltage junction box combined with the high-voltage battery to distribute power from the high-voltage battery to a high-voltage component of a vehicle, and a charge controller configured to detect whether a relay of the high-voltage junction box is fused after the completion of charging of the high-voltage battery.