Contactor Coil Control for Abnormal Signal Detection in PHEVs
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Solution Overview
Problem
Existing contactor systems in plug-in hybrid electric vehicles (PHEVs) fail to accurately distinguish between external impacts and actual failures of the contactor coil control unit, leading to unintended contactor openings and potential sudden vehicle stops, as they lack real-time detection and maintenance modes to prevent abnormal signal-induced contact point openings.
Innovation Solution
A system and method involving a contactor coil control unit and a main control unit that execute real-time detection modes to differentiate between external impacts and actual failures, maintaining contact point connections for a predetermined time and generating alarm signals when necessary, to prevent unintended contactor openings and sudden stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time detection mode is implemented to detect abnormal signals, then the accuracy of distinguishing external impacts from actual failures is improved, but the system complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where the main control unit continuously monitors operation signals from the contactor coil control unit and compares them against expected operational patterns. When abnormal signals are detected, the system feeds back maintenance time information to determine whether to maintain or open contact points, creating a closed-loop control system that improves detection accuracy without requiring overly complex additional hardware
Solution Approach 2:
The patent introduces an intermediary detection mechanism where the main control unit acts as a mediator between the contactor coil control unit and the contactor coil. This intermediary layer processes operation signals, identifies abnormal patterns, and determines appropriate responses based on maintenance time, thereby improving detection accuracy while managing system complexity through centralized control logic
2Ease of operation
If contactor coil control unit applies operation signal to control contactor, then the contactor operation control is achieved, but abnormal signals may cause unintended contactor opening leading to sudden vehicle stop
Solution Approach 1:
The patent applies preliminary anti-action by implementing a detection mode that identifies abnormal signals before they can cause unintended contactor opening. The main control unit monitors operation signals in real-time and detects abnormalities proactively. When abnormal signals are detected, the system takes preventive action by determining maintenance time and deciding whether to maintain contact point connection, thereby counteracting potential harmful effects before they occur
Solution Approach 2:
The patent implements preliminary action by establishing a detection and response mechanism that acts in advance of potential contactor failure. The main control unit continuously monitors operation signals and prepares maintenance time calculations before abnormal conditions escalate. This preliminary monitoring and preparation ensure that if abnormal signals do occur, the system can respond appropriately to prevent sudden vehicle stops
3Reliability
If the contactor contact point is maintained in connection state for predetermined time, then the vehicle sudden stop is prevented, but the response time for actual failures is delayed
Solution Approach 1:
The patent applies dynamics by making the contactor contact point state adaptive rather than static. The system dynamically adjusts the contact point connection state based on real-time analysis of abnormal signal characteristics and calculated maintenance time. This dynamic approach allows the system to maintain connection when beneficial for preventing sudden stops while opening connection when failure patterns indicate safety concerns, optimizing both vehicle continuity and failure response
Solution Approach 2:
The patent implements parameter changes by using maintenance time as a variable parameter that determines contact point state. Rather than maintaining a fixed connection or opening state, the system calculates maintenance time based on abnormal signal characteristics and uses this parameter to dynamically control contact point duration. This parameter-based control allows flexible adjustment of contact point maintenance duration to balance vehicle continuity and failure response requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Accurately determines the source of abnormal signals, defers contact point openings during vehicle operation, and generates alarms for impending stops, thereby preventing safety accidents and ensuring continuous contactor operation monitoring.
Implementation Method 1
when power is supplied to the contactor coil and electromagnetic force is generated, the contact points are in contact with one another and a current may be conducted
Data Source
AI summary
A system and a method in which a contactor coil control unit, which applies an operation signal to a contactor coil (relay coil) that opens or connects contact points of a contactor (Relay), during a travelling of a vehicle applies an abnormal signal to the contactor coil by an external reason or a failure, the abnormal signal is detected in real time, so that it is possible to prevent the contact point of the contactor from being unintentionally opened by the abnormal signal, and it is possible to prevent an operating vehicle from being suddenly stopped by determining whether the vehicle actually travels based on a maintenance time of the abnormal signal and whether the abnormal signal is applied due to an actual failure of the contactor coil control unit.