DC/DC Ground Wire Detection Circuit for Poor Contact Protection
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Solution Overview
Problem
The existing wiring configuration for new energy vehicles' on-board DC/DC converters is prone to large impedance or disconnection issues between the DC/DC ground wire and the vehicle body, leading to excessive current flow and potential wiring harness damage due to poor contact or disconnection.
Innovation Solution
A detection circuit comprising a DSP controller, a comparator, and conductive branches connected to the standby circuit and power-supply negative wire of the on-board DC/DC converter, which detects large currents and controls the output to prevent overheating and damage by reducing or turning off the converter's output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the DC/DC ground wire or ground wire of low-voltage storage battery is connected to vehicle body through nearby ground wire, then wiring cost is reduced, but impedance increases and disconnection risk increases
Solution Approach 1:
The patent applies preliminary action by implementing a detection circuit that proactively monitors ground wire status before disconnection causes damage. The detection circuit continuously checks the connection status of the DC/DC ground wire and storage battery ground wire to the vehicle body, enabling early warning and preventive maintenance before impedance becomes critical or disconnection occurs.
Solution Approach 2:
The patent implements feedback through a detection circuit that provides real-time information about ground wire connection status. The detection circuit monitors the electrical connection between the DC/DC ground wire and vehicle body, and between the storage battery ground wire and vehicle body, feeding this information back to the control system to trigger warnings or protective actions when degradation is detected.
2Ease of operation
If ground wire has poor contact with vehicle body, then wiring installation is simplified, but current flow increases causing overheating and damage
Solution Approach 1:
The patent applies preliminary anti-action by implementing protective measures before overheating and damage can occur. The detection circuit monitors ground wire connection quality and triggers warnings or shuts down the DC/DC converter before excessive current can cause overheating or wiring damage, preventing the harmful effect rather than just responding to it.
Solution Approach 2:
The detection circuit provides continuous feedback on ground wire connection status, enabling the control system to respond to degradation before it leads to overheating. When poor contact is detected, the system can alert the driver or automatically reduce/stop power output to prevent harmful thermal effects.
3Reliability
If detection circuit is added to monitor ground wire status, then safety is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing a detection circuit that serves multiple functions: it monitors both the DC/DC ground wire connection and the storage battery ground wire connection, provides warning signals, and can trigger protective shutdowns. This multi-functional approach consolidates several safety functions into a single integrated circuit rather than requiring separate monitoring systems.
Solution Approach 2:
The detection circuit is designed to be self-contained, using the existing electrical connections and ground wires as part of its sensing mechanism. The circuit leverages the existing wiring infrastructure rather than requiring additional dedicated sensing wires, and automatically monitors its own operating conditions to detect ground wire degradation.
Data Source
AI summary
A detection circuit for the on-board direct current/direct current (DC/DC) ground wire and an on-board device are provided. The circuit includes a digital signal process (DSP) controller, a detection circuit, a standby circuit for an on-board DC/DC converter, and a power-supply negative wire for the on-board DC/DC converter. The detection circuit includes a comparator, a first conductive branch, a second conductive branch, a third conductive branch. In this way, the detection circuit is connected between the DSP controller and the standby circuit for the on-board DC/DC converter, and the detection circuit is connected between the DSP controller and the power-supply negative wire for the on-board DC/DC converter.