Fuel Cell Vehicle Controller Overvoltage Detection
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Solution Overview
Problem
Fuel cell electric vehicles face issues with erroneous overvoltage detection due to abnormalities in voltage sensors, leading to potential vehicle shutdown and device damage.
Innovation Solution
The implementation of a controller that utilizes alternative voltage sensors to estimate the voltage at the inverter's direct current end when the primary sensor indicates overvoltage, allowing the vehicle to continue operating by determining the battery's chargeable or non-chargeable state and adjusting power consumption accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the controller uses the voltage sensor measurement value to determine overvoltage, then overvoltage can be detected, but erroneous detection occurs when the voltage sensor has an abnormality
Solution Approach 1:
The controller changes the detection parameter from direct voltage sensor measurement to battery chargeable state status. By monitoring whether the battery can accept charge, the system indirectly determines actual voltage conditions without being affected by voltage sensor abnormalities.
Solution Approach 2:
The battery chargeable state acts as an intermediary indicator between the voltage sensor and the overvoltage determination. Instead of directly trusting the voltage sensor output, the system uses the battery's charging capability as a mediator to verify actual voltage conditions.
2Object-affected harmful factors
If the vehicle shuts down when overvoltage is detected, then device damage is prevented, but vehicle operation is interrupted due to sensor abnormalities
Solution Approach 1:
The system establishes a feedback mechanism where the battery chargeable state provides continuous information about actual voltage conditions. This feedback loop allows the controller to distinguish between real overvoltage requiring shutdown and false readings allowing continued operation.
Solution Approach 2:
The control strategy dynamically adjusts based on battery chargeable state. When the battery can accept charge, the system operates normally even if voltage sensor reads high. When the battery cannot charge, the system then takes protective action, making the response adaptive rather than static.
3Reliability
If the controller drives the electric power consumption device to reduce voltage, then overvoltage is resolved, but unnecessary power consumption occurs when the voltage sensor is abnormal
Solution Approach 1:
The controller performs preliminary verification by checking the battery chargeable state before activating power consumption devices. This preliminary action prevents unnecessary energy consumption by confirming whether voltage reduction is actually needed based on real system conditions rather than sensor readings alone.
Data Source
AI summary
When a voltage measurement value of a first voltage sensor that measures voltage at a direct current end of an inverter exceeds an overvoltage threshold value, and a battery is non-chargeable, a controller of a fuel cell electric vehicle is configured to drive an electric power consumption device until the voltage measurement value falls below the overvoltage threshold value. When the voltage measurement value exceeds the overvoltage threshold value and the battery can be charged, the controller is configured to cause the fuel cell electric vehicle to continue traveling, while estimating the voltage at the direct current end using a second voltage sensor that measures output voltage of a fuel cell stack or a third voltage sensor that measures output voltage of the battery.