HV Bus Assembly Detection for Traction Battery Isolation
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Solution Overview
Problem
Existing high-voltage systems for electric vehicles lack effective monitoring and control mechanisms during the assembly process, leading to potential errors and safety issues due to the absence of precise detection and management of HV devices and their connections.
Innovation Solution
A system comprising an in-vehicle communication network, a high-voltage bus, a traction battery, and a controller that selectively connects and disconnects the traction battery from the HV bus based on the presence or absence of HV devices, ensuring proper operation and preventing assembly errors by energizing or de-energizing the HV bus accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the traction battery is continuously connected to the HV bus during assembly, then power availability is maintained, but safety risks increase due to potential assembly errors
Solution Approach 1:
The controller performs preliminary detection of device presence/absence through communication networks before energizing the HV bus. This preliminary action ensures all devices are properly installed and recognized before high voltage is applied, preventing assembly errors while maintaining safety.
Solution Approach 2:
The system continuously monitors the HV bus for presence/absence signals from HV devices via communication networks. This feedback mechanism allows the controller to detect assembly status in real-time and adjust battery connection accordingly, ensuring safety while maintaining operational reliability.
2Manufacturing precision
If the controller continuously monitors all HV devices, then assembly accuracy is improved, but system complexity increases
Solution Approach 1:
The controller utilizes existing in-vehicle communication networks and HV bus infrastructure for dual purposes: normal vehicle operation and assembly process monitoring. This multi-functionality enables precise assembly detection without adding dedicated complex monitoring hardware, thus improving assembly accuracy while minimizing system complexity.
Data Source
AI summary
A vehicle includes a high-voltage (HV) bus and a controller. The controller, during assembly of a control system including a plurality of HV devices to be installed in a predefined order such that one of the HV devices is installed before an other of the HV devices, and responsive to detecting presence of the other of the HV devices and absence of the one of the HV devices, disconnects a traction battery from the HV bus.