HV Cable Failure Detection Using Signal Transmission
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Solution Overview
Problem
Current high voltage line failure detection systems in electric and hybrid vehicles, such as HVIL, are not always reliable as they may not simultaneously disconnect with the high voltage line, leading to incomplete failure state monitoring, especially when connectors are plugged in or cables are disconnected.
Innovation Solution
A safety system that employs transmitters and receivers within high voltage devices and energy storage means to send signals through the high voltage cable, using both constant frequency sinus waves and digital information to identify failures, with isolators for protection and an energy management component to control high voltage output, providing visual and audial warnings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate HVIL line is used to detect high voltage line failures, then the detection function is provided, but the reliability is insufficient because the HVIL line may not be torn simultaneously with the high voltage line
Solution Approach 1:
The patent merges the detection function with the high voltage cable itself by making the cable conductive and using it as the signal transmission path. The receiver detects the presence or absence of a test signal transmitted through the cable, so the cable serves both power transmission and integrity monitoring functions simultaneously, eliminating the separate HVIL line and ensuring that cable failure automatically stops signal transmission.
Solution Approach 2:
The high voltage cable is given multiple functions: it transmits electrical power to the device and simultaneously serves as the signal transmission medium for integrity monitoring. This multi-functional approach eliminates the need for a separate dedicated monitoring line and ensures that any cable damage immediately affects both power and signal transmission.
2Measurement precision
If the HVIL line is placed on connectors to detect disconnections, then connector failure detection is enabled, but the measurement precision is insufficient when cables are disconnected from connectors during plugging
Solution Approach 1:
The system implements continuous feedback by having the transmitter send test signals through the high voltage cable to the receiver. The receiver monitors the presence and quality of the returned signal, providing real-time feedback on cable integrity and connector connection status, enabling precise detection of disconnection events during plugging operations.
Solution Approach 2:
The patent uses the high voltage cable itself as an intermediary medium to transmit both power and diagnostic signals. By modulating the cable's electrical properties or using dedicated test signal frequencies, the system can distinguish between cable integrity issues and connector connection issues, providing precise failure state identification.
Data Source
Figure 1
AI summary
The present invention relates to a safety system (1) which detects a failure occurring in the high voltage line that connects electric components in an electric or hybrid vehicle, determines in which device (3) or high voltage line belonging to a device (3) the said failure occurs, and enables a visual and/or accoustic warning to be given and switches off the high voltage supply.