HV System Discharge via Residual Current Detection

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Solution Overview

Problem

High-voltage electrical systems in electric vehicles pose a risk of dangerous touch voltage due to residual currents, which existing protection mechanisms take too long to discharge, prolonging the risk of electrical accidents.

Innovation Solution

Discharging only the Cy capacitance between the critical high-voltage potential and ground when a residual current is detected, rather than the Cx capacitance between two high-voltage potentials, significantly reduces the duration of discharging and the associated risk, by isolating the discharge to the capacitance connected to the touched potential.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the capacitance between high-voltage potentials (Cx capacitance) is discharged to protect against electric shock, then safety is improved, but the discharging duration becomes excessively long

Engineering Contradiction:
ImprovesafetyVSAvoiddischarging duration
Core Design Contradiction:
ReliabilityVSDuration of action of moving object

Solution Approach 1:

The patent segments the discharge process into two distinct phases: first discharging only the Cy capacitance (between critical HV potential and ground) to quickly eliminate touch voltage danger, then separately discharging the Cx capacitance (between HV potentials) to restore system operation. This segmentation resolves the contradiction by prioritizing safety through rapid Cy discharge while handling the time-consuming Cx discharge as a separate, non-critical step.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent applies partial action by discharging only the necessary portion of the total capacitance (Cy capacitance) required to eliminate the immediate safety hazard, rather than discharging the entire Cx capacitance. This partial discharge achieves the safety goal in milliseconds, while the remaining Cx discharge is performed separately without compromising safety.

Inventive Principle:
Principle #16Partial or excessive action

2Loss of energy

If the voltage between two high-voltage potentials is discharged, then complete energy discharge is achieved, but the discharging time increases significantly

Engineering Contradiction:
Improvetotal energy dischargedVSAvoiddischarging time
Core Design Contradiction:
Loss of energyVSLoss of time

Solution Approach 1:

The discharge process is segmented into priority-based stages: Cy capacitance discharge is executed first with high priority to quickly reduce touch voltage and minimize energy transfer time, while Cx capacitance discharge is performed subsequently with lower priority. This segmentation achieves acceptable energy loss while dramatically reducing the critical time parameter.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent rushes through the critical Cy capacitance discharge phase to quickly eliminate the safety hazard, accepting that not all energy is discharged immediately. The less critical Cx capacitance discharge is then completed in a relaxed timeframe, effectively skipping the time-consuming portion of energy discharge until after safety is secured.

Inventive Principle:
Principle #21Skipping (Rushing through)

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

This method quickly reduces the dangerous touch voltage by discharging the relevant capacitance to ground within a few milliseconds, minimizing the risk of electrical accidents and allowing for safer operation of the vehicle high-voltage electrical system.

Implementation Method 1

discharge this HV potential toward ground, wherein only the Cy capacitance between this potential and the ground potential is to be discharged

Methodology Applied
Scientific EffectCapacitance discharge: Capacitance

Implementation Method 2

the magnitude of Cy capacitances is substantially composed of the parasitic capacitances and Cy filter capacitances

Methodology Applied
Scientific EffectParasitic capacitance: Parasitic Capacitance

Data Source

PatentUS20230226953A1Method for discharging a vehicle high-voltage electrical system, on-board vehicle electrical system, and insulation monitoring devices
Publication Date: 2023.07.20 SCHAEFFLER TECHNOLOGIES AG & CO KG
  • US20230226953A1 patent drawing

AI summary

A method for discharging a vehicle high-voltage electrical system, which is galvanically isolated from a ground potential, in the presence of a residual current makes provision for the following step: determining whether a residual current flows between a first HV potential of the vehicle high-voltage electrical system and the ground potential or a residual current flows between a second HV potential of the vehicle high-voltage electrical system and the ground potential. The method furthermore makes provision to discharge only that Cy capacitance which exists between the ground potential and that HV potential from which or to which the residual current flows. The discharging is triggered by determining the existence of a residual current. Furthermore, an on-board vehicle electrical system and an insulation monitoring device which are designed for performing the method are described. In addition, a corresponding charging-station high-voltage electrical system is described.