High-Voltage Harness Thermal Monitoring for Powertrain Derating
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Solution Overview
Problem
High voltage cables in hybrid and electric vehicles face temperature-related issues due to ohmic heat and ambient temperatures, leading to potential degradation and short circuits when temperatures exceed thermal limits.
Innovation Solution
A method and control system that determine temperature characteristics for busbars and adjacent components, as well as current through high voltage cables, to reduce operating characteristics of the powertrain, thereby managing cable temperatures and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltage cables operate at high currents to provide sufficient power, then power output is improved, but temperature increases causing thermal degradation and reduced cable lifespan
Solution Approach 1:
The system performs preliminary thermal monitoring and prediction before thermal damage occurs. The controller continuously monitors temperature characteristics of busbars and adjacent components, and predicts future temperature trends to proactively adjust powertrain operating characteristics before the cable reaches dangerous temperature levels, preventing thermal degradation while maintaining power output
Solution Approach 2:
The system implements closed-loop feedback control by continuously monitoring temperature characteristics of high voltage cables and busbars, comparing them against thermal limits, and automatically adjusting powertrain operating characteristics in response. This feedback mechanism enables dynamic balancing between power output and temperature control, ensuring safe operation while maximizing power delivery
2Temperature
If cooling measures are implemented to reduce cable temperature, then temperature control is improved, but system complexity increases
Solution Approach 1:
The system uses the powertrain's own operational adjustments to control cable temperature rather than adding separate cooling systems. By modifying powertrain operating characteristics (such as reducing power output or adjusting current distribution), the system leverages its existing components to achieve thermal management, avoiding additional cooling equipment and maintaining system simplicity
Solution Approach 2:
The system controls temperature by changing operational parameters of the powertrain rather than adding physical cooling infrastructure. The controller adjusts electrical parameters such as current magnitude, power output levels, and operating mode to control heat generation at its source, achieving temperature management through parameter optimization rather than additional hardware
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
The solution effectively protects high voltage cables by reducing powertrain operating characteristics when temperature thresholds are exceeded, thereby extending cable lifespan and preventing electrical system failures.
Implementation Method 1
The high voltage cables are connected to high voltages and carry high currents that generate significant ohmic heat or a temperature associated therewith which increase the temperature of the cable
Data Source
AI summary
A system and method of controlling a powertrain to protect a high voltage cable by determining a temperature characteristic for a busbar, determining a temperature characteristic adjacent to a component, and determining a current through the high voltage cable. Thereafter, the method reduces an operating characteristic of the powertrain based on the temperature characteristic for the busbar, the temperature characteristic adjacent to the component, and the current.