Insulation Breakdown Diagnosis in Hybrid Vehicle HV Components
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current systems fail to accurately determine which high voltage components in a hybrid electric vehicle have insulation breakdown, leading to inefficient diagnosis and potential incorrect servicing due to the need to sequentially measure and replace all components.
Innovation Solution
A system and method that utilizes a cooperative control between a battery management system and high voltage component controllers to diagnose insulation breakdown by measuring insulating resistance and determining the defective components, including a battery pack, high voltage relay, and high voltage components like motors and generators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all high voltage components are operated simultaneously during driving, then the vehicle can function properly, but it becomes difficult to determine which component has failed when insulation breakdown occurs
Solution Approach 1:
The patent segments the high voltage system into multiple isolatable components (battery pack, high voltage relay, high voltage component controller, and individual high voltage components). By using isolation switches to separate each component, the system can diagnose insulation breakdown in one component without affecting others, enabling precise identification of defective components while maintaining overall system productivity.
2Measurement precision
If insulation breakdown diagnosis is performed by sequentially separating and replacing all high voltage components, then the defective component can be identified, but substantial time and labor force are required
Solution Approach 1:
The patent implements preliminary diagnostic actions by continuously monitoring insulation resistance of each high voltage component through the battery management system before failures occur. The system pre-configures isolation switches and diagnostic circuits for each component, enabling immediate identification of insulation breakdown without time-consuming sequential separation and replacement procedures.
Solution Approach 2:
The battery management system continuously measures insulation resistance of each high voltage component and provides real-time feedback on the insulation status. When insulation breakdown is detected, the system immediately identifies the specific defective component through the feedback from individual measurement circuits, eliminating the need for manual sequential diagnosis and reducing both time and labor requirements.
3Device complexity
If conventional insulation breakdown detection is used, then only the presence of insulation breakdown in the overall system can be determined, but the specific defective component cannot be accurately identified
Solution Approach 1:
The detection system is segmented into multiple independent measurement circuits, each dedicated to a specific high voltage component. The battery management system includes separate insulation resistance measurement functions for the battery pack, high voltage relay, high voltage component controller, and individual high voltage components, enabling precise localization of insulation breakdown while maintaining manageable system complexity through modular architecture.
Solution Approach 2:
The patent introduces isolation switches as intermediary devices between the battery management system and each high voltage component. These switches enable the diagnostic system to selectively connect to and measure individual components without interference from other system parts, facilitating accurate defective component identification while keeping the overall detection system structured and manageable.
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 approach improves service efficiency by accurately identifying defective components, reducing unnecessary labor and incorrect servicing by enabling precise diagnosis of insulation breakdown in high voltage components within hybrid electric vehicles.
Implementation Method 1
measuring insulating resistance while sequentially separating and then replacing all of the high voltage components
Data Source
AI summary
A system and method for diagnosing insulation-breakdown of a vehicle component including a system in a vehicle including high voltage components are provided. The system includes a battery pack that is configured to supply a high voltage to the vehicle and a high voltage relay that is connected to an output stage of the battery pack. Additionally, a high voltage component controller is connected to an output stage of the high voltage relay to turn the high voltage component on and off. A battery management system interlocks with the battery pack, the high voltage relay, and the high voltage component controller to diagnose whether the battery pack, an input stage of the high voltage component controller, and the high voltage component are insulated-breakdown.