HV Interlock Monitoring via Power Rails Without Wire Loops
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Solution Overview
Problem
Traditional high voltage interlock loop (HVIL) systems in electric vehicles are prone to failures due to multiple wire loops, which introduce complexity, potential faults, and reliability issues, complicating troubleshooting and maintenance, and are not compatible with advanced electronic monitoring systems.
Innovation Solution
A system that eliminates the need for multiple wire loops by using a DC voltage converter to convert low voltage power to evaluation voltage, allowing the electric vehicle control unit (EVCU) to verify high voltage connections through voltage report data, ensuring compliance with set points and detecting breaches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire loop HVIL systems are used to monitor high voltage connections, then the system can detect operational status of high voltage rails, but the system complexity increases and reliability decreases due to multiple wire loops and connection points
Solution Approach 1:
The patent extracts and eliminates the wire loop infrastructure from the HVIL system. Instead of using physical wire loops to monitor high voltage connections, the system uses the existing high voltage power rails themselves to carry monitoring signals. This removes multiple wire loops and connection points, directly reducing system complexity and potential failure points while maintaining monitoring capability.
Solution Approach 2:
The patent makes the high voltage power rails serve dual functions: delivering high voltage power to loads and simultaneously carrying low voltage monitoring signals for HVIL detection. By enabling the power rails to perform both power transmission and signal monitoring, the system eliminates the need for separate wire loops, reducing complexity while improving reliability.
2Measurement precision
If multiple wire loops are used to ensure comprehensive monitoring of high voltage connections, then measurement coverage is improved, but troubleshooting and maintenance difficulty increases
Solution Approach 1:
By removing the wire loop infrastructure, the patent eliminates multiple connection points that could fail and complicates troubleshooting. The simplified system using power rails for monitoring reduces the number of components that need to be diagnosed and repaired, making maintenance easier while preserving monitoring accuracy.
Solution Approach 2:
The patent replaces the mechanical wire loop system with an electronic signal transmission approach using the existing power rails. This substitution eliminates physical wire connections that degrade over time and are difficult to diagnose, replacing them with electronic monitoring that integrates with modern diagnostic systems.
3Reliability
If traditional wire loop HVIL systems are implemented, then high voltage connection monitoring is achieved, but the system is not compatible with advanced electronic monitoring and control systems
Solution Approach 1:
The patent replaces the mechanical wire loop system with an electronic-based monitoring approach that uses low voltage signals transmitted over high voltage power rails. This electronic implementation is compatible with modern electronic control units and advanced monitoring systems, enabling better integration, diagnostics, and control capabilities while maintaining reliable high voltage connection detection.
Solution Approach 2:
The patent changes the monitoring signal parameters by using low voltage signals instead of relying on physical wire loop continuity. This parameter change enables compatibility with electronic monitoring systems that can detect and process low voltage electrical signals, allowing integration with advanced control and diagnostic systems in modern vehicles.
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
Simplifies electrical connections, enhances reliability, and integrates with advanced monitoring systems, reducing downtime and maintenance costs while ensuring safety by eliminating wire loop dependencies.
Implementation Method 1
The DC voltage converter may be electrically connected between the HVDB and a low voltage power source. Prior to setting the RESS high voltage connection to the RESS closed state, the DC voltage converter may boost low voltage electrical power from the low voltage power source to evaluation voltage electrical power to be provided to the high voltage load over the load high voltage rail via the HVDB.
Data Source
AI summary
A high voltage interlock loop wire elimination system is provided for eliminating the need for a high voltage interlock loop wire when verifying operational status of high voltage rails between a rechargeable energy storage system, high voltage distribution box, and high voltage load. The high voltage interlock loop wire elimination system may include an electric vehicle control unit (EVCU), communication channel, voltage rail, high voltage distribution box (HVDB), DC voltage converter, and rechargeable electrical storage system (RESS). A method for eliminating the need for a high voltage interlock loop wire when verifying operational status of high voltage rails between a rechargeable energy storage system, high voltage distribution box, and high voltage load using the high voltage interlock loop wire elimination system is also provided.