HV Pathway Failure Detection Using Intrusive Vehicle Control Logic

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Solution Overview

Problem

Current electric-drive vehicles face challenges in detecting high-voltage pathway failures in their electrified powertrains, which can lead to system faults and potential safety issues.

Innovation Solution

The implementation of intelligent vehicle systems with software-based detection methods that sequentially test high-voltage bus connections, using feedback signals from dedicated sensors to identify faults and differentiate between sensor failures and pathway disconnections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If physical high-voltage interlock loops and low-voltage pins are used for fault detection, then system reliability is improved, but device complexity and manufacturing costs increase

Engineering Contradiction:
Improvefault detection capabilityVSAvoidsystem complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces physical mechanical components (high-voltage interlock loops and low-voltage pins) with a software-based detection system. The controller uses feedback signals from sensors to monitor high-voltage pathway integrity through software algorithms, eliminating the need for dedicated physical interlock hardware while maintaining fault detection capability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The controller is designed to perform multiple functions: it manages powertrain control, monitors sensor feedback, and detects high-voltage pathway failures using software logic. This multi-functional approach consolidates what would traditionally require separate dedicated hardware components into a single integrated control system.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Reliability

If physical high-voltage interlock loops and low-voltage pins are used for fault detection, then system reliability is improved, but manufacturing costs increase

Engineering Contradiction:
Improvefault detection capabilityVSAvoidmanufacturing cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces physical mechanical components (high-voltage interlock loops and low-voltage pins) with a software-based detection system. The controller uses feedback signals from sensors to monitor high-voltage pathway integrity through software algorithms, eliminating the need for dedicated physical interlock hardware while maintaining fault detection capability.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of using dedicated physical hardware for each detection function, the system uses software copies of detection logic that can be replicated and executed by the controller. The software-based interlock loop concept creates virtual copies of safety functions that consume minimal additional manufacturing resources.

Inventive Principle:
Principle #26Copying

3Device complexity

If software-based detection is implemented, then device complexity is reduced, but measurement precision may worsen

Engineering Contradiction:
Improvesystem complexityVSAvoidfault detection accuracy
Core Design Contradiction:
Device complexityVSMeasurement precision

Solution Approach 1:

The system continuously monitors feedback signals from sensors in the high-voltage pathway and compares them against expected values. The controller uses this feedback to detect deviations indicating pathway failures, maintaining precision through active monitoring and comparison logic that adapts to system state.

Inventive Principle:
Principle #23Feedback

Solution Approach 2:

The software detection system is pre-configured with knowledge of normal operating parameters and failure modes. By having detection thresholds and logic prepared in advance, the system can rapidly and accurately identify faults without requiring complex real-time analysis, thereby maintaining measurement precision while keeping the system simple.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS12263833B2Intelligent vehicle systems and control logic for intrusive detection of high-voltage pathway failures
Publication Date: 2025.04.01 GM GLOBAL TECHNOLOGY OPERATIONS LLC
  • US12263833B2 patent drawing
  • US12263833B2 patent drawing
  • US12263833B2 patent drawing

AI summary

A method of operating a motor vehicle includes a vehicle controller receiving, from a first feedback sensor of an HV component, a first feedback signal indicative of an electrical characteristic of the HV component, and then detecting an HV system fault if the first feedback signal is less than a predefined electrical threshold. Upon detecting the system fault, the controller commands the HV component to operate at a commanded set-point; after sending the command, the controller receives, from a second feedback sensor of the HV component, a second feedback signal indicative of an operating characteristic of the HV component. An HV pathway failure is detected if the second feedback signal is not equal to or within a predefined operating range of the commanded set-point. Upon detecting the pathway failure in an HV electrical pathway of the HV component, the vehicle controller transmits a command signal to take a remedial action.