HV Relay Sticking Control via Increment Counter
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Solution Overview
Problem
High voltage battery contactors in electric vehicles can stick closed, leading to undesired electrical current flow due to contact welds, which existing systems fail to effectively address.
Innovation Solution
A high voltage relay sticking control system and method that uses an increment counter to cycle coil power through contactors, detecting welds and transmitting sets of coil power cycles to reopen stuck contactors, with a weld diagnostic detection system and vehicle controller managing the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors are left closed to ensure continuous electrical connection, then electrical connectivity is maintained, but contact welds may occur causing the contactors to stick closed
Solution Approach 1:
The system applies periodic coil power cycles to the contactor coils at predetermined intervals to prevent contact welds and ensure reliable contactor operation, transforming the static closed state into a dynamically controlled periodic opening and closing action
2Reliability
If coil power is cycled through contactors to prevent sticking, then contactor reliability improves, but system complexity increases due to control mechanisms
Solution Approach 1:
The controller automatically monitors contactor status and initiates coil power cycling when sticking is detected, enabling the system to self-diagnose and self-correct contactor issues without external intervention or complex additional control mechanisms
3Measurement precision
If weld diagnostic detection system continuously monitors contactors, then detection precision improves, but energy consumption increases
Solution Approach 1:
The weld diagnostic detection system performs monitoring at predetermined intervals rather than continuously, reducing energy consumption while maintaining adequate detection precision to identify contactor sticking conditions
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
Effectively reopens stuck contactors, preventing electrical current flow issues and ensuring safe operation by using an increment counter to manage coil power cycles and detect contactor status.
Implementation Method 1
transmitting at least one set of coil power cycles through the contactor
Data Source
AI summary
A high voltage relay sticking control system for a vehicle having at least one contactor, a high voltage battery pack interfacing with the contactor and a weld diagnostic detection system interfacing with the high voltage battery pack and the contactor includes an increment counter adapted to interface with the contactor, the high voltage battery pack and the weld diagnostic detection system. The increment counter is adapted to transmit at least one set of coil power cycles through the contactor if a weld exists at the contactor. A high voltage relay sticking control method is also disclosed.