Decentralized HV Safety Interlock with Optocoupler Isolation
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Solution Overview
Problem
Existing high-voltage (HV) safety locks in vehicles can lead to unintended shutdown of the entire HV system due to single component failures, causing diagnostic challenges and electromagnetic interference, and do not adequately protect components from damage due to electric arcs or contact-breaking sparks.
Innovation Solution
A decentralized HV safety lock system with electric isolation of the low-voltage (LV) power supply using optocouplers or inductive/capacitive insulators, connected via internal BUS systems like LIN or CAN, allowing targeted fault detection and shutdown of affected components, reducing electromagnetic interference and preventing system-wide shutdowns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a series connection of HV components is used for safety interlock, then safety monitoring is achieved, but system reliability deteriorates because a single component failure causes entire HV system shutdown
Solution Approach 1:
The patent divides the HV system into independent parallel channels instead of a single series connection. Each HV component has its own independent safety monitoring path that can detect faults locally without affecting other components. This segmentation allows the system to maintain reliability while reducing the complexity of coordinated safety monitoring across all components.
2Device complexity
If LV interlock lines are installed close to HV high-current lines, then wiring complexity is reduced, but electromagnetic compatibility deteriorates due to crosstalk and interference
Solution Approach 1:
The patent introduces optocouplers as intermediary devices between the LV control system and HV components. These optocouplers provide galvanic isolation, allowing signal transmission while blocking electromagnetic interference from HV lines. This mediator approach maintains simple wiring layout while effectively preventing crosstalk and electromagnetic compatibility issues.
3Reliability
If complete HV system shutdown is implemented upon fault detection, then safety is improved, but diagnostic capability deteriorates because the faulting component cannot be identified
Solution Approach 1:
The patent implements independent feedback paths for each HV component through the parallel channel architecture. Each component can detect its own faults and communicate this information back to the control system without shutting down the entire HV system. This feedback mechanism enables precise fault identification while maintaining system safety through selective component isolation.
4Reliability
If short-circuit bridges are used in HV plugs to maintain loop closure, then safety interlock functionality is achieved, but protection against electric arcs and contact-breaking sparks is insufficient
Solution Approach 1:
The patent uses optocouplers as intermediary devices that provide galvanic isolation between LV control circuits and HV components. This isolation prevents direct electrical contact that could lead to arcs and sparks, while still maintaining the safety interlock functionality through optical signal transmission. The mediator approach protects against harmful electrical discharge while preserving safety monitoring.
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
Enables selective and adaptive measures for faulty HV components, preventing damage and maintaining system integrity by isolating fault detection and shutdown to the affected component, reducing electromagnetic interference and ensuring safety against electric arcs and sparks.
Implementation Method 1
The LV power supply is always designed with electric isolation from the HV system. The electric isolation of the LV power supply is advantageously designed as an optocoupler or an inductive or capacitive insulator.
Implementation Method 2
The electric isolation of the LV power supply is advantageously designed as an optocoupler or an inductive or capacitive insulator.
Implementation Method 3
The electric isolation of the LV power supply is advantageously designed as an optocoupler or an inductive or capacitive insulator.
Data Source
AI summary
A high voltage (HV) safety lock for HV components in a vehicle has an HV plug, including a safety bridge arranged in the HV plug and connected to a central vehicle control via an internal bus system within the vehicle or a simple switched signal via a decentral control and regulating unit of an HV component. The safety bridge is connected to an LV power supply configured with electric isolation from the HV system.