High-Voltage Testing Device Voltage State Verification
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Solution Overview
Problem
Existing methods for determining the voltage state of on-board high-voltage electrical systems in motor vehicles are unreliable, particularly during maintenance or repair, as they cannot consistently ensure a voltage-free state, posing risks to personnel due to potential re-energization from defective components.
Innovation Solution
A method that supplies a test voltage to the on-board high-voltage electrical system, compares it to a predetermined state, and uses a service switch or intentional circuit interruption to verify a zero-voltage state, providing visual or audible warnings and storing deviations for safety measures, ensuring safe working conditions by reliably detecting malfunctions and permanent de-energization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a testing device is used to detect the voltage state of the on-board high-voltage electrical system, then the voltage state can be determined, but the determination may be erroneous due to device malfunction or defective components
Solution Approach 1:
The method performs preliminary actions by supplying a test voltage to the on-board high-voltage electrical system before actual maintenance work begins. This preliminary voltage supply allows the testing device to verify its own functionality and detect potential malfunctions in advance, preventing erroneous voltage state determinations during subsequent maintenance operations.
Solution Approach 2:
The method implements feedback by comparing the voltage state determined by the testing device with the predetermined voltage state that results from supplying the test voltage. This feedback mechanism allows the system to verify whether the testing device is functioning correctly and whether the on-board high-voltage electrical system is truly voltage-free, thereby preventing erroneous assessments.
2Reliability
If the on-board high-voltage electrical system is de-energized by opening a service switch, then a voltage-free state is achieved, but defective contactors may cause re-energization
Solution Approach 1:
The method performs a preliminary voltage supply to the on-board high-voltage electrical system before maintenance work begins. This preliminary action establishes a known voltage state that can be used to verify the functionality of the service switch and contactors, ensuring that they properly maintain the voltage-free state throughout the maintenance period.
Solution Approach 2:
The method uses feedback by continuously monitoring the voltage state and comparing it with the predetermined state. When the service switch is opened, the system verifies that the voltage drops to zero and remains there. Any deviation from the predetermined voltage-free state triggers an alarm, indicating potential re-energization from defective contactors or other issues.
3Ease of operation
If conventional voltage detection methods are used during maintenance, then voltage state can be assessed, but the assessment may be incorrect due to device malfunction
Solution Approach 1:
The method performs a preliminary self-test of the testing device by supplying a test voltage and verifying that the device correctly detects and reports the voltage state. This preliminary action ensures the testing device is functioning properly before actual maintenance work begins, preventing incorrect assessments during operation.
Solution Approach 2:
The method implements feedback by comparing the voltage state measured by the testing device with the predetermined voltage state. This feedback mechanism verifies the accuracy of the measurement and detects any malfunctions in the testing device, ensuring reliable voltage state determination throughout the maintenance process.
Data Source
AI summary
A method for testing a testing device for determining a voltage state of an on-board high-voltage electrical system of a motor vehicle includes establishing a predetermined voltage state in the on-board high-voltage electrical system by supplying a test voltage to the on-board high-voltage electrical system and determining the voltage state with the testing device and comparing the determined voltage state with the predetermined voltage state This ensures that, before maintenance work on the on-board high-voltage electrical system is performed, a voltage-free state of the on-board high-voltage electrical system determined by the testing device is actually present, thereby eliminating risk to maintenance personnel due to an accidentally applied voltage.