HVIL Relay Circuit for Battery Swapping Without False E-Stop
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Solution Overview
Problem
Existing emergency stop (E-Stop) systems in mobile electric machines with removable power units (RPUs) falsely trigger a shutdown when the RPU is detached, immobilizing the machine and preventing it from moving to a replacement unit, thus causing unnecessary downtime during battery swapping.
Innovation Solution
A configuration of emergency stop (E-Stop) and high-voltage interface lock (HVIL) circuit hardware and software that redirects the safety circuits using a series of electronically controlled relays, actuated by electronic control modules, to maintain functionality during RPU removal, ensuring the machine remains operational.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the emergency stop circuit is configured as a closed circuit that breaks when the RPU is detached, then safety is improved, but the machine becomes immobilized and cannot move to a replacement unit
Solution Approach 1:
The emergency stop circuit is segmented into multiple independent paths: a first circuit path that remains closed during RPU detachment and a second circuit path that provides backup functionality. This segmentation allows the system to maintain safety monitoring while preventing false shutdowns during battery swapping operations.
Solution Approach 2:
A controller acts as an intermediary between the RPU detachment detection and the emergency stop circuit. The controller detects when the RPU is detached and actively maintains the first circuit path in a closed state, preventing the safety system from incorrectly interpreting the detachment as an emergency condition.
2Difficulty of detecting and measuring
If the emergency stop circuit is monitored for open circuits to detect faults, then fault detection capability is improved, but RPU detachment is falsely interpreted as a fault condition
Solution Approach 1:
The monitoring system is segmented into multiple circuit paths with different functions. The first circuit path is configured to remain closed during RPU detachment, while the second circuit path provides actual fault monitoring. This allows the system to distinguish between intentional detachment and actual fault conditions.
Solution Approach 2:
The controller continuously monitors the status of the RPU and provides feedback to maintain the appropriate circuit path states. When detachment is detected, the controller actively maintains the first circuit path closed, providing feedback that prevents false fault interpretation while still allowing second path monitoring to detect actual abnormalities.
3Reliability
If the system requires manual reset after E-stop activation, then safety is improved by preventing accidental restart, but the swapping process cannot be completed efficiently
Solution Approach 1:
The reset functionality is segmented into two independent paths: the first circuit path can be reset automatically or remotely when the RPU is reattached, while the second path maintains the traditional manual reset requirement for actual emergency conditions. This segmentation allows efficient recovery during battery swapping while maintaining safety for genuine emergencies.
Solution Approach 2:
The system performs preliminary actions by pre-configuring the first circuit path to be resettable without manual intervention. When the RPU is detached and reattached, the system is already prepared to automatically restore power through the first path, eliminating the need for manual reset operations during normal battery swapping cycles.
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
The system ensures safe battery swapping by maintaining emergency stop functionality and allowing the mobile electric machine to operate normally during the swap process, reducing downtime and enhancing productivity.
Implementation Method 1
A configuration of emergency stop (E-Stop) and high-voltage interface lock (HVIL) circuit hardware and software that redirects the safety circuits using a series of electronically controlled relays
Implementation Method 2
electronic control modules, to maintain functionality during RPU removal
Data Source
AI summary
A configuration of emergency stop (E-Stop) and high voltage interface lock (HVIL) circuit hardware and software is described that, alone or in combination, allows mobile electric machines with removable power units to function properly when the unit is removed, such as during battery swapping.