Low-Voltage Emergency Stop for High-Voltage Test Vehicle Shutdown
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Solution Overview
Problem
Range-extended electric vehicle test vehicles face high-voltage leakage and power output out-of-control issues due to immature software systems, posing safety risks to test personnel.
Innovation Solution
A system with an emergency stop switch on the low-voltage power supply line controls the vehicle control unit and battery management system to perform high-voltage shutdown and disconnect the battery pack relay, ensuring safe power supply by detecting abnormal low-frequency voltage signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-voltage battery packs are used for power in test vehicles, then the vehicle can perform multiple tests, but any leakage during testing could endanger the safety of the test personnel
Solution Approach 1:
The patent applies preliminary anti-action by implementing multiple protective measures before high-voltage leakage can occur: (1) The emergency stop switch is pre-positioned on the low-voltage power supply line to cut off power before leakage can propagate. (2) The vehicle control unit continuously monitors low-frequency voltage signals to detect potential leakage conditions beforehand. (3) The battery management system pre-disconnects the battery pack relay to isolate the high-voltage battery from the wiring harness when abnormalities are detected, preventing leakage from endangering personnel
2Adaptability or versatility
If the test vehicle software system is immature, then the vehicle can be tested with additional functionality, but power output out-of-control problems occur
Solution Approach 1:
The patent uses the vehicle control unit as an intermediary between the immature software system and the power output control. The vehicle control unit acquires low-frequency voltage signals from the low-voltage power supply line and acts as a mediator to detect abnormalities before they result in power output out-of-control conditions. This intermediary layer provides an additional safety checkpoint that compensates for software immaturity
Solution Approach 2:
The patent applies preliminary action by having the vehicle control unit continuously monitor low-frequency voltage signals from the low-voltage power supply line before power output problems can occur. When the vehicle control unit detects abnormal low-frequency voltage signals, it proactively controls the test vehicle to perform high-voltage shutdown and stops the motor and generator, preventing power output out-of-control situations before they can develop
3Speed
If an emergency stop switch is added to the low-voltage power supply line, then rapid power-down can be achieved, but the device complexity increases
Solution Approach 1:
The patent applies the taking out principle by extracting the emergency stop function from the complex high-voltage control system and placing it on the low-voltage power supply line. This separate, dedicated emergency stop switch provides rapid power-down capability by simply cutting off the low-voltage power supply to the vehicle control unit and battery management system, without requiring complex high-voltage disconnection mechanisms. The emergency stop function is isolated as a simple switch on the low-voltage line, reducing overall system complexity while maintaining fast response
Data Source
Figure 1
AI summary
A system and method for controlling safe power supply of a range-extended electric vehicle test vehicle are proposed, which relates to the technical field of safe power supply for test vehicles. The system includes an emergency stop switch disposed on a low-voltage power supply line of the test vehicle. The low-voltage power supply line is configured to supply power to a vehicle control unit and a battery management system of the test vehicle. The emergency stop switch is configured to, when actuated, cut off power supply from the low-voltage power supply line to the vehicle control unit and the battery management system. By adding the emergency stop switch between the low-voltage power supply line and the vehicle control unit and the battery management system and using the added emergency stop switch as a safety protection device, in the event of leakage or the power output cannot be cut off through signal control, the emergency stop switch can be pressed, combined with a high-voltage interlocking strategy, to cut off the external power supply of the battery pack of the test vehicle , thereby achieving safe and reliable cutting off of high-voltage power output, thereby ensuring the safety of the test personnel and improving the safety and reliability of the test vehicle.