High-Voltage Relay Life Prediction from Excitation Voltage
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Solution Overview
Problem
High-voltage relays in electric and hybrid vehicles generate heat, leading to potential thermal damage and failure, which can result in loss of function and safety risks due to the lack of effective prediction and prevention of durability issues.
Innovation Solution
A method involving an excitation voltage computational measuring device and a logical determination device to detect and calculate the temperature of the high-voltage relay, using voltage-temperature data to predict the remaining life and determine if the relay is at risk of deterioration, triggering warnings and limiting battery output or stopping the vehicle if necessary.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the high-voltage relay operates to regulate battery power supply, then the power regulation function is achieved, but heat generation occurs leading to thermal damage and potential failure
Solution Approach 1:
The system performs preliminary temperature prediction and durability life calculation based on excitation voltage measurements before actual thermal damage occurs. By continuously monitoring excitation voltage and comparing it with reference values, the system predicts future temperature trends and calculates remaining relay life, enabling preventive maintenance before failure happens.
Solution Approach 2:
The system establishes a feedback loop by continuously measuring excitation voltage, predicting temperature, calculating durability life, and providing warnings to the driver. The measurement device, calculation unit, and warning device work together to create a closed-loop monitoring system that adjusts vehicle operation based on relay health status.
2Duration of action of moving object
If the relay operates continuously to maintain power supply regulation, then the power control function is maintained, but durability life decreases due to cumulative thermal stress
Solution Approach 1:
The system calculates remaining durability life in advance by accumulating temperature history and comparing it with reference temperature data. This preliminary calculation allows the system to predict when the relay will fail and warn the driver before actual failure occurs, enabling planned maintenance rather than unexpected breakdowns.
Solution Approach 2:
The relay monitoring system serves itself by using its own operational parameters (excitation voltage) to assess its own health status. The measurement device measures the excitation voltage that the relay itself generates, and the calculation unit uses this data to evaluate the relay's remaining life, creating a self-diagnostic capability.
3Reliability
If thermal damage is allowed to continue without intervention, then the relay may be burned and lose energization regulation function, but continuous monitoring and prediction systems increase device complexity
Solution Approach 1:
The system uses excitation voltage as an intermediary parameter to indirectly measure relay temperature and health status. Instead of directly measuring temperature with complex thermal sensors, the system measures excitation voltage (which is easier to access) and uses it as a proxy to predict temperature and durability, simplifying the monitoring system while maintaining accuracy.
Solution Approach 2:
The system replaces complex thermal measurement mechanisms with electrical measurement. Instead of using thermal sensors, thermocouples, or infrared measurement systems, the patent uses electrical voltage measurement of the excitation coil, which is already present in the relay circuit, to infer thermal conditions and predict failure.
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 predictive maintenance by calculating the remaining life of the high-voltage relay based on temperature changes, preventing overheating and potential failures, ensuring vehicle safety by alerting drivers and limiting battery output or stopping the vehicle when deterioration is detected.
Implementation Method 1
detecting, by an excitation voltage computational measuring device, an excitation voltage applied to an excitation coil of a relay
Implementation Method 2
calculating, by a logical determination device, a temperature of the relay based on the excitation voltage of the relay; calculating, by the logical determination device, the temperature of the relay using at least one of voltage-temperature data of the relay
Implementation Method 3
a relay provided to regulate power supply of a battery
Implementation Method 4
The high-voltage relay inevitably generates heat depending on an environmental temperature and a load
Data Source
AI summary
A vehicle and a method of controlling the vehicle are provided. The method of controlling the vehicle includes detecting, by an excitation voltage computational measuring device, an excitation voltage applied to an excitation coil of a relay provided to regulate power supply of a battery; calculating, by a logical determination device, a temperature of the relay based on the excitation voltage; and calculating, by the logical determination device, a remaining life of the relay based on the calculated temperature of the relay.