CN112904190A - Contactor failure detection method and contactor failure detection system - Google Patents
Contactor failure detection method and contactor failure detection system Download PDFInfo
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- CN112904190A CN112904190A CN202110019133.3A CN202110019133A CN112904190A CN 112904190 A CN112904190 A CN 112904190A CN 202110019133 A CN202110019133 A CN 202110019133A CN 112904190 A CN112904190 A CN 112904190A
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/327—Testing of circuit interrupters, switches or circuit-breakers
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01R—MEASURING ELECTRIC VARIABLES; MEASURING MAGNETIC VARIABLES
- G01R31/00—Arrangements for testing electric properties; Arrangements for locating electric faults; Arrangements for electrical testing characterised by what is being tested not provided for elsewhere
- G01R31/003—Environmental or reliability tests
Abstract
The invention provides a contactor failure detection method and a contactor failure detection system, wherein the contactor failure detection system comprises a detection circuit, a detection module and a control module, the detection circuit is electrically connected with a battery module and a contactor to form a detection loop, the detection module is electrically connected with the detection circuit, the detection module is used for detecting the current flowing through the contactor and the partial voltage corresponding to the contactor to obtain the resistance value of the contact resistance of the contactor, the control module is electrically connected with the detection circuit and the detection module, the detection module is used for calculating the temperature rise of the contactor according to the data information detected by the detection module and judging the effectiveness of the contactor according to the real-time temperature of the contactor.
Description
Technical Field
The invention relates to the field of electrical detection, in particular to a contactor failure detection method and a contactor failure detection system.
Background
The contactor is applied to electric power, distribution and power utilization occasions, wherein the contactor is used as a safety protection device which is used most in the modern electrical industry, and serious electrical accidents can be caused due to self failure. The contactor is subjected to failure protection, so that the whole electric system can be better protected.
The traditional contactor protection strategy is based on the electric service life curve provided by a manufacturer for prediction, and is difficult to accurately judge the current state of the contactor in practice or carry out related protection on a system after the contactor has a fault. That is to say, once the contactor after leaving the factory is installed and used, usually, after a fault occurs, the contactor is replaced by a professional, and it is difficult to detect whether the contactor is in a normal working state by the detection method in the prior art, which easily results in the effectiveness of the contactor during use, thereby affecting the normal operation of the electric equipment. On the other hand, it is difficult to accurately judge whether the contactor needs to be replaced based on the electrical service life curve provided by the contactor manufacturer, and if the contactor is used when exceeding the service life, potential safety hazards are easily caused to users.
In addition, ambient temperature also is the main factor that influences whether contactor can normally work, and contactor is in the course of the work because the resistance of self resistance can change along with ambient temperature change to other factors in the environment also can lead to the resistance change of contactor's resistance, and then influence contactor's normal work, lead to the contactor inefficacy.
Disclosure of Invention
One of the main advantages of the present invention is to provide a contactor failure detection method and a contactor failure detection system, wherein the contactor failure detection system can detect the effectiveness of the contactor in the working process, which is beneficial to reduce the risk of the contactor failure.
Another advantage of the present invention is to provide a method and a system for detecting contactor failure, wherein the contactor failure detection system is adapted to detect the effectiveness of the contactor and provide a corresponding control strategy according to the effectiveness of the contactor, which is beneficial to improve the safety performance of an electrical system.
Another advantage of the present invention is to provide a method and a system for detecting contactor failure, wherein the contactor failure detection system can detect effectiveness of the contactor during operation while the contactor is in operation, which is beneficial to improve safety performance of an electrical system.
Another advantage of the present invention is to provide a method and a system for detecting contactor failure, wherein the contactor failure detection system is located at the positive pole or the negative pole of a circuit, and does not affect the normal operation of the circuit, thereby improving the applicability.
Another advantage of the present invention is to provide a contactor failure detection method and a contactor failure detection system that is suitable for the effectiveness of the contactor when the fuel cell is electrically turned on, which is beneficial for reducing the risk of malfunction.
Another advantage of the present invention is to provide a contactor failure detection method and a contactor failure detection system, wherein the contactor failure detection system is electrically connected to a battery unit adjacent to the contactor, and the contactor failure detection system and the contactor form a detection loop through the fuel cell, so that validity detection of the contactor is achieved without affecting the normal operation of the fuel cell, and the applicability of the contactor failure detection system is improved.
Additional advantages and features of the invention will be set forth in the detailed description which follows and in part will be apparent from the description, or may be learned by practice of the invention as set forth hereinafter.
In accordance with one aspect of the present invention, the foregoing and other objects and advantages are achieved in the present invention by a contactor failure detection system adapted to detect the effectiveness of a contactor electrically connected to a battery module, comprising:
the detection circuit is electrically connected with the battery module and the contactor to form a detection loop;
the detection module is electrically connected with the detection circuit, and detects the current flowing through the contactor and the partial voltage corresponding to the contactor to obtain the resistance value of the contact resistor of the contactor; and
and the control module is electrically connected with the detection circuit and the detection module, the detection module calculates the temperature rise of the contactor according to the data information detected by the detection module, and judges the effectiveness of the contactor according to the real-time temperature of the contactor.
According to an embodiment of the present invention, the detection circuit includes a detection connection, a detection switch and a voltage dividing element disposed on the detection connection, wherein the detection switch and the voltage dividing element are connected in series to the detection circuit, and the detection switch controls the on/off of the detection circuit.
According to one embodiment of the invention, the voltage dividing element is a resistor.
According to an embodiment of the present invention, the detection module includes at least one voltage detection unit that detects the current of the detection loop and at least one current detection unit that detects the current flowing through the contactor.
According to an embodiment of the present invention, the voltage detecting unit further includes a total voltage detecting unit, a switch voltage detecting unit, and a divided voltage detecting unit, wherein the total voltage detecting unit detects a total voltage corresponding to the detection loop, the switch detecting unit detects a divided voltage corresponding to the detection switch, and the divided voltage detecting unit detects a divided voltage corresponding to the divided voltage element.
According to an embodiment of the present invention, the control module comprises a contactor control unit, a switch control unit and a controller unit, wherein the contactor control unit and the switch control unit are communicatively connected to the controller unit, and the controller unit sends a control command to the contactor control unit and/or the switch control unit, wherein the contactor control unit controls the on/off of the contactor based on the control command, and the switch control unit controls the on/off of the detection switch.
According to one embodiment of the present invention, the controller unit is electrically connected to the detection module, and the controller unit calculates a contact resistance of the contactor based on the data information detected by the detection module and determines validity of the contactor according to the contact resistance of the contactor.
According to an embodiment of the present invention, the detection module further includes an environment detection unit, wherein the environment detection unit is adapted to detect an environment temperature and a comprehensive heat dissipation coefficient, and wherein the real-time temperature of the contactor is calculated by integrating data information detected by the control module, so as to determine the effectiveness of the contactor according to the real-time temperature of the contactor.
According to an embodiment of the present invention, the environment detection unit includes a temperature detection element and a heat dissipation detection element, the temperature detection element is used for detecting an environment temperature of the contactor, and the heat dissipation detection element is used for detecting a comprehensive heat dissipation coefficient of the contactor.
According to another aspect of the present invention, the present invention further provides a contactor failure detection method, including:
(a) detecting the resistance value R of the contactor; and
(b) and detecting the current I flowing through the contactor, calculating the heating power and the heat dissipation power of the contactor, and obtaining the real-time temperature t of the contactor according to the heat balance relation so as to judge the effectiveness of the contactor.
According to an embodiment of the invention, the contactor failure detection method further comprises: presetting a rated working temperature t0, comparing the relation between the real-time temperature t of the contactor and the set rated temperature t0, and further judging the effectiveness of the contactor. When the real-time temperature t of the contactor is larger than t0, judging that the contactor is invalid; and if the real-time temperature t of the contactor is not more than t0, judging that the contactor is in an effective state.
According to an embodiment of the present invention, in the step (a) of the contactor failure detection method, a contactor switch of the contactor is closed, and a detection switch of a detection circuit is closed, so that a voltage dividing element of the detection circuit is connected in series with the contactor and forms a loop, so as to calculate the resistance value R of the contactor.
According to one embodiment of the present invention, in the step (b) of the contactor failure detection method, the detection switch is turned off, and the amount of heat generation of the contactor is calculated in an integrated manner; and detecting the environment temperature and the comprehensive heat dissipation coefficient corresponding to the contactor to obtain the heat balance relation of the contactor.
Further objects and advantages of the invention will be fully apparent from the ensuing description and drawings.
These and other objects, features and advantages of the present invention will become more fully apparent from the following detailed description, the accompanying drawings and the claims.
Drawings
Fig. 1 is a circuit diagram of a contactor failure detection system according to a first preferred embodiment of the present invention.
Fig. 2 is a system block diagram of the contactor failure detection system according to the first preferred embodiment of the present invention.
Fig. 3 is a circuit diagram of another alternative implementation of the contactor failure detection system according to the above first preferred embodiment of the present invention.
Fig. 4 is a block diagram of a judgment strategy of the contactor failure detection system according to the first preferred embodiment of the present invention.
Fig. 5 is a schematic diagram of a method of the contactor failure detection system according to the first preferred embodiment of the present invention.
Detailed Description
The following description is presented to disclose the invention so as to enable any person skilled in the art to practice the invention. The preferred embodiments in the following description are given by way of example only, and other obvious variations will occur to those skilled in the art. The basic principles of the invention, as defined in the following description, may be applied to other embodiments, variations, modifications, equivalents, and other technical solutions without departing from the spirit and scope of the invention.
It will be understood by those skilled in the art that in the present disclosure, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," and the like are used in an orientation or positional relationship indicated in the drawings for ease of description and simplicity of description, and do not indicate or imply that the referenced devices or components must be in a particular orientation, constructed and operated in a particular orientation, and thus the above terms are not to be construed as limiting the present invention.
It is understood that the terms "a" and "an" should be interpreted as meaning that a number of one element or element is one in one embodiment, while a number of other elements is one in another embodiment, and the terms "a" and "an" should not be interpreted as limiting the number.
Referring to fig. 1 to 5 of the drawings accompanying the present specification, a contactor failure detection method and a contactor failure detection system according to a first preferred embodiment of the present invention are explained in the following description. The contactor failure detection system comprises at least one detection circuit 10, a detection module 20 and a control module 30, wherein the detection module 20 is electrically connected with the detection circuit 10. The contactor failure detection system is adapted to detect the effectiveness of a contactor 100, wherein the contactor 100 is connected in series in a circuit 400 between a battery module 200 and a powered device 300, wherein the circuit 400 includes a positive connection 410 and a negative connection 420, wherein the contactor 100 is connected in series in either the positive connection 410 or the negative connection 420. The contactor 100 is used to control the on or off operation state of the circuit 400 between the battery module 200 and the electric device 300. It will be appreciated that the contactor failure detection system is adapted to detect the effectiveness of the contactor 100 and control the operating state of the contactor 100 based on the effectiveness of the contactor 100.
In this preferred embodiment of the invention, the contactor 100 is connected in series to the positive connection 410 of the circuit 400, as shown in fig. 1. The contactor 100 includes at least one contactor switch 110, wherein the contactor switch 110 controls the electrical device 300 to be connected to or disconnected from the battery module 200. It is worth mentioning that, in the preferred embodiment of the present invention, the contactor 100 has a certain resistance value, wherein when the contactor switch 110 of the contactor 100 is closed, the contactor 100 is connected in series to the circuit 400 between the battery module 200 and the electric device 300, and when the contactor 100 is turned on, the electric heat is continuously generated by the current, that is, the contactor 100 generates heat in the circuit itself. Assuming that the resistance value of the contactor 100 is R, wherein the resistance value R of the contactor 100 may vary with the environment and the service life, if the resistance value R of the contactor 100 exceeds the set effective resistance value R0, the contactor 100 may not work normally, i.e., the contactor 100 fails. The use of a failed contactor can result in the risk of electrical circuits, such as burning out the consumer, damaging the battery module, and even causing personal injury or death.
It is understood that the contactor 100 is provided with a rated range of operating voltage, a rated range of current, and the contactor 100 is provided with a rated range of resistance R0, and when it is detected that the actual resistance R of the contactor 100 is greater than the rated range of resistance R0 of the contactor 100, the contactor 100 fails, and a fault procedure needs to be taken in time, and a worker is reminded to replace the contactor.
The detection circuit 10 is electrically connected to the battery module 200 and the circuit 400, and the detection circuit 10 forms a path with the battery module 200 through the circuit 400, wherein the contactor 100 is located in the path, and the path formed by the detection circuit 10, the battery module 200 and the circuit 400 is used for detecting the effectiveness of the contactor 100. The detection module 20 is electrically connected to the detection circuit 10, wherein the detection module 20 detects a resistance value R of the contactor 100 during operation, and detects environment-related data, such as a current temperature, a heat dissipation coefficient, and the like of the contactor 100 during operation. The control module 30 is communicatively connected to the detection module 20 and the circuit 10, and the control module 30 controls the circuit 10 so that the detection module 20 collects various data information, such as voltage, current, and the like, when the contactor 100 operates, wherein the control module 30 determines the validity of the contactor 100 based on the various data information collected by the detection module 20, and controls the operating state of the contactor 100, such as entering a fault shutdown process, to maintain the stability and the operational safety of the battery module 200.
It should be noted that, in the preferred embodiment of the present invention, the contactor 100 does not destroy the original circuit connection relationship between the battery module 200 and the electric equipment 300, and a circuit for detecting the state of the contactor 100 is electrically connected between the cell at the end and the adjacent cell directly on the original circuit.
The control module 30 obtains a real-time resistance value R of the contactor 100 based on the data information of the contactor 100 collected by the detection module 20, and determines whether the contactor 100 is in an effective state, that is, whether the contactor 100 is effective according to the resistance value R of the contactor 100; and/or the control module 30 obtains the implementation temperature of the contactor 100 during operation according to the relevant environmental data information based on the real-time resistance value R of the contactor 100 detected by the detection module 20, so as to determine whether the contactor 100 is in an effective operation state, that is, whether the contactor 100 is effective. It should be noted that when the control module 30 detects that the contactor 100 is in the active state, the control module 30 keeps the contactor 100 working normally, for example, the contactor switch 110 of the contactor 100 is controlled to be turned off or turned on according to a control command, and when the control module 30 detects that the contactor 100 is in the inactive state, the control module 30 enters a fault shutdown procedure, for example, the contactor switch 110 of the contactor 100 is controlled to be turned off, that is, the circuit 400 is turned off.
In detail, the detection circuit 10 includes a detection wire 11, a detection switch 12 and at least one voltage dividing element 13 disposed on the detection wire 11, wherein the detection switch 12 and the voltage dividing element 13 are connected in series to the detection wire 11, and are electrically connected to the battery module 200 and the positive wire 410 (negative wire 420) of the circuit 400 through the detection wire 11, so that the battery module 200 forms a detection loop 101 through the positive wire 410 (negative wire 420) of the circuit 400, the detection circuit 10 and the contactor 100. It will be understood by those skilled in the art that the detection circuit 101 is in a conducting state when the detection switch 12 and the contactor switch 110 of the contactor 100 are closed simultaneously (active state), and the detection circuit 101 is in an open state when the detection switch 12 and/or the contactor switch 110 of the contactor 100 are open (inactive state).
In the preferred embodiment of the present invention, the battery module 200 includes, but is not limited to, a power supply device such as a fuel cell, a lithium power battery, and a super capacitor, or the battery module 200 is a battery unit having a single cell or a single section. The battery module 200 includes a positive terminal 210, a negative terminal 220, and at least one battery cell 230 disposed between the positive terminal 210 and the negative terminal 220, wherein the at least one battery cell 230 is electrically connected in series and/or parallel with the positive terminal 210 and the negative terminal 220. It is noted that, in the preferred embodiment of the present invention, the positive terminal 210, the negative terminal 220 and the battery cell 230 of the battery module 200 are power devices or elements electrically connected to each other. Preferably, the battery module 200 is a battery pack composed of a plurality of the battery cells 230, wherein the battery cells 230 are electrically connected in series and/or in parallel. It is understood that, in the preferred embodiment of the present invention, the positive terminal 210 and the negative terminal 220 are the unit cells of the end of the battery module 200, wherein the positive terminal 210 is the whole unit of the battery module 200, and the terminal 220 is the negative terminal of the battery module 200.
By way of example, in this preferred embodiment of the invention, the cell module 200 is a fuel cell, wherein the cell module 200 consists of N single cells. In other alternative embodiments of the present invention, the battery module 200 may also be implemented as other power storage devices, such as a lithium battery pack composed of a plurality of lithium battery cells. In short, in the preferred embodiment of the present invention, the specific type of the battery module 200 is not limited herein. Preferably, in the preferred embodiment of the present invention, the contactor 100 is electrically connected to the positive terminal 210 of the battery module 200 and a battery cell 220 adjacent to the positive terminal 210; or the contactor 100 is electrically connected to the negative terminal 220 of the battery module 200 and a battery cell 230 adjacent to the negative terminal 220.
It is understood that the positive connection 410 of the circuit 400 is electrically connected between the positive terminal 210 of the power module 200 and the positive terminal of the powered device 300, and the negative connection 420 of the circuit 400 is electrically connected between the negative terminal 220 of the power module 200 and the negative terminal of the powered device 300.
As shown in fig. 1, one end of the detection wire 11 is electrically connected to a battery cell 230 of the battery module 200, wherein a certain potential difference exists between the battery cell 230 and the positive terminal 210 (negative terminal 220) of the battery module 200, so that the battery module 200 forms a conductive loop through the detection circuit 10 and the positive wire 410 of the circuit 400.
Preferably, the detection wire 11 of the detection circuit 10 is electrically connected to the battery cell 230 adjacent to the positive terminal 210, wherein the potential of the battery cell 230 electrically connected to the detection wire 11 is close to the potential of the positive terminal 210 of the battery module 200. In other words, the potential difference between the battery cell 230 electrically connected to the detection wire 11 and the positive terminal 210 of the battery module 200 is small, thereby reducing the loss of electric energy by the detection circuit 10 during detection. It can be understood that when the battery module 200 supplies power to the electric device 300, the power loss generated by the detection circuit 10 is small, and the normal operation of the electric device 300 is not affected.
The detection switch 12 and the voltage dividing element 13 of the detection circuit 10 have certain resistance values, respectively, where the resistance value of the detection switch 12 is R1, and the resistance value of the voltage dividing element 13 is R2. Therefore, when the detection circuit 10 is turned on, the detection switch 12 and the voltage dividing element 13 divide the voltage, the divided voltage corresponding to the detection switch 12 is U2, the divided voltage corresponding to the voltage dividing element 13 is U3, and the total voltage between the positive electrode terminal 210 of the battery module 200 and the battery cell 230 is U1. Therefore, when the contactor switch 110 and the detection switch 12 of the contactor 100 are closed, the circuit 101 is conducted, and the corresponding partial voltage of the contactor 100 is U1-U2-U3.
Preferably, in the preferred embodiment of the present invention, the resistance value R2 of the voltage dividing element 13 is equal to or close to the resistance value R3 of the detection switch 12, that is, when the detection circuit 10 is turned on, the voltages corresponding to the detection switch 12 and the detection switch 13 are close to each other. More preferably, in the preferred embodiment of the present invention, the voltage dividing element 13 may be, but is not limited to, a resistor, wherein the resistance R2 of the voltage dividing element 13 is in the order of m Ω.
The detection module 20 is adapted to detect voltage values corresponding to electronic components of the detection circuit 10 and a current of the positive connection 410 of the circuit 400, so as to detect a real-time ground resistance R of the contactor 100, and further determine whether the contactor 100 is valid.
The detecting module 20 includes at least one voltage detecting unit 21 and at least one current detecting unit 22, wherein the voltage detecting unit 21 is disposed in the circuit 400 and the detecting circuit 10 to detect the total voltage U1, the divided voltage U2 corresponding to the detecting switch 12, and the divided voltage U3 corresponding to the divided voltage element 13. The current detection unit 22 is used to detect a current value I of the contactor 100. Accordingly, the current detection unit 22 is connected in series to the positive connection 410 of the circuit 400.
In the preferred embodiment of the present invention, the voltage detecting unit 21 further includes a total voltage detecting unit 211, a switch voltage detecting unit 212 and a divided voltage detecting unit 213, wherein the total voltage detecting unit 211 is configured to detect the value of the total voltage U1, the switch voltage detecting unit 212 is configured to detect the divided voltage U2 corresponding to the detecting switch 12, and the divided voltage detecting unit 213 is configured to detect the divided voltage U3 corresponding to the divided voltage element 13.
The contactor 100 and the detection circuit 10 are controlled by the control module 30, and data information such as corresponding current and voltage is detected by the detection module 20 to calculate the contact resistance of the contactor 100. The control module 30 comprises a contactor control unit 31, a switch control unit 32 and a controller unit 33, wherein the contactor control unit 31 and the switch control unit 32 are communicatively connected to the control unit 33, and the controller unit 33 sends control commands to the contactor control unit 31 and/or the switch control unit 32. The contactor control unit 31 controls the contactor switch 110 of the contactor 100 to switch between an open state and a closed state based on a control command of the controller unit 33. The switch control unit 32 controls the detection switch 12 to switch between an open state and a closed state based on the control instruction of the controller unit 33, that is, the operating state of the detection switch 12 is controlled or switched by the switch controller 32.
The control module 30 controls the contactor switch 110 of the contactor 100 to be closed and controls the detection switch 12 of the detection circuit 10 to be closed, and the voltage detection unit 21 and the current detection unit 22 of the detection module 20 detect data information of voltage and current to obtain a contact resistance R of the contactor 100, wherein R is (U1-U2-U3) ÷ I. It will be understood by those skilled in the art that the contact resistance of the contactor 100 may vary with temperature, wear, etc., and that the effectiveness of the contactor 100 may be affected as the contact resistance value R of the contactor 100 is larger and the more electric heat is generated when the contactor 100 normally operates. The controller unit 33 of the control module 30 is communicatively connected to the detection module 20, wherein the controller unit 33 determines the validity of the contactor 100 according to the obtained resistance value of the contact resistance R of the contactor 100. It is understood that, in the preferred embodiment of the present invention, the current detection unit 22 of the detection module 20 may be, but is not limited to, a current sensor, and the voltage detection unit 21 may be, but is not limited to, a voltage sensor.
When the contact resistance R of the contactor 100 exceeds a set rated resistance value R0, a fault procedure is triggered, and the controller unit 33 of the control module 30 sends a control command to the contactor control unit 31, wherein the contactor control unit 31 opens the contactor switch 110 of the contactor 100 to disconnect the battery module 200 from the electric equipment 300, thereby avoiding a fault or a potential safety hazard caused by the contactor 100 being in an ineffective working state.
It will be understood by those skilled in the art that when the controller unit 33 of the control module 30 determines that the contactor 100 is in the inactive state, the fault procedure triggered by the controller unit 33 may also include other means, such as an alarm to alert or reduce the power generation efficiency of the battery module 200 or even shut down.
Further, the control module 30 obtains the real-time temperature t of the contactor 100 through calculation or estimation and the like based on environmental factors and heat generated during the operation of the contactor 100, and if the real-time temperature t of the contactor 100 exceeds a preset value t0, that is, the operating temperature of the contactor 100 is too high, the controller unit 33 of the control module 30 determines that the contactor 100 is in a non-effective state, and enters a fault procedure.
As shown in fig. 2, the detecting module 20 further includes at least one environment detecting unit 23, wherein the environment detecting unit 23 is used to detect the current working environment of the contactor 100, wherein the environment detecting unit 23 is communicatively connected to the controller unit 33 of the control module 30, wherein each data information detected by the environment detecting unit 23 is transmitted to the controller unit 33 of the control module 30, and the controller unit 33 determines the validity of the contactor 100 according to each data information detected by the environment detecting unit 23.
The environment detection unit 23 includes at least one temperature detection element 231 and at least one heat dissipation detection element 232, wherein the temperature detection element 231 is adapted to detect the temperature of the environment where the contactor 100 is located, and the heat dissipation detection element 232 is adapted to detect the comprehensive heat dissipation coefficient of the contactor 100. It is worth mentioning that in the preferred embodiment of the present invention, the battery module 200 is a dc power source, and the dc power does not consider the skin effect and the proximity effect, and only calculates the resistance loss.
The control module 30 controls the detection switch 12 of the circuit 10 and the contactor switch 110 of the contactor 100 to be turned on and off, the detection module 20 detects the contact resistance R of the contactor 100 and the environmental data related to the contactor 100, and the controller unit 33 of the control module 30 obtains the real-time temperature of the contactor 100 according to the contact resistance loss, the heat dissipation efficiency, the thermal balance relationship and the like, so as to determine the effectiveness of the contactor 100. It is understood that when the contactor 100 is turned on, the contactor 100 itself generates heat due to the contact resistance of the contactor 100 itself. If the heat generated by the contactor 100 is too high, which may cause the temperature of the contactor 100 itself to be too high, the heat may affect the electric devices and the battery module 200, and may even affect the safety of the battery module. In other words, when the heat generated by the contactor 100 itself is too high, and the real-time temperature of the contactor 100 exceeds the set temperature value, the contactor 100 fails, and the control module 30 triggers the fault procedure.
Calculating the heating power P of the contact resistorR＝I2R, wherein PRHeating power (W), I: current (A), R: direct current resistance (Ω). It is understood that the controller unit 33 of the control module 30 may calculate the heating power of the contact resistance R of the contactor 100 according to the current and the resistance value detected by the detection module 20, and only calculate the resistance loss since the direct current does not consider the skin effect and the proximity effect, etc.
Calculating heat dissipation powerRate: pS＝KTA τ, wherein PSTotal heat dissipation power (W), A: effective heat dissipation area (m)2) τ: temperature rise of heating element (K), t-t0 (t: heating element temperature; t 0: ambient temperature), KT: comprehensive heat dissipation coefficient (W/m)2/K)。
For A and KTThe correction value verified by the actual environment should be used to ensure accurate determination of the calculation. In the preferred embodiment of the present invention, t0 is detected by the environment detecting unit 23 of the detecting module 20, and the effective heat dissipation area a is a detected value or a set value.
Then, the real-time temperature of the contactor 100 is obtained by means of integration according to a heat balance relationship, wherein the heat balance relationship is PR*dT＝PSdT + c m d tau, where PR: heating power (W), PS: total heat dissipation power (W), dT: time interval (S), d τ: dT time, temperature increase (K), c: specific heat capacity (J/kg/K) of the heat-generating body, m: mass (kg) of the heating element.
Calculating to obtain the real-time temperature t ═ t0+ (I) of the contactor 100 according to the contact resistance heating power, the heat dissipation power and the heat balance relation2*R*dT)/(KTA × dT + c × m). The controller unit 33 of the control module 30 determines the validity of the contactor 100 according to the calculated real-time temperature value of the contactor 100, and when the contactor 100 is determined to be in a non-valid state, the controller unit 33 of the control module 30 triggers the fault program.
Accordingly, as will be understood by those skilled in the art, the contactor 100 is provided with a rated operating temperature t1 (or a plurality of corresponding rated temperatures tx according to the use environment), when the operating temperature of the contactor 100 exceeds the set rated temperature t1, i.e., t > t1, the contactor 100 conducts a circuit to cause the contactor 100 to generate excessive heat, thereby affecting the normal operation of the electric device 300; or the heat generated by the contactor 100 may build up over time and create a safety hazard.
As shown in fig. 4, the failure determination strategy of the contactor failure detection system is that the contactor 100 is closed by the contactor control unit 31 of the control module 30, whether the current value I detected by the current detection unit 22 of the detection module 20 is greater than the set rated current I0, if I > I0, the current of the circuit 400 is overloaded, a fault procedure is triggered by the controller unit 33 of the control module 30, and a fault state is recorded, and a fault shutdown procedure is entered, such as the contactor switch 110 of the contactor 100 is opened by the contactor control unit 31.
If the detected current I is less than or equal to I0, the switch control unit 32 of the control module 30 closes the detection switch 12 of the detection circuit 10, and the detection module 20 detects the data such as the current and the voltage of the detection circuit 10. The control module 30 performs rationality judgment according to the data information detected by the detection module 20, and if the rationality judgment is reasonable, the execution is continued; if the rationality is determined to be unreasonable, the controller unit 33 of the control module 30 triggers the fault program, and the trigger control unit 31 disconnects the contactor switch 110 of the contactor 100 or generates an alarm prompt message or the like. The rationality judgment method of the control module 30 after the detection switch 12 is closed is as follows: if the switch partial voltage U2 is approximately equal to the total voltage U1 and the resistor partial voltage U3 is approximately equal to 0V, the detection switch 12 is not closed, and the contactor failure detection system works abnormally and is judged to be unreasonable; if the switch partial voltage U2 is approximately equal to 0V, and the resistor partial voltage U3 is approximately equal to total voltage U1, the partial voltage element 13 is disconnected, and the contactor failure detection system works abnormally and is judged to be unreasonable.
When the control module 30 determines that the rationality after the detection switch 12 is closed is reasonable, the controller unit 33 of the control module 30 calculates the contact resistance R of the contactor 100 according to the voltage and current information detected by the detection module 20, and compares the contact resistance R with a set value R0. If R > R0, i.e. the detected contact resistance R of the contactor 100 exceeds a set value, it is determined that the contactor 100 is out of order and a fault procedure is triggered by the control module 30 and the contactor switch 110 of the contactor 100 is opened by the controller unit 31 of the control module 30 and/or a corresponding alarm alert signal is generated.
If R ≦ R0, the detection switch 12 is opened by the switch control unit 32 of the control module 30 and the system operation is started, i.e. the consumer 300 and the battery module 200 are electrically connected. The control module 30 performs rationality judgment, and if the judgment is unreasonable, the controller unit 33 of the control module 30 triggers a fault program, records a fault state, and enters a fault shutdown process. The rationality of the control module 30 after the detection switch is turned off is determined as follows: if the voltage dividing switch U2 is approximately equal to 0V, and the resistance voltage dividing switch U3 is approximately equal to total pressure U1, the detection switch 12 is not actually disconnected, and at the moment, the working state of the contactor failure detection system is judged to be unreasonable; otherwise it is reasonable.
After the control module 30 determines that the contactor failure detection system is reasonable, in the operation process of the electrical equipment, that is, when the contactor switch 110 of the contactor 100 is in the closed state, the controller unit 33 of the control module 30 calculates the calorific value according to the detected resistance value R and the actual current I flowing through the contactor 100, and obtains the corresponding real-time temperature value of the contactor 100 according to the detected environmental data. Preferably, in this preferred embodiment of the present invention, the controller unit 33 may obtain the real-time temperature of the contactor 100 through an estimation or calculation. The controller unit 33 calculates the heating value and the heat dissipation value of the contactor 100 in an integral manner, and obtains the real-time temperature of the contactor 100 through a thermal balance relationship.
Comparing the real-time temperature t of the contactor 100 with the set rated temperature t1, if t is greater than t1, namely the real-time temperature of the contactor 100 exceeds the set maximum temperature value, judging that the working temperature of the contactor 100 is too high, and judging that the contactor 100 fails by the control module 30 and entering a fault program.
Referring to FIG. 3 of the drawings accompanying this specification, another alternative embodiment of the contactor failure detection system is set forth in the description that follows. The contactor failure detection system differs from the preferred embodiment described above in that the contactor 100 is connected in series with the negative terminal 420 of the circuit 400. Accordingly, the contactor failure detection system is electrically connected to the negative terminal 420 of the circuit 400 and forms a circuit with the battery module 200. It should be noted that, in this alternative embodiment of the present invention, the system structure of the contactor failure detection system is the same as that of the above preferred embodiment, and the difference is the installation position of the contactor failure detection system.
As shown in fig. 5, a contactor failure detection method of the present invention is set forth in the description that follows, in accordance with another aspect of the present invention. The contactor failure detection method comprises the following steps:
(a) detecting a resistance value R of the contactor 100; and
(b) detecting the current I flowing through the contactor 100, calculating the heating power and the heat dissipation power of the contactor 100, and obtaining the real-time temperature t of the contactor 100 according to the heat balance relation so as to judge the effectiveness of the contactor 100.
Presetting a rated working temperature t0, and comparing the relation between the real-time temperature t of the contactor 100 and the set rated temperature t0 to further judge the effectiveness of the contactor 100. When the real-time temperature t of the contactor 100 is larger than t0, judging that the contactor 100 is failed; and if the real-time temperature t of the contactor 100 is less than or equal to t0, judging that the contactor 100 is in an effective state.
In step (a) of the failure detection method of the present invention, a contactor switch 110 of the contactor 100 is closed, and a detection switch 12 of a detection circuit 10 is closed, so that a voltage dividing element 13 of the detection circuit 10 is connected in series with the contactor 100 and forms a loop, so as to calculate the resistance value R of the contactor 100. In the step (b) of the above failure detection method, the detection switch 12 is opened, and the heat generation amount of the contactor 100 is calculated in an integrated manner; and detecting the ambient temperature and the comprehensive heat dissipation coefficient corresponding to the contactor 100 to obtain the thermal balance relationship of the contactor 100.
It will be appreciated by persons skilled in the art that the embodiments of the invention described above and shown in the drawings are given by way of example only and are not limiting of the invention. The objects of the invention have been fully and effectively accomplished. The functional and structural principles of the present invention have been shown and described in the examples, and any variations or modifications of the embodiments of the present invention may be made without departing from the principles.
Claims (13)
1. A contactor failure detection system adapted to detect the effectiveness of a contactor electrically connected to a battery module, comprising:
the detection circuit is electrically connected with the battery module and the contactor to form a detection loop;
the detection module is electrically connected with the detection circuit, and detects the current flowing through the contactor and the partial voltage corresponding to the contactor to obtain the resistance value of the contact resistor of the contactor; and
and the control module is electrically connected with the detection circuit and the detection module, the detection module calculates the temperature rise of the contactor according to the data information detected by the detection module, and judges the effectiveness of the contactor according to the real-time temperature of the contactor.
2. The contactor failure detection system according to claim 1, wherein the detection circuit comprises a detection wiring, a detection switch and a voltage dividing element provided to the detection wiring, wherein the detection switch and the voltage dividing element are connected in series to the detection circuit, and the detection switch controls the detection circuit to be turned on or off.
3. The contactor failure detection system of claim 2, wherein the voltage dividing element is a resistor.
4. The contactor failure detection system of claim 2, wherein the detection module comprises at least one voltage detection unit that detects the current of the detection loop and at least one current detection unit that detects the current flowing through the contactor.
5. The contactor failure detection system according to claim 4, wherein the voltage detection unit further comprises a total voltage detection unit, a switch voltage detection unit and a divided voltage detection unit, wherein the total voltage detection unit detects a total voltage corresponding to the detection loop, the switch detection unit detects a divided voltage corresponding to the detection switch, and the divided voltage detection unit detects a divided voltage corresponding to the divided voltage element.
6. The contactor failure detection system of claim 4, wherein the control module comprises a contactor control unit, a switch control unit, and a controller unit, wherein the contactor control unit and the switch control unit are communicatively connected to the controller unit, and the controller unit sends control commands to the contactor control unit and/or the switch control unit, wherein the contactor control unit controls the on/off of the contactor based on the control commands, and the switch control unit controls the on/off of the detection switch.
7. The contactor failure detection system according to claim 6, wherein the controller unit is electrically connected to the detection module, calculates a contact resistance of the contactor based on data information detected by the detection module, and judges validity of the contactor according to the contact resistance of the contactor.
8. The contactor failure detection system of claim 6, wherein the detection module further comprises an environment detection unit, wherein the environment detection unit is adapted to detect an environment temperature and a comprehensive heat dissipation coefficient, and wherein the real-time temperature of the contactor is calculated by integrating data information detected by the control module to determine the effectiveness of the contactor according to the real-time temperature of the contactor.
9. The contactor failure detection system of claim 8, wherein the environment detection unit comprises a temperature detection element for detecting a temperature of an environment in which the contactor is located and a heat dissipation detection element for detecting a comprehensive heat dissipation coefficient of the contactor.
10. A contactor failure detection method is characterized by comprising the following steps:
(a) detecting the resistance value R of the contactor; and
(b) and detecting the current I flowing through the contactor, calculating the heating power and the heat dissipation power of the contactor, and obtaining the real-time temperature t of the contactor according to the heat balance relation so as to judge the effectiveness of the contactor.
11. The contactor failure detection method of claim 10, wherein the contactor failure detection method further comprises: presetting a rated working temperature t0, comparing the relation between the real-time temperature t of the contactor and the set rated temperature t0, and further judging the effectiveness of the contactor. When the real-time temperature t of the contactor is larger than t0, judging that the contactor is invalid; and if the real-time temperature t of the contactor is not more than t0, judging that the contactor is in an effective state.
12. The contactor failure detection method according to claim 11, wherein in the step (a) of the contactor failure detection method, a contactor switch of the contactor is closed, and a detection switch of a detection circuit is closed, so that a voltage dividing element of the detection circuit is connected in series with the contactor and forms a loop, so that the resistance value R of the contactor is calculated.
13. The contactor failure detection method according to claim 12, wherein in the step (b) of the contactor failure detection method, the detection switch is opened, and a heat generation amount of the contactor is calculated in an integrated manner; and detecting the environment temperature and the comprehensive heat dissipation coefficient corresponding to the contactor to obtain the heat balance relation of the contactor.
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