CN114295996A - High-voltage safety testing method for pure electric passenger car - Google Patents
High-voltage safety testing method for pure electric passenger car Download PDFInfo
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Abstract
A high-voltage safety test method for a pure electric passenger car relates to the technical field of high-voltage test of the pure electric passenger car and solves the problem that a high-voltage system of the existing pure electric passenger car has potential safety hazards to human bodies; testing the insulation resistance value of the power battery by adopting an insulation resistance measuring instrument, wherein the insulation resistance from two ends of the power battery to a chassis of the vehicle body is unequal, and the insulation resistance with small resistance value is used as the insulation resistance of the power battery; in the process of measuring the insulation resistance of the power battery, the test can be carried out only by disconnecting the high-voltage power supply of the electric automobile and disconnecting the power battery from the driving circuit. Compared with the method that the whole testing process is manually completed, the testing efficiency is improved, and the testing time is saved.
Description
Technical Field
The invention relates to the technical field of high-voltage test of pure electric passenger cars, in particular to a high-voltage safety test method of the pure electric passenger car.
Background
An important characteristic of the pure electric passenger car is that the pure electric passenger car is provided with a high-voltage power loop, and the working voltage of the pure electric passenger car can even reach more than 800V.
The human body resistance is mainly skin resistance, and the resistance of the human body epidermis cuticle is very large and can reach 6-10 k omega under the dry condition, even higher; and may drop to 10k omega in the wet condition. In theoretical research, a human body is considered as a large resistor (1k omega), when a voltage is applied to the human body, a corresponding current is generated, and the intensity and the acting time of the current cause different injuries to the human body. When the current intensity is more than 50mA and the action time exceeds 10ms, the ventricular fibrillation and the breathing difficulty of a human body can be caused, and the safety of an electric shocker is endangered.
With the advent of more and more pure electric vehicle products, people have shifted their attention to quality and safety from the very beginning of performance and price, and of course, as the core of the entire electric vehicle, the safety of the high-voltage battery, the high-voltage circuit, and the entire electric vehicle is essential. The highest voltage of the pure electric vehicle in the working mode can reach about 600V, and for the high voltage, how to ensure the safety of a consumer is a key point of research when the consumer drives, charges or performs other operations; so as to ensure that the consumer does not have electric shock danger in normal operation or misoperation.
Human sensible direct current is about 2mA, the current value which can cause ventricular fibrillation of human is about 200mA, and when the current reaches a plurality of amperes, serious burn and even death can be caused, and a high-voltage safety test is of no great importance through comparison and analysis of a plurality of quantitative parameters.
In order to reduce the electric shock risk of a high-voltage system to a human body and reduce safety accidents, a high-voltage electric test method is required to be provided for systematically testing the high-voltage electric safety of a whole vehicle in the development stage of a passenger vehicle.
Disclosure of Invention
The invention provides a high-voltage safety testing method for a pure electric passenger car, aiming at solving the problem that the high-voltage system of the existing pure electric passenger car has potential safety hazards to human bodies.
A high-voltage safety test method for a pure electric passenger car comprises the steps of testing the insulation resistance of a power battery, testing the insulation resistance on a loop of a power system, testing the equipotential and monitoring the insulation resistance, and realizing high-voltage safety test;
testing the insulation resistance value of the power battery by adopting an insulation resistance measuring instrument, wherein the insulation resistance from two ends of the power battery to a chassis of the vehicle body is unequal, and the insulation resistance with small resistance value is used as the insulation resistance of the power battery;
testing the insulation resistance on the loop of the power system; selecting a measuring point on the high-voltage loop, and testing the insulation resistance of the measuring point to the chassis of the vehicle body;
the high-voltage assembly is characterized in that a shell of the high-voltage assembly or a conductive outer cover and other parts are connected with a vehicle body bracket by adopting a lead, and the resistance between the shell of the high-voltage assembly and any point of a vehicle body is required to be less than or equal to 0.1 omega;
the insulation monitor is adopted to monitor the insulation resistance of the high-voltage system of the electric automobile to the ground in real time, when the insulation resistance of the high-voltage system to the chassis is lower than a set alarm judgment value, the insulation monitor sends out an alarm signal and cuts off the high-voltage power supply of the automobile, and when the insulation resistance is detected to be lower than 500 omega/V, a circuit is automatically disconnected.
The invention has the beneficial effects that:
1. orange high-voltage wire harness and high-voltage warning marks for reminding safety;
all system wire harnesses higher than B-level voltage on an electric automobile are represented by orange, the orange is called a high-voltage wire in a popular way, the orange is more striking, the orange is better distinguished in the maintenance process, the wire harnesses of the high-voltage system transmit high voltage and bear large current, all electric equipment (PTC and electric compressor) on the high-voltage system and all conversion equipment (vehicle-mounted charger, motor controller and DC/DC) shells are pasted with high-voltage warning marks, and the shells pasted with the marks are not allowed to be directly touched by naked hands in principle, so that the potential danger exists.
2. The electric shock and water proof connector is protected, and safety is guaranteed;
all high-voltage connectors on the electric automobile have electric shock prevention and waterproof functions, and the safety and the sealing performance of the connectors are safety guarantee for ensuring accidental electric shock of passengers;
3. high-voltage interlocking, high-voltage safety second barrier;
through using low voltage signal, inspect the electric integrality (continuity) of whole high voltage product, wire, connector and protecting cover, when discerning the unusual disconnection of return circuit, in time break off high-voltage electricity, high-voltage interlock detection line is adorned on same plug with the power high-voltage line, if the plug pine takes off or breaks off, high voltage battery disconnection high voltage power supply side contactor immediately after the high-voltage interlock line discernment, ensures safety.
4. Insulation monitoring, high-voltage safety real-time monitoring;
the insulation condition of the electric automobile is measured by the insulation resistance of the direct-current positive and negative buses to the ground, once the insulation value is lower than a specified required value, the insulation monitoring module gives an alarm to prompt that the insulation is invalid, and people need to be far away from a high-voltage device. Through the above warning and monitoring measures, the high-voltage safety of the electric automobile is ensured.
In the process of measuring the insulation resistance of the power battery, the method can test the insulation resistance of the power battery only by disconnecting the high-voltage power of the electric automobile and disconnecting the power battery from the driving circuit. Compared with the method that the whole testing process is manually completed, the testing efficiency is improved, and the testing time is saved.
Drawings
Fig. 1 is a schematic block diagram of testing insulation resistance on a power system loop in a high-voltage safety testing method for a pure electric passenger vehicle according to the present invention;
fig. 2 is a functional block diagram of a medium potential test in the high-voltage safety test method for the pure electric passenger vehicle according to the present invention.
Detailed Description
The embodiment is described with reference to fig. 1 and fig. 2, and a method for testing high-voltage safety of a pure electric passenger vehicle includes testing insulation resistance of a power battery, testing insulation resistance on a power system loop, performing an equipotential test, monitoring the insulation resistance, and implementing the high-voltage safety test;
the insulation resistance of the power battery is tested by adopting an insulation resistance measuring instrument, and for the power battery system with the voltage of 60V, U and 1000V, the insulation resistance is required to be calculated according to a standard method in GB18384, and the value obtained by dividing the obtained insulation resistance by the nominal voltage of the battery is not less than 500 omega/V. A specific resistance value needs to be calculated manually.
Insulation resistances from two ends of the power battery to the chassis of the vehicle body are unequal, and in order to ensure safety, a smaller insulation resistance of the power battery is generally adopted.
Before testing the insulation resistance of the power battery, the electric automobile disconnects the high voltage and disconnects the power battery from the driving circuit, and then the test is carried out. If the entire testing process is done manually, it is obviously time consuming and requires repeated data logging and calculations.
As shown in fig. 1, in the insulation resistance test of the power system loop, the insulation resistance of the power system loop needs to be measured by adopting 1.5 times or 500V (the larger of the two) of the nominal voltage of the system, and generally, an insulation resistance measuring instrument is selected for measurement. Insulation resistance testers generally consist of a dc high voltage generator (test voltage) and a leakage current tester (precision ammeter).
And in the measuring process, the electric high-voltage power of the tested electric automobile is disconnected, and the power battery is disconnected with the driving circuit. And selecting a proper measuring point on the high-voltage power circuit, and measuring the insulation resistance of the measuring point to the chassis of the vehicle body.
As shown in fig. 2, in the present embodiment, when an accident such as a collision occurs in the automobile, the leakage of the components on the high-voltage circuit may be caused, and in this case, the two different component surfaces may have unequal potentials. If no equipotential connection is carried out, when a person touches the two components at the same time, current is formed due to the existence of potential difference, and the human body is injured. According to the standard requirement, the equipotential resistance must not be greater than 0.1 Ω.
In the measurement of the equipotential resistance, in order to prevent the electric shock hazard caused by the existence of the potential difference, a mode that a conducting wire is connected with a vehicle body bracket is adopted between a shell of a high-voltage assembly or a conductive outer cover and other parts so as to achieve the equipotential effect, the provision is made for the equipotential, and the resistance from the shell of the high-voltage assembly to any point of a vehicle body is required to be not more than 0.1 omega.
Because the resistance value of the measured resistor is small (not larger than 0.1 omega), in order to obtain a more accurate value, two test lines are led out from each test point of the actually measured resistor, and the two test lines are strictly separated to form independent loops respectively; in the voltage loop, the current flowing through the test loop requiring extremely high input impedance is extremely small and is approximately zero. r represents the sum of the lead resistance and the contact resistance of the probe and the test point. Because the current flowing through the test loop is zero, the voltage drop on R3 and R4 is also zero, and the voltage drop of the excitation current i on R1 and R2 does not influence the voltage drop of i on the tested resistor, the voltmeter can accurately measure the voltage values at two ends of R1, and the resistance value of R1 is accurately measured. The test result is independent of r, and the measurement error is effectively reduced.
In this embodiment, the specific process of monitoring the insulation resistance is as follows: the cable insulation medium of the electric automobile direct current high voltage system is aged or affected by factors such as a humid environment, the insulation performance between a high voltage electrical system and a vehicle chassis is reduced, and a power supply anode lead or a power supply cathode lead forms a leakage loop between an insulation layer and the chassis, so that the potential of the vehicle chassis is increased, and the personal safety of drivers and passengers is endangered.
The insulation monitor can monitor the insulation resistance of the high-voltage system of the electric automobile to the ground in real time, and when the insulation resistance of the high-voltage system to the chassis is lower than a set alarm judgment value, the insulation monitor sends out an alarm signal and cuts off the high-voltage power supply of the automobile.
The alarm judgment value of the insulation monitor on the electric automobile is generally 500 omega/V.
In this embodiment, in order to check the condition of the insulation monitor, the critical state of the insulation resistance may be simulated to observe whether the insulation monitor presents an alarm. Under the condition of power-on, the two AVLHVSafety2000 probes are respectively connected with a high-voltage positive electrode (or negative electrode) and a chassis, an activation test is carried out, the resistance value of a variable load resistor in the instrument is continuously reduced, a critical alarm value is simulated, when the load resistor in the instrument is 200k omega, the vehicle-mounted insulation monitor gives an alarm, at the moment, the power supply of a high-voltage system is cut off, and the voltage value obtained by the AVLHVSafety2000 is smaller than 1V.
While certain exemplary embodiments of the present invention have been described above by way of illustration only, it will be apparent to those of ordinary skill in the art that the described embodiments may be modified in various different ways without departing from the spirit and scope of the invention. Accordingly, the drawings and description are illustrative in nature and should not be construed as limiting the scope of the invention.
Claims (2)
1. A high-voltage safety testing method for a pure electric passenger car is characterized by comprising the following steps: the method comprises the steps of testing the insulation resistance of the power battery, testing the insulation resistance on a loop of a power system, testing the equipotential and monitoring the insulation resistance, and realizing the high-voltage safety test;
testing the insulation resistance value of the power battery by adopting an insulation resistance measuring instrument, wherein the insulation resistance from two ends of the power battery to a chassis of the vehicle body is unequal, and the insulation resistance with small resistance value is used as the insulation resistance of the power battery;
testing the insulation resistance on the loop of the power system; selecting a measuring point on the high-voltage loop, and testing the insulation resistance of the measuring point to the chassis of the vehicle body;
the shell of the high-voltage component or the conductive outer cover is connected with the bracket of the vehicle body by adopting a lead, and the resistance between the shell of the high-voltage component and any point of the vehicle body is required to be less than or equal to 0.1 omega;
the insulation monitor is adopted to monitor the insulation resistance of the high-voltage system of the electric automobile to the ground in real time, when the insulation resistance of the high-voltage system to the chassis is lower than a set alarm judgment value, the insulation monitor sends out an alarm signal and cuts off the high-voltage power supply of the automobile, and when the insulation resistance is detected to be lower than 500 omega/V, a circuit is automatically disconnected.
2. The pure electric passenger vehicle high-voltage safety test method according to claim 1, characterized in that:
when testing the insulation resistance of the power battery and the insulation resistance on a power system loop, the high-voltage electricity of the electric automobile needs to be cut off, and a connecting circuit of the power battery and a driving circuit needs to be cut off.
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| CN202111358153.XA CN114295996A (en) | 2021-11-16 | 2021-11-16 | High-voltage safety testing method for pure electric passenger car |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115267378A (en) * | 2022-06-30 | 2022-11-01 | 中国第一汽车股份有限公司 | Processing method for high-voltage safety detection operation and vehicle |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102897039A (en) * | 2012-09-29 | 2013-01-30 | 北京智行鸿远汽车技术有限公司 | High-voltage safety precaution control method of hybrid electric vehicle |
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- 2021-11-16 CN CN202111358153.XA patent/CN114295996A/en active Pending
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102897039A (en) * | 2012-09-29 | 2013-01-30 | 北京智行鸿远汽车技术有限公司 | High-voltage safety precaution control method of hybrid electric vehicle |
Non-Patent Citations (1)
| Title |
|---|
| "电动汽车的高压安全测试" * |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115267378A (en) * | 2022-06-30 | 2022-11-01 | 中国第一汽车股份有限公司 | Processing method for high-voltage safety detection operation and vehicle |
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Application publication date: 20220408 |