Apparatus and method of monitoring insulation of a DC network that is electrically insulated with respect to the ground potential of a device

• US 6,864,688 B2
• Filed: 02/26/2003
• Issued: 03/08/2005
• Est. Priority Date: 03/21/2002
• Status: Expired due to Fees

• Current Assignee: NuCellSys GmbH (Mercedes-Benz Group AG)
• Original Assignee: Ballard Power Systems Corporation (Superior Plus Corporation)
• Inventors: Landenberger, Karl-Heinz, Beutelschiess, Klaus
• Primary Examiner(s): Deb, Anjan
• Assistant Examiner(s): Benson, Walter
• Application Number:
  US10/375,927
• Publication Number:
  US 20030214306A1
• Time in Patent Office: 741 Days
• Field of Search: 307/70.1, 324/503, 324/509, 324/536, 324/544, 324/551, 324/716, 324/541, 340/647, 702/59
• US Class Current: 324/551
• CPC Class Codes: B60L 2210/40 DC to AC converters
• CPC Class Codes: B60L 3/00 Electric devices on electrically-propelled vehicles for safety purposes; Monitoring operating variables, e.g. speed, deceleration or energy consumption methods or circuit arrangements for monitoring or controlling batteries or fuel cells B60L58/00
• CPC Class Codes: B60L 58/30 for monitoring or controlling fuel cells
• CPC Class Codes: B60L 58/34 by heating
• CPC Class Codes: G01R 31/086 in power transmission or distribution networks, i.e. with interconnected conductors
• CPC Class Codes: Y02T 10/72 Electric energy management in electromobility
• CPC Class Codes: Y02T 90/40 Application of hydrogen technology to transportation, e.g. using fuel cells

Abstract

Insulation monitoring of an electrical network such as a DC network which is electrically insulated with respect to the ground of a device, includes at least two insulation monitoring devices that monitor different network sections, which can be isolated by one or more switches. Non-contacting switches are used to alternatingly connect and isolate respective measuring resistors of the monitoring devices to, and from, ground, as a result of which the insulation monitoring devices can not negatively affect each other'"'"'s measurements.

Claims

1. An apparatus for insulation monitoring of a DC network, the network being electrically insulated with respect to a frame potential of a device that contains the DC network;

the apparatus comprising;

a switch coupled in the network and selectively operable to electrically isolate a first portion of the network from a second portion of the network;

a first insulation monitoring device electrically coupled to the first portion of the network on a first side of the switch to monitor an insulation resistance of the first portion of the network with respect to the frame potential;

a second insulation monitoring device electrically coupled to the second portion of the network on a second side of the switch to monitor the second portion of the network with respect to the frame potential; and

a non-contacting switch selectively operable in a first state to electrically couple the first insulation monitoring device to the frame potential and to electrically decouple the second insulation monitoring device from the frame potential, and selectively operable in a second state to electrically decoupled the first insulation monitoring device from the frame potential and to electrically couple the second insulation monitoring device to the frame potential.

2. The apparatus of claim 1 wherein the first monitoring device comprises a first measuring resistor and the second monitoring device comprises a second measuring resistor.

3. The apparatus of claim 1 wherein the non-contacting switch is a semiconductor relay.

4. The apparatus of claim 1 wherein the network further comprises a power source electrically coupled to the first portion of the network on the first side of the switch;

and a load electrically coupled to the second portion of the network on the second side of the switch.

5. The apparatus of claim 1 wherein the network further comprises a power source with a nominal voltage in the range of approximately 200V to approximately 400 V, a DC/DC converter electrically coupled to step the voltage from the power source down to an operating voltage of less than approximately 50 V, and a storage battery electrically coupled to a low voltage side of the DC/DC converter.

6. The apparatus of claim 1 wherein the network further comprises a fuel cell stack power source with a nominal voltage in the range of approximately 200V and approximately 400 V.

7. The apparatus of claim 1, further comprising:

a controller coupled to control the non-contacting switch and to control the first and the second insulation monitoring devices, the controller configured to evaluate measured values of the insulation resistances.

8. The apparatus of claim 1, further comprising:

a controller configured to open the switch to uncoupled a load from a power source upon detecting a low insulation voltage condition.

9. The apparatus of claim 1 wherein the device containing the DC network is a vehicle.

10. The apparatus of claim 1 wherein the device containing the DC network is an electric vehicle comprising a fuel cell stack and an electric traction motor.

11. An electrical network for an electric vehicle, the network being electrically insulated with respect to a frame potential of the electric vehicle;

the network comprising;

at least one power source;

at least one load;

a first switch coupled between the power source and the load, and selectively operable to electrically isolate a first portion of the network from a second portion of the network;

a first insulation monitoring device electrically coupled to the first portion of the network on a first side of the switch to monitor an insulation resistance of the first portion of the network with respect to the frame potential;

a second insulation monitoring device electrically coupled to the second portion of the network on a second side of the switch to monitor the second portion of the network with respect to the frame potential;

a second switch selectively operable in a first state to electrically couple the first insulation monitoring device to the frame potential and to electrically decouple the second insulation monitoring device from the frame potential, and selectively operable in a second state to electrically decoupled the first insulation monitoring device from the frame potential and to electrically couple the second insulation monitoring device to the frame potential; and

at least one controller coupled to control the second switch and to control the first and the second insulation monitoring devices, and the controller configured to evaluate measured values of the insulation resistances.

12. The apparatus of claim 11 wherein the second switch is a semiconductor relay comprising a pair of optocouplers to receive control signals from the controller and a pair of semiconductor switches to alternatingly electrically couple a respective measuring resistor of the first and the second monitoring devices to a chassis of the electric vehicle.

13. The apparatus of claim 11 wherein the power source comprises a fuel cell stack and the load comprises an electric traction motor.

14. The apparatus of claim 11 wherein the controller is further configured to open the first switch to uncoupled the load from the power source upon detecting a low insulation voltage condition.

15. The apparatus of claim 11 wherein the controller is further configured to perform a plausibility check.

16. The apparatus of claim 11 wherein the first switch is a contactor switch and the second switch is a non-contacting switch.

17. A method of insulation monitoring of an electrical network, the network being electrically insulated with respect to a frame potential of a device that contains the network, at least one power source and at least one load;

the method comprising;

during a first period,

electrically coupling only a first one of a pair of measuring resistors to the frame potential, each of the pair of measuring resistors associated with a respective one of a first and a second measuring device; and

determining an insulation resistance of the network; and

during a second period,

electrically coupling only a second one of the pair of measuring resistors to the frame potential; and

determining an insulation resistance of the network.

18. The method of claim 17 wherein determining an insulation resistance of the network comprises:

applying at least one voltage pulse across a respective one of the measuring resistors that is currently coupled to the frame potential;

measuring at least one voltage a defined time after applying the voltage pulse;

determining a difference between consecutive ones of the measured voltages; and

calculating the insulation resistance based on the determined differences.

19. The method of claim 17, further comprising:

comparing the determined insulation resistance of the network to a minimum insulation resistance threshold; and

selectively operating a switch to electrically isolate a first portion of the network comprising a power source from a second portion of the network comprising a load based on an outcome of the determination.

20. The method of claim 17 wherein electrically coupling the measuring resistors to the frame potential comprises activating a semiconductor relay to electrically couple only one of the measuring resistors to a chassis of an electric vehicle while electrically decoupling the other of the measuring resistors from the chassis.

21. The method of claim 17, further comprising:

checking plausibility.

22. An apparatus for insulation monitoring of an electrical network, the network being electrically insulated with respect to a frame potential of a device that contains the network, the apparatus comprising:

means for electrically coupling a first and a second measuring resistor to the frame potential, alternatingly;

means for determining an insulation resistance of the network when only the first one of the measuring resistors is electrically coupled to the frame potential; and

means for determining an insulation resistance of the network when only the second one of the measuring resistors is electrically coupled to the frame potential.

23. The apparatus of claim 22, further comprising:

a switch selectively operable to electrically isolate a first portion of the network comprising a power source from a second portion of the network comprising a load.

24. The apparatus of claim 22 wherein the means for electrically coupling a first and a second measuring resistor to the frame potential, alternatingly comprises:

a semiconductor relay having a first semiconductor switch and a second semiconductor switch, the first semiconductor switch coupled between a first measuring resistor and the frame potential and the second semiconductor switch coupled between a second measuring resistor and the frame potential; and

control logic to selectively activate the first semiconductor switch while deactivating the second semiconductor switch, and to selectively activate the second semiconductor switch while deactivating the first semiconductor switch.

25. The apparatus of claim 22 wherein the means for electrically coupling a first and a second measuring resistor to the frame potential, alternatingly comprises:

a semiconductor relay having a first semiconductor switch and a second semiconductor switch, the first semiconductor switch coupled between a first measuring resistor and the frame potential and the second semiconductor switch coupled between a second measuring resistor and the frame potential; and

control logic to selectively activate the first semiconductor switch while deactivating the second semiconductor switch when activating a first insulation monitoring device, and to selectively activate the second semiconductor switch while deactivating the first semiconductor switch when activating a second insulation monitoring device.

26. The apparatus of claim 22, further comprising:

means for determining whether the insulation resistance is below a threshold value; and

a switch selectively operable to electrically isolate a first portion of the network comprising a power source from a second portion of the network comprising a load based on the determination of whether the insulation resistance is below the threshold insulation resistance value.