Diagnostic method for contactor resistance failure
First Claim
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1. A controller-implemented diagnostic method, for determining and indicating a contactor fault in an electric vehicle, a controller system causing steps comprising:
- providing a high voltage battery pack interfacing with at least one contactor;
providing a controller interfacing with the high voltage battery pack and the at least one contactor;
determining the electrical contact surface resistance of at the least one contactor in communication with the high voltage battery pack, the electrical contact surface resistance determined at a selected battery current from at least one voltage drop measurement across the at least one contactor, the at least one voltage drop measurement made when the at least one contactor is in electrical communication with the high voltage battery pack and an electrical load, the at least one contactor comprising an open and closed position with respect to electrical communication with the high voltage battery pack;
decreasing the heat dissipation due to electrical contact surface resistance by controlling charge or discharge power limits at the at least one contactor if the electrical contact surface resistance of the at least one contactor has increased relative to a previous determined electrical contact surface resistance value; and
,indicating a faulted status if an estimated electrical contact surface resistance of the at least one contactor is above a predetermined value.
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Abstract
A diagnostic method for contact resistance failure includes estimating electrical contact surface resistance of at least one contactor, determining a faulted status of the at least one contactor and indicating the faulted status of the at least one contactor if the at least one contactor is in the faulted status.
11 Citations
16 Claims
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1. A controller-implemented diagnostic method, for determining and indicating a contactor fault in an electric vehicle, a controller system causing steps comprising:
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providing a high voltage battery pack interfacing with at least one contactor; providing a controller interfacing with the high voltage battery pack and the at least one contactor; determining the electrical contact surface resistance of at the least one contactor in communication with the high voltage battery pack, the electrical contact surface resistance determined at a selected battery current from at least one voltage drop measurement across the at least one contactor, the at least one voltage drop measurement made when the at least one contactor is in electrical communication with the high voltage battery pack and an electrical load, the at least one contactor comprising an open and closed position with respect to electrical communication with the high voltage battery pack; decreasing the heat dissipation due to electrical contact surface resistance by controlling charge or discharge power limits at the at least one contactor if the electrical contact surface resistance of the at least one contactor has increased relative to a previous determined electrical contact surface resistance value; and
,indicating a faulted status if an estimated electrical contact surface resistance of the at least one contactor is above a predetermined value. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A controller-implemented diagnostic method for determining and indicating contact resistance failure, a controller system causing steps comprising:
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providing a high voltage battery pack interfacing with a main positive contactor and a main negative contactor; providing a battery energy electric control module interfacing with the high voltage battery pack and the main positive and main negative contactors; estimating electrical contact surface resistance of the main positive contactor and the main negative contactor, the electrical contact surface resistance estimated at a selected battery current from at least one voltage drop measurement across each of the main positive and main negative contactors, the at least one voltage drop measurement made when at least one of the main positive and main negative contactors is in electrical communication with the high voltage battery pack and an electrical load, each of the main positive and main negative contactors comprising an open and closed position with respect to electrical communication with the high voltage battery pack; decreasing the heat dissipation due to electrical contact surface resistance by controlling charge or discharge power limits of at least one of the main positive contactor and the main negative contactor if the respective estimated electrical contact surface resistance has increased relative to a previously determined respective electrical contact surface resistance; and
,determining a faulted status of at least one of the main positive contactor and the main negative contactor; and indicating the faulted status of at least one of the main positive contactor and the main negative contactor if the at least one of the main positive contactor and the main negative contactor is in the faulted status. - View Dependent Claims (8, 9, 10, 11, 12, 13)
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14. A controller-implemented diagnostic method for contact determining and indicating resistance failure, a controller system causing steps comprising:
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estimating electrical contact surface resistance of a main positive contactor and a main negative contactor interfacing with a high voltage battery pack and a controller, the electrical contact surface resistance estimated at a selected battery current from at least one voltage drop measurement across each of the main positive and negative contactors, the at least one voltage drop measurement made when at least one of the main positive and main negative contactors is in electrical communication with the high voltage battery pack and an electrical load, each of the main positive and main negative contactors comprising an open and closed position with respect to electrical communication with the high voltage battery pack; decreasing the heat dissipation due to electrical contact surface resistance by controlling charge or discharge power limits of at least one of the main positive contactor and the main negative contactor if the respective estimated electrical contact surface resistance has increased relative to a previously determined respective electrical contact surface resistance; and
,determining a faulted status of at least one of the main positive contactor and the main negative contactor; and if the at least one of the main positive contactor and the main negative contactor is in the faulted status, indicating the faulted status of at least one of the main positive contactor and the main negative contactor by illuminating a lamp. - View Dependent Claims (15, 16)
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Specification