Method for monitoring the state of the earthing contacts of a contactor controllable by means of an exciter coil

Abstract

The present invention relates to a method for monitoring the state of the earthing contacts of a contactor controlled by an exciter coil, said contactor being operated as part of an isolation unit for galvanically isolating a voltage source from an electric consumer device connected to the voltage source, wherein a first power loss (22), which is transferred via the earthing contacts, and a second power loss (23), which is transferred via the exciter coil, are detected, and the first power loss (22) and the second power loss (23) are fed as input variables to a thermal model (21) of the contactor, the thermal model (21) determines an earthing contact temperature (24) according to at least one of the input variables and provides said contactor temperature as an output variable, and the provided earthing contact temperature (24) is evaluated.

Claims

1. A method for monitoring the state of earthing contacts (4) of a contactor (3) controllable by an exciter coil (5), said contactor operated as part of an isolation unit (2) for galvanically isolating a voltage source from an electric consumer device connected to the voltage source, the method comprising: calculating a first power loss (22), transferred via the earthing contacts (4) by a computing unit subtracting a measured link voltage (14) from a measured pack voltage (13); and multiplying the difference by a measured pack current (17), and calculating a second power loss (23), transferred via the exciter coil (5) by the computing unit multiplying a measured coil voltage (15, 16) by a measured coil current (18, 19), feeding the first power loss (22) and the second power loss (23) as input variables to a thermal model (21) of the contactor (3), the thermal model (21) determining an earthing contact temperature (24) based on at least one of the input variables and provides said earthing contact temperature as an output variable, and the provided earthing contact temperature (24) is evaluated.

2. The method according to claim 1, wherein a correction variable (30) is fed as a further input variable to the thermal model (21), said correction variable being taken into account when the thermal model (21) determines the earthing contact temperature (24).

3. The method according to claim 1, wherein the thermal model (21) determines a first exciter coil temperature (25) according to at least one of the input variables and provides said exciter coil temperature as a further output variable and that a second exciter coil temperature (29) is determined independently of the thermal model (21), wherein a difference is formed between the first exciter coil temperature (25) and the second exciter coil temperature (29), and the difference is fed as a correction variable (30) to the thermal model.

4. The method according to claim 3, wherein the electrical resistance of the exciter coil (5) is determined and the second exciter coil temperature (29) is determined as a function of the determined resistance.

5. The method according to claim 3, wherein an exciter coil voltage (27), which drops across the exciter coil (5), and an exciter coil current (28), which flows through the exciter coil (5), are determined; the exciter coil voltage (27) and the exciter coil current (28) are fed as input variables to a resistance model (26); the resistance model (26) determines an exciter coil resistance from the supplied input variables, and the second exciter coil temperature (29) is determined as a function of the exciter coil resistance and is provided as an output variable.

6. The method according to claim 5, wherein the resistance model (26) is initially calibrated offline, wherein the input variables of the resistance model (26) are varied and the exciter coil temperatures occurring in each case are acquired using measuring technology.

7. The method according to claim 1, wherein the thermal model (21) is initially calibrated offline, wherein operating parameters are varied and the earthing contact temperatures occurring in each case or the earthing contact temperatures occurring in each case and the exciter coil temperatures are acquired using measuring technology.

8. The method according to claim 7, wherein the electric voltages and/or electric currents influencing the first power loss (22) and/or the second power loss (23) as operating parameters are varied.

9. The method according to claim 5, wherein earthing contact temperatures and/or exciter coil temperatures acquired within the scope of the calibration together with the operating parameters and/or the input variables set thereby in each case are stored as values, and said values are associated with one another.

10. The method according to claim 1, wherein the evaluation of the provided earthing contact temperature (24) comprises a threshold value comparison (33), wherein an action is triggered when a predefined threshold value (34) has been exceeded (36).

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Further advantageous details, features and embodiment details of the invention are explained in detail in connection with the exemplary embodiments depicted in the figures of the drawings. In the drawings:

(2) FIG. 1 shows a battery system known in the prior art, in which contactors are operated as part of an isolation unit;

(3) FIG. 2 shows a simplified block diagram of an exemplary embodiment for a thermal model used when carrying out a method according to the invention;

(4) FIG. 3 shows a simplified block diagram for explaining an exemplary embodiment for an inventive method for monitoring the state of the earthing contacts of a contactor controllable by means of an exciter coil; and

(5) FIG. 4 shows an exemplary embodiment for a contactor in a schematic depiction.

DETAILED DESCRIPTION

(6) The battery system 1 depicted in FIG. 1 comprises a traction battery 10 having a plurality of battery cells that are electrically connected to one another. In addition, the traction battery 10 comprises a service plug 12. In order, in case of emergency, to be able to galvanically isolate the traction battery 10 at all of the poles from a consumer device (not explicitly depicted in FIG. 1), in particular a vehicle or a charging device for charging said traction battery 10, the battery system 1 comprises an isolation unit 2 for galvanically isolating said traction battery 10 from the consumer device.

(7) The isolation unit comprises two contactors 3 controllable in each case by means of an exciter coil 5. The contactors 4 open in the case of a fault and thus galvanically isolate the traction battery 10 from a consumer device connected to said traction battery 10 via the connection terminals 8, 9. Besides the contactors 3, the isolation unit 2 comprises a first current sensor 6, which is designed as a shunt, and a second current sensor 7, which is designed as a Hall sensor. In addition, the isolation unit 2 comprises a current interruption device 20, which is designed as a fuse in the present example.

(8) With the aid of the battery system 1 depicted in FIG. 1, particularly those operating parameters are depicted which are advantageously acquired from the contactors 3 when carrying out a method according to the invention for monitoring the state of the earthing contacts 4. This is preferably the voltage 13 applied to the traction battery 10, which is also known as pack voltage. Furthermore, this is the further voltage 14 applied downstream of the isolation unit 2, i.e. on the vehicle side, said further voltage also being referred to as link voltage. In addition, the current 17, also denoted as pack current, is acquired using measuring technology. Moreover, the currents 18, 19 flowing through the respective exciter coil 5 are advantageously acquired using measuring technology. The voltages 15, 16 dropping across the respective exciter coil 5 are likewise acquired using measuring technology.

(9) In order to obtain an assertion about the earthing contact temperature, a thermal model of the respective contactor 3 is initially created. Such a model is depicted in principle in FIG. 2. The thermal model 21 depicted in FIG. 2 is designed as a stationary MIMO model (MIMO: multiple input/multiple output). Input variables of the thermal model 21 depicted in FIG. 2 are a first power loss 22, which is transferred via the earthing contacts 4 of a contactor 3 (cf. FIG. 1), and a second power loss 23, which is transferred via the exciter coil 5 (cf. FIG. 1). Output variables of the thermal model 21 are an earthing contact temperature 24 determined by means of the thermal model 21 and a first exciter coil temperature 25 determined by means of the thermal model 21.

(10) The first power loss is advantageously detected by the pack voltage 13 (cf. FIG. 1) being acquired using measuring technology, the link voltage 14 (cf. FIG. 1) being acquired using measuring technology and the pack current 17 (cf. FIG. 1) being acquired using measuring technology. In so doing, the voltage dropping across the earthing contacts 4 is ascertained by subtracting the link voltage 14 from the pack voltage 13; and the ascertained value is multiplied by the value ascertained for the pack current 17.

(11) In order to determine the second power loss, the respective coil current 18, 19 (cf. FIG. 1) is acquired using measuring technology. And the respective coil voltage 15, 16 (cf. FIG. 1) is acquired using measuring technology. The second power loss is then determined for a contactor 3 by the value for the ascertained coil voltage 15 being multiplied by the value for the ascertained coil current 18, or respectively the value for the ascertained coil voltage 16 being multiplied by the value for the ascertained coil current 19.

(12) The thermal model 21 is initially calibrated offline, i.e. prior to earthing contact temperatures 24 being determined by means of the thermal model 21. Within the scope of the calibration, the operating parameters, i.e. particularly the pack current 17 (cf. FIG. 1), the respective exciter coil current 18 or 19 (cf. FIG. 1) as well as the exciter coil voltages 15 or 16 (cf. FIG. 1), are varied. In addition, the pack voltage 13 (cf. FIG. 1) and the link voltage 14 (cf. FIG. 1) are varied. The earthing contact temperature ensuing in each case and the exciter coil temperature ensuing in each case are thereby likewise acquired using measuring technology for the operating parameter combination set or prevailing in each case and are associated with the respective values of the operating parameters. Provision is particularly made for a look-up table to be created to this end. The thermal model 21 then checks the input variables in the corresponding look-up table and provides the associated values which are deposited for the earthing contact temperature and the exciter coil temperature and provides the same as output variables 24, 25.

(13) An exemplary arrangement is listed below:

(14) TABLE-US-00001 Measured Variable Normal Case Case of a Fault R.sub.contact/m 0.2 0.8 U.sub.contact/mV 43 172 I.sub.pack/A 215 215 P.sub.elec/W 9.245 37 T.sub.contact/ C. 100 250 T.sub.coil/ C. 50 125 R.sub.coil/ 3.58 4.5 U.sub.coil/V 7.5 7.5 I.sub.coil/A 2.1 3 P.sub.coil/W 15.8 40.5

(15) In this context:

(16) R.sub.contact: the contact transition resistance at the earthing contacts;

(17) U.sub.contact: the voltage falling across the earthing contacts;

(18) I.sub.pack: the pack current;

(19) P.sub.elec: the first power loss;

(20) T.sub.contact: the earthing contact temperature;

(21) T.sub.coil: the exciter coil temperature;

(22) R.sub.coil: the resistance of the exciter coil;

(23) U.sub.coil: the exciter coil voltage;

(24) I.sub.coil: the exciter coil current; and

(25) P.sub.coil: the second power loss.

(26) An advantageous exemplary embodiment for a method according to the invention is explained in detail with the aid of FIG. 3. A first power loss 22, which is transferred via the earthing contacts, and a second power loss 23, which is transferred via the exciter coil, are initially detected in the exemplary embodiment for a method according to the invention for monitoring the state of the earthing contacts of a contactor controllable by means of an exciter coil, said contactor being operated as part of an isolation unit for galvanically isolating a voltage source from an electric consumer device connected to the voltage source. The first power loss 22 and the second power loss 23 are fed as input variables to a thermal model 21 of the contactor. The first power loss 22 and second power loss 23 used in each case as input variables are determined online substantially continuously and the calibrated thermal model 21 additionally provides the earthing contact temperature 24 without having to use temperature sensors to detect the earthing contact temperature 24. The thermal model 21 can thereby be calibrated, in particular as in the connection with FIG. 2.

(27) A correction variable 30 is fed as a further input variable to the thermal model 21. In so doing, the thermal model 21 determines an earthing contact temperature 24 and a first exciter coil temperature 25 according to the observer principle as a function of the first power loss 22 and the second power loss 23 and while taking into account the correction variable 30 and provides said earthing contact temperature 24 and said first exciter coil temperature 25 in each case as output variables.

(28) A second exciter coil temperature 29 is determined by means of a resistance model 26 and is provided as an output variable of the resistance model 26. Provision is thereby particularly made for an exciter coil voltage 27, which drops across the exciter coil of the contactor, and an exciter coil current 28, which flows through the exciter coil of the of the contactor, to be acquired using measuring technology and for the exciter coil voltage 27 and the exciter coil current 28 to be fed as input variables to the resistance modal 26. The resistance model 26 calculates an exciter coil resistance from the supplied input variables by the exciter coil voltage being divided by the exciter coil current.

(29) In an advantageous manner, the resistance model 26 has initially been calibrated offline, i.e. prior to determining second exciter coil temperatures by means of the resistance model 26. In so doing, provision is particularly made for the input variables of the resistance model 26 to be varied at different ambient temperatures and for the exciter coil temperatures occurring in each case to be respectively acquired using measuring technology. As a result, an association of an exciter coil temperature with a determined resistance of the exciter coil is finally advantageously facilitated. In FIG. 3, the profile of the exciter coil temperature is depicted in a temperature unit as a function of the resistance of the exciter coil.

(30) In the exemplary embodiment for the method according to the invention, the correction variable 30 is generated from first exciter coil temperature, which was determined from the thermal model 21, and the second exciter coil temperature 29, which was determined from the resistance model 26, by the second exciter coil temperature 29 being subtracted from the first exciter coil temperature 25 via a subtractor. The fact that the correction variable 30 is taken into account by the thermal model 21 advantageously leads to an even more exact determination of the earthing contact temperature 24.

(31) The earthing contact temperature 24 determined from the thermal model 21 and provided as an output variable is evaluated by the earthing contact temperature 24 being fed to a comparator unit 32, which carries out a threshold value comparison 33. To this end, an earthing contact temperature profile 35 in a temperature unit is depicted over the time in FIG. 3 with the symbolically depicted comparator unit 32. If the earthing contact temperature exceeds a certain threshold value 34 for the earthing contact temperature, as is depicted in FIG. 3 symbolically at a point in time 36, an action is then triggered. Provision is particularly made for a warning to be generated and for a need to replace the contactor to be indicated. In addition, provision is made for an action that the power provided by means of the voltage source to be reduced if a predefined threshold value 34 has been exceeded. If a maximally admissible threshold value for the earthing contact temperature is exceeded, provision is therefore made for the contactors to open in order to galvanically isolate the voltage source from a consumer device connected to the voltage source.

(32) If the method according to the invention is used in a hybrid, plug-in hybrid or an electric vehicle, provision is particularly made for suitable corrective measures to be introduced if the earthing contact temperature determined from the thermal model 21 exceeds temperature threshold values. A triggering of an alarm, a reduction of the power delivered by the battery system and/or an opening of the earthing contacts and therefore a shutting down of the vehicle are particularly provided as corrective measures. The battery system power is advantageously reduced automatically or manually by the operator of the vehicle. The alarm is preferably triggered only automatically and also leads in a preferred manner to automatically shutting down the vehicle. A so-called limp-home mode is particularly provided, in which the driver recognizes when he/she has to reduce the battery system power such that he/she can still travel a certain distance with the vehicle.

(33) In FIG. 4, an exemplary embodiment is depicted for a contactor 3 situated in operation, wherein the earthing contacts 4 are closed. The contactor 3 can thereby be controlled by means of an exciter coil 5. That means an opening and closing of the earthing contacts 4 are controlled by means of the exciter coil 5.

(34) In order to hold the earthing contacts 4 in the closed position, an exciter current 18 flows through the exciter coil 5 and the exciter coil voltage 15 drops. The pack current 17 then flows across the earthing contacts 4 and the voltage 38 drops across the earthing contacts. These variables are advantageously varied at different ambient temperatures in order to calibrate a thermal model 21 (cf. FIG. 2 and FIG. 3), wherein different exciter coil temperatures and earthing contact temperatures occur depending on the setting of the operating temperatures. In FIG. 4, the temperature inputs of the earthing contacts 4 into the exciter coil 5 are depicted schematically by the arrows 39 and 41. The exciter coil temperature occurring at concrete values of the operating parameters is detected by means of a measurement sensor 40 using measuring technology. The earthing contact temperature is likewise detected using measuring technology.

(35) The exemplary embodiments depicted in the figures and explained in connection with said figures are used to explain the invention are not meant to limit said invention.