Intelligent vehicle systems and control logic for intrusive detection of high-voltage pathway failures
A method of operating a motor vehicle includes a vehicle controller receiving, from a first feedback sensor of an HV component, a first feedback signal indicative of an electrical characteristic of the HV component, and then detecting an HV system fault if the first feedback signal is less than a predefined electrical threshold. Upon detecting the system fault, the controller commands the HV component to operate at a commanded set-point; after sending the command, the controller receives, from a second feedback sensor of the HV component, a second feedback signal indicative of an operating characteristic of the HV component. An HV pathway failure is detected if the second feedback signal is not equal to or within a predefined operating range of the commanded set-point. Upon detecting the pathway failure in an HV electrical pathway of the HV component, the vehicle controller transmits a command signal to take a remedial action.
1. A method of operating a motor vehicle with an HV battery pack and a high-voltage (HV) electrical system connecting an HV device with the HV battery pack via an HV electrical pathway, the method comprising:
receiving, via a vehicle controller from a first feedback sensor of the HV device, a first feedback signal indicative of an electrical characteristic of the HV device, the electrical characteristic including a voltage, a current, or a resistance of the HV device when connected to the HV battery pack;
detecting an HV system fault responsive to determining the first feedback signal is less than a predefined electrical threshold calibrated to the HV device;
commanding, via the vehicle controller responsive to the detected HV system fault, the HV device to operate at a commanded set-point calibrated to the HV device;
receiving, via the vehicle controller from a second feedback sensor of the HV device after commanding the HV device to operate at the commanded set-point, a second feedback signal indicative of an operating characteristic of the HV device;
detecting an HV pathway failure in the HV electrical pathway of the HV device responsive to determining the second feedback signal is not equal to or within a predefined operating range of the commanded set-point, the predefined operating range calibrated to the HV device; and
transmitting, via the vehicle controller, a command signal to take a remedial action responsive to the detected HV pathway failure in the HV electrical pathway of the HV device.
2. The method of claim 1 , further comprising:
receiving, via the vehicle controller, an operating state signal indicating the motor vehicle is either powered on or powering on;
receiving, via the vehicle controller from the first feedback sensor responsive to the operating state signal indicating the motor vehicle is powered on and the first feedback signal not being less than the predefined electrical threshold, a third feedback signal indicative of the electrical characteristic of the HV device; and
determining if the third feedback signal is less than the predefined electrical threshold.
3. The method of claim 2 , further comprising transmitting, via the vehicle controller responsive to the operating state signal indicating the motor vehicle is powering on and the first feedback signal not being less than the predefined electrical threshold, an electronic notification indicating the HV system fault is not detected.
4. The method of claim 1 , further comprising determining, via the vehicle controller, if a vehicle speed of the motor vehicle is below a preset maximum speed, wherein transmitting the command signal is further in response to the vehicle speed being below the preset maximum speed.
5. The method of claim 4 , wherein the remedial action includes disconnecting the HV battery pack of the motor vehicle from the HV electrical system and turning off the motor vehicle.
6. The method of claim 1 , wherein the remedial action includes setting the motor vehicle in a limp-home operating mode and restricting a vehicle speed of the motor vehicle to below a preset maximum limp-home speed.
7. The method of claim 1 , wherein the remedial action includes disconnecting the HV device from the HV battery pack resident to the motor vehicle.
8. The method of claim 1 , further comprising transmitting, via the vehicle controller responsive to the second feedback signal being equal to or within the predefined operating range of the commanded set-point, an electronic notification indicating the HV pathway failure is not detected.
9. The method of claim 8 , further comprising transmitting, via the vehicle controller responsive to the first feedback signal being less than the predefined electrical threshold, an electronic notification indicating the HV system fault is detected and the first feedback sensor is faulty.
10. The method of claim 1 , further comprising:
determining, via the vehicle controller responsive to the first feedback signal being less than the predefined electrical threshold, whether or not a sensor fault flag exists; and
transmitting, via the vehicle controller, a command signal to take the remedial action responsive to the first feedback signal being less than the predefined electrical threshold and the sensor fault flag not existing.
11. The method of claim 10 , further comprising:
receiving, via the vehicle controller responsive to the sensor fault flag existing, a contactor closed signal indicating main electrical contactors of an HV battery pack of the motor vehicle are closed; and
detecting, via the vehicle controller responsive to receiving the contactor closed signal and the sensor fault flag existing, the HV pathway failure including determining if the second feedback signal is not equal to or within the predefined operating range of the commanded set-point.
12. The method of claim 1 , wherein the first feedback sensor is distinct from the second feedback sensor, and the electrical characteristic is distinct from the operating characteristic.
13. The method of claim 1 , wherein the first feedback signal is a voltage value, and the electrical characteristic is an operating voltage of the HV device across an HV bus, and wherein the second feedback signal is a voltage value, a pressure/speed value, a current/speed value, or a temperature value, and the operating characteristic is a power module output voltage, a compressor output pressure/speed, a motor current/speed, or a heater output temperature.
14. A non-transitory, computer-readable medium storing instructions executable by one or more processors of a vehicle controller of a motor vehicle, the motor vehicle including a high-voltage (HV) electrical system electrically connecting first and second active HV devices with an HV battery pack via respective first and second HV electrical pathways, the instructions, when executed by the one or more processors, causing the vehicle controller to perform operations comprising:
receiving, from first and second voltage sensors of the first and second HV devices, respectively, first and second sensor signals indicative of first and second feedback voltages of the first and second HV devices, respectively;
detecting an HV system fault responsive to determining the first feedback voltage is less than a first predefined electrical threshold calibrated to the first HV device and/or the second feedback voltage is less than a second predefined electrical threshold calibrated to the second HV device;
commanding, responsive to the detected HV system fault, the first HV device to operate at a commanded set-point calibrated to the first HV device;
receiving, from an intrusive feedback sensor of the first HV device after commanding the first HV device to operate at the commanded set-point, an intrusive feedback signal indicative of a real-time operating characteristic of the first HV device;
detecting an HV pathway failure in the first HV electrical pathway responsive to determining the intrusive feedback signal is not equal to or within a predefined operating range of the commanded set-point, the predefined operating range calibrated to the first HV device; and
transmitting a command signal to take a remedial action responsive to the detected HV pathway failure in the first HV electrical pathway of the first HV device.
15. A motor vehicle, comprising:
a vehicle body;
a plurality of road wheels attached to the vehicle body;
a traction motor attached to the vehicle body and operable to drive one or more of the road wheels to thereby propel the motor vehicle;
a traction battery pack storing and supplying power to the traction motor;
a high-voltage (HV) electrical system electrically connecting the traction battery pack with the traction motor;
an HV device electrically connected to the HV electrical system via an HV electrical pathway; and
a vehicle controller programmed to:
receive a first feedback signal from a first feedback sensor of the HV device indicative of an electrical characteristic of the HV device, the electrical characteristic including a voltage, a current, or a resistance of the HV component when connected to the HV battery pack;
detect an HV system fault responsive to determining the first feedback signal is less than a predefined electrical threshold calibrated to the HV device;
responsive to the detected HV system fault, command the HV device to operate at a commanded set-point calibrated to the HV device;
after commanding the HV device to operate at the commanded set-point, receive a second feedback signal from a second feedback sensor of the HV device indicative of an operating characteristic of the HV device;
detect an HV pathway failure in the HV electrical pathway of the HV device responsive to determining the second feedback signal is not equal to or within a predefined operating range of the commanded set-point; and
transmit a command signal to take a remedial action responsive to the detected HV pathway failure in the HV electrical pathway of the HV device.
16. The motor vehicle of claim 15 , wherein the vehicle controller is further programmed to:
receive an operating state signal indicating the motor vehicle is powered on;
responsive to the motor vehicle being powered on and the first feedback signal not being less than the predefined electrical threshold, receive from the first feedback sensor a third feedback signal indicative of the electrical characteristic of the HV device; and
determine if the third feedback signal is less than the predefined electrical threshold.
17. The motor vehicle of claim 15 , wherein the vehicle controller is further programmed to:
receive an operating state signal indicating the motor vehicle is powering on; and
responsive to the motor vehicle powering on and the first feedback signal not being less than the predefined electrical threshold, transmit an electronic notification indicating the HV system fault is not detected.
18. The motor vehicle of claim 15 , wherein the vehicle controller is further programmed to determine if a vehicle speed of the motor vehicle is below a preset maximum speed, wherein transmitting the command signal is further in response to the vehicle speed being below the preset maximum speed, and wherein the remedial action includes disconnecting the HV battery pack of the motor vehicle from the HV electrical system and turning off the motor vehicle.
19. The motor vehicle of claim 15 , wherein the vehicle controller is further programmed to respond to the second feedback signal being equal to or within the predefined operating range of the commanded set-point by transmitting an electronic notification indicating the HV pathway failure is not detected.
20. The motor vehicle of claim 19 , wherein the vehicle controller is further programmed to respond to the first feedback signal being less than the predefined electrical threshold by transmitting an electronic notification indicating the HV system fault is detected and the first feedback sensor is faulty.