CN-121983912-A - Heterogeneous redundancy protection system and method for PDU (protocol data unit) of commercial vehicle

CN121983912ACN 121983912 ACN121983912 ACN 121983912ACN-121983912-A

Abstract

The invention discloses a heterogeneous redundancy protection system and method for a PDU of a commercial vehicle. The system comprises an intelligent electronic protection module and an integrated physical fusing module which are connected in series with a power supply loop, and an integrated structural member for deeply integrating the intelligent electronic protection module and the integrated physical fusing module into a whole. The intelligent electronic protection module realizes programmable primary active protection based on eFuse principle, the integrated physical blowing module is a metal conductor with a customizable shape, and a thermally-electrically designed blowing part is arranged in the integrated physical blowing module and is used as a secondary final physical protection barrier when electronic protection fails. The integrated structural member realizes mechanical fixation and electrical connection, and the physical fusing module can have heat dissipation or support functions. The invention fundamentally avoids single-point faults through the heterogeneous redundancy principle, meets the high requirement of safety of vehicle rule functions, greatly improves space utilization rate and layout flexibility through deep integration and customizable shape design, and realizes convenient maintenance through modularized design and state indication.

Inventors

ZHANG SHENGDONG
ZHENG JIAYUE

Assignees

欧科佳（上海）汽车电子设备有限公司

Dates

Publication Date: 20260505
Application Date: 20260202

Claims (10)

1. The heterogeneous redundancy protection system for the PDU of the commercial vehicle is characterized by comprising an intelligent electronic protection module, an integrated physical fusing module and an integrated structural member; the intelligent electronic protection module and the integrated physical fusing module are connected in series in a power supply loop of the PDU; the integrated structural member is used for realizing deep integration and fixed connection of the intelligent electronic protection module and the integrated physical fusing module in mechanical, electrical and thermal management to form an integrated functional module; The intelligent electronic protection module is used for realizing primary active protection of the circuit based on the programmable logic; The integrated physical fusing module is used as a section of metal conductor with a customizable shape connected in series in the power supply loop, and at least one fusing part is formed in the integrated physical fusing module and is used for fusing based on the Joule thermal effect to implement secondary final physical protection when the intelligent electronic protection module fails.
2. A heterogeneous redundancy protection system for a commercial vehicle PDU of claim 1, wherein the intelligent electronic protection module comprises: The power switch unit is composed of at least one semiconductor switch device and is connected in series in the power supply loop; The current sampling unit is used for collecting load current signals flowing through the power supply loop in real time; and the control and logic unit is electrically connected with the current sampling unit and the power switch unit and is used for generating a driving signal according to the load current signal and a preset protection algorithm and controlling the on-off state of the power switch unit.
3. The heterogeneous redundancy protection system for a commercial vehicle PDU of claim 2, wherein the intelligent electronic protection module further comprises a communication and diagnostic unit coupled to the control and logic unit for implementing data interactions with a host controller or network, the data interactions including at least one of reporting operational status, fault information, and receiving configuration instructions.
4. The heterogeneous redundancy protection system for a commercial vehicle PDU of claim 1, wherein the fuse portion of the integrated physical fuse module is formed by at least one of: forming a region with reduced local cross-sectional area on the metal conductor; A material weakening mode, namely compounding a low-melting-point metal material in a preset area of the metal conductor; the geometric parameters of the fusing part are determined through thermal-electric simulation based on the target short-circuit current and preset fusing time-current characteristics.
5. The heterogeneous redundancy protection system for a commercial vehicle PDU of claim 1 or 4, wherein the overall three-dimensional shape of the integrated physical fuse module is non-calibrated according to the internal space layout, heat dissipation requirements or avoidance requirements of the PDU.
6. The heterogeneous redundancy protection system for a commercial vehicle PDU of claim 1, wherein the integrated structural member is an insulating housing or a metal bracket provided with a positioning structure and a connection interface for mounting and fixing the intelligent electronic protection module and the integrated physical fuse module, ensuring low impedance and high reliability of electrical connection therebetween.
7. The heterogeneous redundancy protection system for a commercial vehicle PDU of claim 6, wherein the integrated structural member is integrally formed or fixedly connected with the integrated physical fuse module such that a partial region of the integrated physical fuse module has at least one of the following functions: As a heat dissipation substrate, the power device of the intelligent electronic protection module is attached to the heat dissipation substrate; as a structural support for positioning or supporting other components within the PDU.
8.A heterogeneous redundancy protection system for a commercial vehicle PDU as recited in claim 1, further comprising a status indication mechanism disposed on said integrated structural member and associated with said fuse portion of said integrated physical fuse module for providing a visual, mechanical fault indication upon the fuse portion blowing.
9. A heterogeneous redundancy protection method for a PDU of a commercial vehicle, applied to a heterogeneous redundancy protection system for a PDU of a commercial vehicle as claimed in any one of claims 1 to 8, comprising: An intelligent electronic protection module and an integrated physical fusing module are arranged on the power supply loop in series, and are integrated into a whole through an integrated structural member; During the working period of the circuit, the intelligent electronic protection module monitors the current in real time and executes primary active protection action based on a programmable protection strategy; when the failure of the intelligent electronic protection module or the fact that the fault current exceeds the processing capacity of the intelligent electronic protection module is detected, the fault current continuously flows through the integrated physical fusing module to fuse the fusing part of the integrated physical fusing module, so that secondary final physical protection is executed, and the circuit is permanently cut off.
10. The method for heterogeneous redundancy protection for a commercial vehicle PDU as claimed in claim 9, further comprising the step of maintaining, after said integrated physical fuse module is fused, the fault point to be identified by its associated status indication mechanism and said integrated module integrated by said intelligent electronic protection module, integrated physical fuse module and integrated structural member to be removed from the PDU and replaced.

Description

Heterogeneous redundancy protection system and method for PDU (protocol data unit) of commercial vehicle Technical Field The invention relates to the technical field of vehicle electrical systems, in particular to a heterogeneous redundancy protection system and method for a PDU (power distribution unit) of a commercial vehicle, and particularly relates to a circuit protection system and method for a power distribution unit (PDU, in particular to a low-voltage power distribution unit LVPDU) of the commercial vehicle, in particular to a heterogeneous redundancy protection scheme integrating a programmable electronic fuse and a customizable physical fuse link. Background Power Distribution Units (PDUs) are a core hub in the electrical architecture of modern vehicles, in particular commercial vehicles. The system is responsible for reliably distributing and managing the input electric energy from the storage battery or the generator and providing overcurrent and short-circuit protection for various low-voltage loads (such as lamplight, a controller, a sensor, an electromagnetic valve and the like) at the downstream. In the field of commercial vehicles, the low-voltage power distribution unit (LVPDU) usually works on a 24V voltage platform, and the operation environment is extremely harsh and faces various challenges such as severe vibration, wide temperature range change, dust, electromagnetic interference and the like. Thus, the electrical systems of commercial vehicles place extremely high demands on reliability, functional safety levels (ASIL levels as defined by the ISO 26262 standard) and space utilization (due to the compact vehicle space), which place great stress on the design of circuit protection systems inside LVPDU. At present, the overcurrent and short-circuit protection scheme applied to the commercial vehicle PDU/LVPDU mainly follows the following three technical paths, but has obvious defects: First, a purely mechanical fused protection path. The path may be a disposable fuse (e.g., a chip fuse, a bolt fuse) or a thermal fuse. Its advantages are simple structure and low cost. However, the protection characteristics (fusing curve) are fixed and not adjustable, and intelligent fault early warning, delay protection or selective coordination cannot be realized. The fuse-breaking device must be replaced by manual work, and the fault point is not positioned intuitively, so that the maintenance difficulty and the time cost are increased. More importantly, the shape and the mounting mode of the discrete device serving as the standardized appearance are fixed, so that the discrete device cannot be completely suitable for the space layout requirements of high compactness and special shape in the modern PDU, and the miniaturization, the light weight and the improvement of the integration level of the whole PDU design are seriously restricted. Second, the relay and fuse mechanically combine paths. This is currently the most traditional and widely used solution in commercial vehicle PDUs. It is usually composed of an electromagnetic relay (responsible for the on and off control of the circuit) connected in series with a fuse (providing overcurrent protection). The scheme is mature in technology, but has the inherent defects of large volume and extremely low space utilization. The relay and the fuse are independent discrete devices, and the internal layout of the PDU is bulky due to the fact that the relay and the fuse are used in a large amount, and precious space is occupied. Secondly, the function is split and the degree of intellectualization is low. The relay and the fuse lack of electric and logical coordination, so that real-time current monitoring, fault diagnosis or remote communication cannot be realized, the protection strategy is static and passive, and complex load characteristics and fault scenes cannot be adapted. Furthermore, reliability is significantly affected by the environment. Under the conditions of long-term severe vibration, large-current breaking arc, dust pollution and the like, the mechanical contact of the relay has the risks of shortened service life, contact oxidation, adhesion or refusal action and the like. And after the fuse is melted, the complicated manual checking and replacing processes are also required. Third, a pure electronic protection path. The path employs electronic fuse (eFuse) technology to achieve programmable intelligent protection through semiconductor power switches (e.g., MOSFETs) and digital control logic. The system architecture can be seen in fig. 1, and the scheme represents the trend of technology development, and has the remarkable advantages of recoverable protection, real-time current monitoring, programmable protection curve (such as I2t characteristic), fault diagnosis, communication and the like. However, in high current applications (such as the main road or high power load branch of commercial vehicles), pure electronic solutions have not yet