US-12623545-B2 - Anomaly detection in high-voltage bus systems

Abstract

Methods and systems are provided for troubleshooting anomalies in a high-voltage bus system for an electrified vehicle are provided herein. The high-voltage bus system being electrically connected to a plurality of electrical components such that each electrical component in the plurality of electrical components has a similar voltage when the high-voltage bus system is electrified. The method includes detecting individual voltages for each electrical component in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components; determining a baseline voltage for each of the electrical components in the plurality of electrical components, the baseline voltage corresponding to at least a subset of the individual voltages; and comparing any one of the individual voltages to the baseline voltage to determine if that individual voltage is anomalous.

Inventors

• Weiwen Wang
• Martin T. Books

Assignees

• CUMMINS INC.

Dates

Publication Date

20260512

Application Date

20230303

Claims (19)

1. 1 . A method of troubleshooting anomalies in a high-voltage bus system for an electrified vehicle, the high-voltage bus system being electrically connected to a plurality of electrical components such that each electrical component in the plurality of electrical components has the same voltage when the high-voltage bus system is electrified, the method being implemented by a controller of the electrified vehicle and comprising: receiving an indication of one or more individual voltages for each of the electrical components in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components, the voltage sensor being in communication with the controller; receiving an indication of a baseline voltage for each of the electrical components in the plurality of electrical components, the baseline voltage corresponding to at least a subset of the individual voltages for each of the electrical components in the plurality of electrical components; wherein the baseline voltage is determined over an evaluation period of 0.5 second to 2 seconds; receiving an indication of a comparison of any one of the individual voltages to the baseline voltage; and identifying whether any one of the electrical components in the plurality of electrical component requires troubleshooting based on whether the individual voltage is anomalous relative to the baseline voltage.
2. 2 . The method of claim 1 , wherein the baseline voltage is a mean value of the subset of the individual voltages.
3. 3 . The method of claim 2 , wherein the mean value is equal to a total sum of the individual voltages for each of the electrical components included in the subset of the plurality of electrical components divided by a total number of the electrical components on the high-voltage bus system.
4. 4 . The method of claim 2 , wherein when one of the individual voltages is anomalous, the subset of the individual voltages is revised to exclude that individual voltage that is anomalous.
5. 5 . The method of claim 4 , wherein the subset of the individual voltages includes all the individual voltages for each of the electrical components in the plurality of electrical components except for the individual voltage that is anomalous.
6. 6 . The method of claim 1 , wherein the individual voltage is anomalous if at least one of the following conditions is true: the individual voltage is consistently higher than the baseline voltage by 100 volts over the evaluation period, and the individual voltage is consistently lower than the baseline voltage by 100 volts over the evaluation period.
7. 7 . The method of claim 1 , wherein the comparing any one of the individual voltages to the baseline voltage constitutes performing a voltage sensor rationality check on the electrical component that has the individual voltage that is anomalous.
8. 8 . The method of claim 1 , further comprising: receiving an indication that the individual voltage that is anomalous resides at one or more of the connected cabling and corresponding connections between the high-voltage bus system and the electrical component; and recommending a first remedial measure that includes at least one of: replacing the connected cabling and replacing the electrical component.
9. 9 . The method of claim 8 , wherein the first remedial measure is replacing the connected cabling, the method further comprising receiving, after the first remedial measure, an indication that the individual voltage that is anomalous resides at one or more of the connected cabling and corresponding connections between the high-voltage bus system and the electrical component; and recommending as a second remedial measure subsequent to the first remedial measure replacing the electrical component.
10. 10 . The method of claim 1 , further comprising providing an alert to an operator of the electrified vehicle if the individual voltage is anomalous.
11. 11 . The method of claim 10 , wherein the alert indicates a degree to which the individual voltage is anomalous.
12. 12 . A controller for managing anomalies in a high-voltage bus system for an electrified vehicle, the high-voltage bus system being electrically connected to a plurality of electrical components such that each electrical component in the plurality of electrical components has the same voltage when the high-voltage bus system is electrified, the controller being configured to: detect individual voltages for each electrical component in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components; and detect whether any one of the individual voltages is anomalous relative to a baseline voltage for each of the electrical components in the plurality of electrical components, the baseline voltage corresponding to at least a subset of the individual voltages; wherein the baseline voltage is determined over an evaluation period of 0.5 second to 2 seconds.
13. 13 . The controller of claim 12 , wherein the controller is further configured to identify each of the electrical components in the plurality of electrical components and to convey information related to the identity of electrical components to an operator when it is determined that the individual voltage of the electrical component is anomalous.
14. 14 . The controller of claim 12 , wherein the controller is formed as a system control module for the electrified vehicle.
15. 15 . The controller of claim 12 , wherein the controller is further configured to influence a plurality of electrical components that perform voltage conversions using the baseline voltage.
16. 16 . A powertrain for an electrified vehicle, the powertrain comprising: a high-voltage bus system; a plurality of electrical components that are connected to the high-voltage bus system such that each electrical component in the plurality of electrical components has the same voltage when the high-voltage bus system is electrified; and a controller for managing anomalies in the high-voltage bus system, the controller being configured to: detect individual voltages for each of the electrical components in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components; and detect whether any one of the individual voltages is anomalous relative to a baseline voltage for each of the electrical components in the plurality of electrical components, the baseline voltage corresponding to at least a subset of the individual voltages; wherein the baseline voltage is determined over an evaluation period of 0.5 second to 2 seconds.
17. 17 . The powertrain of claim 16 , wherein the powertrain is configured to be integrated into a battery-operated vehicle.
18. 18 . The powertrain of claim 16 , wherein the powertrain is configured to be integrated into a hybrid vehicle.
19. 19 . The powertrain of claim 16 , wherein the controller is further configured to identify each of the electrical components in the plurality of electrical components and to convey information related to the identity of the electrical components to an operator when it is determined that the individual voltage of the electrical component is anomalous, wherein the baseline voltage is a mean value that is equal to a total sum of the individual voltages for each of the electrical components included in the subset of the plurality of electrical components divided by a total number of the electrical components on the high-voltage bus, and wherein the individual voltage is determined to be anomalous if at least one of the following conditions is true: the individual voltage is consistently higher than the baseline voltage by 100 volts over an evaluation period of 0.5 second to 2 seconds, and the individual voltage is consistently lower than the baseline voltage by 100 volts over an evaluation period of 0.5 second to 2 seconds.

Description

CROSS-REFERENCE The present application claims priority to U.S. Provisional Application Ser. No. 63/322,578, entitled “ANOMALY DETECTION IN HIGH-VOLTAGE BUS SYSTEMS,” filed on Mar. 22, 2022, the entire disclosure of which being expressly incorporated herein by reference. TECHNICAL FIELD The present disclosure generally relates to devices, systems, and methods for electrified vehicles and, more particularly, to detect voltage anomalies in an electrified vehicle. BACKGROUND Electrified vehicles are becoming increasingly pervasive in the automotive industry as environmental concerns and industry demands, among other things, beckon for increased efficiency and less emissions. Inherent in such vehicles are electrical connections to ensure that associated components receive sufficient power for operation of the vehicle. As with all vehicles, maintenance and troubleshooting are required to maintain proper operation over the lifespan of the vehicle. SUMMARY In an example, the present disclosure provides a method of troubleshooting anomalies in a high-voltage bus system for an electrified vehicle, the high-voltage bus system being electrically connected to a plurality of electrical components such that each electrical component in the plurality of electrical components has a similar voltage when the high-voltage bus system is electrified, the method comprising: detecting individual voltages for each electrical component in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components; determining a baseline voltage for each of the electrical components in the plurality of electrical components, the baseline voltage corresponding to at least a subset of the individual voltages; and comparing any one of the individual voltages to the baseline voltage to determine if that individual voltage is anomalous. In one aspect of this example the baseline voltage is a mean value of the subset of the individual voltages. In a variant of this aspect, the mean value is equal to a total sum of the individual voltages for each of the electrical components in the plurality of electrical components divided by a total number of the electrical components on the high-voltage bus system. In another variant of this aspect, when one of the individual voltages is anomalous, the subset of the individual voltages excludes that individual voltage that is anomalous. In a further aspect of the variant, the subset of the individual voltages includes all the individual voltages for each of the electrical components in the plurality of electrical components except for the individual voltage that is anomalous. In another feature of this example, the baseline voltage is determined over an evaluation period. In another example including the baseline voltage mentioned above, the individual voltage is determined to be anomalous if at least one of the following conditions is true: the individual voltage is consistently higher than the baseline voltage over the evaluation period, and the individual voltage is consistently lower than the baseline voltage over the evaluation period. This example can optionally include comparing any one of the individual voltages to the baseline voltage to determine if that individual voltage is anomalous step is used to perform a voltage sensor rationality check on the electrical component that has the individual voltage that is anomalous. Further, the method can include checking connected cabling and corresponding connections between the high-voltage bus system and the electrical component that has the individual voltage that is anomalous, and replacing the connected cabling when it is determined that the connected cabling caused the individual voltage to be anomalous. In a variant of this aspect, the method further includes replacing the electrical component if it is determined that the connected cabling did not cause the individual voltage to be anomalous. In another aspect of this example, the method further includes providing an alert to an operator of the electrified vehicle when it is determined that the individual voltage is anomalous. A variant of this aspect includes that the alert indicates a degree to which the individual voltage is anomalous. In another example, the present disclosure provides a controller for managing anomalies in a high-voltage bus system for an electrified vehicle, the high-voltage bus system being electrically connected to a plurality of electrical components such that each electrical component in the plurality of electrical components has a similar voltage when the high-voltage bus system is electrified, the controller being configured to: detect individual voltages for each electrical component in the plurality of electrical components using a voltage sensor of each of the electrical components in the plurality of electrical components; determine a baseline voltage for each of the electrical components in the pl