Wide deployment of high voltage battery systems in traction, industrial and renewable energy installations is raising the concerns for human safety. Exposure to hazardous high voltages may occur due to deterioration of insulation materials or by accidental events. It is thus important to monitor for such faults and being able to provide timely warnings to affected persons. For this purpose it has become mandatory for electrified passenger vehicles (CFR 571.305) to maintain high isolation values which can be continuously monitored by electrical isolation monitoring devices. The task of monitoring isolation resistance within the electrically noisy car environment is not a trivial task and the solution to this problem has become quickly a field of research and innovation for all affected industries.
The function of the isolation monitoring device is to determine the value of the isolation resistance between either of the battery terminals and the chassis. Furthermore it must issue an alarm if the isolation resistance becomes lower than a certain value. This value is determined by the human body tolerance to electrical current. The table of
When an electrical system is not connected to the Earth, as in the case of an electrical vehicle, the system is said to have a “floating” ground. The abbreviation IT comes from the French term “isolé terre” (isolated earth) and it is used by IEC (International Electrotechnical Commission) to describe a power system with “floating” ground.
In this system, the high voltage battery and all the car systems connected to it are isolated from the Chassis ground which consists of the metal body of the car that passengers come in constant contact with. The battery of an electric vehicle is connected through DC to AC converters to motors, generators, which are typically the same motors acting as generators when the car is decelerating or moving downhill, and the various car auxiliary systems through DC to DC converters. The two capacitors shown on the right represent either capacitors placed with the purpose of reducing EMI (electromagnetic interference) noise or the small parasitic capacitances that exist in any electrical system.
This type of grounding serves an important purpose for the safety of a car and those in contact with it. If for example the negative of the battery was connected to the Chassis, and an isolation fault occurred to one of the positive cables, an immediate short would be created at the battery terminals causing fuses to blow. This could result in immediate loss of power in the electric vehicle—including loss of braking power—which could result in accidents or other problems.
In contrast, in an IT power system as shown in
An isolation fault may also occur through excessive deterioration of insulating materials resulting from extreme hot-cold cycles, by sparks and other electrical hazards or even by rodents.
To address these potential risks, the National Highway Traffic Safety Administration (NHTSA) of the Department of Transportation (DOT) issued a final rule amending the electrical shock protection requirements of Federal Motor Vehicle Safety Standard No. 305 (49 CFR 571.305), which mandates for a DC voltage system a minimum number of ohms/volt of isolation of a high voltage source. In essence it specifies the maximum current that can pass through the isolation resistance path, which cannot be more than 2 mA without an isolation monitoring device (500 ohm/volt) or 10 mA with one (100 ohm/volt). As an example, for a DC voltage source of 400 volts with isolation monitoring, the specification is 100 ohm/volt. This translates into a minimum isolation resistance of 40 kilohms. Without isolation monitoring the minimum value for the same system would be 200 kilohms.
The difference between the allowed values of ohms/volt depending on whether an isolation monitoring device is present can be appreciated by understanding the absence of one. If there is no isolation monitoring device, the isolation resistance can be measured only during scheduled service of the vehicle. The only method the vehicle manufacturer has to ensure conformance in this case is by using highly rated materials and wiring protection and hoping that isolation faults will only happen gradually and will be discovered during scheduled inspections. An isolation monitoring device, in contrast, operates all of the time making it the preferred method for future vehicle builds.
One can see the impact of these specifications by looking again at
Together with establishing these requirements, the CFR 571.305 safety standard specifies a method for calculating the isolation resistance. Referred to as the “voltage” method and prescribed for use in vehicle service stations, the method will be described in more detail below. Some improvements to this “voltage” method also exist, about which more will be said below.
In the drawings of
First, the insertion of a resistance in the isolation path may adversely affect the isolation of the IT system. This is because resistor 570 cannot have an arbitrarily high value as the method relies on its effect upon the measured voltage. The measurement method itself may jeopardize isolation. Also, switching loads on and off in a high voltage system requires expensive components. The measurement assumes that the battery voltage remains constant during successive measurements. In an operating vehicle this condition is rarely true (less than 20% of operating time).
U.S. Pat. No. 9,322,867 presents a variation of the method which overcomes the issue of the negative impact of resistor 570 by using instead different types of current limiting devices. The issues of high cost of high voltage switching and the battery noise impact still remain unaddressed.
The pulse method is overcoming some of the problems associated with the “voltage” method by injecting a pulse into the DC network as shown in
Variations of this method are well known and referenced at EP 0 654 673 B1, EP 1 586 910 B1 and DE 101 06 200 C1. The main shortcomings of this method are:
A variation of the “pulse” method is the “frequency” injection method (U.S. Pat. No. 5,450,328, U.S. Pat. No. 9,069,025 B2). In this method an AC signal of known frequency is injected or superimposed on the DC pulse. Through band-pass and low-pass filtering of the resulting signal, the values of impedance and resistance are estimated using digital signal processing techniques.
The method requires digital signal processing capabilities for digital filter implementation as well as the DFT/FFT processing of the monitored responses. The accuracy also is affected by dynamic changes in the load and achieves an acceptable level of accuracy when load changes are small.
The methods described so far are deterministic relying on a unique known input (pulse, frequency, etc.) to produce an output that can uniquely identify the unknown parameters of resistance and capacitance. These methods are simple but fail in most instances when the varying power load signal interferes.
It is beneficial for safety to be able to accurately determine the isolation resistance and capacitance when the power system is active. In the case of an electrified vehicle this would correspond to 80% of the time the vehicle is in use.
The disclosed method uses these widely varying load signals that naturally occur in an IT power system to identify the isolation parameters. As a result, accurate information on the isolation condition can be derived most of the time the system is operational. An auxiliary excitation signal is used in periods of system inactivity in order to ensure 100% monitoring availability.
According to this method, a model is used to represent the IT power system along with the isolation resistances and capacitances between the IT power system and the chassis ground. The objective is to determine the values of the unknown resistive and capacitive isolation paths between the IT power system and the chassis ground. As shown in
The method of determining the values of R1, R2, CY1 and CY2 comprises:
It should be appreciated that this method can utilize the varying voltage of the IT power system as the measurement signal for performing the calculations. If the voltage of the IT power system is idle a voltage signal source can be used instead.
The function of minimizing the deviation between the voltage measurements and the theoretical model for the RC circuits describing the isolation paths can be a least-square error estimate performed over a predetermined number of voltage measurements.
An improvement on the method can be achieved by utilizing a stochastic filter, such as a Kalman filter, to minimize the measurement and model noise.
The combined method consists of two steps:
1. at first, a fixed number of measurements for the voltages at the battery terminals and the excitation voltage are collected and used as inputs for a least-square estimator which produces estimates of the isolation parameters (i.e., leakage resistors and leakage capacitors) together with uncertainties for those estimates,
2. the next step is a filtering step implemented using a Kalman filter and designed to maintain the most likely values for the isolation parameters with associated uncertainties by using the results of the least-square estimator in time.
More details on those two steps are given below.
During operation of the monitoring system, measurements are collected for the values of the voltages at the battery terminals and of the excitation voltage. The purpose of the least-square estimator is to minimize the discrepancy between the measurements and a theoretical model for the isolation paths modeled as RC circuits, the latter expressing the conservation of charge in the monitoring circuit. The least-square estimator therefore receives as inputs a buffer containing a fixed number of the aforementioned voltage measurements and produces as outputs predictions for the isolation parameters, together with uncertainties for those predictions. The predictions are expressed as a vector whose components represent the isolation parameters, and the uncertainties are expressed as a covariance matrix for this vector. It follows that, as the monitoring system is operated, the least-square estimator can be used at any time to provide a prediction of the current isolation parameters vector and the associated uncertainties. In the proposed method, the estimator is used to regularly produce new predictions and uncertainties which are then passed on to the filter described below. The number of voltage measurements as inputs for the least-square estimator can be predetermined or adjusted dynamically depending on the conditions of operation.
It follows from the previous section that the monitoring device uses the least-square estimator to obtain predictions and uncertainties for the isolation parameters as a function of time. That is, as the monitoring device is operated, time series of predictions and uncertainties are generated by the least-square estimator. Those time series can be seen as a stochastic process in itself since the measured data sent to the least-square estimator are themselves originating from a stochastic process. Therefore, the purpose of the filter is to maintain estimates for the most likely values for the isolation parameters vector and the associated uncertainties. This is achieved by using a Kalman filter implementation in which the results from the least-square estimator are assimilated to noisy measurements of the isolation parameters. The filter receives as inputs the previous estimates for the most likely values of the isolation parameters and the associated uncertainties, and predictions from the least square estimator. The outputs are new estimates for most likely values of the isolation parameters and the associated uncertainties.
Experimental results are provided in
When a human body contacts two points of non-identical electrical potential, an electric current may flow through the path between the points. Approximate values for each of these paths through the human body are shown in
A high voltage battery system 200 with a “floating ground” is shown in
An isolation monitoring system alerts the operator and responders to hazardous conditions that develop in an electrical system.
An improvement over the “voltage” method, known as the “pulse” method, is shown in
A variation of the “pulse” method, called the “frequency” injection method also exists. In this method, an AC signal of known frequency is injected or superimposed on the DC pulse.
An exemplary step of minimizing the deviation between measured and estimated values using a least-square estimator is shown in
As shown in
A graph of example results of the best estimate for the most likely value of capacitor CY1 in the monitoring circuit is shown in
Voltage waveforms at the two battery terminals of the apparatus of
A block diagram for the Isolation Measurement Device implemented in hardware is illustrated in
What has been described is a method to estimate a change in values of isolation impedance in an isolated ground (IT) electrical system comprising a power source, the method comprising: modeling a first isolation path between a first reference point and a second reference point and modeling a second isolation path between a third reference point and a fourth reference point, thereby creating a theoretical model of the isolated ground electrical system; providing an initial value of a first isolation resistance for the first isolation path and an initial value of a second isolation resistance for the second isolation path; measuring an initial value of a voltage between the first reference point and the second reference point and storing the measured initial value in a storage medium; measuring an initial value of a voltage between the third reference point and the fourth reference point and storing the measured initial value in the storage medium; measuring a subsequent different value of the voltage between the first reference point and the second reference point and storing the measured subsequent value in the storage medium; measuring a subsequent value of the voltage between the third reference point and the fourth reference point and storing the measured subsequent value in the storage medium; entering the measured initial values of the voltages, the measured subsequent values of the voltages, the provided values of the isolation impedances and an elapsed amount of time between the initial measurements and the subsequent measurements into a mathematical function stored in the storage medium; wherein the mathematical function minimizes the discrepancy between the measured change in values of the voltages and the modeled theoretical values by adjusting values of modeled isolation impedances associated with the isolation paths in the electrical system; extracting estimated values of isolation impedances associated with the isolation paths in the electrical system by application of the mathematical function; and storing the estimated values in the storage medium.
Also described is an apparatus for estimating a change in values or unknown values of isolation impedance in an isolated ground (IT) electrical power system, comprising: a power source having a positive terminal and a negative terminal, said terminals connected in circuit to at least one additional electrical component and isolated from a chassis ground within the electrical system;
wherein the electrical system contains an isolation impedance between each of the terminals and the chassis ground; a storage medium; means measuring an initial value and a subsequent different value of a voltage between the chassis ground and a first reference point and between a second reference point and a third reference point in the electrical system; means storing the measured initial values and the subsequent different values in the storage medium; a mathematical function stored in the storage medium, whereby application of the mathematical function extracts estimated values of isolation impedances associated with the voltage measurements by using a model of the electrical system and minimizing an error function.
Also described is a method to estimate unknown values of isolation impedance in an isolated ground (IT) electrical system comprising a power source and a load, the method comprising: modeling a first isolation path between a first reference point and a second reference point and modeling a second isolation path between a third reference point and a fourth reference point, thereby creating a theoretical model of the isolated ground electrical system; at a time when power from the power source is being dissipated in the load, measuring an initial value of a voltage between the first reference point and the second reference point and storing the measured initial value in a storage medium; at a time when power from the power source is being dissipated in the load, measuring an initial value of a voltage between the third reference point and the fourth reference point and storing the measured initial value in the storage medium; at a time when power from the power source is being dissipated in the load, measuring a subsequent different value of the voltage between the first reference point and the second reference point and storing the measured subsequent value in the storage medium; at a time when power from the power source is being dissipated in the load, measuring a subsequent value of the voltage between the third reference point and the fourth reference point and storing the measured subsequent value in the storage medium; entering the measured initial values of the voltages, the measured subsequent values of the voltages and an elapsed amount of time between the initial measurements and the subsequent measurements into a mathematical function stored in the storage medium; wherein the mathematical function minimizes the discrepancy between the measured initial values of the voltages, the measured subsequent values of the voltages, and the modeled theoretical values by adjusting values of modeled isolation impedances associated with the isolation paths in the electrical system; extracting estimated values of isolation impedance associated with the isolation paths in the electrical system by application of the mathematical function; identifying a minimum resistance path from the estimated values of isolation resistance; and storing the estimated values in the storage medium.
It will be appreciated that one skilled in the art of isolated ground electrical systems, varying output power sources and electrical systems could devise additional obvious improvements and variations upon the invention described and claimed herein. All such obvious improvements and variants are intended to be encompassed by the claims which follow.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2017/056746 | 10/31/2017 | WO | 00 |
Number | Date | Country | |
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62436350 | Dec 2016 | US | |
62436358 | Dec 2016 | US | |
62452966 | Jan 2017 | US |