DESC:FAULT DIAGNOSTICS SYSTEM FOR ON-BOARD CHARGER
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202421079484 filed on 18/10/2024, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to an onboard charger (OBC). Particularly, the present disclosure relates to system(s) and method(s) for fault diagnostics of an onboard charger (OBC) in an electric vehicle.
BACKGROUND
Nowadays, electric vehicles (EVs) are equipped with on-board chargers (OBCs) for charging high-voltage battery packs that supply power to propulsion motors as well as various electrical and electronic subsystems of the vehicle. Typically, such battery packs are recharged through household power sockets or at dedicated service stations by connecting the on-board charger to an external AC power source.
Generally, the performance, efficiency, and service life of EV battery packs are significantly influenced by the stability of the current and voltage supplied by external power source. Usually, the high fluctuations on the charging side may lead to extended charging durations, increased energy consumption, and degradation of battery health. The prolonged exposure to such fluctuations may result in permanent battery damage, which is undesirable from both performance and cost perspectives. Conventionally, the on-board chargers generally lack functionality for monitoring and reporting charging-related parameters, such as the total energy consumed and the corresponding charging cost. Further, the OBC do not provide any estimation or indication of the remaining charging time required for the vehicle. This lack of information limits the user’s ability to manage charging operations efficiently. Furthermore, the existing OBC systems often fail to incorporate mechanisms to detect and mitigate charging side fluctuations proactively. In the absence of such measures, fluctuations that exceed a safe threshold may continue to affect the battery pack, leading to adverse operational and lifecycle consequences.
Therefore, there exists a need for a system and method for fault diagnostics of an on-board charger (OBC) to address one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a system for fault diagnostics of an onboard charger (OBC) in an electric vehicle.
An another object of the present disclosure is to provide a method of fault diagnostics of an onboard charger (OBC) and associated components
In accordance with first aspect of the present disclosure, there is provided a system for fault diagnostics of an onboard charger (OBC) in an electric vehicle, the system comprising:
- a plurality of sensors configured to measure parameters indicative of fault conditions in the OBC and associated components;
- a processor configured to:
- compare the measured parameters with predefined values of the parameters indicative of the fault conditions; and
- initiate a diagnosis routine of the OBC and the associated components.
The present disclosure provides the system for fault diagnostics of the onboard charger (OBC) in the electric vehicle. The system, as disclosed in present disclosure, is advantageous in terms of integrated and intelligent fault diagnostics capability for the OBC and the associated components in electric vehicles. Beneficially, the system enables early detection of abnormal operating conditions, thereby preventing potential damage to the battery pack and charging circuitry. Further, the system ensures timely identification and classification of faults, thereby facilitating preventive and corrective actions. Additionally, by incorporating predefined condition checks, the system avoids false fault triggers and enhances diagnostic accuracy. Furthermore, the inclusion of the safety measures significantly enhances the vehicle safety, prolongs component life, optimizes charging efficiency, and reduces maintenance costs.
In accordance with second aspect of the present disclosure, there is provided a method of fault diagnostics of an onboard charger (OBC) and associated components. The method comprises monitoring a parameters associated with the OBC and associated components, comparing the monitored parameters with predefined values of the parameters indicative of the fault conditions and initiating diagnosis routine of the OBC and associated components, based on the compared values.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a block diagram for fault diagnostics of an onboard charger (OBC) in an electric vehicle, in accordance with an embodiment of the present disclosure.
FIG. 2 illustrates a flow chart of steps involved in a method of fault diagnostics of an onboard charger (OBC) and associated components, in accordance with another embodiment of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a system and method for fault diagnostics of an onboard charger (OBC) in an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
As used herein, the term “fault diagnostics” refers to a process of detecting, identifying, and/or predicting abnormal operating conditions, malfunctions, or failures in a system or the associated components by monitoring one or more operational parameters, comparing the monitored parameters with predefined thresholds, reference values, or permissible ranges, and determining the presence, type, and potential cause of a fault. The fault diagnostics may further include initiating one or more remedial, preventive, or protective actions based on the detected fault conditions to maintain or restore safe, efficient, and reliable operation of the system.
As used herein, the terms “onboard charger” and “OBC” are used interchangeably and refer to an electrical charging device integrated within the electric vehicle, configured to receive electrical energy from an external power source and convert the energy into a form suitable for charging the vehicle’s battery pack. The on-board charger may include, but not limited to, a circuitry for AC-to-DC conversion, a power factor correction (PFC), a voltage and current regulation, a thermal management unit, and a communication interface with vehicle control systems or external charging infrastructure. The OBC is typically adapted to operate with various input voltages and currents, and may incorporate monitoring, control, and safety features to ensure efficient, safe, and reliable battery charging.
As used herein, the terms “plurality of sensors” and “sensors” are used interchangeably and refer to two or more sensing devices configured to detect, measure, and/or monitor one or more operational parameters of the system or the components.
As used herein, the terms “measured parameter(s)” and “parameter(s)” are used interchangeably and refer to values or data obtained from one or more sensors indicative of operational characteristics or conditions of a system or the components. In the fault diagnostics, the measured parameters may include, but not limited to, electrical parameters such as input voltage, output voltage, input current, output current, and PFC (Power Factor Correction) DC levels; thermal parameters such as temperatures of PFC and LLC (Inductor-Inductor-Capacitor) circuits; and status parameters such as connection state, pre-charge status, battery charge FET status, and communication bus conditions. The measured parameters are utilized by a processor for comparison with predefined values to detect, diagnose, and/or predict fault conditions.
As used herein, the terms “fault conditions”, and “indicative fault conditions” are used interchangeably and refer to abnormal, undesirable, or out-of-tolerance operating states of the system or the components, which may adversely affect performance, safety, or reliability. The fault conditions may include, but not limited to, electrical faults such as input over-voltage, input under-voltage, output over-voltage, input over-current, and output over-current; thermal faults such as PFC (Power Factor Correction) over-temperature, LLC (Inductor-Inductor-Capacitor) over-temperature, and temperature sensor failures; and other operational faults such as PFC DC high, PFC DC dip, abnormal communication bus conditions, improper connection status, and malfunction of control or switching elements. Fault conditions may be detected by comparing measured parameters with predefined threshold values.
As used herein, the term “associated components” refers to auxiliary or interconnected elements that operate in conjunction with the on-board charger (OBC) to enable or support the charging functionality within the electric vehicle. The associated components may include, but not limited to, a power factor correction (PFC) circuitry, an LLC (Inductor-Inductor-Capacitor) resonant converter circuitry, temperature sensors, current sensors, voltage sensors, battery charge field-effect transistors (FETs), pre-charge circuits, communication bus interfaces (e.g., Controller Area Network (CAN) modules), and connection assemblies to the external power source and the battery pack. The associated components may perform functions such as power conversion, regulation, protection, monitoring, and communication in coordination with the OBC.
As used herein, the terms “processor”, “processing unit”, “control unit”, and “controller” are used interchangeably and refer to any suitable computational unit or electronic circuitry configured to execute instructions, process data, and perform logic-based operations. The processor may include, but is not limited to, a microcontroller, microprocessor, digital signal processor (DSP), application-specific integrated circuit (ASIC), field-programmable gate array (FPGA), or any combination thereof. The processor may be configured to operate independently or in conjunction with other hardware or software components, and may include associated memory, communication interfaces, and input/output modules as required for executing specific control, diagnostic, or computational tasks within the system.
As used herein, the term “predefined values” refers to threshold limits, reference ranges, or permissible operating values of one or more parameters, determined in advance based on design specifications, operational requirements, safety standards, or empirical data. The predefined values may include, but not limited to, maximum and minimum allowable voltages, maximum allowable currents, permissible temperature limits for PFC and LLC circuits, acceptable ranges for PFC DC levels, and operational status conditions such as valid communication bus states, proper connection status, correct pre-charge completion, and so forth. The predefined values are stored in a memory accessible to a processor and are used as reference criteria for comparing measured parameters to detect, diagnose, and/or predict fault conditions.
As used herein, the term “diagnosis routine” refers to a predefined sequence of operations executed by the processor to evaluate the operational status of the system in response to detected or anticipated fault conditions. The diagnosis routine may include, but not limited to, acquiring measured parameters from the plurality of sensors, comparing the measured parameters with predefined values, identifying the type and severity of the fault, verifying associated component statuses, recording diagnostic data, and initiating one or more safety or corrective actions.
As used herein, the terms “at least one voltage sensor” and “voltage sensor” are used interchangeably and refer to one or more sensing devices configured to detect and/or measure electrical voltage levels at specific points within a system. The at least one voltage sensor may be adapted to measure parameters indicative of fault conditions, including, but not limited to, input over-voltage, input under-voltage, and output over-voltage of the on-board charger. The voltage sensor may operate using analog or digital sensing techniques and is integrated within the on-board charger circuitry or provided as a separate component. The measured voltage values are communicated to the processor for analysis, comparison with predefined values, and execution of fault diagnostics.
As used herein, the terms “at least one current sensor” and “current sensor” are used interchangeably and refer to one or more sensing devices configured to detect and/or measure electrical current levels at specific points within a system. The at least one current sensor may be adapted to measure parameters indicative of fault conditions, including, but not limited to, input over-current and output over-current of the on-board charger. The current sensor may operate using analog or digital sensing techniques, such as shunt resistors, Hall effect sensors, or current transformers, and is integrated within the on-board charger circuitry or provided as a separate component. The measured current values are communicated to the processor for analysis, comparison with predefined values, and execution of fault diagnostics.
As used herein, the terms “input over voltage” and “input voltage” are used interchangeably and refer to a fault condition in which the voltage received at the input of the on-board charger from an external power source exceeds a predetermined maximum allowable value. Such condition may arise due to fluctuations or surges in the external power supply, incorrect connection to a higher-than-rated voltage source, or malfunction of upstream electrical equipment. The input over-voltage is detected by at least one voltage sensor, and upon detection, the processor may initiate the diagnosis routine and implement safety measures such as isolating the charger from the power source, reducing power flow, or alerting the vehicle operator to prevent potential damage to the charger, battery pack, and associated components.
As used herein, the terms “input under voltage” and “under voltage” are used interchangeably and refer to a fault condition in which the voltage received at the input of the on-board charger from an external power source falls below a predetermined minimum allowable value. Such a condition may occur due to supply instability, excessive load on the source, poor grid quality, or faults in the upstream electrical infrastructure. The input under-voltage is detected by at least one voltage sensor, and upon detection, the processor may initiate the diagnosis routine and implement safety measures such as suspending or limiting charging operations, alerting the vehicle operator, or logging the event to prevent inefficient charging, extended charging times, or potential damage to the charger, battery pack, and associated components.
As used herein, the terms “output over voltage” and “output voltage” are used interchangeably and refer to a fault condition in which the voltage delivered at the output of the on-board charger to the battery pack exceeds a predetermined maximum allowable value. Such a condition may result from control circuit malfunctions, sensor failures, power conversion errors, or irregularities in voltage regulation within the charger. The output over-voltage is detected by at least one voltage sensor, and upon detection, the processor may initiate the diagnosis routine and implement safety measures such as reducing or shutting down charging output, isolating the charger from the battery pack, alerting the vehicle operator, or recording the event to prevent overcharging, battery degradation, or damage to the charger and associated components.
As used herein, the terms “input over current” and “input current” are used interchangeably and refer to a fault condition in which the electrical current drawn at the input of the on-board charger from an external power source exceeds a predetermined maximum allowable value. Such a condition may occur due to short circuits, component failures, grid supply anomalies, or excessive load conditions. The input over-current is detected by the at least one current sensor, and upon detection, the processor may initiate the diagnosis routine and implement safety measures such as limiting current draw, suspending charging, isolating the charger from the power source, alerting the vehicle operator, or logging the event to prevent overheating, component damage, or upstream supply disruptions.
As used herein, the terms “output over current” and “output current” are used interchangeably and refer to a fault condition in which the electrical current delivered at the output of the on-board charger to the battery pack exceeds a predetermined maximum allowable value. Such a condition may result from short circuits within the battery pack, excessive load demand, malfunctioning power regulation circuitry, or faults in associated components. The output over-current is detected by at least one current sensor, and upon detection, the processor may initiate the diagnosis routine and implement safety measures such as reducing charging current, suspending charging, isolating the charger from the battery pack, alerting the vehicle operator, or recording the event to prevent overheating, damage to the battery cells, degradation of charger components, and safety hazards.
As used herein, the terms “plurality of temperature sensors” and “temperature sensors” are used interchangeably and refer to two or more sensing devices configured to detect and/or measure temperature at specific locations within a system. The plurality of temperature sensors may be positioned to monitor thermal conditions such as the power factor correction (PFC) circuitry, the LLC (Inductor-Inductor-Capacitor) resonant converter circuitry, and other heat-sensitive elements of the on-board charger. The temperature sensors are configured to measure parameters indicative of fault conditions, including but not limited to, PFC over-temperature, LLC over-temperature, and temperature sensor failures. The measured temperature values are communicated to the processor for analysis, comparison with predefined values, and execution of the diagnosis routine to prevent overheating, component damage, and operational inefficiency.
As used herein, the terms “PFC over temperature” and “Power Factor Correction over temperature” refer to a fault condition in which the temperature of the Power Factor Correction (PFC) circuitry in the on-board charger exceeds a predetermined maximum allowable limit. Such a condition may arise due to excessive current flow, inadequate cooling, ambient temperature rise, or component degradation within the PFC stage. The PFC over-temperature is detected by the at least one temperature sensor positioned to monitor the thermal condition of the PFC circuitry. Upon detection, the processor may initiate the diagnosis routine and implement safety measures such as reducing charging power, disabling the on-board charger, activating additional cooling systems, alerting the vehicle operator, or logging the fault event to prevent overheating, component damage, or reduced operational efficiency.
As used herein, the terms “LLC over temperature” and “Inductor-Inductor-Capacitor over temperature” are used interchangeably and refer to a fault condition in which the temperature of the LLC (Inductor-Inductor-Capacitor) resonant converter circuitry in the on-board charger exceeds a predetermined maximum allowable limit. Such a condition may result from prolonged high-load operation, inadequate heat dissipation, malfunctioning cooling systems, or component wear and degradation within the LLC stage. The LLC over-temperature is detected by the at least one temperature sensor positioned to monitor the thermal condition of the LLC circuitry. Upon detection, the processor may initiate the diagnosis routine and implement safety measures such as reducing charging power, shutting down the on-board charger, activating enhanced cooling, alerting the vehicle operator, or recording the fault to prevent overheating, component damage, and loss of charging efficiency.
As used herein, the term “PFC temperature sensor failure” refers to a fault condition in which the temperature sensor assigned to monitor the thermal condition of the Power Factor Correction (PFC) circuitry malfunctions or provides invalid, missing, or out-of-range readings. Such a condition may occur due to sensor disconnection, wiring faults, calibration errors, physical damage, or degradation of the sensing element. The PFC temperature sensor failure is detected by the processing unit through self-diagnostic checks, plausibility analysis, or comparison with readings from other sensors. Upon detection, the processor may initiate the diagnosis routine and implement safety measures such as limiting or suspending charger operation, switching to a fail-safe cooling mode, alerting the vehicle operator, or logging the fault to prevent undetected overheating and potential damage to the PFC circuitry.
As used herein, the term “LLC temperature sensor failure” refers to a fault condition in which the temperature sensor designated to monitor the thermal condition of the LLC (Inductor-Inductor-Capacitor) resonant converter circuitry malfunctions or provides invalid, missing, or out-of-range readings. Such a condition may result from sensor disconnection, wiring faults, calibration errors, physical damage, or degradation of the sensing element. The LLC temperature sensor failure is detected by the processor through the self-diagnostic routines, plausibility checks, or correlation analysis with readings from other temperature sensors. Upon detection, the processor may initiate the diagnosis routine and implement safety measures such as reducing charging load, suspending charger operation, activating a fail-safe cooling strategy, alerting the vehicle operator, or logging the fault to prevent undetected overheating and potential damage to the LLC circuitry.
As used herein, the terms “PFC DC parameters” and “PFC Direct Current parameters” are used interchangeably and refer to the direct current characteristics monitored or controlled within a Power Factor Correction (PFC) circuit. The PFC DC parameters typically comprises the DC bus voltage, DC bus current, and related stability or ripple values after AC input is rectified and regulated by the PFC stage. The PFC DC parameters are essential for ensuring that the PFC stage maintains a stable and efficient DC output for the downstream converter stages, such as the LLC resonant converter.
As used herein, the term “PFC DC high” refers to a condition where the DC bus voltage generated by the Power Factor Correction (PFC) stage exceeds a predefined upper threshold. The PFC DC high usually indicates an overvoltage situation on the DC link, may occur due to input surges, control loop failure, or load disconnection, and may be potentially damage the downstream components like the LLC converter or inverter stage. In such cases, the control system typically triggers a protection mechanism, such as shutting down the PFC stage or engaging a crowbar circuit, to prevent damage.
As used herein, the term “PFC DC dip” refers to a condition where the DC bus voltage from the Power Factor Correction (PFC) stage drops below a predefined lower threshold. The PFC DC drop may result from a sudden increase in load demand, a dip in the AC mains input, poor PFC regulation, or faults like a blown fuse or failed switching device. If the DC bus voltage dips too far, downstream converters may malfunction, leading to reduced performance or a system shutdown. The control systems often respond by reducing load, entering standby, or attempting to restore bus voltage through fast PFC compensation.
As used herein, the terms “OBC power status” and “power status” are used interchangeably and refer to the monitored state indicating whether the OBC is actively delivering power, in standby, or in a fault/shutdown condition.
As used herein, the term “pre-charge status” refers to the operational state of the pre-charge circuit in an electric vehicle’s power system, typically within an On-Board Charger (OBC) or traction battery system. In this stage, the high-voltage DC bus capacitors are gradually charged through a pre-charge resistor before full contactor closure, preventing inrush current that could damage components. The pre-charge status indicates whether the process is in progress, successfully completed, or has failed, and is often monitored by comparing the measured DC bus voltage against a target threshold before switching to normal operation.
As used herein, the term “connection status” refers to an operational parameter indicating whether an electrical connection between the on-board charger (OBC) and an external power source or between the OBC and the battery pack is properly established and maintained. The connection status may be determined through one or more sensing or communication mechanisms, such as voltage presence detection, current flow detection, mechanical connector position sensing, or communication handshake verification over a control bus. Further, monitoring the connection status enables the processor to verify that charging operations may be safely initiated and to detect abnormal conditions such as loose connectors, incomplete mating, disconnection during charging, or incorrect power source attachment. Upon detection of an improper connection status, the processor may initiate the diagnosis routine and implement safety measures such as preventing or suspending charging, alerting the vehicle operator, or logging the event to ensure safe and reliable operation of the OBC and associated components.
As used herein, the terms “battery charge FET status”, “battery charge status”, and battery charge Field-Effect Transistor status” are used interchangeably and refer to the operational state of one or more field-effect transistors (FETs) that control the electrical connection between the on-board charger and the battery pack for charging operations. The battery charge FET status may indicate whether the FET is in an ON state (allowing charging current to flow), an OFF state (blocking charging current), or a fault state (such as short-circuit, open-circuit, or abnormal switching behavior). Further, monitoring the battery charge FET status enables the processor to verify proper charging operation, detect malfunctions, and ensure safe engagement or disengagement of the charging circuit. The abnormal FET status conditions may trigger the diagnosis routine and result in safety measures such as disabling the charger, isolating the battery pack, alerting the vehicle operator, or logging the event to prevent unsafe charging conditions or damage to system components.
As used herein, the terms “CAN condition” and “Controller Area Network condition” are used interchangeably and refer to the operational status and integrity of the Controller Area Network (CAN) communication interface used for data exchange between the on-board charger, the battery management system (BMS), and other vehicle control modules. The CAN condition may include, but not limited to, normal communication, communication errors, message loss, bus-off states, abnormal message timing, or unexpected data values. Further, monitoring the CAN condition allows the processor to verify proper data transfer required for safe and efficient charging operations. If the CAN condition indicative of a fault is detected, the Processor may initiate the diagnosis routine and implement safety measures such as halting charging, switching to the default control mode, alerting the vehicle operator, or logging the event to prevent mis-operation or communication-related failures in the OBC and associated components.
As used herein, the terms “battery pack voltage” and “battery voltage” are used interchangeably and refer to the electrical potential difference measured across the positive and negative terminals of the electric vehicle’s battery pack. The battery pack voltage serves as the operational parameter used to assess the charging state, health, and safety of the battery system. Further, monitoring the battery pack voltage enables detection of abnormal conditions such as over-voltage, under-voltage, imbalance between cells, or improper charging behavior. The voltage may be measured by one or more voltage sensors, and the measured value is communicated to the processing unit for comparison with predefined values to determine the presence of fault conditions and, if necessary, initiate safety measures such as adjusting charging power, suspending charging, or isolating the battery pack from the on-board charger.
As used herein, the term “vehicle park mode” refers to the operational state of the electric vehicle in which the propulsion system is disengaged from driving the wheels, and the vehicle is stationary with the transmission system set to a non-driving position. The vehicle park mode serves as one of the predefined conditions to be verified before initiating a diagnosis routine of the on-board charger and associated components, ensuring that diagnostic operations and certain charging functions are performed when the vehicle is in a safe, non-operational state. The detection of the vehicle park mode may be achieved through signals from the vehicle’s transmission control system, parking brake system, or other onboard sensors and control units.
As used herein, the term “control module” refers to an electronic unit comprising one or more processors, memory units, communication interfaces, and associated circuitry, configured to receive input signals from one or more sensors, process the signals according to stored instructions or algorithms, and generate output signals to control, regulate, or coordinate the operation of one or more components, subsystems, or systems of a device or vehicle. The control module may be implemented as a standalone unit, an embedded controller, an application-specific integrated circuit (ASIC), a programmable logic controller (PLC), or any equivalent processing device, and may be integrated with or distributed among other modules.
Figure 1, in accordance with an embodiment describes a system 100 for fault diagnostics of an onboard charger (OBC) in an electric vehicle. The system 100 comprising a plurality of sensors 102 and a processor 104. The plurality of sensors 102 are configured to measure parameters indicative of fault conditions in the OBC and associated components. Further, the processor 104 is configured to compare the measured parameters with predefined values of the parameters indicative of the fault conditions and initiate a diagnosis routine of the OBC and the associated components.
In an embodiment, the plurality of sensors 102 comprises at least one voltage sensor 102a and at least one current sensor 102b. The at least one voltage sensor 102a may be configured to measure parameters indicative of the fault conditions comprising at least one of an input over-voltage, an input under-voltage, and an output over-voltage. The measured parameters from the voltage sensor 102a and the current sensor 102b are transmitted to the processor 104 for comparison against predefined values to determine the presence of any fault conditions. Further, upon detecting that the measured parameters are equal or in a close proximity to the predefined fault thresholds, the processor 104 initiates the diagnosis routine for assessing the operational status of the OBC and the associated components. Beneficially, by incorporating both the at least one voltage sensor 102a and the at least one current sensor 102b, the system 100 is capable of detecting a wide range of electrical anomalies on both the input and output sides of the OBC, thereby ensuring comprehensive fault detection coverage. Furthermore, the ability to monitor specific fault conditions allows for early detection of harmful operating states that may lead to reduced charger efficiency, component damage, or battery degradation. Moreover, the system 100 enables real-time monitoring of electrical parameters, facilitating prompt initiation of the diagnosis routines and safety measures to prevent further faults or failures.
In an embodiment, the plurality of sensors 102 comprises a plurality of temperature sensors 102c may be configured to measure parameters indicative of the fault conditions comprising at least one of a PFC (Power Factor Correction) over-temperature, an LLC (Inductor-Inductor-Capacitor) over-temperature, a PFC temperature sensor failure, and an LLC temperature sensor failure. The temperature sensors 102c are strategically positioned to monitor heat-critical components in real time, thereby enabling the system 100 to detect abnormal thermal conditions or sensor malfunctions promptly. Furter, upon detection of the fault condition, the system 100 may initiate protective actions such as reducing the load, shutting down affected components, or alerting the control unit to prevent damage and maintain operational safety. Beneficially, the use of plurality of thermal sensor 102c improving the operational reliability through real-time thermal monitoring of key power conversion components, early detection of both overheating and sensor malfunctions, and enhances the protection against component damage caused by thermal stress. Furthermore, the integration of failure detection for temperature sensors 102c ensures that the system 100 remains trustworthy, thereby reducing the risk of undetected faults and extending the lifespan of the overall power conversion system.
In an embodiment, the plurality of sensors 102 may be configured to measure PFC DC (Direct Current) parameters and detect the fault conditions including PFC DC high and PFC DC dip. The plurality of sensors 102 interface with a control module that continuously monitors the measured parameters and compares the measured parameters against predefined thresholds to identify abnormal operating conditions. Further, upon detection of PFC DC high, the system 100 initiates the protective actions such as load regulation or shutdown to prevent component damage, while detection of PFC DC dip may trigger the corrective measures to maintain stable operation. Beneficially, the configuration including PFC DC parameters offer enhanced protection of the PFC circuit from overvoltage or undervoltage conditions. Furthermore, reliability of the system 100 is significantly improved through early fault detection, and reduces risk of downtime or catastrophic failures, thereby extending the operational lifespan of the system 100.
In an embodiment, the processor 104, before initiating the diagnosis routine, may be configured to check predefined conditions of the OBC and the associated components. The predefined conditions comprises an OBC power status, a pre-charge status, a connection status, a battery charge FET (Field-Effect Transistor) status, a CAN (Controller Area Network) condition, a battery pack voltage, and a vehicle park mode. Further, the predefined conditions verified by the processor 104 prior to initiating the diagnosis routine includes a plurality of operational and safety checks. The OBC power status is evaluated to confirm that the on-board charger is powered and in a ready state for operation. Furthermore, the pre-charge status is checked to ensure that the pre-charging process for the high-voltage components has been successfully completed, thereby preventing inrush currents and ensuring electrical stability. Moreover, the connection status is verified to ascertain that the charger is correctly interfaced with both the external power supply and the vehicle’s battery system, thereby ensuring a secure and stable electrical connection. Moreover, the battery charge Field-Effect Transistor (FET) status is examined to determine whether the battery charging path is enabled and ready to transfer energy. Moreover, the Controller Area Network (CAN) condition is monitored to confirm reliable communication between the OBC and other vehicle control units, ensuring accurate data exchange for subsequent diagnostic operations. Moreover, the battery pack voltage is measured to verify that the battery pack remains within an acceptable voltage range suitable for safe charging and diagnostic procedures. Lastly, the vehicle park mode status is checked to ensure that the vehicle is stationary and in a safe operating state, thereby preventing diagnostics from being conducted while the vehicle is in motion. The processor 104 acquires relevant data for each of the afore-mentioned conditions from the plurality of sensors 102 and the control modules, and only when all predefined conditions are satisfied, the system 100 proceeds to initiate the diagnosis routine for detecting faults in the OBC and the associated components. Beneficially, by verifying multiple predefined operational and safety conditions before initiating diagnostics, the system 100 prevents false fault detection that may arise from transient or unsafe states. Further, the processor 104 ensures that the diagnostic routines are only performed under stable and controlled conditions, thereby improving the reliability and accuracy of fault detection. Furthermore, the inclusion of parameters such as OBC power status, pre-charge status, and connection status enhances safety of the system 100 by preventing the initiation of diagnostics when the OBC is unpowered, improperly connected, or not electrically stabilized. Moreover, the monitoring of the battery charge FET status and battery pack voltage ensures that electrical load paths and energy storage systems are in a safe operational range, thereby protecting sensitive components from potential damage. Additionally, incorporating the vehicle park mode as the prerequisite, adds an additional layer of safety, ensuring that diagnostics do not interfere with driving operations, thereby enhancing user safety and compliance with automotive operational standards.
In an embodiment, the processor 104 may be configured to trigger the diagnosis routine of the OBC and the associated components, when the measured parameters may be in close proximity of the predefined values. The measured parameters may include, but not limited to, voltage, current, and/or temperature. Further, the processor 104 continuously monitors the measured parameters with the help of the plurality of sensors 102 and compares the real-time data with the predefined thresholds. When the measured parameters approach the predefined limits, the processor 104 automatically initiates the diagnosis routine without requiring manual intervention, thereby enabling early detection of potential faults or performance degradation in the OBC and the associated circuitry. Beneficially, the comparison of the measured parameters with the predefined threshold enhances the reliability and operational safety of the OBC. Furthermore, the processor 104 facilitates proactive fault detection by identifying abnormal conditions in the on-board charger (OBC) and associated components before critical failures occur. Furthermore, by detecting potential issues at an early stage, the system 100 is able to reduce downtime through predictive maintenance, as necessary repairs or adjustments may be planned in advance rather than in response to unexpected breakdowns. Beneficially, the early detection capability significantly lowers the repair costs by addressing faults in the initial stages, preventing damage from escalating to more severe component failures. Moreover, the processor 104 ensures that the OBC operates within optimal parameters, thereby improving the overall efficiency and reliability of the system 100. Additionally, the configuration also minimizes false diagnostic triggers by initiating the diagnosis routine only when measured parameters are close to predefined threshold values, which in turn helps to optimize workload of the processor 104.
In an embodiment, the processor 104 may be configured to implement safety measures based on the diagnosis routine, including one or more of: disabling the OBC, reducing power output, alerting the vehicle operator, and logging the fault condition. The diagnosis routine is initiated upon detection of one or more fault conditions in the OBC or associated components, as determined by comparing parameters measured by the plurality of sensors 102 with predefined values. Further, the safety measures may be implemented individually or in combination, depending on the nature and severity of the detected fault, thereby enabling adaptive and responsive fault handling in the charging system. Beneficially, by automatically implementing safety measures based on diagnostic results, the system 100 enhances operational safety and prevents damage to the OBC, battery pack, and other associated components. Furthermore, the ability to disable the OBC or reduce power output mitigates the risk of overheating, overvoltage, or overcurrent conditions, thereby extending the service life of the charger and improving charging reliability. Moreover, alerting the vehicle operator ensures that maintenance actions may be taken promptly, thereby reducing the downtime and avoiding potential hazards. Moreover, the logging fault conditions enables trend analysis and predictive maintenance, allowing for early detection of recurring issues and improving overall reliability of the system 100. Collectively, the capabilities of the safety measures contribute to improved safety, operational efficiency, and lifecycle management of the electric vehicle’s charging infrastructure.
The present disclosure provides the system 100 for fault diagnostic of the battery onboard charger (OBC). The system as disclosed in present disclosure is advantageous in terms of enhance the safety, reliability, and operational efficiency of electric vehicle charging systems. Beneficially, by employing the plurality of sensors 102 to continuously measure critical electrical, thermal, and operational parameters, the system 100 enables accurate detection of the wide range of fault conditions, comprising over-voltage, under-voltage, over-current, over-temperature, and sensor failures. Further, the integration of the processor 104 configured to compare the measured parameters with predefined values allows for early identification of abnormal conditions before the conditions escalate into severe failures, thereby reducing the risk of damage to the OBC, battery pack, and associated components. Furthermore, the capability to check predefined operational conditions such as OBC power status, pre-charge status, and vehicle park mode, prior to initiating the diagnosis routine ensures that the diagnostic and safety actions are only taken under appropriate and safe circumstances, thereby avoiding unintended disruptions. Moreover, the ability of the processor 104 to trigger diagnosis routines when parameters are in close proximity to fault thresholds, provides the predictive maintenance function, thereby enabling corrective measures before critical failure occurs. Moreover, the incorporation of safety measures, such as disabling the OBC, reducing power output, alerting the vehicle operator, and logging the fault condition, ensures rapid fault containment, user awareness, and detailed fault history for future analysis. Additionally, features afore-mentioned, collectively extend the service life of the charging system, minimizes downtime, reduce maintenance costs, and contribute to improved lifecycle management of the electric vehicle’s charging infrastructure.
In an embodiment, the system 100 for fault diagnostics of the onboard charger (OBC) in the electric vehicle. The system 100 comprising the plurality of sensors 102 and the processor 104. The plurality of sensors 102 are configured to measure parameters indicative of fault conditions in the OBC and associated components. Further, the processor 104 is configured to compare the measured parameters with predefined values of the parameters indicative of the fault conditions and initiate the diagnosis routine of the OBC and the associated components. Further, the plurality of sensors 102 comprises the at least one voltage sensor 102a and the at least one current sensor 102b. Furthermore, the plurality of sensors 102 comprises the plurality of temperature sensors 102c configured to measure parameters indicative of the fault conditions comprising the at least one of a PFC (Power Factor Correction) over-temperature, the LLC (Inductor-Inductor-Capacitor) over-temperature, the PFC temperature sensor failure, and the LLC temperature sensor failure. Moreover, the plurality of sensors 102 configured to measure PFC DC (Direct Current) parameters and detect the fault conditions including PFC DC high and PFC DC dip. Moreover, the processor 104, before initiating the diagnosis routine, configured to check predefined conditions of the OBC and the associated components. The predefined conditions comprises the OBC power status, the pre-charge status, the connection status, the battery charge FET (Field-Effect Transistor) status, the CAN (Controller Area Network) condition, the battery pack voltage, and the vehicle park mode. Moreover, the processor 104 configured to trigger the diagnosis routine of the OBC and the associated components, when the measured parameters are in close proximity of the predefined values. Moreover, the processor 104 configured to implement safety measures based on the diagnosis routine, including one or more of: disabling the OBC, reducing power output, alerting the vehicle operator, and logging the fault condition.
Figure 2, describes a method 200 of fault diagnostics of an onboard charger (OBC) and associated components. The method 200 starts at step 202 and completes at 206. At step 202, the method 200 comprises monitoring a parameters associated with the OBC and associated components. At step 204, the method 200 comprises comparing the monitored parameters with predefined values of the parameters indicative of the fault conditions. At step 206, the method 200 comprises initiating diagnosis routine of the OBC and associated components, based on the compared values.
It would be appreciated that all the explanations and embodiments of the portable device 100 also applies mutatis-mutandis to the method 200.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.
,CLAIMS:WE CLAIM:
1. A system (100) for fault diagnostics of an onboard charger (OBC) in an electric vehicle, the system (100) comprising:
- a plurality of sensors (102) configured to measure parameters indicative of fault conditions in the OBC and associated components;
- a processor (104) configured to:
- compare the measured parameters with predefined values of the parameters indicative of the fault conditions; and
- initiate a diagnosis routine of the OBC and the associated components.
2. The system (100) as claimed in claim 1, wherein the plurality of sensors (102) comprises at least one voltage sensor (102a) and at least one current sensor (102b), wherein the at least one voltage sensor (102a) is configured to measure parameters indicative of the fault conditions comprising at least one of an input over-voltage, an input under-voltage, and an output over-voltage, and wherein the at least one current sensor (102b) is configured to measure parameters indicative of the fault conditions comprising at least one of an input over-current and an output over-current.
3. The system (100) as claimed in claim 1, wherein the plurality of sensors (102) comprises a plurality of temperature sensors (102c) configured to measure parameters indicative of the fault conditions comprising at least one of a PFC (Power Factor Correction) over-temperature, an LLC (Inductor-Inductor-Capacitor) over-temperature, a PFC temperature sensor failure, and an LLC temperature sensor failure.
4. The system (100) as claimed in claim 1, wherein the plurality of sensors (102) are configured to measure PFC DC (Direct Current) parameters and detect the fault conditions including PFC DC high and PFC DC dip.
5. The system (100) as claimed in claim 1, wherein the processor (104), before initiating the diagnosis routine, is configured to check predefined conditions of the OBC and the associated components, and wherein the predefined conditions comprises an OBC power status, a pre-charge status, a connection status, a battery charge FET (Field-Effect Transistor) status, a CAN (Controller Area Network) condition, a battery pack voltage, and a vehicle park mode.
6. The system (100) as claimed in claim 1, wherein the processor (104) is configured to trigger the diagnosis routine of the OBC and the associated components, when the measured parameters are in close proximity of the predefined values.
7. The system (100) as claimed in claim 1, wherein the processor (104) is configured to implement safety measures based on the diagnosis routine, including one or more of: disabling the OBC, reducing power output, alerting the vehicle operator, and logging the fault condition.
8. A method (200) of fault diagnostics of an onboard charger (OBC) and associated components, wherein the method (200) comprises:
- monitoring a parameters associated with the OBC and associated components;
- comparing the monitored parameters with predefined values of the parameters indicative of the fault conditions; and
- initiating diagnosis routine of the OBC and associated components, based on the compared values.