DE102019205663A1 - Method and device for monitoring and checking a power supply system of a motor vehicle - Google Patents

Abstract

In the method for continuously monitoring and checking a power supply system of a motor vehicle with a test system, wherein the power supply system of the motor vehicle at least one battery (20), a generator (32) with associated controller (34) and a plurality of subsystems (48, 54) with individually switchable A) a plurality of measuring sensors, including at least measuring sensors for the battery voltage, the battery temperature, the battery current, the rotational speed of the generator (32), the output voltage from the generator (32) from the generator (32 ), current and voltage in at least two subsystems (48, 54), b) a data processing system having a processor, a memory, a display unit, a program, a bus, the following method steps are carried out:
1) storing the data collected by the plurality of measuring sensors,
2) display the current values of the plurality of measurement sensors in the display unit,
3) determining the measured values and derived values (such as average values, maxima, minima, frequency of occurrence, etc.) for the data of at least individual sensors and display of these values; and
4) Represent a circuit diagram of the power system in which the values according to steps 2) and 3) are inserted and in which the characteristics of the components are displayed.

Description

Current vehicle systems are becoming increasingly complex, whereby the robustness of the design is not always given. This complexity poses challenges to engineers when trying to find fault sources in vehicles with customer complaints. Often the complexity of the systems and the interactions of different subcomponents in these systems are difficult to analyze. The vehicle's electrical supply system is unique because it supplies power to all modules or subsystems. As a result, the electrical supply system is connected to all subsystems.

Interactions may not be deterministic and are not intended or defined interactions between the subsystems, but often interactions that should not occur, such as e.g. a "crosstalk" between electrical systems including bus systems (eg single-wire LIN bus) or non-unique or multiply defined signals on these buses. This constructive complexity (deterministic system design available in the system description) and the un-described couplings (not in the system description) of any subsystem make it extremely difficult to find the causes of faults in the power system.

The goal must be to identify such complex errors in the complex systems as quickly and precisely as possible. The warranty costs involved in such troubleshooting and troubleshooting are directly dependent on the ability of engineers and persons at the manufacturer and in workshops. However, to date, there is no suitable tool to efficiently assist engineers and workshop personnel in finding errors or analyzing the systems.

Moreover, compared to other automotive subsystems, the power system is particular in that there is no dedicated microcontroller responsible for the battery or generator that could perform a self-test of the system. It is therefore very tedious to diagnose each component individually.

An individual analysis of subsystems in a complex system does not provide sufficient insight into the correlations / interactions between the various subsystems. It is also usually not possible to detect a reaction in the level of a subsystem in a system monitoring of the entire system.

Thus, due to the complexity and distributed nature of the power system, an assistive tool is obviously desirable to assist in the analysis, design, optimization of the system as well as in the search for failures in the systems in both prototype and production vehicles (eg, false operating points of the alternator or faults that charge the battery or discharge at rest).

Currently, power systems are being monitored via external multimeters or shunts. This method allows the observation of a limited number of subsystems at a time. Mostly only one subsystem can be observed. In this way, the observation is cumbersome, takes a lot of time and provides the measurement data in a non-processed form. As a result, the overview of the measurement data must take place offline as an additional processing step.

However, this does not support real-time observations of the overall system, as the number of sensors needed would simply be too high. The further calculations and transformations of the measured data, in particular also the generation of additional data from the combination of measurements, is far too cumbersome with this current method.

From the JP S54-40433 A Also, only one measurement or analysis system for a single electrical circuit in a vehicle is known. In this case, only one value of the electrical circuit, such as the voltage is checked ("circuit checker"). At the same time, the electrical contacts in the form of plug connections or wire connections in the cable harness are checked ("harness checker"), namely whether the cabling of the individual components is intact and undisturbed. The measured value and the state of the cable connection can be displayed. However, the system is only suitable for checking the security of the cabling. An analysis of the electrical supply system of a motor vehicle, which comprises several subsystems, in order to identify a complex fault in the system (such as the functional state of subsystems with individually connectable consumers), is with the system of JP S54-40433 A not possible.

Devices for monitoring a vehicle electrical system in a motor vehicle, which can be used both in production as well as for service and diagnosis, z. B. by the company Siemens under the name ECOS - Electronic Check Out System - manufactured and used in the production and service of motor vehicles for vehicle electrical system monitoring and diagnostics. An ECOS The system enables the analog measurement of current, voltage and electrical power, the diagnosis of the installed control units, the programming of the installed control units, the testing of complete pre-assembly groups as well as the testing of dynamic processes on test benches. The connection of the mobile testing station to the motor vehicle electrical system via one or more current clamps, which is designed in the case of the Siemens system as a radio-frequency power tool. The ECOS system measures the current flowing out of the battery before and after a consumer is switched on, and from this, as well as from the specifications of upper and lower limit values, a statement about the proper functioning of the consumer to be checked. The ECOS system is integrated in a higher-level production or diagnostic system and receives its test order as well as the specifications of the expected signal progression from there. After completion of the measurement, the result is communicated to the higher-level information system and visualized on a display.

Attaching the radio pliers or the ECOS adapter in production means an additional step, which is as well as the provision and calibration of the system associated with financial expense.

From the WO2006 / 048125 a monitoring system for a vehicle electrical system is known in which, in addition to the intelligent battery sensor system (IBS), all electrical and electronic devices to be monitored are connected to the power distribution controller (SAM) via at least one bus system (CAN, LIN). The power distribution module known in specialist terminology as a transmission and control module (SAM) has either directly or via a gateway (6) a diagnostic interface to which an external information system (IS) can be connected. The information system may be a production information system used to verify the correct mounting of the numerous electrical and electronic equipment during the manufacture of the motor vehicle, or the information system may be a diagnostic system, such as computer based service and electronic equipment Motor vehicle workshops is used. The power distribution module has a test mode in which the consumers connected to the on-board power supply are switched on and off individually, and the current and voltage measurement is coordinated and carried out by means of the intelligent battery sensors during the switch-on period of the consumers.

It is in accordance with WO2006 / 048125 checks the vehicle electrical system during the sleep phase of the vehicle with respect to the present bias current, this review is terminated when the quiescent current falls below a defined threshold. Then, the battery sensor in the form of the monitoring system is put in a sleep mode. Accordingly, neither cyclic activations nor cyclical awakening of subsystems can be reliably and continuously detected. Continuous monitoring and verification of the power supply system is therefore not guaranteed. The system according to WO2006 / 048125 is therefore blind to cyclic activations or waking of components at rest. However, this waking loads the battery of the vehicle enormously, so that the system is in need of improvement in terms of battery consumption.

From the DE 10 2014 214 840 A1 a device for monitoring a high-voltage electrical system of an electrically operable vehicle to the presence of an overload is known, wherein the high-voltage electrical system comprises as components one or more energy sources and / or one or more energy sinks, each having a Leitererstranganordnung with a first supply potential line and are connected to a second supply potential line, wherein each of the components is associated with a current sensor which is adapted to detect a current flowing through the component in question and to transmit an information representing the height of the current to an evaluation unit for evaluation, wherein the evaluation unit is adapted to compare the current with a first current threshold and a second current threshold and output a shutdown signal at least for the component associated with the current sensor, if as a first criterion, the magnitude of the current and the duration d he level of the current between the first and the second current threshold is.

From the DE 10 2015 204 242 A1 Method for error analysis and / or optimization of a first power plant network of a first motor vehicle by at least a first software-controlled computer system is known, which is arranged in particular in the motor vehicle. In order to make known, expensive and therefore only implemented in experimental vehicles datalogger dispensable and, for example, to provide an improvement in reliability in production vehicles, the following steps according to the invention are proposed. In a first step, a plurality of electrical variables characterizing the energy on-board network of the specific motor vehicle or of the specific motor vehicle type and their respective threshold values are assigned to the specific motor vehicle or the specific motor vehicle type and the vehicle assignment and the associated electrical variables and their respective threshold values are stored in a database of the first computer Systems deposited. In a second step, the characterizing electrical variables actually occurring in the energy on-board network of the specific motor vehicle are determined and transmitted from the vehicle to the first computer system. In a third step, the first computer system performs a comparison between the actually determined characterizing electrical quantities and the respective threshold values stored in the database of the computer system. If at least one of the actual electrical quantities exceeds or falls below the relevant threshold value and / or differs therefrom in a predetermined manner, at least one further step is carried out.

On this basis, the present invention seeks to improve existing measuring and monitoring systems and to provide a method for monitoring and checking a power supply system of a motor vehicle, which provides a deeper insight into the actually detectable conditions, especially directly measured variables (currents, voltages and temperatures) and statistically recorded quantities (age of the battery, number of charge cycles, statistics on quiescent currents, ...), allows and improves visual presentation.

• - wobei das Stromversorgungssystem des Kraftfahrzeugs mindestens eine Batterie, einen Generator mit zugehörigem Regler und mehrere Subsysteme mit einzeln zuschaltbaren Verbrauchern aufweist,
• - wobei das Prüfsystem a) eine Vielzahl von, vorzugsweise fahrzeugeigenen, Messsensoren, darunter zumindest Messsensoren für die Batteriespannung, die Batterietemperatur, den Batteriestrom, die Drehzahl des Generators, die vom Generator abgegebene Spannung, den vom Generator abgegebenen Strom, den Strom und die Spannung in mindestens zwei Subsystemen, und b) ein Datenverarbeitungssystem mit einem Prozessor, einem Speicher, einer Anzeigeeinheit, einem Programm, einem Bus aufweist,
• - mit folgenden Verfahrensschritten:
  1. 1) Abspeichern der von der Vielzahl von Messsensoren erfassten Daten in einem Speicher;
  2. 2) Anzeige der aktuellen Werte der Vielzahl von Messsensoren;
  3. 3) Ermitteln aufbereiteter Werte und abgeleiteter Werte (wie z.B. Durchschnittswerte, Maxima, Minima, Häufigkeiten, etc.) für die Daten zumindest einzelner Sensoren und Anzeige dieser Werte; und
  4. 4) Darstellen eines Schaltplans des Stromversorgungssystems, in dem die Werte gemäß der Schritte 2) und 3) eingefügt sind und in dem die Kennwerte der Komponenten angezeigt werden.

This object is achieved by a method for continuously monitoring and checking a power supply system of a motor vehicle with a, preferably external, test system (eg a PC which is connected to the vehicle),

• - The power supply system of the motor vehicle has at least one battery, a generator with associated controller and a plurality of subsystems with individually switchable consumers,
• - The test system a) a plurality of, preferably on-board, measuring sensors, including at least measuring sensors for the battery voltage, the battery temperature, the battery current, the speed of the generator, the output voltage from the generator, the output current from the generator, the current and the voltage in at least two subsystems, and b) a data processing system having a processor, a memory, a display unit, a program, a bus,
• - with the following procedural steps:
  1. 1) storing the data acquired by the plurality of measurement sensors in a memory;
  2. 2) display the current values of the plurality of measurement sensors;
  3. 3) determining conditioned values and derived values (such as averages, maxima, minima, frequencies, etc.) for the data of at least individual sensors and displaying these values; and
  4. 4) Represent a circuit diagram of the power system in which the values according to steps 2) and 3) are inserted and in which the characteristics of the components are displayed.

This data processing system can on the one hand be designed as an external PC, which is connected to the vehicle or can also be configured directly as an internal system in the vehicle.

Several sensors and monitoring systems, e.g. ECUs, deliver, collect and use data from the vehicle's power system. These different sets of data are prepared and then presented in an appropriate manner. The proposed solution allows a clear graphical representation and thus diagnosis of the power supply. It collects all significant data from different sources and clearly helps to understand the deterioration or failure of the individual components of the power supply system.

In terms of apparatus, the object is achieved by a device for carrying out the method for continuously monitoring and checking a power supply system of a motor vehicle, wherein the power supply system of the motor vehicle at least comprises a battery, a generator with associated controller, a plurality of subsystems with individually switchable consumers, and wherein the device A test system comprising a) a plurality of measurement sensors, including at least battery voltage measuring sensors, battery temperature, battery current, generator speed, generator output voltage, generator current, current and voltage in at least two subsystems , and b) a data processing system comprising a processor, a memory, a display unit, a program, a bus, and wherein at least a majority of the parts summarized under a) is permanently arranged in the motor vehicle, preferably Sweise also at least a part of b) combined parts is permanently arranged in the motor vehicle.

The invention relates to a method and a device for detecting and visualizing the data of the power supply system for real-time system monitoring in the sense of a master display for the entire system. The relevant data is also recorded from all connected subsystems in the vehicle. There is a record of all relevant data and storage of this data to create time-dependent records. Furthermore, the sensor data combined and transformed, ie converted, to create a visualization (histograms, etc.). In the process, overview plots and figures for graphic visualization are generated. Historical data are taken into account in order to generate information plots about the previous system behavior. The monitor display shows a system overview consisting of online sensor data, calculated data, system characteristics and historical data. This is an online presentation that can be used for system monitoring / evaluation in the vehicle. There is a functional evaluation of the data and preparation for an optimal graphical representation of the results. By further calculations and transformations of the measurement data, additional data are achieved and displayed by combining the obtained measured values. In a system extension, it is possible to obtain a more detailed real-time online observation of certain defined components via additional external sensors (preferably designed as radio sensors), eg current clamp, multi-meter. The test system may be permanently located in the motor vehicle or preferably connected to it via a wireless or wired connection. It can be used for the connection protocols such as BT, XPC, WLAN or other protocols.

A subsystem is defined as a separate area of consumers, which is usually secured by its own backup. Such a subsystem can include, for example, the adjustment of the vehicle seats, or it includes the external illumination of the motor vehicle, or auxiliary equipment, such as an air conditioner. The measuring sensors are designed according to the prior art.

The method according to claim 2 makes it possible to detect deviations from the normal state quickly. The data of the power supply system of the vehicle to be examined are present in a memory or can be obtained from a corresponding database. In this case, the original states (reference states and also the historical course of this data) of the battery, the consumer, the generator etc. are stored in the memory and any change or deviation can be tracked. It is possible to compare a current value with a value earlier in time (for example, the value of the measured variable when manufacturing the motor vehicle) or with a statistical value, in particular a statistical value determined from the vehicle history, that is to say before a problem occurs. This comparison with historical data makes it possible to detect creeping changes better or even at all. Creeping changes can be better recognized. The details of the deviation of 10% and 5% in claim 2 are exemplary, the deviations are based on the failure or deterioration of individual components.

The method makes it possible to determine the failure of individual components and also their deterioration. For this purpose, it is particularly advantageous that the individual subsystems can be switched on and off individually. This allows an error to be located in a specific subsystem. In addition, interactions of different subsystems can also be analyzed.

Particularly advantageous is the use of the already existing on-board display of the motor vehicle as a monitor of the data processing system. Preferably, this monitor is touch-sensitive. It is advantageous that the method according to the invention is started by a corresponding input in the motor vehicle, preferably in the display of the motor vehicle. It is possible to make this inaccessible to the normal user of the motor vehicle, but only for service purposes. Also possible is the arrangement of the device according to the invention partly within a motor vehicle and partly outside a motor vehicle. Outside is, for example, the monitor or even the entire processing unit with monitor and storage system that can be connected to the vehicle. The connection between the two parts of the device according to the invention preferably takes place via a plug connection or wirelessly. The method makes it possible to issue warnings when critical operating conditions of individual components, for example the battery in winter are reached. A warning may be given to replace the battery when it is foreseeable that the capacity of the battery will be insufficient for the next starts. It is also possible to determine a prediction of the battery life on the basis of historical measured value profiles and thus to specify a replacement time.

• - für ein umfassendes Sammeln relevanter Daten aus allen Stromversorgungs-Subsystemen im Fahrzeug,
• - für die Aufzeichnung aller relevanten Daten und Speicherung dieser Daten, u.a. zur Erstellung zeitabhängiger Aufzeichnungen,
• - für ein Kombinieren der Sensordaten und Umwandeln der Sensordaten, um eine Visualisierung zu erzeugen,
• - für eine Erstellung von Übersichtsplots / Abbildungen zur grafischen Visualisierung auf einer Übersichtsseite (auf einem Bildschirm auf einem Service-Laptop, Anpassung an beliebige mobile Geräte),
• - für ein Verarbeiten von historischen Daten, um Informationsplots über das bisherige Systemverhalten zu generieren,
• - für eine Systemübersicht mit Online-Sensordaten,
• - für ein Online-Live-Display für Echtzeit-Systemüberwachung im Fahrzeug, die die Identifikation von Teilen mit reduzierter Funktionalität ermöglicht, z.B. eine von n Dioden der Lichtmaschine ist defekt,
• - für ein Ermöglichen einer einfachen Identifizierung von defekten Teilen im Stromversorgungssystem,
• - für ein Eröffnen mehrerer Möglichkeiten, auf die Informationen zuzugreifen, z.B. Bluetooth-OBD-Schnittstelle, direkte OBD-Verbindung, andere drahtgebundene oder drahtlose Verbindungen mit oder ohne OBD. Zukünftige Implementierungen können einen internen Server nutzen, der die Schnittstelle zu den verschiedenen elektronischen Modulen sein könnte,
• - für ein funktionales Auswerten der Daten und für eine Vorbereitung einer optimalen grafischen Darstellung der Ergebnisse,
• - für weiteres Berechnen und Transformieren der Messdaten, insbesondere auch die Erzeugung von zusätzlichen Daten aus der Kombination von Messungen,
• - für ein Erstellen einer Kommunikation zwischen Auto und Infrastruktur, um z.B. Technikern den Zugang in der Werkstatt zu erleichtern,
• - für ein Abschätzen des technischen Zustands der Batterie aus den beobachteten Eigenschaften der Batterie,
• - für ein Ermöglichen einer zeiteffizienten Prüfung von Fahrzeugen in der Prototypenentwicklung, der späteren Fahrzeugentwicklung und bei der Bewertung von Kundenfahrzeugen und -flotten.

The proposed solution aims at several aspects of creating a new tool:

• - for comprehensive collection of relevant data from all power subsystems in the vehicle,
• - for the recording of all relevant data and storage of this data, including the creation of time-dependent records,
• for combining the sensor data and converting the sensor data to produce a visualization,
• - for a compilation of overview plots / illustrations for graphic visualization on one Overview page (on a screen on a service laptop, adapt to any mobile devices),
• for processing historical data to generate information plots of past system behavior,
• - for a system overview with online sensor data,
• - For an online live display for real-time system monitoring in the vehicle, which allows the identification of parts with reduced functionality, eg one of n diodes of the alternator is defective,
• for enabling easy identification of defective parts in the power system,
• - for opening up several ways to access the information, eg Bluetooth OBD interface, direct OBD connection, other wired or wireless connections with or without OBD. Future implementations may use an internal server, which could be the interface to the various electronic modules
• - for a functional evaluation of the data and for a preparation of an optimal graphical representation of the results,
• for further calculating and transforming the measurement data, in particular the generation of additional data from the combination of measurements,
• - for creating communication between the car and the infrastructure, for example to facilitate technician access in the workshop,
• for estimating the technical condition of the battery from the observed characteristics of the battery,
• - for enabling a time-efficient test of vehicles in prototype development, later vehicle development and in the evaluation of customer vehicles and fleets.

The graphical interface collects all significant data from different sources and helps significantly to understand degradation or failure of the power supply components.

The completely developed system is a new measuring and diagnostic system for complete power supply systems.

Future power systems will become even more complex in complexity, and the power generation / power / power modes must be under developer control and must be understood by the workshops.

The proposed tool represents a major step towards improving the handling and maintenance of power systems.

The above object is also achieved by a method for monitoring and checking a power supply system of a motor vehicle with a test system in which the power supply system of the motor vehicle has at least one battery, a generator with associated controller and multiple subsystems with individually switchable consumers, and the test system a variety measuring sensors, including at least battery voltage measuring sensors, battery temperature, battery current, generator speed, generator output voltage, generator current, current and voltage in at least two subsystems, and a processor-based data processing system; a memory and a display unit, for carrying out the method steps 1) storing the data detected by the sensors in the memory; 2) display the current values of the sensors in the display unit; 3) determining a processed value (in particular average value, maximum, minimum, frequency) for the data of at least individual sensors and display of the processed value; and 4) Represent a circuit diagram of the power system in which the values according to steps 2) and 3) are inserted. In this respect, such a procedure is granted independent protection. The further, above-described features or features of the remaining, dependent claims are also transferable to such a method.

Furthermore, the above object is achieved by a device for carrying out such a method for monitoring and checking a power supply system of a motor vehicle, wherein the power supply system of the motor vehicle has at least one battery, a generator with associated controller and a plurality of subsystems with individually switchable consumers, and wherein the device a test system comprising a) a plurality of measurement sensors, including at least battery voltage measuring sensors, battery temperature, battery current, generator speed, generator output voltage, current output, current and voltage in at least two Subsystems, and b) a data processing system having a processor, a memory, a display unit, a program, a bus, and wherein at least a majority of under a) combined parts is permanently arranged in the motor vehicle, preferably also at least a part of the b) summarized parts is permanently arranged in the motor vehicle. In this respect, such a device is independent protection. The other features described above or features of the remaining, dependent claims are also transferable to such a device.

• 1 ein vereinfachtes Schaltbild der Vorrichtung,
• 2 ein Beispiel für die Darstellung auf einem Monitor der Vorrichtung,
• 3 ein Beispiel für einen zweiten konkreten Betriebszustand des in 2 dargestellten Stromversorgungssystems,
• 4 ein Beispiel wie 3 für einen dritten Betriebszustand,
• 5 ein Beispiel für eine Darstellung eines vierten Betriebszustandes mit anderen statistischen Werten als 2, und
• 6 ein Beispiel für die Darstellung eines fünften Betriebszustandes mit wiederum anderen Werten.

Further features of the invention will become apparent from the remaining claims and the description which follows. For this purpose, the invention will be explained in more detail with reference to the drawing, wherein the figures of the drawing represent only embodiments of the invention. These embodiments are not intended to be limiting. In the drawing show

• 1 a simplified circuit diagram of the device,
• 2 an example of the representation on a monitor of the device,
• 3 an example of a second concrete operating state of in 2 illustrated power supply system,
• 4 an example like 3 for a third operating state,
• 5 an example of a representation of a fourth operating state with different statistical values than 2 , and
• 6 an example of the representation of a fifth operating state with in turn other values.

The newly developed method combines the presentation of historical data with live data from the vehicle. The historical data, provided either as histograms or as plain text messages, helps to reduce the background of e.g. to understand a customer complaint.

1 shows in the upper part of a simplified circuit diagram of a power supply system of a motor vehicle not shown here. As usual, a battery 20 provided that has a date of manufacture, a date of installation, a certain power of, for example, 60 Ah at an output voltage of, for example, 12 V and a certain peak current of, for example, 650 A. The negative pole of the battery 20 is via a first current sensor 22 and a battery management system 24 associated with zero in the prior art. A first voltage sensor 26 detects the current battery voltage. A first temperature sensor 28 detects the temperature of the battery 20 , The positive pole is over a main line 30 with a generator 32 connected, also called alternator. In known manner is a regulator 34 interposed. Furthermore, a second current sensor 36 interposed. A second voltage sensor 38 detects the voltage on the generator 32 , A speed sensor 40 detects the speed of the generator 32 , a second temperature sensor 42 provides a signal about the temperature of the controller 34 , Furthermore, the basic data of the controller 34 known and stored, for example, the dependence of the current generated by the speed, the installation date, the type of rectifier used, etc.

Continue to the main line 30 two different subsystems 44 . 46 connected. In the first subsystem 44 is a first consumer 48 exemplified for the individual consumers of this subsystem 44 , This first consumer 48 is via a switch 50 switched on. A third current sensor 52 captures the first subsystem 44 flowing electricity. Preferably, a subsystem has multiple consumers that can be turned on individually. The voltage at the individual consumers is preferably detected by voltage sensors (not shown) arranged on them. Additional measurement data can be acquired by the consumers of the subsystems.

The second subsystem 46 is according to the first subsystems 44 built up. It has a second consumer 54 and a fourth current sensor 56 , It is in the main 30 still a fifth current sensor 57 provided that captures the total power to all consumers and subsystems.

The described sensors are part of a test system. This test system also includes the in the lower part of 1 illustrated arrangement 58 which is basically built like a microcomputer. Each of the sensors is connected via a supply line, which is not shown here in detail, with the arrangement 58 connected. This connection can be made for example via a multiple plug-in device, but it can also be wireless.

The connection of the individual sensors with the arrangement 58 is for the arrangement 58 shown simplified by a variety of arrows. These lead to an input unit 60 which with a processor 62 is connected, the connection takes place, as well as the other connections of the arrangement 58 , over a bus 64 , The processor 62 is with a memory 66 connected. Furthermore, a display unit 68 with a monitor 70 to the bus 64 connected.

A typical one, on the monitor 70 appearing picture is in 2 shown, while the following figures only parts of the overall picture of the 2 demonstrate.

In 2 In the upper line is the histogram of the state of charge SoC of the battery 20 shown. In addition, a histogram of the battery temperature is shown. On the far right is a histogram of the quiescent current of the battery 20 , The line below shows a histogram of the charge balance and next to it the histogram of the battery voltage. Underneath is a simplified, abstracted circuit diagram 1 , 2 shows in the upper part mainly historical data, while in the lower part are current data. These show that the electricity of the generator 32 of 43 A is split to the battery 20 with about 23 A charge and the electrical systems with about 19 A to supply.

3 shows the state after switching on outdoor lights and heating. This leads to a power requirement of 120 amperes. Because at idle (918 rpm) the generator 32 Being able to deliver only 115 amps of the required 120 amps becomes the battery 20 Power taken to support the network by supplying the remaining 5 amps.

4 now shows the following state: By increasing the speed to 2345 is the generator 32 able to deliver 150A. At this higher speed, the generator can deliver about 144A to the vehicle and the battery 20 charge with the remaining approx. 6A.

• • Leistungsverlust des Generators 32, z.B. wegen einer defekten Diode in der Gleichrichteranordnung,
• • ein niedriger Ladestrom zeigt auf, dass die Batterie 20 sich verschlechtert hat oder gar nicht mehr wieder aufgeladen werden kann.

By observing the dynamic behavior of the power system, it is possible to understand whether the power system is intact or not. For example, the following errors can be easily detected:

• • Power loss of the generator 32 , eg because of a defective diode in the rectifier arrangement,
• • A low charging current indicates that the battery 20 has deteriorated or can not be recharged.

Other anomalies can also be observed. The last measured quiescent current of the battery 20 , also called Key-Off-Load (KOL), is recorded and is in the 2 . 5 and 6 specified. Typically, the quiescent current is in the range of 3 to about 20 mA, depending on the individual features of the vehicle.

The upper right graph and the text below the graph in 5 indicate an excessively high quiescent current of 239 mA. This affects the ability to start the car. The excessively high quiescent current loads the battery 20 stronger than assumed during development. This leads to a more frequent charging of the battery 20 as predicted. A more frequent charge will cause the battery 20 must be replaced earlier than planned, since higher cycle rates (measured in Cn) to an earlier deterioration of the health of the battery 20 to lead.

6 shows a key-off load distribution that is within specification, mainly below 10 mA, a few times below 20 mA.

For better visualization, additional sensors (eg wireless current sensors) can be used to provide additional data on the monitor 70 the display unit 68 provide. Wireless clamps can be connected to circuits to check the correct current behavior, especially to find the cause of too high a quiescent current.

1. 1) Abspeichern der von den Sensoren erfassten Daten,
2. 2) Anzeige der aktuellen Werte der Sensoren in der Anzeigeeinheit,
3. 3) Ermitteln der Messwerte und abgeleiteter Werte wie z.B. Durchschnittswerte, Maxima, Minima, Auftrittshäufigkeiten, etc. für die Daten zumindest einzelner Sensoren und Anzeige dieser Werte; und
4. 4) Darstellen eines Schaltplans des Stromversorgungssystems, in dem die Werte gemäß der Schritte 2) und 3) eingefügt sind und in dem die Kennwerte der Komponenten angezeigt werden.

In the method for monitoring and checking a power supply system of a motor vehicle with a test system, wherein the power supply system of the motor vehicle at least comprises a battery 20 , a generator 32 with associated controller 34 and several subsystems 44 . 46 with individually switchable consumers, the test system comprising: a) a plurality of measuring sensors, including at least measuring sensors for the battery voltage, the battery temperature, the battery current, the rotational speed of the generator 32 that from the generator 32 discharged voltage from the generator 32 output current, current and voltage in at least two subsystems 44 . 46 , b) a data processing system comprising a processor, a memory, a display unit, a program, a bus, the following method steps are carried out:

1. 1) storing the data acquired by the sensors,
2. 2) display the current values of the sensors in the display unit,
3. 3) determining the measured values and derived values such as average values, maxima, minima, frequency of occurrence, etc. for the data of at least individual sensors and display of these values; and
4. 4) Represent a circuit diagram of the power system in which the values according to steps 2) and 3) are inserted and in which the characteristics of the components are displayed.

Terms, such as substantially, preferably, and the like, as well as possibly inaccurate indications, are to be understood to mean a deviation of plus minus 5%, preferably plus minus 2%, and most preferably plus minus one percent of normal. The applicant reserves the right to any features and sub-features of the claims and / or to combine any features and also partial features from a set of the description in any manner with other features, sub-features or partial features, even outside the features of independent claims.

In the different figures, equivalent parts are always provided with the same reference numerals with respect to their function, so that these are usually described only once.

LIST OF REFERENCE NUMBERS

20

battery

22

first current sensor

24

Battery Management System

26

first voltage sensor

28

1. temperature sensor

30

main

32

generator

34

regulator

36

Second current sensor

38

second voltage sensor

40

Speed sensor

42

2. Temperature sensor

44

1st subsystem

46

2nd subsystem

48

1. Consumers

50

switch

52

third current sensor

54

2. Consumers

56

4. Current sensor

57

5. Current sensor

58

arrangement

60

input unit

62

processor

64

bus

66

Storage

68

display unit

70

monitor

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• JP 54040433 A [0009]
• WO 2006/048125 [0012, 0013]
• DE 102014214840 A1 [0014]
• DE 102015204242 A1 [0015]

Claims (11)

Method for continuously monitoring and checking a power supply system of a motor vehicle with a test system, wherein the power supply system of the motor vehicle at least one battery (20), a generator (32) with associated controller (34) and a plurality of subsystems (44, 46) with individually switchable consumers The test system comprises a plurality of measuring sensors, including at least measuring sensors for the battery voltage, the battery temperature, the battery current, the rotational speed of the generator (32), the voltage delivered by the generator (32), the current output by the generator (32), the current and the voltage in at least two subsystems (44, 46), and the test system comprises a data processing system having a processor (62), a memory (66) and a display unit (68) for carrying out the method steps: 1) storing the data acquired by the plurality of measurement sensors in the memory (66); 2) displaying the current values of the plurality of measurement sensors in the display unit (68); 3) determining a processed value (in particular average value, maximum, minimum, frequency) for the data of at least individual sensors and display of the processed value; and 4) Represent a circuit diagram of the power system in which the values according to steps 2) and 3) are inserted. Method according to Claim 1 , characterized in that the deviation of the current value obtained according to step 2) from the prepared value determined according to step 3) is constantly checked and a warning signal is displayed if the deviation is greater than a predetermined critical value, in particular 10% and preferably 5% is. Method according to one of the preceding claims, characterized in that features of the components of the power supply system in the memory (66) are stored, for example, installation date or age of the battery (20) and / or the generator (32) and / or individual consumers. Method according to one of the preceding claims, characterized in that the quiescent current of the battery (20) is constantly detected when the motor vehicle is switched off (ignition key in the off position) and compared with historical data. Method according to one of the preceding claims, characterized in that individual subsystems (44, 46) are switched on and off during the test and the values obtained are displayed in the monitor of the display unit (68), in particular that the deviation of the step 2) for each subsystem (44, 46) and for deviations greater than a predetermined critical value, in particular as 10% and preferably 5%, the data processing system checks which failure of which individual component of the observed deviation can be assigned. Method according to one of the preceding claims, characterized in that warning signals are output when critical operating conditions are reached, for example, an excessively high temperature of the generator (32), an uneven running of the generator (32), an irregular behavior of the controller (34), too high or too low a temperature of the battery (20). Method according to one of Claims 1 to 6 , characterized in that the data processing system is designed as an external, connectable to the motor vehicle PC. Method according to one of Claims 1 to 6 , characterized in that the data processing system is formed as an internal system in the motor vehicle. Apparatus for carrying out the method for continuous monitoring and checking of a power supply system of a motor vehicle according to one of Claims 1 to 8th in that the power supply system of the motor vehicle has at least one battery (20), a generator (32) with associated controller (34) and a plurality of subsystems (44, 46) with individually switchable consumers, and the device has a test system which has a) a A large number of measuring sensors, including at least battery voltage measuring sensors, the battery temperature, the battery current, the rotational speed of the generator (32), the voltage delivered by the generator (32), the current output by the generator (32), the current and the voltage in at least two subsystems (44, 46), and b) a data processing system having a processor (62), a memory (66), a display unit (68), a program, a bus (64), and wherein at least a majority of the a) combined parts is permanently arranged in the motor vehicle, preferably also at least a part of the parts combined under b) is permanently arranged in the motor vehicle. Device after Claim 9 , characterized in that the on-board display of the motor vehicle is used as a monitor of the display unit (68). Device after Claim 8 or 9 , characterized in that the data processing system is provided and arranged in the motor vehicle.

Images