宋成建

摘 要：汽车高压配电系统（PDU）是汽车高压电能的集散、分配关键件，将来自动力电池的高压电能，通过各相关控制、经过高压继电器及熔断器准确传递至各高压用电器。相关传递是经过配电系统上高压线束及插件实现的，为确保安全，相关插接件上设置有高压互锁端子，利用低压电路监控高压电路连接状态，避免人员触电风险。相关高压互锁检测电路，是通过各插接件上的高压互锁端子实现传递的。当插接件间高压互锁端子出现回缩，系统为确保安全、将切断高压，直到问题解决。

关键词：高压配电系统 动力电池 高壓电能 高压继电器 熔断器 高压互锁 上高压

Improvement of the Retraction Problem of the High-voltage Interlock Terminal of the Power Battery Plug-in in the High-voltage Power Distribution System

Song Chengjian

Abstract：Automotive high-voltage power distribution system （PDU） is a key component of the collection and distribution of high-voltage electric energy in automobiles. It accurately transfers the high-voltage electric energy from the power battery to various high-voltage electrical appliances through various related controls， through high-voltage relays and fuses. The relevant transmission is realized through the high-voltage wiring harness and plug-ins on the power distribution system. To ensure safety， high-voltage interlock terminals are provided on the relevant plug-in connectors， and the low-voltage circuit is used to monitor the connection status of the high-voltage circuit to avoid the risk of electric shock. The relevant high-voltage interlock detection circuit is transmitted through the high-voltage interlock terminals on the connectors. When the high-voltage interlock terminals between the connectors retract， the system will cut off the high-voltage to ensure safety until the problem is solved.

Key words：high-voltage power distribution system， power battery， high-voltage electric energy， high-voltage relay， fuse， high-voltage interlock， high-voltage

1 改进前现状

1.1 零件说明：

高压配电系统接动力电池插头由护套本体、锁止扣、护套盖子及内嵌的高压互锁端子。其中高压互锁端子作用是与动力电池侧高压互锁端子连接配合，以便系统确定动力电池插头已插接到位、系统可正常上高压。

当高压互锁端子退缩时，即无法正常与动力电池测高压互锁端子对接，系统判断为动力电池插头未插接好，整车将无法上高压。护套结构如图1、2、3所示。

1.2 数据调查：

2019.9.20项目期间，总装反馈陆续发现7台E200无法上高压，结合线旁、三方库房排查，数据如下。相关数据如表1所述。

1.3 问题症结：

小组成员详细分析现场故障件，对高压配电系统接动力电池高压互锁端子回缩问题的故障模式进行调查，同时结合相关数据分析，有以下症结：

插头对接过程高压互锁端子被顶回缩。……