某新能源汽车压缩机接触器绝缘故障问题分析

Analysis of Insulation Failure of Compressor Contactor of a New Energy Vehicle

为了有效解决某量产新能源汽车压缩机使用过程中出现的接触器绝缘故障问题,文章通过实验确定故障主要原因是未考虑电动空调压缩机输入端滤波电容,导致空调压缩机启动瞬间有较大冲击电流,触点铜排烧蚀。对标几种畅销纯电动汽车压缩机控制回路,坚持改动最小且能有效解决问题的原则对量产车型电路进行整改,在现有空调回路中增加预充控制回路。文章分析结果为其他车型空调控制回路设计提出有效思路,避免因大电流冲击导致绝缘问题。

For solving effectively the contactor insulation problem during the use of the compressor of a mass produced electric car,in this paper,the reason for the failure was determined by experiments that the filter capacitor at the input end of the electric air conditioning compressor was not taken into account,which resulted in a large impulse current at the start moment of the air conditioning compressor and the copper plate ablation at the contact point.Based on the standard control circuits of several popular pure electric vehicle compressors,the circuits of mass production models were corrected in accordance with the principle of minimum modification and effective solution to the problem,and the pre-charging control circuit was added to the existing air conditioning circuit.The analysis results of this paper provide effective ideas for the design of air conditioning control loop of other car models to avoid insulation problems caused by large current impact.