Hanteng EM11 after-sales

technical training
power part
 Learning goals

1. Understand the structure and characteristics of

electric vehicles
2. Master the power components of the EM11 electric
car

3. Master the control strategy of EM11 electric vehicle

4. Master the analysis and maintenance of typical faults

5. Master high voltage electrical maintenance and

matters needing attention

2
 CONTENTS

一 概述
Summary

二 充电系统system
Charging

三 电池管理系统
Battery management system

四 电机控制系统
Motor Control System

整车控制系统
五 Vehicle
Vehiclecontrol
controlsystem
system

六 高压电
High voltage
3
 1 Summary

4
 Summary
Electric Vehicle

 Electric Vehicle (EV) is a Vehicle which is

powered by vehicle-mounted power

supply and driven by Electric motor. It

conforms to various requirements of

road traffic and safety regulations。

5
 Summary
Electric Vehicle and Traditional Vehicle
Traditional Vehicles and Electric
Vehicles
Power System Difference

Traditional Vehicles
Engine Electric Vehicle
Control Unit ECU Motor and Motor Controller
Transmission Vehicle Controller VCU
tank Fixed Speed Ratio Reducer
Starter/generator and Power battery
other accessories

Electric cars differ mainly from conventional cars in terms of power。

6
 Summary
Electric Vehicle and Traditional Vehicle
 Traditional Vehicle are mainly composed of engine, chassis, body and electricity.

Compared with fuel-fired Vehicle, the structure of electric vehicles mainly increases the

electric drive control system, but cancels the engine

 The electric drive system mainly includes: vehicle controller (VCU), motor controller, motor,

etc., which is able to efficiently convert the electric energy stored in the power battery into

the kinetic energy of the wheels, and to convert the kinetic energy of the wheels into

electrical energy to be stored in the power battery when the vehicle decelerates and braking.
7
 Summary
EM11 power composition

Power battery Electric machinery

Reducer
8
 Summary
EM11 power composition

High voltage
Battery charger
distribution Box

Motor Controller

9
 Summary
EM11 Power System Parameters
Project Parameter Project Parameter

Permanent magnet Ternary lithium

The motor type Battery type
synchronous machine ion battery

Drive form Motor front Transmission type Central reducer

Maximum power（kW） 95 Maximum torque（Nm） 260

Maximum speed（km/h) 140 Maximum gradient 26%

0-100km/h acceleration Mileage under comprehensive

≤11.9 252
time（s) operating conditions（km）
60km/h Equal speed
330 Slow charging time（h） 14
continuity（km）
30min charge from 20%
Fast Charging Time
to 80%

10
 Summary
EM11 Electric Vehicle Structure
 The structure of EM11 electric vehicle is a combined

drive mode of motor-drive axle with parallel motor

Power
battery
axle and drive axle, which adopts a front-drive.
Motor
Controller

 This driving mode can ensure that the vehicle has Electric
machinery

good dynamic performance under starting, climbing, Reducer

accelerating and overtaking conditions.

11
 Summary
EM11 structure of electric drive control system
 The electric drive control system of
combination EM11 electric vehicle mainly includes:
Motor instrument
Controller VCU (vehicle controller), power battery,
motor controller, driving motor and so
on.
 VCU is the core of electric vehicle
power control, and the
Driving
motor communication between control
Power
modules is mainly through CAN bus.
battery
BMS
12
 Summary
Working Principle of EM11 Electric Vehicle
 Energy flow: power battery→ motor controller →motor

transmission system→ Drive the car.

 According to the driver's intention, VCU sends torque Power

Power
battery
battery
output instructions to the motor controller, while the
Motor
Motor
Controller
Controller
power battery provides high voltage direct current to the
Electric
Electric
motor controller. The motor controller outputs three- machinery
machinery

phase electricity to the driving motor according to the Reducer

Reducer

torque output instructions, and the motor drives the

13 vehicle through the mechanical transmission system.

 Summary
What are the advantages of electric cars?
1. Simple structure, easy maintenance.

2. High energy conversion efficiency

and diversity.

3. No pollution and low noise.

4. Single source of electricity

5. The peak and valley differences of

the power grid are stabilized.

14
 2 Charging system

15
 Charging system
Summary
The main power source of EM11 electric vehicle is power battery, which can be recharged

repeatedly. The main ways of charging power batteries by external power supply: DC fast

charging and AC slow charging.

DC fast charging AC slow charging

16
DC fast charging
composition
 DC fast charging is the direct charging of power batteries by using high current in non-

vehicle chargers. It can charge about 80% of the power batteries in a short time. It mainly

includes charging piles, DC charging sockets, power batteries, combined instruments, etc.

 The dc charging socket is installed at the front grid logo.

Note:
 DC fast charging can only be charged by DC charging pile, and charging pile has its
own charging gun!
17
 Charging time: 30 minutes SOC from 20% to 80%.
 DC fast charging
Definition of DC charging socket port Contact Rated
Function definition
mark voltage/current
 National Standard 9-core charging socket,
DC+ 750V 125A DC power supply+
specification DC750V/125A。 DC- 750V 125A DC power supply-
S- 30V 2A Fast Charge CAN-L
S+ 30V 2A Fast Charge CAN-H
Charging connection
CC2 30V 2A
confirmation
Charging connection
CC1 30V 2A
confirmation
Low Voltage Auxiliary
A- 30V 20A
Power Supply-
Low Voltage Auxiliary
A+ 30V 20A
Power Supply+
Protective ground
PE -
18 connection
 DC fast charging
DC charging socket
DC+(Red)、DC-(Black)
Junction box(Fast
Charging)

PE(Ground
connection)

Low Voltage Communication Interface

Connecting Front Cabin Wire Harness

19
DC fast charging
直流充电低压通讯接口
DC Charging Low Voltage Communication Interface

Terminal Definition
1 DC+Temperature detection 1
Fast Charging Connection Confirmation
2
CC2
3 fast charge CAN-H

4 fast charge CAN-L

5 Charging wake-up input

6 Ground connection

7 DC+Temperature detection 2

8 DC-Temperature detection1

9 DC-Temperature detection2
20
 DC fast charging
 When the power battery power is low,
Working Principle of DC Fast Charging
connect the DC charging pile with the
charging pile charging gun charging gun Electric vehicle
DC charging socket. The charging pile
Electronic
lock
measures the voltage of CC1 point to
Power
battery judge whether the charging gun is fully
connected with the charging socket.
Note：
Equipment Bodywork
location

Charging
pile
control
device
After the charging pile is judged to be
for
Checkpoint 1
fully connected, the electronic lock is
electric Vehicle
vehicle Control
Device

Checkpoint 2 controlled to stop, so that the vehicle can

not be driven in the charging process
(that is, it can not start the vehicle)!

21 Coupling order：PE→ CC2 → DC&DC- → A+& A- → S-&S+ → CC1 。

 DC fast charging
Working Principle of DC Fast Charging
 After the charging pile judges that the
charging pile charging gun charging gun Electric vehicle

Electronic
charging gun and the charging socket have
lock

been fully connected, it carries out self-

Power
battery
inspection (insulation detection, etc.) and
Equipment Bodywork makes the low-voltage auxiliary power
location

Charging
pile circuit turn on after no fault.
control
device
for
electric
Checkpoint 1 Vehicle  BMS judges whether the charging socket
vehicle Control

and the charging gun are fully connected

Device

Checkpoint 2

by measuring the CC2 voltage. After fully

connected, the BMS wakes up the battery
management system.。

22
 DC fast charging
Working Principle of DC Fast Charging  After BMS wakes up, the whole vehicle

charging pile charging gun charging gun Electric vehicle enters the DC charging stage by
Electronic
lock communicating with charging pile

Power through S-&S+.

battery
 In the charging stage, BMS sends
Equipment
location
Bodywork
charging demand to the charging pile in
Charging
pile
control real time. The charging pile adjusts
device
for
electric
vehicle
Checkpoint 1 Vehicle
Control charging voltage and current according
Device

Checkpoint 2 to the charging demand to ensure the

normal charging process. In addition,
charging piles and BMS send state
information to each other.
23
 DC fast charging
Matters needing attention
 he charging operation is carried out strictly according to the operation instructions of
the DC fast charging pile.
 DC fast charging voltage and current are high. When charging and repairing, pay
attention to personal safety。
 DC fast charging will use larger charging current and power, which will have a certain
impact on the life of power batteries.
 When the ambient temperature is higher or lower, the actual charging current will be
less than the rated charging current value, and the charging time will be prolonged.
 Influenced by the performance of batteries, when the ambient temperature is below 0
℃, fast charging can not be used for charging.

24
 DC fast charging
Common faults of DC fast charging

Fault phenomenon Suspicious location

1.Incorrect charging operation

2.DC charging pile fault (charging pile power supply,
DC charging fault, that is charging pile itself, charging gun fault, etc.)
charging connection
3.Fault of fast charging socket (wear of charging socket,
indicator is not on or
disconnection of connector, poor grounding, etc.)
charging indicator is not
on 4.Junction box fault.
5.Power Battery Fault (BMS Fault, Battery Internal Fault,
high or low Temperature)

25
 AC slow charging
composition
 Ac slow charging is to convert alternating current into high-
voltage direct current through the vehicle charger and then
transfer to the power battery. The charging power depends
on the power of the charger.
 Ac slow charging can adopt single-phase ac charging at home
and single-phase ac charging at charging pile, which is mainly
composed of a charger, a charging socket, etc. The former
vehicle is separately equipped with a charging gun, while the
latter charging pile is equipped with a charging gun.

Note:

DC fast charging socket is different from AC slow charging socket !

26
 AC slow charging
Charging gun

 National standard seven-core

charging plug, specification AC250V- Power supply
plug
16A.
 t has the functions of over-current, Vehicle plug
over-voltage, under-voltage, leakage
Control box
protection, ungrounded detection and
so on.
Charging cable
 Judging the charging status by the
indicator lamp on the control box。

27
 AC slow charging
Technical parameters of charging gun
Items Parameter
Rated input voltage 220VAC±10%,50Hz
Rated charging current 13A
Over current limiting 15A(First limit)/18A(Second limit)
Duty cycle of output signal 21.7%
Over / under voltage 220VAC±25%
Leakage current 25±5mA
Insulation resistance ≥100MΩ
IP67(Control box)，IP55(When plugged into a charging
Protection level
socket)
Life of Plugging More than 10000 times
Storage temperature -40℃-85℃
Working temperature -40℃-55℃
28 Plug-in/pull-out force of vehicle plug ≤100N / ＞200N
 AC slow charging
Control box Indicator Status Indicator light status description
Charging in progress

Charging completed
Unconnected

Leakage protection
Over current protection
Overvoltage/under
voltage protection
Ungrounded

Power fault
29
 AC slow charging
AC slow charging socket
 National Standard 7-core charging socket.
 CC (Connection Confirmation): Make sure that
the charging gun is properly connected to the
charging socket.
 CP (Connection Boot): Contact
Function definition
mark
 PE continuous monitoring, L1 Power input
 Confirmation of correct connection between L2 NC
L3 NC
charging gun and charging socket.
N Midline
 Power supply/power off control function, Protective grounding, power supply
PE grounding of connecting equipment
 Charging current monitoring. and body grounding
CC Charging Connection Confirmation
30 CP Control and guidance
 AC slow charging
Working Principle of AC Slow Charging
 When charging, a charging gun is used
Control box Vehicle interface vehicle
Charging Charging to connect the single-phase AC with the
plug socket
off-board
Three
pin plug
charger charging socket. The charging machine

Leakage
collects the monitoring point 3 (CC) and
Signal
current Ground
the resistance between the ground
Detection
protector connection
Device

Power
Checkpoint 3
(about 680Ω) to determine whether the
Supply

charging gun is connected properly. If

Control
Device
Checkpoint 1 Checkpoint 2

the charging gun is faultless, the control

guide circuit can be formed with the
Coupling order：
control box (S1 switching to the PWM
Grounding (PE), AC Power (L1) & Midline (N), Connection
position).
31
Confirmation (CC) & Control Guidance (CP)。
 AC slow charging
Working Principle of AC Slow Charging
 If the connection is normal, the charger self-
Control box Vehicle interface vehicle
checks without fault, the power battery is in Charging Charging
plug socket
off-board
a rechargeable state, the control box starts Three
pin plug
charger

automatically, and the car charger is ready Leakage

Signal
current Ground
Detection
(S2 closed).
protector connection
Device

Checkpoint 3
Power
Supply
Control
 After the power supply control device in the Device
Checkpoint 1 Checkpoint 2

control box detects that the switch S2 is

Note：
closed, the closed contactors K1 and K2
make the AC power supply circuit turn on, After connecting, pay attention to observe whether
and the AC terminal of the charger gets the status of each indicator is normal!
32
electricity and charges.
 AC slow charging
Charger
 Installed in the front cabin, the charging gun
is connected to the AC power grid or
charging pile to convert alternating current
into high-voltage direct current to charge the
power battery.
 Constant voltage and constant current
control can be carried out, and charging
power can be adjusted according to charging
status, so as to realize intelligent control of
vehicle charging.

33
 AC slow charging
DCDC转换器
DCDC Converter
 EM11 electric vehicle DC-DC converts the high-voltage
direct current of power battery to 13.8V low-voltage
direct current by receiving the target voltage of VCU,
which provides electric energy for low-voltage electrical
apparatus of vehicle, and charges the battery when 12V
battery is in short supply.
 After the VCU is woken up, the DCDC is woken up by the
hard wire. The DCDC is output or stopped according to
the working mode sent by the VCU. When the high
voltage is cut off, the VCU turns off the DC-DC through
the hard wire.

Note：
The whole vehicle is placed in the "ON" state, and the internal and control lines
of BMS and dc-dc are fault-free, and DCDC will always output!
34
 AC slow charging
充电机技术参数
Technical parameters of charger
Items Parameter
Model VCDC01-A
Input voltage(VAC) 220±15%
Output voltage(VDC) 240-420
Input current(A) ≤15.2
Maximum output current(A) 12
Rated power(kW) 3.3
tarting impulse current(A) ≤130%
IP Protection level IP67
Working temperature(℃) -30-55
Machine weight(kg) ＜10
Cooling mode Air cooling
35
AC slow charging
Technical parameters of DCDC
Items Parameter

DCDC Input voltage(VDC) 240-420

DCDC Output voltage(VDC) 10-16

DCDC Rated output current(A) 100

DCDC Rated power(kW) 1.4

Peak Output Power and Duration 1.5KW@6min

Full load efficiency ＞93%

IP Protection grade IP67

Working temperature -30~55

Cooling mode Air cooling

36
AC slow charging
Charger structure

DCDC+

High and Low Voltage Wire

Harness Interface

搭铁
Ground
37
 AC slow charging
High voltage interface of charger
High Voltage DC interface: junction
box
- High Voltage DC Output of
Charger (Power Battery Charging)
- High Voltage Direct Current
Input (DCDC) for Power Batteries

AC Input Interface: Connect

directly with AC slow charging

and electric socket.

38
 AC slow charging
Low voltage communication interface of the charger

Termin
Terminal Definition Definition
al

A CAN-H G CP

B CAN-L H 12V output

High voltage
C 12V Power Supply I
interlock+
High voltage
D 12V Power Supply J
interlock-

E DCDC Enable signal K IGN power awaken

DCDC Fault
F CC M
39
signal
AC slow charging
Common faults of AC slow charging

Fault phenomenon Suspicious location

1.Incorrect charging operation

2.Charging gun fault

3.AC charging socket fauit (charging socket wear,
AC charging failure, that
disconnection of connectors, poor grounding, etc.)
is ,charging connection
indicator is not on or 4.Charger fault
charging indicator is not
on 5.Branch box fault

6.12V Battery fault (low voltage, battery damage, etc.)

7.Power battery fault (BMS fault, internal battery fault,
over or under temperature)
40
 Charging system
Charging indicator

Charging：Charging Connection Indicator light Light up, Charging indicator Light up(Yellow)。

Charging completed：Charging Connection Indicator light Light up, Charging indicator

Light41up(GREEN)
 Charging system
Charging indicator light signal transmission

 When charging fast, BMS detects CC2 and sends charging connection signal;In slow

charging, the charger sends CC connection signal and lights up the connection

indicator light of the charging line.

 When the charging reaches the cut-off voltage, the sending state is full and the light

meter is full of indicator light.

 When charging, BMS sends the status of charging, and lights the indicator light of

charging.
42
 Charging system
Common fault of charging
If the charging plug is normal and the vehicle is trouble-free, please check it as follows:
Fault diagnosis Possible reasons Solution
When the power battery is full, the charging
1.Power batteries are full
will stop automatically.
2.Power battery temperature Place the vehicle in an appropriate temperature
The power supply
is too low or too high and charge it when the temperature is normal.
interface and vehicle
interface are well 3.12VOverdischarge of storage After charging the 12V battery, recharge it.
connected, but can battery
not be charged. After confirming that the battery fault alarm
4.Fault of vehicle or light on the display screen of the combined
charging plug instrument is lit, please contact the 4S shop
for maintenance.
When the power is restored, the charging plug
1.Power outage
will automatically start charging again.
If the temperature of the power battery is too
Stop charging while 2.Excessive temperature of
high, the charging will stop automatically, and
charging power battery
the battery will be recharged after cooling.
Confirm the charging plug or the vehicle has a
3.Fault of vehicle or
fault warning, please contact the 4S shop for
43 charging plug
maintenance.
 Charging system
Notes for vehicles before and during charging:
 Before charging, please ensure that the power supply socket is well grounded to avoid the wrong phase of the power
supply socket, it is strictly prohibited to use external wire in order to avoid fire or electric shock；
 Before charging, please ensure that there is no water or foreign matter in the charging socket and charging gun, and
the metal terminal is free from damage or influence caused by rust or corrosion;
 Do not use wet hands or stand in the water to plug or unplug the vehicle, so as not to cause electric shock and
personal injury;
 When charging, ventilation must be ensured in the charging place. It is strictly prohibited to charge in a closed and
narrow space.
 For users who use electronic medical devices (such as implanted pacemakers), charging may cause the device to not
work properly and cause personal injury;
 If you notice an unusual smell or smoke coming out of the car while charging, stop charging immediately.
 When there is lightning, do not charge the vehicle. Lightning may damage the charging device and cause personal
injury.
 Do
44
not expose the vehicle plug to flammable gas during charging to avoid danger.
 Charging system
In order to avoid damage to the charging gun and charging socket:
 Do not close the charging port cover when the dust cover of the charging socket is open;
 Do not pull or twist the charging cable, do not impact the charging gun;
 Do not put the charging gun near the heater or other heat sources. Do not put the charging gun in water
or in rain or snow.
 The domestic power supply shall be installed with circuit breakers, and the power supply socket shall
strictly use the standard socket meeting the requirements of the national standard, and the current
carrying capacity shall be sufficient. The front-end wiring of the socket shall meet the requirements of the
standard single-phase three-wire system.
 For convenient operation and safe use, it is recommended that the power supply socket should be no
more than 30cm above the ground, and the control box should be fixed to avoid the force of the plug,
otherwise it will easily lead to the fall and damage of the product;
 The charging socket is an electronic product. It should be avoided to be placed in direct sunlight or damp
place.
45
 3 Battery management system

46
 Battery management system
Summary

 Battery management system (BMS) is an electronic device that can monitor and

manage power batteries. By collecting and calculating parameters such as voltage,

current, temperature and SOC, the charging and discharging process of batteries can

be controlled to realize the protection of batteries and improve the comprehensive

performance of power batteries, so that power batteries can work well.

 Features: Simple, accurate, stable and safe.

47
 Battery management system
Function
Total Voltage Detection of Battery fault analysis and
Single Battery/Battery Pack on-line alarm
Total Temperature Detection of
Single Battery/Battery Pack SOC estimation of battery packs

Charge-discharge balance Leakage protection and insulation

function detection
Charge and Discharge
Current Detection of Key Data Storage Functions
Battery
Power-up and power-down Charge management
control function of the system
Battery pack high voltage Estimation of maximum permissible
module management charge and discharge power or
current
CAN Communication
function Thermal management control
48
 Battery management system
Discharge High Voltage Charging Control
 High voltage charging is divided into pre-charging process and charging process. Precharging can reduce
the impact of high voltage on motor controller.
 The whole vehicle power supply is switched to ON state, the VCU wakes up the BMS and issues charging
command. After BMS self-check is no fault, the pre-charge/main-negative contactor is controlled to close.
The high-voltage power is supplied to the high-voltage DC terminal of the motor controller through the pre-
charge resistance, and the vehicle enters the pre-charge state. When the voltage difference between the high
voltage DC terminal voltage and the high voltage DC bus voltage in the motor controller is less than the
prescribed value, the pre-charging is judged to be completed. Otherwise, the pre-charging fails and the fault
indicator lights of the whole vehicle are lit.
 After successful pre-charging, BMS controls the main and forward contactors to close, the charging of the
high voltage system is completed, the read indicator lights up, and the vehicle is in a feasible state.

49
Battery management system
Slow Charging Up and Down Control
 Close the charging circuit relay according to the connection state of the charger and
the VCU state.
 Cut off the charging circuit according to the battery pack's electric quantity and
temperature state。

Fast Charging Up and Down Control

 After BMS is awakened, it receives VCU status and enters the fast charging process
when BMS is in fault-free state.
 The fast charging process and protocol are implemented according to the
communication protocol between the non-vehicle conductive charger and the
battery management system of the electric vehicle
50
 Battery management system
Fault Handling Strategy

level- 1 fault handling strategy:

- When a fault occurs that requires the relay to be cut off immediately, the BMS
shall immediately cut off the relay.
- When a fault occurs that does not require the relay to be cut off immediately,
BMS waits for VCU command to cut off the relay. If no VCU command is received within
10s (the calibration value), BMS will cut off the relay by itself.
Level-2 / level-3 fault handling strategy: when there is a level-2 / level-3 fault, BMS
only reports the fault information.

51
 Battery management system
Discharge power control
 BMS is based on SOC and temperature of power battery, combined with discharging
current of battery pack cores at different temperatures and SOC conditions, allowable
discharging current/power is sent to VCU to determine the current vehicle
discharging power.

Discharge feedback power control

 BMS is based on SOC and temperature of power battery, combined with discharging
current of battery pack cores at different temperatures and SOC conditions, allowing
discharging feedback current/power to be sent to VCU to determine the current
vehicle discharging feedback power.

52
 Battery management system
Passive Equilibrium Strategy

 BMS adopts a passive equilibrium mode, namely energy dissipation equilibrium.

 Batteries are connected in parallel with a discharge resistance that can be switched on
and off. BMS controls the switch of the resistance to discharge single batteries with
higher voltage. Electric energy is dissipated in the form of heat.

 Equilibrium triggering condition is 40 mV difference between unit voltage and

average voltage, 100Ω value of discharge resistance and 50 mA equalization current

53
Battery management system
SOC estimation strategy
 The battery SOC is estimated by accumulating the battery's charge during charging
or discharging.

Discharge correction strategy

 The SOC is modified by open-circuit placement method.
 When the system detects that the static time is enough, SOC is calculated by checking
the table of the relationship between open circuit voltage and temperature and SOC.。

Charging Correction Strategy

 When charging is over and charging cut-off condition is reached, BMS automatically
corrects SOC to 100%.

54
 Battery Management System
Relay Adhesion Detection
 When power is on, the adhesion between main and negative relays and fast charging
relays is detected. BMS determines whether the relay is adhering according to the voltage
ratio collected by hard wires.
 When power down, the main and negative relays are not disconnected after disconnection.
If the voltage drop within 3S is less than 20V, the main positive adhesion is judged.

Charging Current Control Strategy

 Firstly, charge with constant current, and charge with constant voltage at the charging
end.
 During the charging process, when the maximum voltage of the monomer reaches 4.15V,
the current will be lowered. The current reduction method is: based on the current
charging request current, each time the current is reduced to 60%, waiting for 5 seconds
to adjust the charging current for the charger. During this period, the charging current is
not adjusted. When the maximum monomer voltage is 4.15V and the charge request
55current is less than 8A, the charge is terminated.
 Battery Management System
Collision power off control

 BMS receives the CAN signal from SRS. When collision is detected, BMS cuts off all high

voltage circuits.

 The collision signal is input to BMS through the vehicle CAN network. At the same time,

BMS also receives the hard-wire collision signal, and determines the breaking of the

high-voltage circuit by judging the collision degree by the different wavelength of the

hard-wire signal.

56
 Battery Management System
Power Battery Voltage, Current and Insulation Monitoring
动力电池电压、电流及绝缘监测
 The total voltage of the battery pack is detected by
connecting the total positive and negative terminals
of the battery with the conductor.
 The charging and discharging current of the current
power battery is detected by a shunt connected in
series to the total negative terminal.
 The total battery voltage and charge-discharge
current detected were analyzed to obtain the current
Electricity Electric
power battery capacity. (SOC-Charged state, refers to meter
Voltage SOC current

the current capacity of the battery, which represents

the remaining capacity of the battery when
discharged
57 after full charge).
 Battery Management System
Thermal management control
 When BMS monitors the high temperature of the power Battery
Power
battery, it transmits the signal to the air-conditioning cooling
battery
kettle
controller and compressor through CAN bus to start the
pump, compressor and the solenoid valve of the heat
exchanger. The coolant in the heat exchanger is cooled by the Water Plumbing
pump PTC
evaporation and heat absorption of refrigerant and circulated
to the battery pack to dissipate heat to the power battery.
 When charging, BMS monitors the lower temperature of the Heat
Exchanger Expansion heat
power battery, and transmits the signal to the air valve exchanger
Solenoid
conditioning controller and the water heating PTC through Valve

the CAN bus, starts the pump, and enters the cooling fluid of High Pressure High Pressure
Pipeline of Air Pipeline of Air
the
58
water heating PTC into the power battery to heat the Conditioning Conditioning

power battery.
 Battery Management System
Composition of heat management control

Terminal Definition

Pump Relay Output

1
Power Supply

2 Pump PWM Control

Electrical
3
grounding
Power Battery Heat Dissipation:

 Located below the heat exchanger.

 An air conditioning controller controls the closure of the pump relay to control whether

59 the pump works or not.

 Battery Management System
Composition of heat management control

Terminal Definition

1 Power Supply
Solenoid valve
2
control

Heat Exchanger Solenoid Valve:

 Located below the heat exchanger, the refrigerant flowing into the heat exchanger is

controlled.

 It is controlled by air conditioning controller.

60
Battery Management System
Composition of heat management control

Terminal Definition

1 CAN-H

2 CAN-L

3 12V Power Supply

Plumbing PTC: 4 Electrical grounding

 Located behind the front cabin cooling fan, it is used to heat coolant,
air conditioning, heating air and power battery.
 It is controlled by air conditioning controller.
61
 Battery Management System
Composition of heat management control

Terminal Definition
Water valve motor
1
+/-
Electric water valve (to power battery):
Water valve motor -
2
 The utility model is located on the cooling fluid inlet pipe /+

of the power battery and is used to control the on-off of 3 Sensor ground
4 -
the cooling fluid entering the power battery.
Sensor 5V Power
Air conditioning controller is directly controlled.
 62 5
Supply
Battery Management System
Composition of heat management control

Heat exchanger:

Located in front right of the front cabin, refrigerant expands

through the expansion valve of the heat exchanger, enters

the heat exchanger, evaporates and absorbs heat, cools

through the cooling fluid of the heat exchanger, and then

cools the power battery.。

63
 Power battery
Power Battery Composition

 Battery module: composed of three-element single core in

series;
 BMS: BMU, CSC acquisition board and corresponding
voltage, temperature and current acquisition device,
implement battery management;
 The high and low voltage electrical parts are composed of
MSD, main positive/negative relay and pre-charging
module.
 Necessary fixed installation and reinforcement
components

64
 Power battery
Technical parameters of power battery
动力电池技术参数
Items Parameters Remarks
Model YT-331.2-129
Battery type Ternary lithium-ion battery
Total energy（KWh） 42.72 3-4.2V
Available Energy of Vehicle
41.44 3-4.15V
（KWh）
Rated capacity（Ah） 129 3-4.2V，Over 44
Rated voltage（V） 331.2 Unit rated voltage 3.6V
Working Voltage Range（V） 276-381.8 92 strings and 3 combinations
Mass（kg） 357(Without water cooling) 390kg(With water cooling)
Environmental temperature When placed in the required environment,
requirements for battery -20℃-50℃ the life and performance are not
packs to withstand seriously affected.
Cooling mode water cooling
65
Protection level IP67
 Power battery
Technical parameters of power battery
Items Parameters Remarks
Charging: 0-55 (-20 ~0 C, start heating, start
charging after heating to the rechargeable
temperature of the battery); Discharge: -20-55 (-20
Working temperature requirements -20℃～55℃ 20 C, the battery pack requirements can be used to
reduce performance and power, specific values can
be calibrated according to the actual capacity of
the battery.）
Slow Charging Time(h) 14

Fast Charging Time 30min charge from 20% to 80%

SOC Discharge window 97% 0%-97%（BOL）

Full discharge window is required to meet this
Continuous discharge power（KWh） ≥53
requirement at room temperature.
It lasts for 30 seconds and requires the full
Peak discharge power（KWh）
≥105 discharge window to reach this target at room
（SOC≥20%）
temperature.
Minimum rechargeable temperature and
Slow charging：0℃/10KW SOC 50% 10s
power of battery system
Minimum discharge temperature and power
66
-20℃/10KW SOC 50% 30s
of battery system
 Power battery
External structure of power battery

Maintenance
switch device

67
 Power battery
Power Battery Connector
动力电池接插件
32 pin low voltage Charging interface
interface to branch box

12 pin low voltage

interface
Coolant inlet

Coolant outlet

68
 Power battery
Power Battery 12 PIN Port Definition

Terminal Definition

D Precharging relay control 12-

E Motor Controller Relay Control 12-

F Slow Charging Relay Control 12-

G Fast Charging Relay Control 12-

Motor Controller Relay Adhesion Detection
K
-
Adhesion Detection of Slow Charging Relay
L
+
Adhesion Detection of fast Charging Rela
M
+

69
Note: Unmarked terminals are empty!
 Power battery
Power Battery 32 PIN Port Definition
Terminal Definition Terminal Definition
1 12V power supply 16 The vehicle CAN-L
The Second Fast Charging
3 CAN-H 17
Temperature Detection Line+
Second Fast Charging Temperature
4 Fast Charge CAN-L 18
Detection Line-
The First Fast
5 Charging Temperature 19 Power Supply GND
Detection Line+
The First Fast
Fast Charging Connection
6 Charging Temperature 20
Confirmation 2
Detection Line-
7 Power Supply GND 21 Collision signal
Fast Charging CAN
11 22 High voltage interlock+
Shielding Ground
Vehicle CAN Shielding
12 23 High voltage interlock-
Ground
14 12V power supply 27 Ignition awaken
70 Fast Charge Awaken/Slow Charge
15 Vehicle CAN-H 31
Awaken
Power battery
Power Battery Fault Indication
Indicator light/alarm Lighting
Reason
light state
Low power
Too Low Power Battery
indicator flashing
Volume
(red)
Power battery
Insulation performance of
insulation Always
power battery is lower than
fault alarm on.
extreme value
light (red)
Power battery
Always
fault alarm Power Battery Fault
on
light (red)
The power supply is in "ON"
Power battery
Always state and the high voltage
cut off alarm
on power system is
light (yellow)
71 disconnected.
Power battery
Common failures of power batteries

Fault phenomenon Suspicious location

1.Incorrect or damaged installation of maintenance switch
device
Power Battery Cut-off Alarm 2.Loosening or Damage of High Voltage Wire Harness of
Lighting Power Battery
3.Internal fault of power battery

Power Battery Fault Alarm 1.Wiring harness fault

Lighting 2.Internal fault of power battery

72
 Power battery
Power Battery Storage Requirements
动力电池存储要求
 n order to make the batteries in the best condition, please use external charging device
regularly to charge the batteries. It is recommended that the batteries be fully charged at
least once a week.
 Vehicles should be placed in a ventilated, clean, dry, cool and non-corrosive environment
when they are out of service for a long time.
 Direct sunlight and rain should be avoided.
 Keep away from heat source (temperature higher than 50 C).
 Storage temperature should not exceed the range of - 20 - 40 C.
 The storage charge is between 40% and 80%.
 Make sure all electrical appliances of the vehicle are turned off before placing them.

73
 Power battery
Power Battery Placement Requirements

Other items
power
Battery power
Power battery Battery

74
 Power battery
Emergency Response: When Power Battery Fires

 Power back the vehicle to OFF block and disconnect the 12V battery if conditions permit;
 Disconnect the maintenance switch device;
 Look for fire extinguishers nearby (do not use water-based extinguishers);
 If the vehicle is on fire and the fire is small and slow, please use a dry powder fire
extinguisher and immediately call for help.
 If the fire is large, rapid development, please immediately away from the vehicle, call the
fire telephone waiting for rescue.

75
 Power battery
Emergency Response: When Power Battery Leaks
 Please power back the vehicle to OFF gear, and disconnect the 12V battery and the
maintenance switch device when conditions permit.
 In case of a small amount of leakage, please keep away from the fire source, put it in an airtight
container after adsorption with an absorbent cloth or incinerate it. Please wear acid-proof and
alkali-proof gloves before operation.
 In case of a large amount of leakage, please collect them uniformly and treat them as hazardous
chemicals. Calcium gluconate solution can be added to deal with the generated HF.
 In case of accidental contact with the leaked liquid, the body should be immediately washed
with plenty of water for 10 to 15 minutes. If there is pain, the body can be coated with 2.5%
calcium gluconate ointment or soaked with 2% ~ 2.5% calcium gluconate solution for pain
relief. If there is no improvement or discomfort symptoms, please seek medical advice
76
immediately.
Maintenance switch device
maintenance switch device（MSD）
 The repair switch is located below the auxiliary
instrument panel.
 In order to protect the safety of the technicians who
repair vehicles under high voltage environment or to
respond to emergencies, the connection of high voltage
circuit can be quickly separated, so that maintenance
and other work can be carried out in a relatively safe
state (such as external short circuit protection), and high
voltage power needs to be disconnected during
maintenance.
Note: Before disassembling the high-voltage components,
77
disconnect the maintenance switch first!
Junction box
Summary
 The junction box is installed in the front cabin of
the vehicle.
 The junction box mainly distribute high-voltage
electrical distribution and short-circuit protection.
High-voltage electrical appliances include chargers,
water heating PTC, air conditioning compressors,
motor controllers, mainly including fuses and so on.

78
 Junction box
Internal structure of junction box

DCDC fuse(25A) Charger fuse (25A)

High Voltage PTC fuse(25A)

Interlock Switch

AC fuse (40A)

79
 Junction box
Internal schematic block diagram of junction box
junction box

Fast Charging Relay

Fast charge

Fast charge

Slow Charge Fuse Slow Charging Relay

Slow
charge

Slow
charge

Fuse

Precharge
resistance

Fuse

Main
Precharge
resistance relay
Interlock-

Precharge control Fuse

Main control
Fast Charging Adhesion Detection
Slow charging control
Fast Charging Adhesion Detection
Slow Charging Adhesion Detection
Fast charge control
Interlock
80
 Junction box
External structure of junction box
Charging +,
HV+、 HV- Charging-
Connecting power DC fast charging
battery socket
AC+, AC-
Connecting
compressor

PTC+, PTC-
Plumbing PTC

Low Voltage
Caontroal Interface
MC+ (purple), MC-
Connecting
(black)
Charger + DCDC
Connecting Motor
Assembly
Controller
81
 Junction box
Low Voltage Communication Interface of Junction Box
Low voltage
control Termi
Termi
Definition nal Definition
nal

High voltage Slow Charging Relay

A F
interlock + Control 12-
High voltage Fast Charging Relay
B G
interlock- Control 12-
Motor Controller
C Power Supply 12V K Relay Adhesion
Detection -
Precharging relay Adhesion Detection of
D L
control 12- Slow Charging Relay +
Motor Controller Fast Charging Relay
E M
Relay Control 12- Adhesion Detection +

82
 Junction box
Internal relay control
 Junction box is sucked by 12V low voltage control high voltage relay. BMS starts switch ON
signal and VCU state according to one key. BMS controls main and positive relay for power up
and down control. The order of pre-charging and total positive relay suction is as follows:
Precharge
Precharging relay completed Precharging relay
Main relay suction
suction disconnection
 BMS controls closed slow charging circuit relay according to charging connection status of charger and
VCU charging enabling signal. The charging circuit is cut off according to the temperature state of the
battery pack. In the slow charging process, VCU is not allowed to send high-voltage power-on
commands.
 When charging fast, BMS is awakened, and the VCU charging enabling signal signal is received when the
battery system is in trouble-free state. The fast charging relay is sucked in and entered the fast charging
process. In the fast charging process, VCU is not allowed to send high-voltage power-on commands.
83
 Junction box
Internal relay detection

 When power on, BMS judges whether the relay is adhering by reading the state of the

relay when power on or off.

 When power down, BMS detects the nominal resistance of MCU terminal. When the

relay adheres, it can detect the nominal resistance value and judge it as adhesion. If

the nominal resistance value can not be detected, it will not adhere.

84
 4 Motor Control System

85
 Motor Control System
Summary
 Motor control system is a direct participant in vehicle control, mainly composed of
motor controller, drive motor and so on. It realizes the conversion between electrical
energy and mechanical energy.
 The main functions are as follows:
- Torque Analysis to Realize Vehicle Driving
- Measurement of Speed and Pole Position of Driving Motor
- Measurement of Working Temperature of Driving Motor and Motor Controller
- Function of fault diagnosis and calibration for oneself
- Energy Feedback Converts Vehicle Kinetic Energy into Electric Energy to Charge
Power Batteries

86
 system composition
Motor Controller
 The motor controller is installed in the front cabin of the
vehicle.
 Its main functions are as follows:
- Receiving and parsing VCU torque instructions, transporting
three-phase AC to drive motor, driving vehicle operation
- When driving the motor, the conversion between HVDC and
three-phase AC can be realized, and the three-phase AC phase
sequence can be changed.
Note:
- When braking, three-phase alternating current is converted
The vehicle regress is through the motor
to high-voltage direct current to realize energy recovery.
controller to change the alternating
- Receive and output motor speed, magnetic pole position,
current phase sequence control motor
temperature signal
reversal!
87
 system composition
Technical parameters of motor controller
Items Parameters

Model KM7035W03

Working Voltage Range（VDC） 280-420

Rated input voltage（VDC） 345

Maximum output voltage（VDC） 380

Nominal output capacity（KVA） 100

Maximum capacity（KVA） 150

Continuous working current(A) 130

Short-term working current(A) 330

Maximum working current(A) 380

Over current protection(A) 360

88
 system composition
Technical parameters of motor controller

Items Parameters
Over voltage protection（VDC） 460
Under voltage protection（VDC） 240
Over heat protection(℃) 85
Working temperature range(℃) -40-125
Control power supply voltage（VDC） 12
Mass（kg） 15
Cooling mode/coolant flow rate Liquid cooling /8
Work system S9
Insulation level H
Protection level IP67
89
 system composition
External structure of motor controller

MC+ (purple), MC-

(black)
Junction box

Low Voltage
Communicati
on Interface

Coolant
outlet

Three-phase electricity:
冷却液近水口 connected to motor
U (yellow), V (green), W (red)

90
 system composition
Low Voltage Communication Interface of Motor Controller
Termina
Definition Terminal Definition
l

1 Constant power supply 12V+ 22 Motor Rotary COS- Signal S4

2 Constant power supply 12V+ 23 Motor Rotary COS+ Signal S2

3 High voltage interlock + 24 Constant power supply ground

4 IGN Power Supply 25 Constant power supply ground

5 S2/R4 Rotary Shielding Signal 30 CAN Bus shielding layer

6 R1/R2 Rotary Shielding Signal 31 CAN Bus interface CAN_L

Motor Temperature Signal

9 32 CAN Bus interface CAN_H
TEMP_L

Motor Temperature
10 33 S1/S3 Rotary Shielding Signal
SignalTEMP_H

Motor Rotation Excitation

11 34 Motor Rotation SIN- Signal S3
Signal R2

Motor Rotation Excitation

12 35 Motor Rotation SIN+ Signal S1
Signal R1
91
14 High voltage interlock -
 system composition
Driving motor

 EM11 electric vehicle adopts permanent magnet

synchronous motor, which consists of stator and rotor.
The rotor is permanent magnet. When three-phase AC
is connected to the stator winding of the motor, the
AC rotating magnetic field is generated, and the rotor
rotates under the action of magnetic force.
 A resolver and a temperature sensor are installed
inside the motor.
 The resolver detects the position and speed of the
magnetic pole.
 Temperature sensor detects motor temperature.
92
 system composition

What are the advantages of permanent magnet synchronous motor?

1. Simple structure.

2. Small volume.

3. Light in weight.

4. Low dissipation factor.

5. High efficiency.

93
 system composition
Technical parameters of motor
Items Parameters
Name Permanent magnet synchronous motor
Model YTD050W07
Connection mode Y
Phase number 3
Rated voltage 244V
Continuous rating 53KW
Continuous torque 127Nm
Continuous torque 4000rpm
Maximum speed 9000
Peak power/duration 95KW/1min
Peak Torque/Duration 260Nm/1min

94
 system composition
Technical parameters of motor

Items Parameters
Locked rotor torque 260Nm
Speed Control Accuracy 1%
Torque Control Accuracy Below 200Nm 5Nm/ above 200Nm 3%
Speed response time 0-9000rpm：2s
Torque response time 0-260Nm：520ms
Working temperature range -40℃-125℃
Insulation level H
Working mode S9
Cooling mode Liquid cooling
Weight (kg) 65

95
 system composition
External structure of motor

Coolant inlet
U (yellow), V (green),
W (red)
Connecting Motor
Controller
Low Voltage
Communication
Interface

Coolant outlet

Note:
When three-phase electrical connection, it is strictly forbidden to connect
96 incorrectly.
 system composition
Motor Low Voltage Communication Interface
Termi Termi
Definition Definition
nal nal

Rotation excitation Spinning Cosine

A F
positive signal R1 Negative Signal S3

Rotation excitation Temperature signal

B G
negative signal R2 TEMP_H

Rotary sinusoidal Temperature signal

C H
signal S2 TEMP_L

Rotation sinusoidal
D L Shielding ground
negative signal S4

Rotation cosine
E sinusoidal signal M Shielding ground
S1

97
 system composition
Rotation transformer

 Rotation transformer is a kind of electromagnetic sensor, which consists of stator and

rotor. It is used to measure the position and speed of the magnetic pole of the motor.
 The resolver is installed at the motor end, and it is coaxially installed with the motor
rotor. The resolver generates sinusoidal and cosine voltage through the change of
magnetic field when the rotor rotates. The position information of the motor's rotor can
be obtained by analyzing the encoder in the motor controller, and the speed and pole
position of the motor can be determined.
Note:

Rotation transformer is a precise part. It can not be disassembled and repaired. If it is

damaged,
98
the motor should be replaced.
 System control
Principle block diagram

HV+ MC+ U

Power Junction V
battery box
HV- MC-
Motor W Driving
Controller Speed/pole
motor
position
CAN bus
VCU Temperature

Combined
instrument

99
 System control
Motor control
 Vehicle status is "READY". VCU collects information of shift knob and electronic
acceleration pedal opening. According to driver's intention, it calculates the current
status of vehicle power and power battery, and sends torque demand to motor
controller through CAN bus.
 The motor controller receives the torque command and controls the output of three-
phase electricity according to the current motor temperature and magnetic pole
position information, so as to realize the forward or backward movement of the vehicle.
 When the vehicle brakes, the motor converts the kinetic energy of the wheel into
electric energy. At this time, according to the position sensor signal of the brake pedal,
the VCU controls the motor controller to convert the three-phase electricity into high-
voltage direct current for charging the power battery and realizing the brake energy
100
recovery.
 Cooling system
Cooling system
 The cooling of motor and motor controller is mainly composed of cooling fan, cooling

pipeline and electronic water pump.Its main function is to drive the motor, motor

controller for cooling.

Expansion kettle

Motor
Note:
radiator cooling
Motor and motor controller
fan
cooling and power battery
Electronic Motor
water pump controller cooling belong to different
cooling systems!
101
 Cooling system
Cooling system components

Terminal Definition
Pump relay output
Electronic water pump: 1
power supply
Located behind the front chamber 2 -

vacuum tank, controlled by VCU 3 -

102 4 Electrical grounding
 Cooling system
冷却系统部件
Cooling system components

Cooling fan: Terminal Definition

Located behind the radiator in the front cabin, 1 Low Speed Relay Output
the VCU controls the high and low speed relay
2 High Speed Relay Output
to realize the high and low speed operation of
the fan. 3 Electrical grounding
103
 System Fault Display
Fault alarm light

Lighting
Alarm light Reasons
state

Overheat
alarm light Excessive
Always
for motor and temperature of motor
on
controller or controll
(red)
Fault alarm
light for
Motor or controller
motor and flashing
fault
controller
(red)
104
 Fault detection
Common Faults in Motor Control System
Fault phenomenon Suspicious location
1.Insufficient coolant
2.Excessive ambient temperature
3.Too long working hours
4.Short Circuit Heating of Electric Machine Wading in
Water
Overheat alarm light of 5.Electronic water pump fault (control line fault,
motor and controller electronic water pump damage)
6.Cooling Pipeline Fault
7.Cooling fan fault (control line fault, fan damage)
8.Radiator fault (blockage)
9.Motor or controller fault
105
10.CAN Communication Fault
 5 Vehicle Control System

106
 Vehicle Control System
Summary

Vehicle control system is mainly composed of vehicle controller, motor and motor

controller, battery and BMS, charger, air conditioning controller, cooling system, vacuum

booster system and so on. Each system influences each other. In order to ensure the safety,

comfort and maneuverability of the vehicle in the course of driving, balanced control

strategy should be considered comprehensively and controlled reasonably from all aspects.

The system enables the vehicle to achieve the desired optimal operation state in the course

of operation.

107
System composition
Vehicle Controller (VCU)

 The VCU is mounted on the floor under the

accessory seat.
 VCU is the control core of the vehicle. It
collects acceleration pedal signal, brake pedal
signal, gear signal and other components
signal. After making judgment based on the
above signals, it controls the lower parts to
perform relevant actions to drive the vehicle.

108
System composition
Terminal Definition of Vehicle Controller

Definination
Terminal Definination Terminal Terminal Definination

Accelerator pedal 2 power Fan High Speed Relay

1 Battery power supply 6 13
supply Control
5V Power Supply for Brake Relay control of motor cooling
2 IGN Power Supply 7 14
Vacuum Sensor water pump
5V Power Supply for Acceleration pedal 2
3 cruise control - 9 16
Atmospheric Pressure Sensor grounding
Brake pedal angle sensor Normally Closed Signal of Acceleration pedal 1 position
4 10 17
ground Brake Switch power supply

109
Brake Switch Frequently Open
5 Acceleration pedal floor 1 11 18 Brake pedal angle sensor 5V
Signal
System composition
Terminal Definition of Vehicle Controller
Terminal
Definination Terminal Definination Terminal Definination

Fan Low Speed Relay

20 DC fault signal 34 43 CAN-L
Control
Charging wake-up Atmospheric
21 36 Shift switch signal 1 45
input pressure signal
Grounding of Brake
22 Start signal 37 Shift switch signal 2 53
Vacuum Sensor
Atmospheric
27 Ground connection 38 Shift switch signal 3 61
pressure sensor
Brake Vacuum Sensor Vacuum pump relay
29 39 Shift switch signal 4 75
Signal control
Acceleration pedal 2 Brake pedal angle DCDC Enabling
30 41 78
position signal sensor signal Signal号
Acceleration pedal
110 31 CAN-H 42 80 Cruise control +
plate 1 position signal
 System composition
Electronic acceleration pedal

 An electronic acceleration pedal position sensor is

integrated in the electronic acceleration pedal.
 The position sensor of electronic acceleration pedal
is connected with VCU through hard wire. VCU
supplies 5V power supply to the sensor. When the
acceleration pedal is pressed down, the sensor
outputs two sets of signals to VCU at the same time
to ensure the reliability of the output signal.

111
 System composition
Terminals Definition of Electronic Acceleration Pedal Connectors
Terminal De,finition
Acceleration pedal 2 position
1
signal
Acceleration pedal 2
2
grounding
Accelerator pedal 2 power
3
supply
Acceleration pedal plate 1
4
position signal
Acceleration pedal 1
5
grounding
Acceleration pedal 1 position
6
power supply
112
 System composition
Shift knob
 The shift knob of EM11 electric vehicle has automatic lifting
function.
 VCU real-time acquisition of gear knobs D, N, R status (hard
wire), through the CAN bus sent to the combined instrument
to display gear.
 Only when the brake signal is received can the gear be
replaced normally.
Items Parameter
Working voltage 9-16V
Standby current <0.5mA
Working temperature -40℃-125℃
Storage temperature -40℃-150℃
113
 System composition
Terminals Definition of Shift Knob Connector

Terminal Definition Terminal Definition

Backlight
1 - 7
input

2 Phase signal 1 8 P signal

3 Phase signal 2 9 Braking signal

IGN Power
4 Phase signal 3 10
Supply

5 Phase signal 4 11 -

electrical Battery power

6 12
grounding supply
114
 System composition
Shift knob lifting control

 When the vehicle is in the "ON" state,the knob rises and enters the P gear.

 When the vehicle is powered off, the shift knob is currently in non-N gear, then the

shift knob is delayed for 10 seconds, and then the knob falls into dormancy. If the

vehicle is powered off in N gear, the shift knob falls into dormancy after 10 minutes

of delay.

115
 System composition
Brake pedal angle sensor
 Brake pedal position sensor provides brake pedal opening and transmits signal to

VCU through hard wire to participate in brake energy feedback control.

116
 System composition
Terminals definition of Brake Pedal Angle Sensor Connector

Terminals Definition

1 sensor

2 -

3 -

Brake pedal angle

4
signal

5 5V power supply

6 -

117
 System composition
Constant speed cruise button

Button Function

Turn on constant speed cruise

Turn off constant speed cruise

Cruise State Recovery Button

RES+ Cruise status can be set speed
increase
Cruise speed setting button
SET- Cruise state can set speed
reduction
118
 System composition
VCU control block diagram
Atmospheric
Start signal Atmospheric pressure
PEPS Controller pressure
sensor
Gear signal Vacuum degree
Brake Vacuum Sensor
Gear switch DCDC enabllation
Normally and failure
Brake switch open/normally closed
Charging Charger + DCDC
awaken
Brake pedal angle Pedal angle VCU
sensor Motor cooling water
pump
Acceleration pedal
sensor Vacuum pump
cruise control
Steering wheel button
Cooling fan
CAN Communication
System
119
 System control
Vehicle information display
After the signal received by VCU is processed, it is sent to the ICU and displayed in the
form of pointer, number or indicator light to provide the driver with in-car status
information. The information displayed on the ICU is partly sent out after the external
signal collected by VCU is processed, and the other part is directly collected by the ICU on
CAN bus.The information processed by VCU is as follows:

Vehicle start-stop control

When the driver is in N gear, the vehicle enters the no-power output mode and naturally

glides until it stops.When the driver is in P gear, if the vehicle is stationary, then P gear is

executed and the vehicle has no power output.When the VCU detects the charging

connection signal, prohibit the vehicle to drive.

120
 System control
Vehicle power distribution
According to the driver's intention (brake pedal switch and depth, acceleration pedal

depth), the allowable discharge power of BMS, the maximum executable torque of the

motor controller, the current speed, gear position and the fault level of the whole

vehicle, VCU issues target torque, gear position status and motor operation mode to the

motor controller based on comprehensive judgment.Motor controller according to the

target torque, stop state, motor operation mode to perform positive and negative drive

or power generation.
121
 System control
Vehicle information display
After the signal received by VCU is processed, it is sent to the ICU and displayed in the form of pointer, number or
indicator light to provide the driver with in-car status information. The information displayed on the ICU is partly
sent out after the external signal collected by VCU is processed, and the other part is directly collected by the ICU
on CAN bus.The information processed by VCU is as follows:

System Signal name Processing mode

Gear Gear signal/fault Information processing of gear collected by VCU is sent to ICU
Key Key signal Information processing of gear collected by VCU is sent to ICU
Vehicle High According to the comprehensive judgment of the fault level of each part, the system fault level is sent
System fault level
Voltage System to the ICU
According to the DC feedback fault level and the detected low voltage voltage value to determine
DCDC DC state
whether DC fault

Vacuum pump Vacuum pump state According to the working condition of vacuum pump, feedback the fault state of vacuum pump

Cruising state Whether the cruise is started or not

cruise
Cruise target speed Feedback of target cruise vehicle speed based on analog quantity of cruise key
When the brake pedal is pressed for more than 10 minutes, the brake signal time-out fault will be
Brake
122 pedal Brake signal timeout
reported.
System control
Fault Handling Strategy
The main purpose of fault treatment is to ensure the safety, reliability and stability of the vehicle, and
to adopt a hierarchical fault treatment strategy.

Level 3 fault: fault that needs Level 2 fault : power

Level 1 fault：Alarm only
to be cut off reduction fault

VCU receives the level 3 fault When VCU receives the level 2 When the VCU receives the
uploaded by MCU or BMS, and if fault of MCU or BMS, it will level 1 faults of motor
VCU cannot receive all signals on report the level 2 fault of the controller and BMS, it will
CAN network, it will report the report the level 1 faults of the
whole vehicle.VCU will quickly
level 3 fault of the whole vehicle,
reduce torsion to 50% of whole vehicle, and level 1
rapidly drop the torque, and issue
required torque.The level 2 faults will not be limited by
the instruction of cutting off the
fault can be recovered in real torque. level 1 faults can be
high voltage at the same time. The
time. recovered in real time.
level 3 fault CAN only be restored
after being powered up again.
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 System control
Gear control function

The VCU determines the actual gear output by detecting the gear signal of the gear
controller and combining with the current running state of the vehicle.
Effectiveness judgment of gear action: It is required that the target gear stay time is
more than 200 ms before the gear action is considered effective.
Pull in P gear: Pull in P gear from any gear, in addition to requiring more than 300 ms
residence time in P gear, must meet the current actual twist.The moment is close to 0,
and the motor speed is close to 0.
Pull in R or D gear: Put in R or D gear from any gear, except that the residence time
in target gear is more than 200 ms.The actual torque should be close to 0.
Insert N gear: Insert N gear only to meet the residence time of more than 300 ms in
the position of N gear.
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 System control
Energy feedback function
Driving Motor Power
Wheels Differiencial Decelerator
motor controller battery

Mechanical Electric
energy energy

 Taxiing Feedback: Currently the vehicle is in Ready state, if the speed is greater than 10km/h, and
the acceleration pedal and brake pedal are loosened at this time.Then the vehicle will enter the
taxiing feedback mode, at this time, compared with the situation without energy recovery, there
will be a more obvious sense of deceleration.
 Brake Feedback: Currently the vehicle is in Ready state. If the speed is greater than 10km/h and
the brake pedal is pressed at this time, the vehicle will enter.In the braking feedback mode, there
will
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be a more obvious sense of deceleration than in the case of no energy recovery.
System control
Anti-theft and diagnostic function
PEPS detects the key and stepped ON the brake
pedal, then control ON relay suck, VCU
requirements ON signal detected and PEPS
security certification, send security authentication
codes to VCU PEPS, VCU to receive feedback
information to PEPS after matching the
authentication codes, PEPS after receiving the
signal control relay and ST, VCU ST signal
detected vehicle level fault is detected at the
same time send PEPS, start signal PEPS Ready
signal is disconnected ST back ON.
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 System control
Other accessories control
 DCDC control: under normal circumstances, DCDC will be started within 5s after the
normal upper voltage, and the output voltage is about 13.8v.
 Air conditioning control: VCU gives the maximum output power of air conditioning
according to the maximum output power of battery pack and the current demand power
of DCDC and MCU. The air conditioning limits the output according to this maximum
power, so as to ensure that the operation of air conditioning will not affect the power
output of the whole vehicle.
 Cooling fan control: when the motor, MCU and air conditioner have cooling requirements,
VCU will comprehensively judge and control the opening and closing of high and low
speed fans according to fan requirements of the three (high-speed fan is preferred).

127
 System control
Other accessories control
 Vacuum pump control: when the vacuum degree in the vacuum tank is insufficient, VCU controls
the vacuum pump to ensure that the brake pedal has sufficient braking power at any
time.Normally, the brake pedal is pressed and the vacuum pump is started.The vacuum pump shall
not be operated for 2min during each uninterrupted working time, otherwise the instrument will
report the vacuum pump failure, and the alarm shall be restarted after 30s under power.
 Control of water pump: when the vehicle is in the Ready, and the tests on the R/D block, VCU
control open water pump, or when the MCU temperature 40 ℃ or higher, VCU will control open
water pump;When the above two conditions are not met, the pump is closed.
 Creep function: when the vehicle is Ready and the road is flat, hang the gear in D or R gear and do
not step on the accelerator pedal. The vehicle slowly accelerates and the final speed remains at a
uniform speed of 4~6km/h.
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 System control
Other accessories control
 Charging control:
 Slow Charging: VCU detects that the charging wake-up signal of OBC is activated, and
then receives the connection signal of charging gun sent by OBC as the connection state,
and if BMS has no primary failure, it sends charging enable signal to BMS, allowing BMS
to charge. At any time, the VCU finds that the DC/DC can not work due to a fault and will
stop sending charging power.
 Fast charging: The VCU detects that the charging wake-up signal of the fast charging gun
is activated. At this time, it receives the connecting signal of the charging gun sent by
BMS as the connecting state and sends the charging enabling signal to BMS to allow the
battery to charge if there is no primary failure in BMS. At any time, the VCU finds that the
DC/DC can not work due to a fault and will stop sending charging power.
129
Fault detection
Common Faults of Vehicle Control System

Fault phenomenon Fault phenomenon

1.Wiring harness fault
2.High Voltage Interlocking Fault
System fault indicator
on, "READY" indicator 3.Motor controller fault
off
4.Driving motor fault
5.Fault of Vehicle Controller
1.Damage of Wire Harness of Fixed-speed Cruise
Switch
Fixed-speed cruise
function failure 2.Damage of Fixed-speed cruise switch
3.Vehicle controller fault
130
 Fault detection
Common Faults of Vehicle Control System

Fault phenomenon Fault phenomenon

1.Wiring harness fault
2.Electronic Acceleration Pedal Failure
Acceleration anomaly 3.Fault of Driving Motor System
4.Motor controller fault
5.Fault of Vehicle Controller
1.Wiring harness fault
2.Brake switch fault
Unable to shift gears
3.Shift knob malfunction
4.Vehicle controller
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 6 High voltage

132
 High voltage
Summary
Electric vehicle contains high voltage part, power
battery voltage can reach 386V (DC). When
overhauling high voltage parts, it poses a serious
danger to people. Pay attention to high voltage
warning signs.

Note：
When checking and repairing the high-voltage electrical
of electric vehicles, we should strictly follow the Hanteng
Automobile "Hybrid Electric Vehicle and Pure Electric
Vehicle Maintenance Safety Code"!
133
 High voltage
high voltage component

Power battery Junction box Motor Controller Charger

Air conditioning
134
Motor Plumbing PTC
compressor
 High voltage
High Voltage Wire Harness Assembly

Fast charging Fast charge

PTC cable cable socket

Slow charging Slow charge Junction box to Compressor cable

socket cable charger cable

Junction headstock
box direction
Fast charge socket
Grounding cable

Junction box to
DC Bus Cable Motor three-phase
motor controller
cable
cable

Note：
135 All high voltage cables are orange!
 High voltage
High Voltage Cable Structure
 Single-wire High Voltage Cable Structure

 Double-wire High Voltage Cable Structure

136
 High voltage
Unlocking and Assembly of High Voltage Connectors
 Air conditioning compressor, charger end to junction box connector:

Buckle Unlock Position 1. Press the unlock position first.

2. After the buckle is removed from the convex
1 position, the plug is pulled out.
3. Assembly: After the plug is aligned with the
direction and position of the socket, insert
the plug forcefully, hear the "click" sound,
2

confirm that the buckle completely enters the

buckle, and the assembly is completed.

137
 High voltage
Unlocking and Assembly of High Voltage Connectors
 Junction box terminal air conditioning compressor, PTC high-pressure
connector:
Secondary Lock 1. First, pull out the position of the secondary lock slider.
Primary Lock Location
Position
2. Press the next lock position and pull out a section so that it
2 4
1

leaves the buckle.

3. Press the second lock position to pull the plug out.

4. Assembly: After the plug is aligned with the direction and

3

position of the socket, insert it forcefully, push forward again

5

when you hear the "click" sound, and push forward the
Secondary lock slider
second lock slider when you hear the "click" sound again.
138
 High voltage
Unlocking and Assembly of High Voltage Connectors
 DC Bus Cable Connector, Branch Box End Fast Filling Connector, and Maintenance Switch:

Lock catch Pull rod

1. First pull up the lock buckle;

2. Then pull the pull rod along the direction shown in figure 2 and 3 to the end of
the plug, and pull the plug upward.
3. Assembly: after the plug is aligned with the direction and position of the socket,
insert it forcefully, pull the pull rod along the direction 2 and 3 shown in the
139
figure to the top of the plug, and press the lock button.
 High voltage
Unlocking and Assembly of High Voltage Connectors
 The motor controller end is connected to the cable connector of the junction box
and the three-phase cable connector of the motor.

3 1. Pull out the lock pin first.

2. After pulling out the lock, pull out the connector.

2

3. Assembly: After the plug is aligned with the

direction and position of the socket, insert it

forcefully, set the lock to the limit position and

Lock Locking
install the lock stop pin lock.
catch pin

140
 High voltage
High voltage interlock
 Maintenance Switch Device(MSD): When the maintenance switch device is in place, the

salient of the maintenance switch press the interlock

switch in the socket to close the interlock switch,

otherwise the interlock will fail.

Interlock Convex
switch platform Note:
 High Voltage Connector： 1.The high voltage connector and socket of the
whole vehicle have interlocking mechanism, and
are interconnected!
2.If the interlock fails, the high voltage cannot be
Interlocking Interlocking
socket plug mounted, and the fault indicator light is lit!
141
High voltage
High Voltage Interlocking Structure Block Diagram
22 23
BMS

K 3

Battery charger Motor Controller

J 14

J2 A

Air conditioning J3 B
Junction box
compressor

142
 High voltage
Insulation detection

 In the high voltage electrical system, the positive

terminal and negative terminal terminal of electrical
equipment (such as power battery) and their connecting
wiring harness have insulation resistance to the shell and
the body respectively. If the resistance is too small, the
insulation will fail.
 According to the requirements of national standard, the
insulation shall be not less than 500 Ω/V.
 To measure the insulation resistance, the insulation meter
should be used after disconnecting the power battery
maintenance switch.
143
 High voltage
Insulation Detection of High Voltage Cable

1. Shielding internal conductors;

Using measurement adapters !

2. Ground terminal of shielding vehicle;

3. The internal conductor is connected to the

ground end of the vehicle (measuring voltage:

Measuring voltage Insulation resistance value

500V/1000V DC voltage). 500V 0.1-50MΩ

1000V 0.1-100MΩ
144
 High voltage
Insulation Detection of Motor Stator
Connector housing/shielding housing
 Standard values:
Measuring tool

Measuring
voltage

Measuring voltage Insulation resistance value

stator
500V 0.1-50MΩ
Fault resistance
1000V 0.1-100MΩ
Insulation resistance measurement

Measuring For example

Note：
voltage

If the measured value is lower than the standard

temperature value, the insulation failure will occur and the faulty
coefficient

Time
parts need to be replaced!
145
 Electrical hazards
How much electricity can the body carry?

ￚ 5mA : It creates a numbness that can

divert electricity.
ￚ 10mA : The current limit is derived
and the body begins to contract.
ￚ 30~50mA : Respiratory arrest,
ventricular fibrillation.

ￚ 80mA : Fatal value。

Contact voltage

146
 Electrical hazards
Internal resistance of human body

 Blood in all blood vessels is a good conductor.

 Different contact points in electrical accidents have

different effects on human body.

Note：

 For the high current caused by high voltage, the

corresponding resistance value in human body is

very low!
147
 Electrical hazards
Grounding fault of high voltage components
 At this time, the human body contacts
the two ends to form a potential
difference, and there is electric current
through the human body, which is
harmful to the human body.

Note：
Grounding Grounding
When the high voltage components are fault fault

deformed and the vehicle collides, it is

forbidden to touch the vehicle without

148
ensuring safety.
 Electrical hazards
When the potential of each high voltage component is balanced
 At this time, the human body
contacts both ends of the
potential balance, and
maintenance personnel are
relatively safe.

Note：
If the grounding is disconnected at this Grounding Grounding
fault fault
time, the potential difference between the
two ends of human contact will be formed,
Potential equilibrium
so during the overhaul, it is necessary to
ensure that the grounding is good！
149
 Electrical hazards
Hazards of penetrating current

 If a person is bridged between two different

potentials, an electric current flows through
Resistance inflow contact
their body, and the magnitude of the current is R resistance
affected by different factors.
 It can lead to coma, respiratory and heart U R Body resistance
failure and death.

Note： Resistance outflow

R contact resistance
 More than 25V ac, more than 60V dc are dangerous!

 The lower the frequency of the ac voltage, the higher the

danger!
150
 Electrical hazards
Short circuit hazard
 When short-circuit arc formation, its temperature may reach 4000 ℃ above, depending on

the time of the voltage and current。

 The following causes may cause arcing

- Loose or oxidized contacts, tight screws,

- Insulation defect,，

- Using the wrong wire connector，

- Damp/dirty (electrically conductive dust)

- Foreign bodies, small pieces of metal falling off

 Arc effect: effect on hearing, thermal effect,

151 toxic effect。

 Electrical hazards
Electric shock and accident consequences

All of the body's functions

Shock effect Chemical effect
Current inlet and and muscle movements
are controlled by the brain
outlet position burns Blood and cell fluids
Get rid of the shock through electrical
and carbonization, are electrolytes, stimulation of the central
response below the
nervous system When the
and internal burns which can be broken
threshold and the body is subjected to too
The result is kidney down The result is much electrical current, it
resulting risk of
severe poisoning, causes muscle spasms and
overload, which can
injury due to the brain can no longer
which can be
lead to death。 exert influence on muscle
uncontrolled detected only a few tissue.
behavior and days later, so it is
balance disorders. Heat effect highly latent。 Muscle stimulating effect

152
 Matters needing attention
Precautions for personal protection
 Wear overalls, insulating gloves,

insulating shoes, goggles, etc.,

and use insulating pads correctly.

 Maintenance tools must be use Insulating gloves Insulating shoes Goggles

 Strictly follow the requirements

for high voltage electrical

appliances, circuit inspection

operation. safety helmet Insulation tool Insulating pad

153
 Matters needing attention
Notes for high-voltage live inspection

 Do not open the junction box and the high voltage parts, otherwise there is a danger of

electric shock.

 Do not touch any input/output terminals of power battery, motor controller, drive motor,

charger, electric air conditioner compressor, PTC, or there is a risk of electric shock.

 The disconnected high-voltage connector shall be wrapped or treated with insulating

tape or other insulating materials, and shall not be exposed outside to prevent short-

circuit hazard.

154
 Matters need attention
High voltage electrical disassembly installation notes

 Only professional technicians can repair high-pressure parts and place hazard warning
signs 。
 Before disassembly and installation, the power supply must be set at OFF, the negative
terminal wiring harness of the battery should be disconnected, the MSD insurance
(maintenance switch) should be pulled out, and the disassembly should be carried out
after waiting for 5 minutes
 In the process of disassembly, it is forbidden for power batteries, motor controllers,
on-board chargers and other devices to suffer mechanical impact 。
 High voltage system components confirmed damage, need to be replaced as a whole,
unauthorized disassembly is strictly prohibited maintenance.
 Only after the inspection is completed and the identification on the high-voltage
wiring harness and high-voltage components is consistent can the connectors be
connected
155
 Rescue measure
What should you do if you find an electrocuter
 Your own security is the highest priority

 Keep calm. Think before you act

 Avoid direct contact with people who have been electrocutedCut off the power of

the electrical equipment immediately!(turn off the power of the whole vehicle or

disconnect the maintenance switch)

 Use non-conductive tools (wood, broomstick, etc.) to separate the casualty or

current conductor from the power supply

156
 Ask your emergency doctor for help!
 Rescue Measure
Rescue Measure

 Call the fire department!

 Do not inhale smoke!
 CO2, ABC or foam fire extinguishers shall be used to
extinguish the fire on the power equipment. Fire
blanket may also be used. It is prohibited to
extinguish the fire with water!
 Do not use CO2 fire extinguishers to put out fires for
people on fire (asphyxiation hazard)！

157
 Sample room

158
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