Deriving the Validation Protocol for Isolator Switches Used in Commercial Vehicles Ashok Leyland Technical Center

Format:

Conference/Event

Author/Creator:

Dhanesh, Dhanesh, author.

Contributor:

A, Thuyavan

Langu, VenkataSatish

Conference Name:

WCX World Congress Experience (2018-04-10 : Detroit, Michigan, United States)

Language:

English

Physical Description:

1 online resource

Place of Publication:

Warrendale, PA SAE International 2018

Summary:

AbstractAll automotive components undergo stringent testingÂprotocol during the design validation phase.ÂNevertheless, there are certain components inÂthe field which are seldom captured during design validation. One of these components is the battery isolator switch.ÂThis project aims at optimizing a validation methodology for this component based on field usage and conditions. The isolator switch is the main control switch which connectsÂand disconnects the electrical loads from the battery.ÂThis switch is used in the electrical circuit of theÂvehicleÂto prevent unwanted draining of battery when it is not needed and when the vehicle is in switched off. An electrical version of this switch uses electromagnetic coils to short the contacts. The failure mode being investigated is a high current load causing the input and output terminal to be welded. The instrumented isolator switch was fitted in a customer vehicle to acquire various parameters like coil voltage, coil current, battery voltage, contact voltage and contact current values during engine cranking with different state of charge (SOC) in the battery. Battery voltage and coil voltage values were found to be most critical factor affectingÂthe isolator switch performance, over a certain state of charge ofÂthe battery. There was a huge dip in battery voltage duringÂcranking the engine. To reproduce the same, the entireÂsetup was assembled with a suitable wiring harness with the engine to conduct the lab level simulation. Durability test was carried out at certain SOC to the corresponding coil voltage and contact current values observed in vehicle. Analysis of these tests showed that coil resistance and coil material used could lead to failure of the isolator switch. AfterÂthe design modification, revised design isolator switch samples were validated and achieved an improved life over the earlier design

Notes:

Vendor supplied data

Publisher Number:

2018-01-0128

Access Restriction:

Restricted for use by site license