Safe Pre-Charge and Break Sequencing Under 1,000V DC Potential
Managing millisecond-accurate pre-charge resistor bypass to prevent inverter DC-link capacitor inrush welding, coupled with isolated auxiliary contact welding diagnostics.
Pre-Charge Synchronization Algorithm
Monitoring DC link voltage until capacitor potential reaches 95% of battery voltage before commanding main contactor closure, limiting inrush currents under 10A.
- Zero contactor welding incidents over 100,000 operational cycles.
- Pre-charge cycle completion in under 250 milliseconds.
- Active DC link discharge under 60V in less than 2.0 seconds post-crash.
- Diagnostic economizer feedback detecting sticking contacts.
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