Definitions/Meaning
EV5.7.1 A circuit that ensures that the intermediate circuit is pre-charged to at least 95% of the actual TS accumulator voltage before closing the second AIR must be implemented. Therefore, the intermediate circuit voltage must be measured.
General Requirements
EV5.7.2 The pre-charge circuit must use a mechanical, normally open type relay. All pre-charge current must pass through this relay.
Last year 2022
The Pre-charge circuit is the last unit in the shutdown circuit, it connects the shutdown line to the AIRs, first, it toggles a contactor that connects the high voltage line through a power resistor (1k2 100W), and after reading 95% voltage at the vehicle side compared to the accumulator side, it toggles the second contactor who connects the high voltage line directly. The pre-charge logic consist of op-amps and voltage dividers to measure the voltage over the + HV AIR of the TS and sending a signal which command the wanted state of the AIR contactor.
the pre-charge units is both passive and active unit, the pre-charging sequence begin as soon as the circuit is provided with the shutdown circuit, but the circuit output R2D (ready to drive) signal only after the pre-charge has finished.
The full schematics of the Pre-Charge circuit can be found in our drive:
https://drive.google.com/drive/folders/1MRbSpvXV2A04051hqhXLJMwBLjDQx9W6
last year 22
Pre-charge circuit of University of Wisconsin-Madison