电动汽车高压继电器失效机制分析和故障排查研究

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中图分类号：U469.72 文献标识码：B 文章编号：1003-8639（2026）01-0174-03

Analysis of Failure Mechanism and Troubleshooting of HighVoltageRelay inElectric Vehicles

Zhao Jian

(Shanxi Open University, Taiyuan O3OO27, China)

【Abstract】To resolve a sudden power interuption fault in a specific batch of pure electric vehicles,this study investigatedthefailureof thehigh-voltagepositivecathoderelayinthevehiclemodel.Throughdiagnosticinstrumentdata collection,component comparison tests,andsystemenvironment analysis,we identified three rootcauses:relaycontact oxidatioadhesionand mechanical jamming; moisture infiltration caused byPDUsealing defects leading toelectrolytic oxidation and increased contact resistance;and mechanical sticking exacerbated by high-temperature oxidation cycles; as well as mechanical jamming due to bracket moisture absorption and impurity accumulation.The proposed solution combines "component upgrade+structural optimization+program improvement,"including replacing oxidation-resistant contact relays, upgrading PDU sealing components,and optimizing VCU control logic. Results demonstrated a 66.7% （20 increaseinrelayelectricallifespanpost-repairand"zero complaints"regarding relatedfaults,validating theeffectiveness of this implementation.

【Key words】electric vehicles；high voltage relays;failure mechanisms;troubleshooting

0 引言

近些年，中国新能源产业快速发展，高压系统的可靠性已成为制约电动汽车产品品质的核心因素。（剩余4722字）