Systems and methods for adding contactors at or near the MSD.

Abstract

The system can be configured to replace the manual service circuit breaker (MSD). Some embodiments may include: providing a set of batteries comprising the MSD; removing the MSD; and installing a contactor at the MSD. Replacement can be performed using a housing substantially similar to that previously used for the MSD.

Description

Technical Field

[0001] This disclosure generally relates to systems and methods for integrating contactors into battery packs that previously included manual service circuit breakers (MSDs) and / or fuses, without requiring substantial modifications to the battery pack and corresponding components. Background Technology

[0002] The MSD establishes a connection, and removing the MSD intentionally terminates the connection. The MSD is protected by disconnecting the battery pack, making it safer to operate and preventing short circuits. The contactor can be electrically controlled to relay high voltage (HV) connections and can also be physically removed. Each contactor can disconnect one or more HV connections.

[0003] Relays are known to have coils that generate the magnetic force needed to mechanically operate electrical contacts. Contactors typically do the same, but relays are used for low- and medium-power applications, while contactors are used for high-power devices.

[0004] Battery packs are known to be integrated in original equipment manufacturer (OEM) applications, such as commercial electric vehicles. The same battery modules or individual cells (e.g., having 6, 8, 10, or other numbers of cells) can be installed in each battery pack. They can be configured in series, parallel, or a combination of both to provide the required voltage, capacitance, or power density.

[0005] Once a country’s certification body and / or approves a battery pack in accordance with safety regulations, there is an urgent need to increase the requirements for full recertification of safety and functionality. Summary of the Invention

[0006] Systems and methods for replacing MSDs and / or fuses are disclosed, requiring minimal modifications to the certified system and / or housing to update the contactor by providing an effective plug-in replacement (e.g., adding the contactor to a battery pack not designed for it). Therefore, one or more aspects of this disclosure relate to systems and / or methods for replacing MSDs, for example, by providing a battery pack including the MSD; removing the MSD; and installing a contactor at the MSD.

[0007] This method is implemented by a system including a battery pack, contactors, and one or more hardware processors configured with machine-readable instructions and / or other components and / or signal communication with one or more controllers. Implementations of any described techniques or architectures may include methods or processes, apparatus, devices, machines, or systems.

[0008] This document discloses some aspects of exemplary implementations of systems, apparatus, and methods associated with replacing a manually serviceable circuit breaker (MSD) with a portable power source by providing a set of batteries comprising the MSD; removing the MSD; and installing a contactor at the MSD. In some cases, the contactor is configured to be electrically connected to a socket originally designed for the MSD. In some cases, the front surface of the contactor is integrated into the cavity of the MSD. In some cases, the rear surface of the contactor is coupled to a cover plate having substantially the same form factor as the cover plate of the MSD.

[0009] Examples of embodiments are described below with reference to the accompanying drawings, which form part of this document, and specific embodiments of this disclosure that can be used are illustrated by way of description. Other embodiments may be used and structural changes may be made without departing from the scope of this disclosure. Attached Figure Description

[0010] Details of the specific embodiments are set forth in the following drawings and description. Throughout the specification, the same reference numerals may refer to the same elements. Other features will be apparent from the following description, including the drawings and claims. However, the drawings are for illustrative and descriptive purposes only and are not intended to be limiting of this disclosure.

[0011] The invention can be better understood by referring to the following accompanying drawings. The components in the drawings are not necessarily to scale, but rather to emphasize the principles of the invention. In the drawings, the same reference numerals denote corresponding parts in different views.

[0012] Figure 1 Examples of systems in which contactors can be integrated are shown according to one or more embodiments.

[0013] Figure 2 shows an example of a battery pack according to the prior art.

[0014] Figures 3A-3B Two examples of contactors according to one or more embodiments are shown.

[0015] Figure 4 shows two views of the contactor and its dimensions according to the prior art.

[0016] Figure 5 Examples of contactors according to one or more embodiments are shown.

[0017] Figure 6 shows an example of a battery pack according to the prior art.

[0018] Figures 7A-7C An example of a contactor with a cover installed at the battery pack is shown according to one or more embodiments.

[0019] Figure 8 shows an example of a low-voltage (LV) connector according to the prior art.

[0020] Figure 9 shows an example of a contactor according to the prior art.

[0021] Figure 10 An example of a contactor installed at a battery pack according to one or more embodiments is shown.

[0022] Figure 11 An example of logic for controlling a contactor according to one or more embodiments is shown.

[0023] Figure 12 An example of a mounting plate coupled to a battery pack according to one or more embodiments is shown.

[0024] Figure 13 An example of a contactor coupled to a mounting plate of a battery pack according to one or more embodiments is shown.

[0025] Figure 14-15 Different ways of mounting a contactor to the surface of a battery pack or panel are shown according to one or more embodiments.

[0026] Figure 16-17 Different views of examples of contactors installed near the power connector of a battery pack, according to one or more embodiments, are shown.

[0027] Figure 18-19 An example of a contactor mounted on a mounting plate above a panel of a battery pack, according to one or more embodiments, is shown.

[0028] Figure 20 A battery pack with a mounting plate according to one or more embodiments is shown, along with its exemplary dimensions.

[0029] Figure 21 Examples of contactor housings according to one or more embodiments are shown.

[0030] Figure 22-24 Examples of accommodated contactors mounted relative to a battery pack according to one or more embodiments are shown.

[0031] Figure 25-28 Different examples of contactors mounted relative to a battery pack according to one or more embodiments are shown.

[0032] Figure 29 A process for providing an integrated contactor according to one or more embodiments is illustrated.

[0033] All descriptions and annotations in the accompanying drawings, and all contents thereof, are incorporated herein by reference (as fully illustrated herein). Detailed Implementation

[0034] As used herein, the word “may” is used in a permissive sense (i.e., implying potential) rather than in a mandatory sense (i.e., requiring). Words such as “including,” “comprising,” and “having” mean, but are not limited to, those included. As used herein, the singular forms of “a,” “an,” and “the” include plural references unless the context clearly specifies otherwise. As used herein, the term “numerical” should refer to an integer of 1 or greater (i.e., a plurality).

[0035] As used herein, the statement that two or more parts or components are “coupled” means that the parts are directly or indirectly (i.e., through one or more intermediate parts or components) connected or operated together whenever a link occurs. As used herein, “direct coupling” means that two elements are in direct contact with each other. As used herein, “fixed coupling” or “fixed” means that two components are coupled so as to move as a single component while maintaining a constant orientation relative to each other. Directional phrases used herein (such as, for example but not limited to, top, bottom, left, right, upper, lower, front, rear, and their derivatives) relate to the orientation of the elements shown in the accompanying drawings and do not limit the claims unless expressly stated herein.

[0036] These drawings may not be drawn to scale or accurately reflect the structural or performance characteristics of any given embodiment, and should not be construed as defining or limiting the scope of values ​​or properties covered by the example embodiments.

[0037] Unless otherwise specified, it will be apparent from the discussion that in this specification, the use of terms such as “processing,” “operation,” “calculation,” “determining” refers to the actions or processes of a particular device, such as a dedicated computer or similar dedicated electronic processing / computing device.

[0038] This invention discloses methods for providing plug-in contactors, each of which (i) actively replaces an existing MSD or fuse (e.g., in the MSD housing) and / or (ii) is properly coupled in a junction box at the battery pack to prevent environmental impact. Therefore, by including one or more contactors on the battery pack without substantially redesigning the battery pack, technology can be upgraded without requiring full recertification, thereby improving safety. For example, existing MSD connections can be modified to replace them with contactors. In the event of a collision, overvoltage condition, or other form of fault, the contactor functions by disconnecting at least one terminal of the circuit (i.e., removing current), thus breaking the circuit.

[0039] Figure 1System 10 is shown, configured to easily add contactors to different battery packs, including different models or types of battery packs not currently configured for their use. The contactors provide similar and / or redundant functionality to MSDs, but with the added advantage of remote control. Furthermore, the contactors can be provided for battery systems of any size. Some exemplary implementations may involve custom provision of new contactors and / or special reconfiguration of existing contactors. For example, connecting strips, pins, or other types of connectors may be provided for engagement with slots, sockets, or other types of connector interfaces previously designed for MSDs (any type or brand) and fuses. In this example or another example, a lower voltage coil may be provided to operate the contactor. In one or more of these or another examples, the added contactor may provide secondary monitoring of its primary contacts, for example, to determine positioning and / or the presence of solder.

[0040] In some exemplary embodiments, contactor 56 may be configured to directly replace existing MSDs and / or fuses that may exist within the housing. The relay operation of the contactor may be controlled by a vehicle control unit (VCU), a battery management system (BMS), and / or another controller (e.g., which may coordinate its actuation based on separate logic, the VCU, and / or the BMS).

[0041] In some exemplary embodiments, each contactor 56 may be equipped with a custom housing, such as Figures 7A-7C The cover 55 (e.g., mates with a pre-existing MSD housing 53) or Figure 21 The housing 62. This housing can provide a weatherproof (e.g., waterproof) connection to the MSD housing 53.

[0042] In some exemplary embodiments, the contactor 56 can be mounted to the battery pack 50 by minimizing vibration at the electrical connection.

[0043] In some exemplary embodiments, one or more contactors 56 may be configured with connectors or other connections to support LV interfaces.

[0044] In some exemplary embodiments, the contactor 56 may be integrated into the battery pack 50, for example, without physically modifying the battery pack or any existing high-power cables, such as Figures 7A-7C As shown in the example. This installation of the contactor is improved by eliminating the need to bolt the contactor to the battery pack 50, and therefore eliminates the need for a new sealing housing. An exemplary embodiment with a contactor 56 embedded in the MSD (as shown in the example). Figures 7A-7C (as shown) and exemplary embodiments having contactors mounted on plate 60 (as shown in) Figure 12-13 and Figure 16-20(As shown) the examples can avoid the need for new bolts that introduce the risk of leakage. One or more of these exemplary embodiments can avoid the need for repeating vibration / shock testing and / or terminating high-power cables at new locations.

[0045] In some exemplary embodiments, contactor 56 can be remotely operated, for example, to remove high voltage. In an exemplary embodiment, the contactor or its controller may obtain an output signal from a sensor (e.g., an impact sensor). In this or another exemplary embodiment, when power is removed, for example, by disconnecting a circuit, the contactor may automatically protect or preserve the corresponding battery or battery pack.

[0046] In some exemplary embodiments, system 10 can achieve safety (e.g., by saving battery pack 50) by supplementing or replacing MSD, fuses, and / or disabling / controlling other circuitry via one or more contactors 56. This ensures that no electrical connection is provided to at least one of the terminals or connectors (e.g., 80, 81, etc.), effectively preventing injury in the event of a short circuit or electric shock caused by someone touching the terminals.

[0047] In some exemplary embodiments, contactor 56 may be a high-voltage contactor that can be directly inserted into MSD inserts 51-52. Therefore, the addition of the MSD can be performed (i) without altering the high-voltage (HV) cable connections, thus exposing HV wiring, and (ii) with minimal increase in weight. By adding the contactor, replacement or adjustment of the MSD can be further performed without altering the base portion 53 of the panel 54 of the battery pack 50. For example, only the MSD replacement cover 55 may differ in configuration from a pre-existing MSD cover. In this example, the MSD replacement cover 55 can be formed by using an O-ring 59 (as shown in the example of Figure 6), which extends around the outside of the MSD base 53 when mated with the MSD replacement cover 55 after connection at 58A-58B. When the contactor 56 is embedded therein, the seal can be maintained or improved, for example, at ingress protection level 65 (IP65), IP66, IP67, IP68 or other IP levels, based on the seal being made from a pre-existing MSD cover.

[0048] In some exemplary embodiments, contactor 56 can be modified, such as Figures 3A to 3BThe adjustment is shown. More specifically, when the contactor is inserted into slots 51-52 of panel 54, the fasteners and bolt-on terminals 57A-57B can be removed, and plugs 57C-57D can be added instead to allow for direct connection. For the normally open (NO) configuration of the contactor, the positive (or negative) connection may not be energized, i.e., there is no connection to it. Therefore, Figure 3A A relatively small contactor with standard connections is depicted, while Figure 3B A contactor with additional pins 57C-57D for making HV connections is depicted.

[0049] Figure 6 shows a panel 54 of the battery pack 50, including slots 51-52 into which an existing MSD can be inserted. The panel may be metallic and therefore possess a certain degree of rigidity and strength. Furthermore, the panel may be connected to and supported by a substrate, which may be a bottom metal cooling plate.

[0050] In some exemplary embodiments, contactor 56 may be integrated into group 50 to enable remote control of the power supply terminal (e.g., applying a low voltage to the coil shown in FIG9 via wire 90). For example, the contactor may be pulled in or released (e.g., in the event of a sensor detecting an accident, the power can be unplugged from the contactor, and the contactor may be disconnected without anyone being there to unplug it, just like an MSD or fuse).

[0051] Figures 7A-7C A contactor 56 is shown modified and configured to insert into a housing (e.g., the housing of an MSD or another existing circuit conditioning device). For example, the contactor's HV connection 57 can be configured to be electrically connected at sockets 51-52 originally designed for the MSD. And, as... Figure 7A As shown, the front (i.e., left-hand side) surface of the contactor 56 can be integrated into the cavity 53 of the MSD, while the rear surface (i.e., right-hand side) of the contactor can be coupled to the cover plate 55, which has a form factor that is substantially the same as that of the cover plate of the MSD.

[0052] Figures 7A-7B The contactor 56 is shown during installation, for example, by inserting it into slots 51-52 of the existing MSD cavity 53. In this configuration, the MSD is effectively removed at this point, for example, by cutting its metal parts in half. Thus, the pins 57C-57D of the contactor 56 can be inserted into slots 51-52 respectively, for example, without a continuous strip between them. However, a physical connection can be made inside the contactor, while correctly and securely holding the contactor in the slot.

[0053] In some exemplary embodiments, contactor 56 may be coupled to a metal plate, such as an aluminum busbar previously used as an MSD. For example, when the busbar is cut in half, two pieces 57C-57D may be connected to the terminals of the contactor. These pieces are then mounted together in cavity 53 via slots 51-52, thereby maintaining the structural strength of the contactor. In this example, mounting can be performed by fastening the contactor's protrusions into openings in the busbar, such as... Figure 7B As shown in the bottom right corner.

[0054] In some exemplary embodiments, the MSD replacement cover 55 may include a sleeve that increases the current size of the existing MSD cover by a minimum amount (e.g., 5-6 mm). In other embodiments, the cover 55 may not make the MSD cover taller, but may have the same height (i.e., the contactor is fitted within the housing of group 50) or smaller. In some exemplary embodiments, the MSD replacement cover 55 may be formed as part of a custom housing.

[0055] In some exemplary embodiments, the housing 55 may be developed to cover the contactor 56, for example, when the contactor extends slightly beyond the existing MSD cover (e.g., 5-10 mm). In some exemplary embodiments, the housing contactor 56 may be formed by the cover 55 and a cavity base and wall 53. When the contactor 56 is integrated therein, the housing may further include connectors for the LV coil wire 90 and the secondary contactor position contact 92 (i.e., for checking the position of the primary contact). Figure 8 illustrates an example of an LV connection, which may include, for example, a panel-mount connector for integration into the contactor housing (e.g., at the cover 55, the insert (side wall or base portion) 53, the housing 62, or another suitable compartment). Thus, weather resistance can be provided at both low-voltage and high-voltage connections.

[0056] In some exemplary embodiments, opening 86 may be formed along the boundary of cavity 53, for example, to fasten or bolt cap 55 thereto. For example, the same bolt holes used for the original MSD cap may be used to fasten cap 55. And, as described above, when cap 55 is secured in this way, O-ring 59 may be used to better seal cavity 53.

[0057] The advantage of mounting the contactor 56 within the MSD housing is the reuse of existing cable connections. Another advantage is the saving of mounting components on the battery pack 50 panel 54 and the front surface 49 of the battery pack (e.g., by using the same xy dimensions at the cover 55 as the existing MSD cover when mating at the cavity 53, as shown in Figure 6), such as... Figures 7A-7CAn example of the contactor 56 being embedded in the insert 53 is shown. Furthermore, in this configuration, the contactor can be mounted without its housing protruding significantly (e.g., beyond the extent of mounting with the MSD housing), thereby minimizing the probability of damage to its surroundings.

[0058] In an exemplary embodiment, when the contactor 56 is not integrated under the cover 55 at the cavity 53, the contactor may require a separate (e.g., IP68) housing 62, for example, to protect against environmental influences, including moisture, humidity, dust, pressure, and / or other environmental factors. In the embodiments disclosed herein, when used to secure the contactor, the housing 62 or cover 55 may meet or improve the IP rating of the battery pack 50.

[0059] Figure 13 and Figure 21 Junction box 62 is shown. This housing allows the contactor to be installed in a waterproof manner (e.g., when sealed inside).

[0060] In some exemplary embodiments, contactor 56 may be a NO contactor (i.e., normally not connected), which automatically protects or preserves the environment of a mobile power source (e.g., a vehicle) when low-voltage (LV) power is lost due to an open circuit. For example, in the event of a car collision, contactor 56, which replaces the MSD, can perform automatic safety functions.

[0061] In some exemplary embodiments, contactor 56 may be an electrically controlled switch or relay of a power circuit, for example, a switch that operates at a much higher power level than the circuit it directly controls. As shown in FIG9, the contactor may have any configuration, such as NO (e.g., for disconnecting the circuit in the event of a power outage during an accident, when communication with the contactor is lost for any reason, or when the controller receives an LV command).

[0062] In some exemplary embodiments, contactor 56 may utilize secondary contact 92 (e.g., Figures 7A-7B (As shown), it is used for monitoring and subsequent warning of solder contact points at or near the contactor. In some exemplary embodiments, for example, energizing the coil of contactor 56 via LV connection 90 can cause the two main contacts to pull in, for example, connecting between slots 51-52, similar to or the same as the mounting method of existing MSDs. In these or other embodiments, contactor 56 may include a second set of contacts 92 for notifying the location of the connection and indicating whether they are actually pulled in as expected.

[0063] In some implementations, the connections on contactor 56 may be soldered or jammed, for example, when a very high current passes through the contacts. Therefore, the second set of contacts (LV) indicates whether the HV contacts of the relay have been soldered due to a high-current event, rendering group 50 unsafe (due to a fault in the closed-circuit configuration). Physical and visual inspection of contactor 56 may not indicate this problematic state where the HV terminals appear unenergized but may actually be energized.

[0064] In some exemplary implementations, such as Figures 7A-7B Figures 9-10 and Figure 14-15 As shown, contactor 56 may include two primary contacts and two secondary contacts or wires. One may be grounded, while the other may be 12 volts (V), such that when 12 volts are applied to it, the contactor pulls in (or extends) and connects. As previously described, the other two wires may be secondary contacts used to indicate the position of the primary contactor contacts. For example, after receiving a 12V command to actuate the contactor, these secondary contacts may be there to indicate the correct response or to indicate the presence of a fault condition.

[0065] In some exemplary embodiments, one or more contactors may be controlled by a battery management system (BMS), a vehicle control unit (VCU), and / or a separate controller that coordinates these and / or other (one or more) controllers. For example, contactor 56 may be controlled by two or more different devices, including the BMS, VCU, and / or another controller. The BMS and VCU may be implemented at the battery management unit 32 and the vehicle control unit 34, respectively.

[0066] In some exemplary embodiments, the computing device controlling the contactor may have a predetermined location, and the control is performed based on coordination between the BMS, VCU, and other control units. For example, the control logic may be based on one or more signals (e.g., the output of a collision sensor). In some exemplary embodiments, the location of the power source may also be predetermined (e.g., via a battery system or directly via vehicle power).

[0067] In some exemplary embodiments, the coordination of contactor control can be based on the closing sequence of multiple other different contactors (e.g., on a battery pack, in a junction box, at a distribution box connecting all the various groups, and / or at another location or for a different function). For example, before actuating one contactor, the controller can query the status of other (one or more) contactors to determine (i) whether it is safe or appropriate to continue, or (ii) whether it is best to wait for a period of time or wait for a message to be received. In this way, multiple contactors (e.g., including contactors of different types) can all be controlled by a single integrated controller (e.g., via contactor coordination component 36). Alternatively, the logic for controlling contactor 56 can be implemented at the VCU or BMS.

[0068] In some exemplary implementations, these contactors may require a certain amount of time to pull in (e.g., 50 milliseconds (ms)), which may necessitate closing these contactors before the main contactor in the junction box closes. Therefore, the likelihood of contactor soldering is significantly reduced.

[0069] In some exemplary implementations, such as Figure 10 As shown, there may be multiple battery packs (50 or more) that will enter a junction box. Furthermore, this junction box may contain individual contactor groups or larger contactors, allowing the entire battery system to be connected and disconnected in a single operation. Therefore, there may be different sequences or orders required to actuate the different contactors (e.g., relative to the recharging contactor). A proper contactor actuation sequence can significantly extend the contactor's lifespan.

[0070] Figure 11 Inputs and outputs (I / O) for controlling contactor 56 are shown. For example, the control logic described herein can be implemented via contactor coordination component 36 to acquire and process several inputs for controlling one or more contactors 56. For example, a primary sensor and / or an auxiliary sensor (e.g., a collision sensor, a roll sensor, or another type of sensor) can output signals acquired at the control logic for controlling the contactors.

[0071] like Figure 11As shown, one input to the control logic (e.g., implemented via the contactor coordination component 36 of processor 20) can be the High Voltage Interlocked Circuit (HVIL) loop state. This signal may be related to safety features of hybrid and all-electric vehicles that protect people during vehicle assembly, repair, maintenance, and operation. For example, an HVIL system can protect anyone who may come into contact with HV components at any stage of its lifespan. As a circuit breaker, HVIL alerts the driver if a high-voltage connection becomes loose, disconnected, or damaged during vehicle operation. HVIL also helps protect the vehicle's driver and passengers in the event of an accident. HVIL uses a continuous LV loop that monitors all high-voltage connectors and components in the vehicle. If the LV HVIL signal is interrupted for any reason, it indicates a problem with the HV system.

[0072] Contactor control can involve the generation and manipulation of variable-sized signals. For example, a variable-sized signal can be created using a switch block. The input signals to the switch block can vary in number and size. The output of the switch block can be a two-dimensional (2D) variable-sized signal with a maximum size of 3x2. In this or another example, a variable-sized signal can be created from a single data signal. The data signal (constant 5) can be a 3x4 matrix. The pulse generator used can represent a control signal that selects start and end index values, and then the selector block can use these index values ​​to select different portions of the data signal at each time step and output a variable-sized signal.

[0073] In some exemplary embodiments, the contactor coordination component 36 can implement simplified control of the contactor 56. In a first example, the contactor can operate normally, for example, closing 50ms before the S-box master contactor receives a closing command and opening 50ms after the S-box master contactor receives an opening command.

[0074] In the second example, charging is possible, but since there may be no key signal (e.g., the contactor closes 50ms before the S-box main contactor receives a closing command and opens 50ms after the S-box main contactor receives an opening command), 12V is required to be always on.

[0075] In the third example, maintenance for other services can be performed even with the S-box MSD removed (but the key open). In this example, the contactor can disconnect immediately after the high-voltage board (HVB) senses the absence of the MSD (if there is no HV or auxiliary contact); the S-box main contactor also opens, and since the MSD is not present, timing is not critical. If the MSD is reinserted, the contactor can close 50ms before the S-box main contactor receives a closing command.

[0076] In the fourth example, a collision or other accident may occur (key turns on or off, and MSD is removed). If the key is turned off before removing the MSD, a normal shutdown can be performed (i.e., the first example). If the MSD is removed while the key is energized, the contactor can immediately disconnect after the HVB detects the absence of the MSD; the S-box main contactor can also disconnect. After a collision, the MSD may not be reinserted until a full system diagnostic can be performed.

[0077] In the fifth example, an HV isolation fault may be detected. Therefore, the contactor can be immediately disconnected. Furthermore, if the isolation fault is resolved, the contactor can reclose 50ms before the S-box master contactor receives the closing command.

[0078] The method disclosed herein improves upon the mobile power supply by adding at least one contactor without requiring substantial redesign or a complete revalidation of the (one or more) battery packs 50. For example, an existing vehicle may have (one or more) battery packs 50, with at least one battery pack having the added (one or more) contactor, without needing to adjust the location of the HV connection and / or the wiring of existing cables at the vehicle. Eliminating this need for rewiring power cables is crucial because they tend to be very high-gauge wires, which hinders their ability to bend sharply.

[0079] In some exemplary embodiments, panel 54 may include a housing as shown on the right side of FIG. 6, where the negative terminal of battery pack 50 may be located. This allows high-voltage cables to enter from the right side of metal connector 81. For example, the cable may pass directly through the housing and be bolted to the negative terminal of the battery within the housing. In this or another example, the corresponding positive connection may enter from the left side of connector 80, also shown in FIG. 6. One or more positive cables or wires may pass inward toward MSD cavity 53, and they will be bolted to one or more of connection points 58A-58B, for example, before cover 55 is installed over the cavity to seal it.

[0080] In some exemplary embodiments, panel 54 may have one or more additional connectors for battery pack 50, as shown in FIG6. For example, connections 82A-82B may engage with the internal heater interface within the pack. In this or another example, connections 83A-83B may be used for LV connections, such as for Controller Area Network (CAN) communication and for 12V or 24V vehicle power to power some electronics within the battery pack. Panel 54 may also include a vent port 84, for example, to allow pressure to be balanced inside and outside the pack when the vehicle changes height, preventing any type of water or moisture from entering the pack.

[0081] In an exemplary implementation of the BMS, the BMS can control the contactor 56 via wiring from (one or more) LV connectors 83A and / or 83B.

[0082] Figure 9 illustrates the electrical connections of battery pack 50 (e.g., a CATL pack). For example, connection A2(+) can be connected to the existing HV+ connection of battery pack 50, and connection A1(-) can be connected to a new HV output to the next pack or system junction box “S box”. In this or another example, the coil of contactor 56 may have X2(-) and X1(+) connections for connecting to pins 7 and 6, respectively. Pin 7 may always have LV ground, and pin 6 may have 12V applied when the contactor is expected to close, and 12V can be removed when the contactor is expected to open. In this or another example, pins T1 and T2 of a NO switch or relay may be provided for connecting to pins 8 and 9, respectively. When the main contactor is closed, a 12V voltage can be applied to pin 9 through the NO contact. If any contactor is stuck in the closed (ON) state (typically caused by high current soldering the contacts together), a high voltage may be present at the output where pin 6 is not applied 12V.

[0083] To ensure a long service life for the high-power connection of contactor 56, the contactor can be closed only before the S-box contactor closes and opened after the S-box contactor opens.

[0084] Figure 10 The electrical connections of multiple battery packs 50 in parallel and / or series configurations are shown.

[0085] In some exemplary embodiments, contactor 56 may be integrated as an additional contactor (e.g., adjacent to the positive connection or another connection). For example, the contactor may be mounted at a 90-degree angle to the input on the panel, at 0 degrees or 180 degrees in a straight line to the input, within the cavity 53, or at another location near the panel of the battery pack 50. For example, contactor 56 may be configured to replace the MSD at the base / cavity 53 originally designed for the MSD, so that no modification to the battery pack 50 is required. This example is in... Figures 7A-7B As shown in the image.

[0086] Figure 3A Contactor 56 is shown, which has only an HV connection 57 and an LV coil connection 90. Therefore, when contactor 56 is reconfigured according to the disclosed method (e.g.) Figure 3B As shown), you can add an LV location connection to 92 (e.g. Figure 3B and Figure 14(As shown in the example) and the HV connection 57 can be modified to insert directly into the MSD / fuse housing 53 (specifically, in slots 51-52). In an exemplary embodiment with LV connections, the panel mount connector (as shown in Figure 8) can be integrated into a new contactor housing, for example, to waterproof these connections.

[0087] Figure 3A Figure 4 depicts the Gigavac GX14 type HV contactor.

[0088] Figure 5 An enlarged version of the battery pack negative terminal box using two terminals is shown; this configuration includes a shielded cover with a gasket.

[0089] Figure 13 An example of a contactor located outside the MSD cavity is shown, for example, with a new HV cable and connector for connecting the contactor to a vehicle. However, when such... Figure 7C When the contactor 56 is integrated into the cavity 53, the HV cable connection remains unchanged (e.g., from connector 80 to the vehicle). Another difference in these exemplary embodiments is that, although no live wire is added when the contactor is integrated under the cover 55 ( Figure 7C (This can be indicated), but adding a contactor to board 60 (such as...) Figure 13 and Figure 16-19 (As shown) may require live connections outside group 50. In the event of a vehicle collision, any cables outside the battery pack may be damaged.

[0090] In some exemplary embodiments, plate 60 can be mounted on plate 54 using the same bolt pattern as that used for mounting plates to battery pack 50, such as... Figure 12 As shown.

[0091] In some exemplary embodiments, the battery pack 50 may have a specific location for mounting the MSD, and this location may be physically robust and / or capable of handling shocks and vibrations (e.g., when cantilevered over a heavy component). Thus, shocks and vibrations may be easily supported (i) by contactors 56 integrated in the cavity 53 or (ii) by contactors 56 mounted on the plate 60.

[0092] In an exemplary embodiment, when integrated into a cavity, the contactor can be configured to be mounted in the cavity and support high currents from the battery pack (e.g., 250 amps (A) of continuous current, with peak currents of 600 A or more, depending on the specific battery pack type).

[0093] In some exemplary embodiments, the battery 50 may support the contactor 56 as a surface mount component (SMC), but since the battery pack may have composite materials, mounting thereon may pose risks over time (e.g., related to vibration-induced failures). Therefore, a plate 60 may be developed for mounting the contactor 56, as directly mounting the contactor to the composite surface material of the battery pack 50 (e.g., a CATL pack) would lead to failure in the presence of vibration due to its suspended weight. In some exemplary embodiments, the plate 60 may be mounted to the pack 50 using at least some of the same mounting bolts or fasteners (e.g., through opening 85) used to secure the panel 54 to the end of the pack. And the housing 62 may be developed to encapsulate the contactor when both the housing and the contactor are coupled to the pack.

[0094] In some exemplary embodiments, the contactor 56 may be mounted externally to the cavity 53 on the mounting plate 60. For example, the contactor may be mounted within the housing 62, forming part of a new component. In this example, the mounting plate may use at least some (e.g., such as...) Figure 12 The eight existing fasteners shown are used to secure the panel 54 to the battery pack 50.

[0095] Figure 13 A contactor 56 integrated on a mounting plate 60 is shown. As described above, the contactor can be mounted in housing 62 or another junction box. Figure 14 A contactor 56 integrated onto a mounting plate 60 in another configuration with a 90-degree turn is shown, wherein the HV and LV wires extend outward toward their designated connections. For example, the HV wire 57 can be connected to the vehicle's motor, while at least one of the LV wires 90, 92 can be connected (e.g., via a connector similar to that in Figure 8) to connector 83B, as shown. Figure 13 As shown.

[0096] Figure 13 An exemplary implementation is described, in which the contactor is configured linearly with the MSD. For example, an HV cable connection can be led out from connector 80, through contactor 56, and then out to the right. This allows the cable to travel a path that results in its direction being 180 degrees from its previous direction. This does not result in a simple plug-in replacement.

[0097] Figure 14 Another exemplary embodiment is shown in which a contactor (e.g., via mounting plate 60 or directly via other means) is coupled to the surface of battery pack 50. Figure 15 An exemplary description of the relationship with Figure 13 The implementation is similar to that of other implementations (e.g., where the contactor is in line with the connector 80 of the MSD and panel 54). In Figure 15In the example, no additional HV wiring is required to directly insert the contactor.

[0098] Figure 15 A contactor 56 is shown integrated into a mounting plate 60 in a linear configuration.

[0099] Figure 16-17 Another exemplary embodiment of a linear contactor using mounting plate 60 is shown. Figure 16 Contactor 56, as a GV242 type contactor, is shown. More specifically, the contactor can be mounted at a 90-degree side bend. In this configuration, the terminals on the contactor may be too far from the battery pack surface to be directly aligned with the cable. Furthermore, the contactor may protrude further above the end of group 50. Figure 17 It shows Figure 16 Different views of the configuration of computer-aided design (CAD) drawings.

[0100] Figure 18-19 Another exemplary embodiment of a linear contactor using mounting plate 60 is shown, which has (i) more complex wiring due to 180-degree turns, and (ii) a more compact horizontal protrusion or horizontal range (e.g., with...). Figure 16-17 (Compared to similar examples). In one example, the terminals on the contactor may extend too far from the surface of the group to align directly with the cable. In this example, the contactor may extend beyond one end of the battery pack.

[0101] Figure 17 and Figure 19 Different implementations of adding a contactor to battery pack 50 are shown. Figure 17 In the example, particularly in the upper right corner, the contactor may problematically extend beyond the battery pack. Therefore, other exemplary embodiments disclosed herein can address this issue by preventing the added contactor from extending beyond the pack's envelope. For example, Figure 19 The lower left image depicts mounting the contactor onto a portion of the plate 60 using a curve on the upper part of the battery pack 50, so that the horizontal envelope is not elongated. This curve (e.g., at the front surface 49) is also shown in the example of Figure 2.

[0102] Figure 18 Contactor 56 is also described as a GV242 type contactor. More specifically, the contactor can be coupled with... Figure 16 Different rotational installations. This configuration may require more complex wiring, but it can be more compact (e.g., compared to...). Figure 16-17 (Compared to). When rotated 180 degrees, this contactor configuration works better with certain battery packs. Figure 19 It shows Figure 18 Different views of the configured CAD drawing.

[0103] Figure 20 An isometric view of mounting plate 60 is shown, which is coupled to panel 54 using a subset of existing fasteners for securing panel 54 to assembly 50. This example configuration is similar to... Figure 12 The configuration shown is illustrated. Exemplary dimensions are... Figure 20 This is shown in the depiction on the right side of the isometric view. Thus, there is available space to accommodate the mounting plate 60, on which the HV contactor 56 and housing 62 can be mounted.

[0104] Figure 21 The housing 62 of the HV contactor 56 is shown in an embodiment where the contactor does not directly replace the MSD. More specifically, the housing 62 can be designed based on the HV contactor dimensions (as shown in Figure 4). In this way, the contactor 56 in its customized housing can be mounted on the mounting plate 60.

[0105] In some exemplary implementations, such as Figure 22 As shown, Figure 21 The housing 62 shown in the example can be mounted at the corner of group 50, or alternatively mounted near the corner, such as... Figure 23 As shown. Problems may occur when the HV contactor in housing 62 extends beyond the outer surface of the face of battery 50. Figure 24-25 The example depicts yet another alternative for mounting the contactor 56 when it is in housing 62; more specifically, external wiring may be required, with one or more turns of wiring, to connect between the contactor and the power connector 80 (or 81) of panel 54.

[0106] Figure 22 Two different views of yet another exemplary embodiment are shown, in particular in which the contactor extends upward in a 90-degree direction while being directly coupled to the terminals of the battery pack 50. Figure 23 Similarly, two different views of yet another exemplary embodiment are depicted, in particular in which the contactor is directly coupled to the terminals of the battery pack 50 and extends outward in the same direction.

[0107] Figure 24 Three different views of yet another exemplary embodiment are shown, in particular in which the contactor is indirectly (e.g., by means of a cable at each end, one end of which is rotated down 90 degrees) coupled to the terminals of the battery pack 50.

[0108] Figure 25-28 Some other examples of coupling a contactor to battery pack 50 are shown. Figure 28 In some examples, there may not be enough space to accommodate the contactor and its housing, and the contactor is mounted via an additional mounting surface.

[0109] Figure 1The electronic memory 22 includes an electronic storage medium for electronically storing information. The electronic storage medium of the electronic memory 22 may include system memory that is integrally provided with system 10 (i.e., substantially non-removable) and / or removable memory that can be removably connected to system 10 via, for example, a port (e.g., a USB port, a FireWire port, etc.) or a drive (e.g., a disk drive, etc.). The electronic memory 22 may be a separate component within system 10, or it may be integrally provided with one or more other components of system 10 (e.g., user interface (UI) device 18, processor 20, etc.) (all or part of them). In some embodiments, the electronic memory 22 may be located in a server along with processor 20, in a server as part of external resource 24, in UI device 18, and / or in other locations. The electronic memory 22 may include a memory controller and one or more optically readable storage media (e.g., optical discs, etc.), magnetically readable storage media (e.g., magnetic tape, magnetic hard disk drives, etc.), charge-based storage media (e.g., EPROM, RAM, etc.), solid-state storage media (e.g., flash drives, etc.), and / or other electronically readable storage media. Electronic memory 22 may store software algorithms, information obtained and / or determined by processor 20, information received via UI device 18 and / or other external computing systems, information received from external resources 24, and / or other information that enables system 10 to function as described herein.

[0110] External resources 24 may include information sources (e.g., databases, websites, etc.), external entities participating in system 10, one or more servers outside system 10, networks, electronic storage devices, equipment related to Wi-Fi technology, and others. Technology-related equipment, data input devices, power supplies (e.g., battery-powered or line-powered connections, such as direct connection to 110V AC or indirect connection via AC / DC converter), transmitting / receiving elements (e.g., antennas configured to transmit and / or receive wireless signals), network interface controllers (NICs), display controllers, graphics processing units (GPUs), and / or other resources. In some embodiments, some or all of the functions attributed herein to external resource 24 may be provided by other components or resources included in system 10. Processor 20, external resource 24, UI device 18, electronic memory 22, network, and / or other components of system 10 may be configured to communicate with each other via wired and / or wireless connections (such as networks (e.g., local area networks (LANs), the Internet, wide area networks (WANs), radio access networks (RANs), public switched telephone networks (PSTNs), etc.), cellular technologies (e.g., GSM, UMTS, LTE, 5G, etc.), Wi-Fi technology, another wireless communication link (e.g., radio frequency (RF), microwave, infrared (IR), ultraviolet (UV), visible light, centimeter waves, millimeter waves, etc.), base stations, and / or other resources).

[0111] One or more UI devices 18 of system 10 may be configured to provide an interface between one or more users and system 10. UI devices 18 are configured to provide information to one or more users and / or receive information from one or more users. UI devices 18 include UI and / or other components. The UI may be and / or include a graphical UI configured to present views and / or fields configured to receive input and / or selection regarding specific functions of system 10, and / or provide and / or receive other information. In some embodiments, the UI of UI device 18 may include multiple separate interfaces associated with processor 20 and / or other components of system 10. Examples of suitable interface devices included in UI device 18 include touchscreens, keypads, touch-sensitive and / or physical buttons, switches, keyboards, knobs, joysticks, displays, speakers, microphones, indicator lights, audible alarms, printers, and / or other interface devices. This disclosure also anticipates that UI device 18 may include a removable storage interface. In this example, information can be loaded from removable storage (e.g., smart card, flash drive, removable disk) into UI device 18, which allows users to customize the implementation of UI device 18.

[0112] In some embodiments, UI device 18 is configured to provide system 10 with a UI, processing power, a database, and / or electronic storage. Thus, UI device 18 may include processor 20, electronic storage 22, external resources 24, and / or other components of system 10. In some embodiments, UI device 18 is connected to a network (e.g., the Internet). In some embodiments, UI device 18 does not include processor 20, electronic storage 22, external resources 24, and / or other components of system 10, but instead communicates with these components via dedicated lines, buses, switches, networks, or other communication means. Communication may be wireless or wired. In some embodiments, UI device 18 is a laptop, desktop computer, smartphone, tablet, and / or other UI device.

[0113] Data and content can be exchanged between various components of System 10 via communication interfaces and paths using any of a variety of communication protocols. In one example, data can be exchanged using protocols for transmitting data over the packet-switched Internet, such as the Internet Protocol Suite (also known as TCP / IP). Data and content can be transmitted from a source host to a destination host using datagrams (or packets) based solely on their addresses. For this purpose, the Internet Protocol defines the addressing methods and structures for datagram encapsulation. Of course, other protocols can also be used. Examples of Internet Protocol versions include Internet Protocol version 4 (IPv4) and Internet Protocol version 6 (IPv6).

[0114] In some embodiments, processors 20 may form part (e.g., in the same or separate housing) of user equipment, consumer electronic devices, mobile phones, smartphones, personal data assistants, digital tablets / tablet computers, wearable devices (e.g., watches), augmented reality (AR) goggles, virtual reality (VR) goggles, reflective displays, personal computers, laptops, notebook computers, workstations, servers, high-performance computing (HPC), vehicles (cars, trucks, buses, etc.), trains, ships, gaming or entertainment systems, set-top boxes, monitors, televisions (TVs), panels, spacecraft, or any other device implementing battery systems, electric motors, lighting, heating, capacitor banks, thermal evaporators, or other electrical loads.

[0115] In some embodiments, processor 20 is configured to provide information processing capabilities in system 10. Processor 20 may include one or more of a digital processor, an analog processor, digital circuitry designed to process information, analog circuitry designed to process information, a state machine, and / or other mechanisms for electronically processing information. Although processor 20 in Figure 1The processor 20 is shown as a single entity, but this is for illustrative purposes only. In some embodiments, the processor 20 may include multiple processing units. These processing units may be physically located within the same device (e.g., a server), or the processor 20 may represent the processing functions of multiple devices operating in concert (e.g., one or more servers, UI device 18, devices that are part of external resource 24, electronic storage 22, and / or other devices).

[0116] like Figure 1 As shown, processor 20 is configured to implement one or more computer program components via machine-readable instructions. The computer program components may include one or more of an information component 30, a battery management component 32, a vehicle control component 34, a contactor coordination component 36, and / or other components. Processor 20 may be configured to execute components 30, 32, 34, and / or 36 by: software; hardware; firmware; a combination of software, hardware, and / or firmware; and / or other mechanisms for configuring the processing capabilities on processor 20.

[0117] It should be understood that, despite Figure 1 Components 30, 32, 34, and 36 are shown as co-located within a single processing unit, but in embodiments where processor 20 includes multiple processing units, one or more of components 30, 32, 34, and / or 36 may be positioned remotely from other components. For example, in some embodiments, each of processor components 30, 32, 34, and 36 may include a separate and distinct group of processors. The description of the functionality provided by the different components 30, 32, 34, and / or 36 described below is for illustrative purposes and not restrictive, as any of components 30, 32, 34, and / or 36 may provide more or less functionality than described. For example, one or more of components 30, 32, 34, and / or 36 may be eliminated, and some or all of their functionality may be provided by other components 30, 32, 34, and / or 36. As another example, processor 20 may be configured to execute one or more additional components that may perform some or all of the functionality attributed to one of components 30, 32, 34, and / or 36.

[0118] Figure 29A method 100 for integrating a plug-in contactor (e.g., with a housing or form factor substantially the same as existing MSDs) according to one or more embodiments is illustrated. Method 100 can be performed using a computer system including one or more computer processors and / or other components. The processor is configured by machine-readable instructions to execute computer program components. The operational intent of method 100 presented below is illustrative. In some embodiments, method 100 can be accomplished with one or more additional operations not described and / or without one or more of the operations discussed. Furthermore, the operation of method 100 in… Figure 29 The order shown and described below is not intended to be limiting. In some embodiments, method 100 may be implemented in one or more processing devices (e.g., digital processors, analog processors, digital circuits designed to process information, analog circuits designed to process information, state machines, and / or other mechanisms for electronically processing information). The processing device may include one or more devices that perform some or all of the operations of method 100 in response to instructions electronically stored on an electronic storage medium. The processing device may include one or more devices configured by hardware, firmware, and / or software specifically designed to perform one or more operations of method 100.

[0119] In operation 102 of method 100, a battery pack including an installed MSD may be provided. In some embodiments, operation 102 is performed by an OEM and / or distributor.

[0120] In operation 104 of method 100, the MSD can be rendered inoperable by cutting the busbar included in the MSD in half. For example, the busbar can be cut into two or more pieces. In some embodiments, operation 104 is performed by a technician.

[0121] In operation 106 of method 100, the contactor can be configured to be electrically connected at a socket originally designed for the MSD. As an example, pins 57C-57D of contactor 56 can be inserted into slots 51-52. In some embodiments, operation 106 is performed by a technician.

[0122] In operation 108 of method 100, a sealing gasket may be provided to prevent moisture, ensuring that the contactor meets the same original IP ratings as the battery pack upon installation. As an example, when integrated below contactor 56, the existing bolt pattern 86 for the cover of the MSD can be used by cover 55. In some embodiments, operation 108 is performed by a technician.

[0123] In operation 110 of method 100, the MSD can be replaced with a contactor without substantially adjusting the form factor of the device. In some embodiments, operation 110 is performed by a technician, and subsequent control of the installed contactor can be performed by the contactor coordination component 36.

[0124] For example, the processor suitable for controlling contactor 56 may, by way of example, include general-purpose and special-purpose microprocessors, as well as any one or more processors of any type of digital computer. Typically, the processor receives instructions and data from read-only memory or random access memory, or both. Essential components of a computer are a processor for executing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices for storing data, such as magnetic disks, magneto-optical disks, or optical disks, or operatively coupled to such mass storage devices to receive data from or transfer data to, or both. Information carriers suitable for embodying computer program instructions and data include all forms of non-volatile memory, including, by way of example, semiconductor storage devices such as EPROM, EEPROM, and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD-ROM and DVD-ROM discs. The processor and memory may be supplemented by or incorporated into special-purpose logic circuitry.

[0125] It is understood that various aspects or details of this disclosure may be changed, combined, or deleted without departing from the scope of the invention. This is not exhaustive and does not limit the claimed invention to the precise form disclosed. Furthermore, the foregoing description is for illustrative purposes only and not for limiting purposes. Modifications and variations are possible based on the foregoing description, or may be obtained from practicing the invention. The claims and their equivalents define the scope of the invention.

Claims

1. A method for replacing a manually serviceable circuit breaker (MSD) for a portable power bank, the method comprising: A set of batteries, including an MSD, is provided, the set of batteries being configured as a power bank; Remove the MSD from the power bank; A contactor is provided, which is configured to be electrically connected to a socket originally designed for the MSD; Install the contactor in place of the MSD; Provides a seal to protect the sealed environment from external moisture or humidity, such that the installed contactor meets an ingress protection rating, i.e., an IP rating, similar to the MSD on the aforementioned battery pack; and The contactor is a high-voltage switch or relay used to disable high-voltage and / or high-current power supplies, and the contactor includes a high-voltage, i.e., HV primary contact and a low-voltage, i.e., LV secondary contact, the LV secondary contact being configured to provide a monitoring device with information on whether the HV primary contact is soldered.

2. The method according to claim 1, wherein, The front surface of the contactor is integrated into the cavity of the MSD.

3. The method according to claim 1, wherein, The rear surface of the contactor is coupled to a cover plate having a shape factor substantially the same as that of the cover plate of the MSD.

4. The method of claim 3, wherein the MSD comprises at least one of a busbar and a fuse.

5. The method for replacing the manual maintenance circuit breaker (MSD) of a portable power supply according to claim 1, the method further comprising: The computing device controlling the contactor has a predetermined location, and the control is performed based on coordination between (i) the battery management system, i.e., BMS, (ii) the vehicle control unit, i.e., VCU, and (iii) another control unit that obtains output from the collision sensor.

6. The method for replacing the manual maintenance circuit breaker (MSD) of a portable power supply according to claim 1, the method further comprising: The contactor is actuated based on a low voltage signal applied to the coil to perform at least one of pulling in or releasing the contactor.

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