Convertible parallel configuration for modular battery systems

Abstract

The invention relates to a convertible parallel configuration for a modular battery system. A modular battery system includes a battery pack having multiple battery modules electrically interconnected via a plurality of cables. The plurality of switches selectively connect the multi-cell module. A direct current (DC) charging connector is configured to electrically connect the battery pack to an off-board DC fast charging station via a plurality of cables. The battery pack circuit is adapted to transition between a first configuration and a second configuration based on respective positions of the plurality of switches. The controller is configured to select a respective position of each of the plurality of switches in response to an input signal indicative of a requested mode of operation of the battery pack to transition the battery pack circuit between a first configuration and a second configuration. The first configuration provides three parallel electrical paths and the second configuration provides two parallel electrical paths.

Description

Technical Field

[0001] The present disclosure generally relates to modular battery systems and motor vehicles having the same. More specifically, the present disclosure relates to modular battery systems that can be converted between parallel configurations. Background Art

[0002] The present disclosure generally relates to modular battery systems and motor vehicles having the same. More specifically, the present disclosure relates to modular battery systems that are capable of switching between parallel configurations. The use of mobile platforms that employ rechargeable energy sources (both as dedicated energy sources and non-dedicated energy sources) has greatly increased over the past few years. Rechargeable energy storage devices having battery packs can store and release electrochemical energy as needed during a given operating mode. The electrochemical energy can be employed for propulsion, heating or cooling of vehicle compartments, powering vehicle accessories, and other uses. Summary of the invention

[0003] A modular battery system having a battery pack is disclosed herein, the battery pack having multiple battery modules and multiple cables. The multiple battery modules are electrically interconnected via multiple cables in the battery pack circuit. The system includes multiple switches that selectively connect the multiple battery modules. The multiple battery modules are divided into a first group, a second group, a third group, and a fourth group. A direct current (DC) charging connector is configured to electrically connect the battery pack to an off-board DC fast charging station via multiple cables. The battery pack can be selectively connected to a propulsion output.

[0004] The battery pack circuit is adapted to switch between a first configuration and a second configuration based on respective positions of a plurality of switches. The controller is configured to select respective positions of each of the plurality of switches in response to an input signal indicating a requested operating mode of the battery pack so that the battery pack circuit switches between the first configuration and the second configuration. The respective battery cells in the battery pack circuit are arranged in a combination of series interconnection and parallel interconnection. The first configuration provides three parallel electrical pathways, and the second configuration provides two parallel electrical pathways. The parallel electrical pathways refer to individual battery cells of the respective battery cells arranged in parallel, or groups of the respective battery cells arranged in parallel.

[0005] The first configuration may represent a propulsion mode, and the second configuration may represent a charging mode. In one embodiment, the first configuration provides a propulsion power of approximately 400 volts, and the second configuration provides a charging power of approximately 600 volts. The multi-battery modules may be divided into a first group, a second group, a third group, and a fourth group. The first group includes two modules positioned at the negative end of the battery pack circuit, and the fourth group includes another two modules positioned at the positive end of the battery pack circuit. The second group and the third group each include a single module positioned in the middle of the battery pack circuit.

[0006] The plurality of switches may include a first load switch configured to electrically connect the battery pack circuit to a positive leg of the propulsion output, and a second load switch configured to electrically connect the battery pack circuit to a negative leg of the propulsion output. The plurality of switches may include a first charge switch configured to electrically connect the battery pack circuit to a positive leg of the DC charging connector, and a second charge switch configured to electrically connect the battery pack circuit to a negative leg of the DC charging connector.

[0007] In some embodiments, the first group includes one third of the corresponding battery cells in the battery pack circuit, the fourth group includes another third of the corresponding battery cells in the battery pack circuit, and the second and third groups together include the remaining third of the corresponding battery cells in the battery pack circuit.

[0008] The plurality of switches may include a central switch configured to, when in a respective closed position: electrically connect the respective positive branch of the second group to the respective positive branch of the first group, and electrically connect the respective negative branch of the fourth group to the respective positive branch of the first group. At least one of the plurality of switches may be an electromechanical contactor. At least one of the plurality of switches may be a solid-state switch and / or a diode.

[0009] The first configuration can be achieved when: the central switch is in a corresponding closed position; the first load switch and the second load switch electrically connect the battery pack circuit to the propulsion output; the corresponding negative branch of the second group is selectively connected to the propulsion output; and the corresponding positive branch of the third group is selectively connected to the propulsion output. The second configuration can be achieved when: the central switch is in a corresponding open position; the first charging switch and the second charging switch electrically connect the battery pack circuit to the DC charging connector; the corresponding positive branch of the first group is selectively connected to the corresponding negative branch of the second group; and the corresponding positive branch of the third group is connected to the corresponding negative branch of the fourth group.

[0010] The plurality of switches may include a first bidirectional switch having two closed positions. In one of the two closed positions, the first bidirectional switch is configured to electrically connect the corresponding negative branch of the second group to the propulsion output. In the other of the two closed positions, the first bidirectional switch is configured to electrically connect the corresponding positive branch of the first group to the corresponding negative branch of the second group.

[0011] The plurality of switches may include a second bidirectional switch having two closed positions. In one of the two closed positions, the second bidirectional switch is configured to electrically connect the corresponding positive branch of the third group to the propulsion output. In the other of the two closed positions, the second bidirectional switch is configured to electrically connect the corresponding positive branch of the third group to the corresponding negative branch of the fourth group.

[0012] Disclosed herein is a motor vehicle with a battery pack, the battery pack having multiple battery modules and multiple cables. The multiple battery modules are electrically interconnected via multiple cables in the battery pack circuit. The battery pack can be selectively connected to a propulsion output to generate propulsion power for the vehicle. The battery pack includes a direct current (DC) charging connector configured to electrically connect the battery pack to an off-board DC fast charging station via multiple cables, and the multiple battery modules are divided into a first group, a second group, a third group, and a fourth group. The battery pack includes multiple switches that selectively connect multiple battery modules, and the battery pack circuit is suitable for switching between a first configuration and a second configuration based on the corresponding positions of the multiple switches. The controller is configured to select the corresponding position of each of the multiple switches in response to an input signal indicating the requested operating mode of the battery pack, so that the battery pack circuit is transformed between the first configuration and the second configuration. The first configuration provides three parallel electrical paths, and the second configuration provides two parallel electrical paths.

[0013] The present invention includes the following technical solutions:

[0014] 1. A modular battery system comprising:

[0015] A battery pack having a plurality of battery modules and a plurality of cables, the plurality of battery modules being electrically interconnected via the plurality of cables in a battery pack circuit, the plurality of battery modules being divided into a first group, a second group, a third group, and a fourth group;

[0016] a direct current (DC) charging connector configured to electrically connect the battery pack to an off-board DC fast charging station via the plurality of cables, the battery pack being selectively connectable to a propulsion output;

[0017] a plurality of switches selectively connecting the multiple battery modules, the battery pack circuit being adapted to switch between a first configuration and a second configuration based on respective positions of the plurality of switches;

[0018] a controller having a processor and a tangible, non-transitory memory having instructions recorded thereon, the controller adapted to select respective positions of the plurality of switches in response to an input signal indicative of a requested operating mode of the battery pack to cause the battery pack circuit to switch between the first configuration and the second configuration;

[0019] wherein the respective battery cells in the battery pack circuit are arranged in a combination of series interconnection and parallel interconnection; and

[0020] Wherein, the first configuration provides three parallel electrical paths and the second configuration provides two parallel electrical paths, the parallel electrical paths referring to individual battery cells of the corresponding battery cells arranged in parallel, or groups of the corresponding battery cells arranged in parallel.

[0021] 2. The system of claim 1 , wherein the first configuration represents a propulsion mode and the second configuration represents a charging mode.

[0022] 3. A system according to Option 1, wherein the first configuration provides approximately 400 volts of propulsion power and the second configuration provides approximately 600 volts of charging power.

[0023] 4. The system according to claim 1, wherein the plurality of switches comprises:

[0024] a first load switch configured to electrically connect the battery pack circuit to a positive branch of the propulsion output;

[0025] a second load switch configured to electrically connect the battery pack circuit to a negative branch of the propulsion output;

[0026] a first charging switch configured to electrically connect the battery circuit to a positive branch of the DC charging connector; and

[0027] A second charging switch is configured to electrically connect the battery circuit to a negative branch of the DC charging connector.

[0028] 5. The system according to claim 1, wherein:

[0029] The first group includes two modules positioned at a negative end of the battery circuit, and the fourth group includes another two modules positioned at a positive end of the battery circuit; and

[0030] The second group and the third group each include a single module positioned in the middle of the battery pack circuit.

[0031] 6. The system according to claim 5, wherein:

[0032] The first group includes one third of the respective battery cells in the battery pack circuit;

[0033] The fourth group includes another third of the corresponding battery cells in the battery pack circuit; and

[0034] The second group and the third group together include the remaining one third of the respective battery cells of the battery pack circuit.

[0035] 7. The system of claim 5, wherein the plurality of switches include a central switch, the central switch being configured to, when in a corresponding closed position:

[0036] electrically connecting the respective positive branches of the second group to the respective positive branches of the first group; and

[0037] The respective negative branches of the fourth group are electrically connected to the respective positive branches of the first group.

[0038] 8. The system according to claim 7, wherein the first configuration is implemented under the following circumstances:

[0039] The central switch is in a corresponding closed position;

[0040] a first load switch and a second load switch electrically connecting the battery pack circuit to the propulsion output;

[0041] The respective negative branches of the second set are selectively connected to the propulsion output; and

[0042] A respective positive branch of the third set is selectively connectable to the propulsion output.

[0043] 9. The system according to claim 7, wherein the second configuration is implemented in the following cases:

[0044] The central switch is in a corresponding disconnected position;

[0045] A first charging switch and a second charging switch electrically connect the battery pack circuit to the DC charging connector;

[0046] selectively connecting the respective positive branches of the first group to the respective negative branches of the second group; and

[0047] The respective positive branches of the third group are connected to the respective negative branches of the fourth group.

[0048] 10. The system according to claim 7, wherein:

[0049] The plurality of switches includes a first bidirectional switch having two closed positions;

[0050] In one of the two closed positions, the first bidirectional switch is configured to electrically connect a corresponding negative branch of the second set to the propulsion output; and

[0051] In the other of the two closed positions, the first bidirectional switch is configured to electrically connect the respective positive branch of the first group to the respective negative branch of the second group.

[0052] 11. The system according to claim 7, wherein:

[0053] The plurality of switches includes a second bidirectional switch having two closed positions;

[0054] In one of the two closed positions, the second bidirectional switch is configured to electrically connect a corresponding positive branch of the third group to the propulsion output; and

[0055] In the other of the two closed positions, the second bidirectional switch is configured to electrically connect the respective positive branch of the third group to the respective negative branch of the fourth group.

[0056] 12. The system of claim 1 , wherein at least one of the plurality of switches is an electromechanical contactor.

[0057] 13. The system of claim 1 , wherein at least one of the plurality of switches comprises a solid-state switch and / or a diode.

[0058] 14. A motor vehicle comprising:

[0059] a battery pack having a plurality of battery modules and a plurality of cables, the plurality of battery modules being electrically interconnected via the plurality of cables in a battery pack circuit, the battery pack being selectively connectable to a propulsion output to generate propulsion power for the vehicle;

[0060] Wherein, the battery pack comprises:

[0061] a direct current (DC) charging connector configured to electrically connect the battery pack to an off-board DC fast charging station via the plurality of cables, the plurality of battery modules being divided into a first group, a second group, a third group, and a fourth group;

[0062] a plurality of switches selectively connecting the multiple battery modules, the battery pack circuit being adapted to switch between a first configuration and a second configuration based on respective positions of the plurality of switches;

[0063] a controller configured to select a respective position of each of the plurality of switches to cause the battery pack circuit to transition between the first configuration and the second configuration in response to an input signal indicative of a requested operating mode of the battery pack; and

[0064] wherein the corresponding battery cells in the battery pack circuit are arranged in a combination of series interconnection and parallel interconnection;

[0065] Wherein, the first configuration provides three parallel electrical paths and the second configuration provides two parallel electrical paths, the parallel electrical paths referring to individual battery cells of the corresponding battery cells arranged in parallel, or groups of the corresponding battery cells arranged in parallel.

[0066] 15. The vehicle of claim 14, wherein:

[0067] The first group includes two modules positioned at a negative end of the battery circuit, and the fourth group includes two modules positioned at a positive end of the battery circuit; and

[0068] The second group and the third group each include a single module positioned in the middle of the battery pack circuit.

[0069] 16. The vehicle of claim 14, wherein:

[0070] The first group includes one third of the respective battery cells in the battery pack circuit;

[0071] The fourth group includes another third of the corresponding battery cells in the battery pack circuit; and

[0072] The second group and the third group together include the remaining one third of the respective battery cells of the battery pack circuit.

[0073] 17. The vehicle of claim 14, wherein the plurality of switches include a central switch, the central switch being configured to, when in a respective closed position:

[0074] electrically connecting the respective positive branches of the second group to the respective positive branches of the first group; and

[0075] The respective negative branches of the fourth group are electrically connected to the respective positive branches of the first group.

[0076] 18. The vehicle according to claim 17, wherein the first configuration is achieved when:

[0077] said central switch being in said corresponding closed position;

[0078] a first load switch and a second load switch electrically connecting the battery pack circuit to the propulsion output;

[0079] The respective negative branches of the second set are selectively connected to the propulsion output; and

[0080] A respective positive branch of the third set is selectively connectable to the propulsion output.

[0081] 19. The vehicle according to claim 17, wherein the second configuration is achieved when:

[0082] The central switch is in a corresponding disconnected position;

[0083] A first charging switch and a second charging switch electrically connect the battery pack circuit to the DC charging connector;

[0084] selectively connecting the respective positive branches of the first group to the respective negative branches of the second group; and

[0085] The respective positive branches of the third group are connected to the respective negative branches of the fourth group.

[0086] 20. A modular battery system comprising:

[0087] A battery pack having a plurality of battery modules and a plurality of cables, the plurality of battery modules being electrically interconnected via the plurality of cables in a battery pack circuit, the plurality of battery modules being divided into a first group, a second group, a third group, and a fourth group;

[0088] a direct current (DC) charging connector configured to electrically connect the battery pack to an off-board DC fast charging station via the plurality of cables, the battery pack being selectively connectable to a propulsion output;

[0089] a plurality of switches selectively connecting the multiple battery modules, the battery pack circuit being adapted to switch between a first configuration and a second configuration based on respective positions of the plurality of switches, the plurality of switches including a center switch;

[0090] a controller having a processor and a tangible, non-transitory memory having instructions recorded thereon, the controller adapted to select respective positions of the plurality of switches in response to an input signal indicative of a requested operating mode of the battery pack to cause the battery pack circuit to transition between the first configuration and the second configuration;

[0091] wherein the corresponding battery cells in the battery pack circuit are arranged in a combination of series interconnection and parallel interconnection;

[0092] wherein the first configuration provides three parallel electrical pathways and the second configuration provides two parallel electrical pathways, the parallel electrical pathways referring to individual ones of the corresponding battery cells arranged in parallel, or groups of the corresponding battery cells arranged in parallel;

[0093] wherein the first configuration is achieved when the central switch is in a corresponding closed position, the corresponding positive branch of the first group is selectively connected to the corresponding negative branch of the second group, and the corresponding positive branch of the third group is selectively connected to the corresponding negative branch of the fourth group; and

[0094] The second configuration is achieved when the central switch is in a corresponding open position, the corresponding negative branch of the second group is selectively connected to the propulsion output, and the corresponding positive branch of the third group is selectively connected to the propulsion output.

[0095] The above features and advantages and other features and advantages of the present disclosure are readily apparent from the following detailed description of the best modes for carrying out the disclosure when taken in connection with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0096] Figure 1 is a schematic diagram of a modular battery system having multiple battery modules;

[0097] Figure 2 Can be used in Figure 1 a schematic diagram of an example battery circuit in a system of FIG. 1 , the battery circuit being in a first configuration; and

[0098] Figure 3 yes Figure 2 a schematic diagram of a battery circuit shown in , the battery circuit being in a second configuration;

[0099] Representative embodiments of the present disclosure are shown in the accompanying drawings by way of non-limiting examples and are described in more detail below. However, it should be understood that the novel aspects of the present disclosure are not limited to the specific forms illustrated in the drawings listed above. Instead, the present disclosure will cover modifications, equivalents, combinations, sub-combinations, arrangements, groups and alternatives that fall within the scope of the present disclosure as, for example, covered by the appended claims. DETAILED DESCRIPTION

[0100] Referring to the drawings, wherein like reference numerals refer to like parts, Figure 1 A modular battery system 10 is schematically illustrated having a battery pack 12 with multiple battery modules 14. Each module 14 may include respective battery cells having different chemistries (including but not limited to lithium-ion batteries, lithium-iron batteries, nickel-metal-hydride batteries, and lead-acid batteries). It should be understood that the number of battery cells in each module and the number of modules in the battery pack 12 may vary based on the application at hand.

[0101] The modular battery system 10 can be part of a rechargeable energy storage device for powering a vehicle 16. The vehicle 16 can be partially electric or fully electric. The vehicle 16 can be a mobile platform such as, but not limited to, a passenger vehicle, a sport utility vehicle, a light truck, a heavy vehicle, an ATV, a minivan, a bus, a transit vehicle, a bicycle, a mobile robot, an agricultural implement (e.g., a tractor), sports-related equipment (e.g., a golf cart), a boat, an airplane, and a train. It should be understood that the vehicle 16 can take many different forms and have additional components.

[0102] Convertible battery pack circuits face limitations in implementing various configurations. For example, a circuit having a convertible configuration with a 2:1 ratio (two parallel electrical paths in one configuration and one parallel electrical path in the other configuration) cannot support a battery pack with 300 cells in a 3P100S configuration to convert to a higher voltage for charging. Here the number before P is the number of parallel cells in the battery pack 12, and the number before S is the number of cells in series. This

[0103] This is because the integers in the ratio represent actual cells that cannot be divided. Therefore, it is not trivial to design a battery circuit with a convertible configuration in a specific ratio in order to meet various requirements for component reuse, packaging, and voltage.

[0104] As described below, the battery pack 12 includes a specific set of modules, switches, and interconnects that allow the battery pack 12 to be operated in different Figure 2-3 The first configuration 100 shown in the figure is converted between the first configuration 100 and the second configuration 200. The first configuration 100 provides three parallel electrical paths (3P mode), and the second configuration 200 provides two parallel electrical paths (2P mode). The structure described below achieves a 3:2 ratio, so that the battery pack 12 with a 3P100S configuration can be easily converted to a 2P150S configuration.

[0105] refer to Figure 2-3 The multiple battery modules 14 are electrically interconnected via multiple cables 18 in a battery pack circuit 20. The battery pack circuit 20 includes multiple switches 22 adapted to selectively connect the multiple battery modules 14. Figure 1 The modular battery system 10 includes a controller C adapted to select a corresponding position of each of a plurality of switches 22 in response to an input signal indicative of a requested operating mode of the battery pack 12 so as to switch the battery pack circuit 20 between a first configuration 100 and a second configuration 200 .

[0106] refer to Figure 1 , the controller C has at least one processor P and at least one memory M (or a non-transitory tangible computer-readable storage medium), wherein instructions for controlling the operation of the plurality of switches 22 are recorded on the memory M. The memory M may store an executable instruction set, and the processor P may execute the instruction set stored in the memory M. The modular battery system 10 avoids having to redesign the motor and inverter by using the same circuit for various operating modes.

[0107] refer to Figure 2-3 , the multiple battery modules 14 can be selectively connected to a direct current (DC) charging connector 24 via one of a plurality of cables 18. Figure 1 , the vehicle 16 may undergo a direct current (DC) fast charging operation, wherein the battery pack 12 is electrically connected to an off-board DC fast charging station 26 via a vehicle charging port 28. The battery pack 12 is connected to the charging port 28, which may be selectively coupled to the off-board DC fast charging station 26 via additional accessories, such as a connector 25.

[0108] refer to Figure 2-3 , the multi-battery modules 14 are divided into a first group 30 , a second group 32 , a third group 34 and a fourth group 36 . Figure 2The first group 30 marked in comprises two modules 14A, 14B positioned at the (most) negative end of the battery circuit 20. The fourth group 36 comprises two modules 14E, 14F positioned at the (most) positive end of the battery circuit 20. Figure 2 The second and third groups 32 , 34 , labeled in FIG. 1 , include a single module 14C, 14D, respectively, positioned in the middle of the battery circuit 20 .

[0109] A parallel electrical path refers to a single battery cell or an array of n battery cells in parallel. The corresponding battery cells in the battery pack circuit 20 are arranged in a combination of series interconnection and parallel interconnection. The total number of battery cells in the circuit can be (SXP) arranged in an array so that the current is evenly distributed between each battery cell and the voltage drop is evenly applied to each battery cell. In the first configuration 100, relative to the second configuration 200, the parallel count P is 3 / 2 and the series count S is 2 / 3. The first group 30 and the fourth group 36 can be constructed by two modules connected in series or as two modules connected in parallel, each module having the same number of battery cells. Although the examples shown use a minimum number of parallel battery cells (i.e., 1P and 2P), it should be understood that larger battery packs can be made of 2P and 4P modules with the same battery cells to obtain higher energy capacity. Additionally, if the battery pack 12 is constructed using smaller cells (e.g., cylindrical), a larger number of cells may be employed, such as ten cells in parallel for the second and third groups 32, 34; and twenty cells in parallel for the first and fourth groups 30, 36.

[0110] In some embodiments, first group 30 includes one third of the respective cells in battery circuit 20 and fourth group 36 includes another third of the respective cells in battery circuit 20. Second group 32 and third group 34 together include the remaining third of the respective cells of battery circuit 20.

[0111] The battery pack circuit 20 allows the battery pack 12 to switch between a first configuration 100 (3P mode with three battery cells in parallel in each group) to a second configuration 200 (2P mode with two battery cells in parallel in each group), thereby enabling the battery pack 12 to generate an ideal voltage under various operating conditions. In the embodiment shown, the first configuration 100 represents a propulsion mode and the second configuration 200 represents a charging mode. In one example, the first configuration 100 provides a propulsion power of approximately 400 volts and the second configuration 200 provides a charging power of approximately 600 volts.

[0112] refer to Figure 2-3, the plurality of switches 22 include a first load switch 40, a second load switch 42, a first charging switch 44, a second charging switch 46, and a central switch 48. In one embodiment, the plurality of switches 22 include at least one electromechanical contactor. The plurality of switches 22 may include at least one solid-state switch and / or a diode. It should be understood that the plurality of switches 22 may have additional components and take different forms.

[0113] refer to Figure 2-3 , the first load switch 40 is configured to electrically connect the battery pack circuit 20 to the negative branch of the propulsion output 50 (via the propulsion connector 52). The propulsion output 50 transmits propulsion power to one or more electric machines for use by the vehicle 16. The second load switch 42 is configured to electrically connect the battery pack circuit 20 to the positive branch of the propulsion output 50. The first charging switch 44 is configured to electrically connect the battery pack circuit 20 to the negative branch of the DC charging connector 24. The second charging switch 46 is configured to electrically connect the battery pack circuit 20 to the positive branch of the DC charging connector 24.

[0114] The plurality of switches 22 may include a first bidirectional switch 60 and a second bidirectional switch 62. Alternatively, the first bidirectional switch 60 and the second bidirectional switch 62 may be replaced by two unidirectional switches, respectively. Figure 2-3 , the first bidirectional switch 60 has a first node N1 that can be alternately connected to the second node N2 and the third node N3. The second bidirectional switch 62 has a node referred to herein as a fourth node N4, which can be alternately connected to the fifth node N5 and the sixth node N6. In other words, the first bidirectional switch 60 and the second bidirectional switch 62 each have two closed positions.

[0115] refer to Figure 2 , when the center switch 48 is in a respective closed position, the first node N1 of the first bidirectional switch 60 is electrically connected to the second node N2, and the fourth node N4 of the second bidirectional switch 62 is electrically connected to the fifth node N5, a first configuration 100 of the battery pack circuit 20 is achieved. When the center switch 48 is closed, it electrically connects the respective positive branch of the second group 32 to the respective positive branch of the first group 30, and electrically connects the respective negative branch of the fourth group 36 to the respective positive branch of the first group 30. Additionally, the first load switch 40 and the second load switch 42 are closed, so that the propulsion output 50 is electrically connected to the battery pack circuit 20. In the first configuration 100, the first charging switch 44 and the second charging switch 46 are in their respective open positions.

[0116] exist Figure 2In the first configuration 100, when the first node N1 of the first bidirectional switch 60 is electrically connected to the second node N2, the corresponding negative branch of the second group 32 is electrically connected to the propulsion output 50. When the fourth node N4 of the second bidirectional switch 62 is electrically connected to the fifth node N5, the corresponding positive branch of the third group 34 is electrically connected to the propulsion output 50.

[0117] refer to Figure 3 , when the central switch 48 is in the corresponding open position, the first node N1 of the first bidirectional switch 60 is electrically connected to the third node N3, and the fourth node N4 of the second bidirectional switch 62 is electrically connected to the sixth node N6, the second configuration 200 is achieved. Figure 3 In the second configuration 200 shown in FIG. 1 , the battery pack 12 is being charged. Additionally, in the second configuration 200, the first load switch 40 and the second load switch 42 are in their respective open positions. The first charging switch 44 and the second charging switch 46 are closed and electrically connect the battery pack circuit 20 to the negative and positive branches of the DC charging connector 24, respectively.

[0118] exist Figure 3 In the second configuration 200, when the first node N1 of the first bidirectional switch 60 is connected to the third node N3, the corresponding positive branch of the first group 30 is electrically connected to the corresponding negative branch of the second group 32. When the fourth node N4 of the second bidirectional switch 62 is connected to the sixth node N6, the corresponding positive branch of the third group 34 is electrically connected to the corresponding negative branch of the fourth group 36.

[0119] refer to Figure 1 , the battery pack 12 may include a management unit 70 embedded with a microcircuit. The microcircuit may be an assembly of electronic components having a core implemented by a microcontroller and including a wireless communication interface available to those skilled in the art. The microcircuit may include an associated memory, an associated processor, and an integrated electronic control unit, such as an application specific integrated circuit (ASIC). Reference Figure 1 The battery pack communicator 72 may be linked or connected to the controller C, for example, via a communication bus, which may be a serial communication bus in the form of a local area network. The controller C (via the battery pack communicator 72) may be adapted to wirelessly interact with the battery pack 12 (via the management unit 70) via a wireless network 74.

[0120] The wireless network 74 may be a short range network or a long range network. Figure 1The wireless network 74 may be a wireless local area network (LAN) that links multiple devices using a wireless distribution method, a wireless metropolitan area network (MAN) that connects several wireless LANs, or a wireless wide area network (WAN) that covers a large area (such as a neighboring town or city). The wireless network 74 may be WIFI or Bluetooth. TM Bluetooth is defined as a short-range radio technology (or wireless technology) designed to simplify communication between Internet devices and between devices and the Internet. TM Is an open wireless technology standard for transmitting data between fixed and mobile electronic devices over short distances and creating personal networks operating in the 2.4 GHz frequency band. Other types of connections may be employed.

[0121] In summary, the modular battery system 10 includes a specific set of modules, switches, and interconnects that allow the battery pack 12 to be efficiently converted between a first configuration 100 (3P mode) and a second configuration 200 (2P mode). In one embodiment, the modular battery system 10 is employed in an electric vehicle 16 to generate a propulsion power of approximately 400 volts in the first configuration 100 and a charging voltage of approximately 600 volts in the second configuration 200. Relative to a non-convertible 600 volt system, being able to convert from a higher charging voltage (e.g., 600 volts) to a lower propulsion voltage (e.g., 400 volts) avoids applying overvoltage to the propulsion components. Alternatively, relative to a non-convertible 400 volt system, for equivalent power, it avoids excessive current passing through the charging port / connector, or for the same current, it avoids charging at a reduced power.

[0122] Figure 1 The controller C may be an integral part of other controllers of the vehicle 16 , or a separate module operably connected to other controllers of the vehicle 16 . Figure 1The controller C includes a computer-readable medium (also referred to as a processor-readable medium), including a non-temporary (e.g., tangible) medium that participates in providing data (e.g., instructions) that can be read by a computer (e.g., by a processor of a computer). Such media can take a variety of forms, including, but not limited to, non-volatile media and volatile media. Non-volatile media can include, for example, optical or magnetic disks and other permanent memories. Volatile media can include, for example, dynamic random access memory (DRAM), which can constitute a main memory. Such instructions can be transmitted via one or more transmission media, including coaxial cables, copper wires, and optical fibers, including lines that include a system bus connected to a processor of a computer. Some forms of computer-readable media include, for example, floppy disks, floppy disks, hard disks, tapes, other magnetic media, CD-ROMs, DVDs, other optical media, physical media with a pattern of holes, RAMs, PROMs, EPROMs, FLASH-EEPROMs, other memory chips or cassettes, or other media from which a computer can read.

[0123] Lookup tables, databases, data repositories or other data storages described herein may include various types of mechanisms for storing, accessing and retrieving various types of data, including hierarchical databases, a set of files in a file system, an application database in a proprietary format, a relational database management system (RDBMS), etc. Each such data storage may be included in a computing device that employs a computer operating system (such as one of those operating systems mentioned above), and may be accessed via a network in one or more multiple ways. The file system may be accessed from a computer operating system and may include files stored in various formats. In addition to the language for creating, storing, editing and executing stored procedures, RDBMS may also employ structured query language (Structured Query Language (SQL)), such as the PL / SQL language mentioned above.

[0124] The numerical values ​​of parameters (e.g., quantities or conditions) in this specification (including the appended claims) will be understood to be modified by the term "about" in each corresponding instance, regardless of whether "about" actually appears before the numerical value. "About" indicates that the numerical value set forth allows some slight imprecision (almost close to exact in value; approximately or reasonably close to the value; almost). If the imprecision provided by "about" is not otherwise understood in this ordinary sense in the art, the "about" used herein at least indicates the changes that may be caused by the common methods of measuring and using such parameters. In addition, the disclosure of the range includes the disclosure of each value and the further divided range within the entire range. Each value within the range and the endpoints of the range are thus disclosed as separate embodiments.

[0125] The detailed description and the accompanying drawings or figures are supportive and descriptive of the present disclosure, but the scope of the present disclosure is limited only by the claims. Although some of the best modes and other embodiments for implementing the claimed disclosure have been described in detail, there are various alternative designs and embodiments for practicing the disclosure defined in the appended claims. In addition, the embodiments shown in the drawings or the features of the various embodiments mentioned in this specification are not necessarily to be understood as embodiments independent of each other. Instead, it is possible that each feature described in one of the examples of the embodiments can be combined with one or more other desired features from other embodiments, resulting in other embodiments that are not described in words or with reference to the drawings. Accordingly, such other embodiments fall within the framework of the scope of the appended claims.

Claims

1. A modular battery system comprising: A battery pack having a plurality of battery modules and a plurality of cables, the plurality of battery modules being electrically interconnected via the plurality of cables in a battery pack circuit, the plurality of battery modules being divided into a first group, a second group, a third group, and a fourth group; a direct current (DC) charging connector configured to electrically connect the battery pack to an off-board DC fast charging station via the plurality of cables, the battery pack being selectively connectable to a propulsion output; a plurality of switches selectively connecting the multiple battery modules, the battery pack circuit being adapted to switch between a first configuration and a second configuration based on respective positions of the plurality of switches; a controller having a processor and a tangible, non-transitory memory having instructions recorded thereon, the controller adapted to select respective positions of the plurality of switches in response to an input signal indicative of a requested operating mode of the battery pack to cause the battery pack circuit to switch between the first configuration and the second configuration; wherein the respective battery cells in the battery pack circuit are arranged in a combination of series interconnection and parallel interconnection; and Wherein the first configuration provides three parallel electrical paths and the second configuration provides two parallel electrical paths, the parallel electrical paths referring to individual battery cells of the corresponding battery cells arranged in parallel, or groups of the corresponding battery cells arranged in parallel.

2. The system according to claim 1, wherein: The first configuration represents a propulsion mode and the second configuration represents a charging mode.

3. The system according to claim 1, wherein: The first configuration provides a propulsion power of approximately 400 volts, and the second configuration provides a charging power of approximately 600 volts.

4. The system according to claim 1, wherein: The plurality of switches include: a first load switch configured to electrically connect the battery pack circuit to a positive branch of the propulsion output; a second load switch configured to electrically connect the battery pack circuit to a negative branch of the propulsion output; a first charging switch configured to electrically connect the battery circuit to a positive branch of the DC charging connector; and A second charging switch is configured to electrically connect the battery circuit to a negative branch of the DC charging connector.

5. The system of claim 1, wherein: The first group includes two modules positioned at a negative end of the battery circuit, and the fourth group includes another two modules positioned at a positive end of the battery circuit; and The second group and the third group each include a single module positioned in the middle of the battery pack circuit.

6. The system of claim 5, wherein: The first group includes one third of the respective battery cells in the battery pack circuit; The fourth group includes another third of the corresponding battery cells in the battery pack circuit; and The second group and the third group together include the remaining one third of the respective battery cells of the battery pack circuit.

7. The system according to claim 5, wherein: The plurality of switches include a central switch, the central switch being configured, when in a respective closed position: electrically connecting the respective positive branches of the second group to the respective positive branches of the first group; and The respective negative branches of the fourth group are electrically connected to the respective positive branches of the first group.

8. The system according to claim 7, wherein: The first configuration is achieved when: The central switch is in a corresponding closed position; a first load switch and a second load switch electrically connecting the battery pack circuit to the propulsion output; The respective negative branches of the second set are selectively connected to the propulsion output; and A respective positive branch of the third set is selectively connectable to the propulsion output.

9. The system according to claim 7, wherein: The second configuration is achieved when: The central switch is in a corresponding disconnected position; A first charging switch and a second charging switch electrically connect the battery pack circuit to the DC charging connector; selectively connecting the respective positive branches of the first group to the respective negative branches of the second group; and The respective positive branches of the third group are connected to the respective negative branches of the fourth group.

10. The system of claim 7, wherein: The plurality of switches includes a first bidirectional switch having two closed positions; In one of the two closed positions, the first bidirectional switch is configured to electrically connect a corresponding negative branch of the second set to the propulsion output; and In the other of the two closed positions, the first bidirectional switch is configured to electrically connect the respective positive branch of the first group to the respective negative branch of the second group.

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