Modular battery for electric vehicle

Abstract

The invention relates to a power supply for electric vehicles and can be used in the transportation industry. The aim of the invention is to reduce the risk of damage to electronic components of an electric vehicle during operation of a modular battery (100, 200, 300, 400). This object is achieved by a modular battery (100, 200, 300, 400) of an electric vehicle in that a control unit (110, 210, 310, 410) enables execution of traction motor inverter capacitor pre-charge logic.

Description

FIELD OF THE INVENTION

[0001] The present invention relates to a power source for an electric vehicle and can be used in the transportation industry. BACKGROUND OF THE INVENTION

[0002] Existing modular batteries (MB) for electric vehicles include modules, each module including a battery pack of a switching unit of a power circuit connectable to an inverter of a traction motor of an electric vehicle [US7960943, publication date: June 14, 2011. IPC: H02J7 / 00].

[0003] A disadvantage of the known technical solution is a high risk of damage to the electronic components of an electric vehicle due to a decrease in the safety of the operation of the modular battery due to possible electrical failures of the battery pack.

[0004] The prototype is a modular battery for an electric vehicle, the modular battery including modules, each module including a control unit with a connected battery pack, these battery packs being connectable to a switching unit of a power circuit of an inverter of a traction motor of an electric vehicle, wherein one of these control units ensures receiving data on the state of the battery pack, including data on the state of the battery pack from other control units, and data shared with the control unit of the electric vehicle [CA3044173, publication date: December 19, 2013. IPC: B60K1 / 04; B60L58 / 26; B60W10 / 26].

[0005] The advantage of the prototype over the existing technical solution is a higher safety of the modular battery, since each module includes a control unit with a connected battery pack, and the control unit of one of these modules collects data on the state of the battery pack from the control units of other modules, thereby monitoring electrical failures of the battery packs of each individual module, thereby reducing the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0006] A disadvantage of the prototype is still a high risk of damage to the electronic components of the electric vehicle, especially the switching unit of the power circuit of its traction motor inverter, since during the charging of the inverter capacitor during the start of the traction motor and the connection of the modular battery to the inverter power circuit, an inevitable delay occurs, which can lead to an arc between the contactor elements connecting the modular battery and the inverter, which leads to a local temperature increase, which inevitably leads to the melting or welding of the contacts to each other and the failure of the contactor or other electronic components of the electric vehicle.

[0007] TECHNICAL OBJECTIVE

[0008] The object of the present invention is to reduce the risk of damage to the electronic components of an electric vehicle during the operation of a modular battery. Summary of the Invention

[0009] One aspect of the present invention is a modular battery for an electric vehicle, the modular battery comprising modules, each module comprising a control unit having a connected battery pack, the battery packs being connectable to a switching unit of a power circuit of a traction motor inverter of the electric vehicle.

[0010] One of these control units ensures receipt of data on the state of the connected battery packs and data on the state of the battery packs from the control units of the other modules, and enables execution of the pre-charging logic of the traction motor inverter capacitors.

[0011] Another aspect of the present invention is a method for reducing the risk of damage to the electronic components of an electric vehicle during the operation of a modular battery, the method comprising a control unit in one of the modules of the modular battery receiving data on the state of the connected battery packs and data on the state of the battery packs from the control units of the other modules, and, taking these data into account, executing the pre-charging logic of the traction motor inverter capacitors. In doing so, the control unit activates a capacitor pre-charging unit of the electric vehicle traction motor inverter connected to the traction motor inverter power circuit.

[0012] Objective Achievement

[0013] The objective of reducing the risk of damage to the electronic components of an electric vehicle during the operation of a modular battery is achieved by the fact that the modular battery further comprises a capacitor pre-charging unit of the electric vehicle traction motor inverter connected to the traction motor inverter power circuit, and the control unit enables the pre-charging logic to be executed by the traction motor inverter capacitors.

[0014] Positive Effects of the Present Invention

[0015] The modular battery may comprise a traction motor inverter capacitor pre-charging unit connected to the traction motor inverter power circuit, thereby further reducing the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0016] The modular battery may comprise an additional traction motor inverter capacitor pre-charging unit connected to the traction motor inverter power circuit, thereby further reducing the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0017] Each module may include a motherboard or other integrated board, which may have a capacitor pre-charging unit, contactors connecting each battery module and the inverter, and a control unit for each module, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery.

[0018] Each module may include a circuit breaker that provides positive disconnection of the circuit between battery packs, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the repair or maintenance of the modular battery.

[0019] Each module of the modular battery may include a lid housing with a limit switch that ensures interruption of the traction motor inverter power circuit when the lid is open, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the repair or maintenance of the modular battery.

[0020] The traction motor inverter capacitor pre-charging unit may be designed as a series-connected high-voltage relay and current-limiting resistor, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery.

[0021] When executing the traction motor inverter capacitor pre-charging logic, the control unit may poll the control units of other modules to obtain feedback, and in the absence of feedback, and when no feedback is available, it may send a signal of modular battery failure to the control unit of the electric vehicle and disable one module or the entire modular battery, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery.

[0022] When executing the traction motor inverter capacitor pre-charging logic, the control unit may receive data on the state of the battery packs (including from the control units of other modules), and if these parameters deviate from the permitted values, it may send a signal of modular battery failure to the control unit of the electric vehicle and / or disable one module or the entire modular battery, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery.

[0023] When executing the traction motor inverter capacitor pre-charging logic, the control unit may send a control signal with a length of 0.3 s to 0.8 s to the capacitor pre-charging unit, thereby further reducing the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery. In this case, the length of the control signal sent by the control unit to the pre-charging capacitor unit may be at least 0.5 s, which also further reduces the risk of damage to the electronic components of an electric vehicle during the operation of the modular battery.

[0024] When executing the traction motor inverter capacitor pre - charge logic, the control unit can send a control signal before the value of the current from the battery pack decreases, which further reduces the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery. At the same time, the control signal can be applied until the current value is between 1 A and 2 A, which further reduces the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0025] The control unit can enable the logic for detecting the unbalanced electrical performance of the modules by comparing the values of the voltage or current parameters of different modules, which further reduces the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery in the case where the module with the largest deviation is shut down.

[0026] If there are more than one capacitor and / or inverter and / or traction motor available in the electric vehicle design, the control unit can execute selection logic for one or all of the capacitor, inverter, or traction motor. This logic can be executed in cases where it is necessary to shift the drive shaft of the vehicle, in cases where one of the above - mentioned components of the electric vehicle fails, in cases where it is necessary to activate all of the above - mentioned components to provide maximum power, etc. It can also be executed in cases where it is necessary to operate the auxiliary capacitor, inverter, or traction motor (if any) of special equipment, which uses a power - consuming device connected separately from the main traction motor for operational reasons.

[0027] The control unit or an optional controller can accumulate data on the state of the battery pack and store this data in the internal memory, which provides the possibility of maintaining statistical information and further reduces the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0028] The module can include a heater and / or a cooler for the battery pack, which also further reduces the risk of damage to the electronic components of the electric vehicle during the operation of the modular battery.

[0029] The module can include communication tools using any known communication protocol (optical or laser line, telephone or coaxial cable, CAN bus, Ethernet, GSM, wireless WiFi, Bluetooth, or other wired and wireless standards, including those commonly used in Web 3.0, Web 4.0, IoT) that transmit the battery pack status and battery pack operation statistical information to other switches or control units in the vehicle or external devices (such as servers, communication hubs, dispatching centers, other vehicles, charging station control units, traffic control units, sensors, and other receiving devices) or provide a two - way exchange of meaningful information, including commands and instructions as well as updated software. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1

[0031] Figure 1 shows a functional diagram of a modular battery connected to a motor power circuit of an electric vehicle, where a capacitor pre-charging unit and a power circuit switch unit designed as a contactor are manufactured as separate components.

[0032] Figure 2

[0033] Figure 2 shows a functional diagram of a modular battery connected to a motor power circuit of an electric vehicle, where a capacitor pre-charging unit and a power circuit switch unit designed as a contactor are integrated into each battery module.

[0034] Figure 3

[0035] Figure 3 shows the pre-charging logic of the traction motor inverter capacitor executed by the main control unit of the modular battery of the electric vehicle. DETAILED DESCRIPTION

[0036] The following are embodiments that can be modified or supplemented in any way to demonstrate the feasibility of the present invention and a better understanding of the essence of the present invention. Therefore, the present invention is in no way limited by the presented embodiments.

[0037] PARAMETERS

[0038] The modular battery of an electric vehicle (which may include buses, trucks or passenger cars, aircraft (including space machinery), tunnel vehicles, floating vehicles (including underwater vehicles), utility and service vehicles (including their robotic and driverless versions)) includes modules 100, 200, 300 and 400. Each of these modules can be located in its own or shared sealed housing. The modules include: control units 110, 210, 310, 410, which can be designed as chips, controllers or processors; and battery packs 120, 130, 220, 230, 320, 330, 420, 430, which can be designed as separate elements or batteries with heaters and coolers, and these heaters and coolers are in the form of electrical components connected to the control units 110, 210, 310, 410 or in the form of heat exchangers with radiator units. In addition, modules 100, 200, 300 and 400 also include battery pack status sensors, such as voltage, current, temperature sensors, etc. ​​​

[0039] In addition, the modular battery includes: a CAN bus 500, or other means for sharing data between electronic components, such as cables or optical fibers; and a pre-charge unit 600 for a traction motor inverter capacitor of an electric vehicle, which includes a high-voltage relay or other circuit switch and a current-limiting resistor connected in series, and the pre-charge unit is installed in one of these modules or presented as a separate component.

[0040] The control units 110, 210, 310, and 410 are interconnected (via the CAN bus 500) and connected to the capacitor pre-charge unit 600, the contactor 700, the electric vehicle control unit 800, and the inverter 900; the inverter 900 is connected to the electric vehicle traction motor 1000.

[0041] When the electric vehicle is put into operation, the control unit 110 is set as the master by the operator, and the other units are designated as slaves. The units 110, 210, 310, and 410 can also be remotely set by a control center that generates appropriate commands, including in the automatic mode, without the operator's participation. The master / slave switch can be performed mechanically or electronically by setting appropriate roles in the unit software. To improve reliability, an electronically controlled robotic mechanical relay can also be used to change the master / slave. However, to prevent two or more master units from being applied simultaneously, the device can include a mechanical or electronic safety interlock that restricts the simultaneous application of multiple master units and restricts the application of another master unit when one master unit has already been applied.

[0042] When activated by the user of the electric vehicle or otherwise activated, and if the vehicle is connected to a charger in step 1100, a control signal is sent from the control unit 800 to the control unit 110 to enable the execution of the traction motor inverter capacitor pre-charge logic. This logic can also be activated when the device "wakes up", for example, when waiting for a long time in traffic congestion or a stopover, or when the consumer otherwise needs to be in a power-saving mode. If several traction motors 1000 are installed on one vehicle and each traction motor can operate independently, this logic can also be activated.

[0043] When executing this algorithm, the unit 110 first performs step 1110 to poll the slave units 210, 310, 410 for feedback, and if no feedback is available, at step 1120, the unit 110 signals to the unit 800 that the modular battery has malfunctioned and it is disabled.

[0044] If the slave units 210, 310, 410 are successfully polled by the unit 110, step 1130 is executed to receive sensed parameters, such as temperature, voltage, current, etc., from them and from the battery packs 120 and 130.

[0045] Then, step 1140 compares the resulting parameter value with the permitted values stored in its internal memory. If the parameter value is outside the parameter value range, unit 110 initiates step 1120 and signals to unit 800 that the modular battery has failed and it is disabled.

[0046] If the parameter value is within the tolerance range, unit 110 initiates step 1150 and sends a signal to the capacitor pre - charging unit 600 for at least 0.5 s, causing the high - voltage relay to close, thereby charging the capacitors of the inverter 900 of the electric vehicle traction motor via battery packs 120, 130, 220, 230, 320, 330, 420, 430.

[0047] The control signal is applied by control unit 110 before the current rate in battery packs 120, 130, 220, 230, 320, 330, 420, 430 is reduced to a value between 1 A and 2 A. Then, in step 1160, control unit 110 applies a control signal to contactor 700, ensuring that the circuit is closed without the risk of melting the contact elements and causing them to fail. Logic - driven data regarding the state of battery packs 120, 130, 220, 230, 320, 330, 420, 430 is stored by unit 110 in its internal memory and can be further used to collect statistical information regarding the state of the modular battery.

[0048] Industrial feasibility

[0049] The present invention can be made from known materials using known tools, which demonstrates its compliance with the patentability criterion of "industrial feasibility".

[0050] Patent literature

[0051] Patent document 1: Patent EP3723157

[0052] Patent document 2: Patent CA3044173

Claims

1. A modular battery (MB) for an electric or hybrid vehicle, comprising: - Modules, each of the modules including a control unit having at least one battery pack with a power circuit switch capable of being connected to an inverter of a traction motor of the electric vehicle, wherein: - One of the control units enables: - Receiving data on the state of one or more connected battery packs, and data on the state of battery packs from other control units, the data being shared with the control unit of the electric vehicle; - Executing traction motor inverter capacitor pre-charging logic.

2. The modular battery according to claim 1, further comprising a capacitor pre-charging unit for the inverter of the traction motor of the electric vehicle, the capacitor pre-charging unit being connected to the power circuit of the traction motor inverter.

3. The modular battery according to claim 2, each module including a main board or other integrated board having a capacitor pre-charging unit mounted therein, a contactor connecting each battery module and the inverter, and a control unit for each module.

4. The modular battery according to claim 2, wherein the capacitor pre-charging unit of the traction motor inverter is designed as a series-connected high-voltage relay and a current-limiting resistor.

5. The modular battery according to claim 1, the control unit enabling execution of logic to select one or all of the electric vehicle capacitor and / or inverter and / or traction motor.

6. The modular battery according to claim 1, when executing the traction motor inverter capacitor pre-charging logic, the control unit polls the control units of other modules for feedback, and in the absence of feedback, sends a signal of modular battery failure to the control unit of the electric vehicle and / or disables one of the modules or the entire modular battery.

7. The modular battery according to claim 1, when executing the traction motor inverter capacitor pre-charging logic, the control unit provides data on the state of the battery pack, including data from the control units of other modules, and in the case of deviation of these parameters from the allowable values, sends a signal of modular battery failure to the control unit of the electric vehicle and / or disables one of the modules or the entire modular battery.

8. The modular battery according to claim 1, when executing the traction motor inverter capacitor pre-charging logic, the control unit sends a control signal to the capacitor pre-charging unit for at least 0.3 s to 0.8 s.

9. The modular battery according to claim 8, wherein the control unit sends a signal to the pre-charging capacitor unit for at least 0.5 s.

10. The modular battery according to claim 1, when executing the traction motor inverter capacitor pre-charging logic, the control unit sends the control signal until the value of the current from the battery pack decreases.

11. The modular battery according to claim 10, wherein the control unit transmits the control signal until the current value decreases to a value between 1 A and 2 A.

12. The modular battery according to claim 1, wherein the control unit enables the execution of logic for detecting the unbalanced electrical performance of the modules.

13. The modular battery according to claim 1, wherein the module includes a heater and / or a cooler for the battery pack.

14. The modular battery according to claim 1, wherein each module thereof includes a power switch that provides a positive disconnection of the circuit between the battery packs.

15. The modular battery according to claim 1, wherein each module (or the entire modular battery) includes a lid housing having a limit switch to ensure that the traction motor inverter power circuit is disconnected when the lid is opened.

16. A method for reducing the risk of damage to the electronic components of an electric vehicle during the operation of a modular battery, wherein: - a control unit in one of the modular battery modules receives data on the state of the connected battery pack and data on the state of the battery pack from the control units of the other modules; - the pre-charging logic of the capacitor of the electric vehicle traction motor inverter is performed by a capacitor pre-charging unit connected to the power circuit of the traction motor inverter related to the electric vehicle.

17. The method according to claim 16, wherein when performing the pre-charging logic of the capacitor of the traction motor inverter, the control unit polls the control units of the other modules for feedback, and in the absence of available feedback, sends a signal of a modular battery failure to the control unit of the electric vehicle and / or disables one of the modules or the entire modular battery.

18. The method according to claim 16, wherein when performing the pre-charging logic of the capacitor of the traction motor inverter, the control unit receives data on the state of the battery pack, including data from the control units of the other modules, and in the case where these parameters deviate from the allowable values, sends a signal of a modular battery failure to the control unit of the electric vehicle and / or disables one of the modules or the entire modular battery.

19. The method according to claim 16, wherein when performing the pre-charging logic of the capacitor of the traction motor inverter, the control unit sends a control signal to the capacitor pre-charging unit for at least 0.3 s to 0.8 s.

20. The method according to claim 19, wherein the length of the signal sent by the control unit to the capacitor pre-charging unit is at least 0.5 s.

21. The method according to claim 16, wherein when performing the pre-charging logic of the capacitor of the traction motor inverter, the control unit applies the control signal until the value of the current from the battery pack decreases.

22. The method according to claim 21, wherein the control unit applies the control signal until the current value decreases to a value between 1 A and 2 A.

23. The method according to claim 16, wherein the control unit executes a logic for detecting an unbalanced electrical performance of the module.

24. The method according to claim 16, wherein, in a case where the electric vehicle has more than one capacitor and / or inverter and / or traction motor, the control unit executes a logic to select one or all of the capacitor, the inverter, or the traction motor.

25. The method according to claim 16, wherein when the modular battery "wakes up", the control unit executes the pre-charging logic of the traction motor inverter capacitor.

26. The method according to claim 16, wherein, in a case where a plurality of traction motors are installed on the same vehicle and the plurality of traction motors operate independently of each other, the control unit executes the pre-charging logic of the traction motor inverter capacitor.

Images