Battery configuration contactor assembly

Abstract

In a particular embodiment, a battery configuration contactor assembly is disclosed that includes a single housing enclosing a motor-driven cam shaft and a plurality of switches mechanically actuated by rotation of the cam shaft and operatively coupled to the cam shaft. In this embodiment, rotation of the cam shaft selectively configures electrical connections between a first battery portion and a second battery portion among a plurality of battery configuration states including at least: a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery-only connection state.

Description

BATTERY CONFIGURATION CONTACTOR ASSEMBLYBACKGROUND

[0001] Electromechanical switching devices, such as contactors and relays, are commonly used to selectively connect and disconnect electrical energy sources in high-power electrical systems. Such devices are particularly important in battery-powered systems, including electric vehicles, hybrid vehicles, and stationary energy storage systems, where large currents and voltages must be managed safely and reliably.

[0002] Modern battery systems often include multiple battery portions or battery packs that may be electrically reconfigured to support different operating modes. For example, battery portions may be connected in series to increase operating voltage, connected in parallel to increase current capability or capacity, isolated for safety or fault handling, or selectively connected to enable charging, balancing, or maintenance operations. The ability to reconfigure battery connections dynamically can improve system flexibility, efficiency, and safety.

[0003] Conventional approaches to battery reconfiguration frequently rely on multiple discrete contactors or modular contactor assemblies that are combined to achieve desired electrical configurations. While such approaches can provide functional flexibility, they tend to increase component count, physical size, weight, wiring complexity, and assembly effort. In addition, coordinating the operation of multiple independent contactors can be challenging, particularly in high-current applications where precise timing is required to avoid electrical arcing, voltage transients, or excessive inrush current.

[0004] High-current battery systems must be designed to safety withstand fault conditions, such as short-circuit events. During such events, electromagnetic forces generated by high current flow can adversely affect contact performance in some switching devices, potentially leading to reduced contact force, increased arcing, or thermal damage. Ensuring robust short-circuit performance while maintaining compact size and low contact resistance remains a significant technical challenge.

[0005] Accordingly, there is a continuing need for improved battery configuration switching solutions that reduce size and complexity, enable reliable and flexible reconfiguration of battery connections, limit inrush current and electrical stress during transitions, and provide robust performance under fault conditions. It is desirable that such solutions be well suited for integration into electric vehicles and other high-power battery systems.SUMMARY

[0006] The following summary is meant to help one skilled in the art understand the various presently disclosed combinations of features. It is not meant to unduly limit the scope of any pending or future claims relating to the disclosure.

[0007] The present disclosure relates to a compact battery configuration contactor assembly configured to selectively reconfigure electrical connections between multiple battery portions. The contactor assembly includes a plurality of switches and a motor-driven cam shaft integrated within a single housing and is operable to establish a plurality of battery configuration states, including series, parallel, fully open, and single-battery connection states. Coordinated actuation of the switches by the cam shaft enables controlled transitions between battery configuration states, including transitions that avoid complete interruption of current flow, thereby reducing electrical transients and contact wear. In some embodiments, the contactor assembly further provides improved short-circuit performance by arranging contacts and current paths such that electromagnetic forces generated during high-current events increase contact force. The compact, purpose-built architecture reduces component count, size, and complexity, making the contactor assembly well suited for use in electnc vehicles and other high-power battery systems.

[0008] In a particular embodiment, a battery configuration contactor assembly is disclosed that includes a single housing enclosing a motor-driven cam shaft and a plurality of switches mechanically actuated by rotation of the cam shaft and operatively coupled to the cam shaft. In this embodiment, rotation of the cam shaft selectively configures electrical connections between a first battery portion and a second battery portion among a plurality' of battery configuration states including at least: a series connection state, a parallel connection state, a fully open state, a first-battery -only connection state, and a second-battery-only connection state.

[0009] In another embodiment, a battery' system is disclosed that includes a first battery portion, a second battery portion, a power distribution unit, and a battery configuration contactor assembly. The assembly includes a single housing enclosing a motor-driven cam shaft and a plurality of switches operatively coupled to the cam shaft. In this embodiment, rotation of the cam shaft selectively establishes electrical connections between the first battery' portion and the second battery portion among a plurality' of battery configuration states including a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery-only’ connection state. In addition, the battery configuration contactor assembly electrically couples the first battery portion and thesecond battery portion to the power distribution unit.

[0010] In another embodiment, a method of configuring a battery system is disclosed that includes providing a battery configuration contactor assembly including a motor-driven cam shaft and a plurality of switches enclosed within a single housing. The method also includes controlling rotation of the cam shaft and selectively establishing, in response to rotation of the cam shaft, one of a plurality of battery configuration states between a first battery portion and a second battery portion. In this embodiment, the battery configuration states includes a series connection state, a parallel connection state, a fully open state, a I'irst-battery-only connection state, and a second-battery-only connection state.

[0011] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular descriptions of exemplary embodiments of the invention as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts of exemplary embodiments of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0012] One or more aspects of the present disclosure are discussed below with reference to the accompanying Figures. It will be appreciated that for simplicity and clarity of illustration, elements shown in the drawings have not necessarily been drawn accurately or to scale. For example, the dimensions of some of the elements may be exaggerated relative to other elements for clarity or several physical components may be included in one functional block or element.

[0013] Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. For purposes of clarity, however, not every component may be labeled in every drawing. The Figures are provided for the purposes of illustration and explanation and are not intended to be limiting. In the Figures:

[0014] FIG. 1 A illustrates an exploded view7of a compact battery configuration contactor assembly in accordance with at least one embodiment of the present disclosure.

[0015] FIG. IB illustrates an assembled portion of the compact battery configuration contactor assembly of FIG. 1A.

[0016] FIG. 1C illustrates a side view of the compact battery configuration contactor assembly of FIG. 1A.

[0017] FIG. ID illustrates a bottom view of the compact battery configuration contactor assembly of FIG. 1A.

[0018] FIG. IE illustrates another side view of the compact battery configuration contactor assembly of FIG. 1A.

[0019] FIG. 2 is a flowchart of an example method of operating a compact battery configuration contactor assembly according to at least one embodiment of the present disclosure.

[0020] FIG. 3 is a flowchart of an example method of configuring a batten system according to at least one embodiment of the present disclosure.

[0021] FIG. 4 is a flowchart of an example method of configuring a battery system according to at least one embodiment of the present disclosure.

[0022] FIG. 5 is a flowchart of an example method of configuring a batten system according to at least one embodiment of the present disclosure.DETAILED DESCRIPTION

[0023] In the following detailed description, various combinations of embodied features are disclosed in order to provide one skilled in the art an understanding of the aspects and implementations of the present disclosure. It will be understood by those of ordinary skill in the art that those may be practiced without some of the specific details that are set forth. In some instances, well-known methods, procedures, components and structures may not be described in detail so as not to obscure the details of the implementations of the present disclosure. The following detailed description is not meant to unduly limit any present or future claim scope in this or subsequent related applications. This disclosure may use different names, or different numerical identifiers, to describe the same feature or partially the same part. Further, where considered appropriate, reference numerals may be repeated among the drawings to indicate corresponding or analogous elements. For purposes of clarity, however, not every' component may be labeled in every' drawing.

[0024] The terminology used herein for the purpose of describing particular examples is not intended to be limiting for further examples. Whenever a singular form such as '’a", “an” and “the” is used and using only a single element is neither explicitly nor implicitly defined as being mandatory, further examples may' also use plural elements to implement the same functionality. Likewise, when a functionality is subsequently described as being implemented using multiple elements, further examples may implement the same functionality using a single element or processing entity. It will be further understood that the terms “comprises”, “comprising”, “includes” and / or “including”, when used, specify the presence of the stated features, integers, steps, operations, processes, acts, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, processes, acts, elements, components and / or any group thereof.

[0025] It will be understood that when an element is referred to as being “connected” or“coupled” to another element, the elements may be directly connected or coupled or via one or more intervening elements. If two elements A and B are combined using an “or”, this is to be understood to disclose all possible combinations, i.e., only A, only B, as well as A and B. An alternative wording for the same combinations is “at least one of A and B”. The same applies for combinations of more than two elements.

[0026] Accordingly, while further examples are capable of various modifications and alternative forms, some particular examples thereof are shown in the figures and will subsequently be described in detail. However, this detailed description does not limit further examples to the particular forms described. Further examples may cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.

[0027] In modem battery-powered systems, such as electric vehicles and energy storage systems, it is often desirable to reconfigure electrical connections between multiple battery portions to support different operating modes. For example, different battery configurations may be used for propulsion, charging, balancing, fault isolation, or system startup. Achieving such reconfiguration reliably in high-voltage, high-current environments presents significant technical challenges, including minimizing size and weight, limiting inrush current, avoiding electrical arcing, and maintaining safe operation during fault conditions.

[0028] Conventional battery7configuration solutions often rely on multiple discrete contactors or modular contactor assemblies that are stacked or combined to achieve different electrical configurations. While such modular approaches offer flexibility, they tend to increase component count, packaging volume, assembly complexity, and cost. In addition, many conventional systems require fully opening current paths during transitions between configurations, which can lead to undesirable voltage transients, electrical stress, and reduced system reliability.

[0029] The present disclosure addresses these challenges by providing a compact, purpose-built battery configuration contactor assembly that integrates multiple electrically actuated switches and a motor-driven actuation mechanism within a single housing. The contactor assembly is configured to selectively establish a plurality of battery configuration states, including series, parallel, fully open, and single-battery connection states, using coordinated mechanical actuation. By integrating the switching and actuation components and enabling controlled transitions between battery configurations, the disclosed contactor assembly reduces size and complexity while improving operational robustness.

[0030] In some embodiments, the disclosed battery configuration contactor assembly enables transitions between selected battery configuration states without completely interruptingcurrent flow, thereby reducing electrical transients and contact wear. In some embodiments, the contactor assembly further provides improved short-circuit performance by arranging current paths and contact geometries such that electromagnetic forces generated during high-current events increase contact force. These and other features make the disclosed contactor assembly particularly well suited for use in electric vehicles and other high-power battery systems.

[0031] The structure and operation of exemplary embodiments of the battery configuration contactor assembly are described in further detail below with reference to the accompanying drawings.

[0032] Exemplary methods and apparatuses for a battery configuration contactor assembly in accordance with the present disclosure are described with reference to the accompanying drawings, beginning with FIG. 1 A. For further explanation, FIG. 1A sets forth an exploded view of a compact battery configuration contactor assembly 100 in accordance with at least one embodiment of the present disclosure. FIG. IB sets forth an assembled portion 200 of the compact battery configuration contactor assembly 100 of FIG. 1A. FIG. 1C illustrates a side view of the compact battery configuration contactor assembly 100, FIG. ID illustrates a bottom view of the compact battery configuration contactor assembly 100, and FIG. IE illustrates another side view of the compact battery configuration contactor assembly 100. For ease of illustration and explanation, not all components of the compact battery configuration contactor assembly 100 are illustrated in every figure, and certain components may be omitted or simplified in particular views.

[0033] The compact battery configuration contactor assembly 100 is a purpose-built electromechanical switching device configured to selectively establish multiple electrical interconnection states between a plurality of battery portions, such as first and second battery’ portions of a vehicle battery system. In particular embodiments, the compact battery configuration contactor assembly 100 is configured to selectively establish a series connection state, a parallel connection state, a fully open state, a first-batteiy-only connection state, and a second-battery-only connection state, thereby enabling flexible battery reconfiguration during vehicle operation, charging, or balancing.

[0034] Unlike modular contactor systems that employ multiple interchangeable contact modules that are stacked or combined to achieve different configurations, the compact battery configuration contactor assembly described herein is a purpose-built, non-modular device optimized for battery configuration applications. The integration of multiple switch assemblies and a motor-driven cam shaft within a single housing reduces component count.assembly steps, overall size, and weight, while improving reliability- and cost effectiveness for battery reconfiguration applications.

[0035] As shown in FIGs. 1A-1B, the compact battery configuration contactor assembly 100 includes a cam assembly 101 comprising a plurality of cams 102, 103 mounted on and coupled for rotation with a cam shaft 105. The cam shaft 105 extends through the assembly and is rotatably supported within the housing. Rotation of the cam shaft 105 is driven by a motor 106, which may be an electric motor coupled directly or indirectly to the cam shaft via one or more gears or transmission elements.

[0036] In the illustrated embodiment, the motor 106 is controlled by a printed circuit board (PCB) 140 that receives command signals via electrical wires 130. The PCB 140 may include control electronics configured to energize the motor 106 in a selected direction and for a selected duration to rotate the cam shaft 105 to a desired angular position corresponding to a selected battery configuration state. In other embodiments, motor control electronics may be external to the compact battery configuration contactor assembly 100. The motor driving the cam shaft may be a brushed motor, a brushless motor, a stepper motor, or another rotary actuator capable of controlled bidirectional rotation.

[0037] The compact battery configuration contactor assembly 100 includes a plurality of switch assemblies, including a first switch assembly 190 and a second switch assembly 191 in the illustrated embodiment. Each switch assembly includes at least one fixed contact and at least one movable contact, wherein movement of the movable contact relative to the fixed contact selectively opens or closes an electrical current path.

[0038] In the illustrated embodiment, the first switch assembly 190 includes two fixed contacts 150, 151 and a first rocker 112 carrying a movable contact 187. The second switch assembly 191 includes three fixed contacts 152. 153, 154. a second rocker 113 carrying a movable contact 188, and a third rocker 114 carrying a movable contact 186. Each rocker is mechanically coupled to and actuated by a corresponding cam 102, 103 such that rotation of the cam shaft 105 causes controlled displacement of the rockers and corresponding opening or closing of the associated electrical contacts.

[0039] In the example of FIGs. 1A-1B, the fixed contacts 150-154 are substantially C-shaped and define inner contact surfaces and outer surfaces. The movable contacts 186-188 carried by the rockers 112-114 are oriented to selectively engage the inner contact surfaces of the fixed contacts, thereby forming a low-resistance electrical connection when closed. The C-shaped geometry facilitates high current carrying capability and, in some embodiments, contributes to improved electromagnetic force behavior during fault conditions.

[0040] In some embodiments, the arrangement of the fixed contacts and movable contacts is such that electrical current flowing through the contactor assembly during a short-circuit event generates electromagnetic (Lorentz) forces that act to increase the contact force between mating contact surfaces. This increased contact force during high-current fault conditions reduces arcing, contact separation, and thermal damage, thereby improving short-circuit performance and safety.

[0041] In the illustrated embodiment, the cams 102, 103 include cam profiles having round portions, flat portions, and / or other contoured surfaces. Depending on the angular position of the cam shaft 105, the cams selectively engage or disengage the corresponding rockers to establish desired switch states. Other cam shapes, such as lobes, notches, stepped profiles, or combinations thereof, may also be employed.

[0042] In some embodiments, one or more switch assemblies may be configured as normally closed switches, while in other embodiments one or more switch assemblies may be configured as normally open switches. In normally open configurations, a protruding cam lobe or actuation surface applies a force to the rocker to move the movable contact into engagement with the fixed contact. Combinations of normally open and normally closed switch assemblies may be used within the same compact battery configuration contactor assembly.

[0043] The cams mounted on the cam shaft 105 may differ from one another by cam profile shape, angular orientation, axial position along the cam shaft, or combinations thereof. By appropriately selecting cam shapes and orientations, different switch assemblies may be actuated at different angular positions of the cam shaft, and multiple switch assemblies may be actuated simultaneously to distribute current across multiple contacts.

[0044] In some embodiments, rotation of the cam shaft 105 is configured such that transitions between battery configuration states occur with overlapping actuation of the switch assemblies. In particular embodiments, at least one switch remains closed during transitions between selected battery configuration states, thereby avoiding complete interruption of current flow during reconfiguration.

[0045] In some embodiments, the cam profiles and angular orientations are selected such that electrical connections are established in a predetermined sequence when transitioning between battery configuration states. In particular embodiments, transitions to the parallel connection state are performed with overlapping actuation of switches to temporarily maintain a controlled impedance path, thereby limiting inrush current when electrically combining the first battery portion and the second battery portion.

[0046] Although a fully open state is provided as one selectable battery configuration state, transitions between other battery configuration states need not pass through the fully open state. In some embodiments, the compact battery configuration contactor assembly transitions directly between selected battery configuration states while maintaining at least one closed switch during the transition.

[0047] In some embodiments, the plurality of battery configuration states are achieved by selectively closing and opening different subsets of the switches. For example, in a series connection state, a first subset of switches is closed to electrically connect the first battery portion in series with the second battery portion. In a parallel connection state, a second subset of switches is closed to electrically connect corresponding terminals of the first and second battery portions in parallel. In a first-battery-only connection state, switches associated with the first battery portion are closed while switches associated with the second battery portion remain open. In a second-battery-only connection state, switches associated with the second battery portion are closed while switches associated with the first battery portion remain open. In a fully open state, switches associated with both battery portions are open.

[0048] The compact battery configuration contactor assembly 100 may be used in an electric vehicle to selectively connect batten' portions to a vehicle power distribution system for propulsion, charging, balancing, or other operational modes.

[0049] As illustrated in FIGs. 1A, 1C. ID. and IE, the assembled portion 200 of the compact battery configuration contactor assembly 100 is enclosed by housing portions including a first housing portion 120 having a lid 141 and a bottom plate 122, and a second housing portion 124 having a bottom portion 125. In some embodiments, the housing portions together form a single integrated housing enclosing the switch assemblies, cam shaft, motor, and associated drive components.

[0050] In some embodiments, the compact battery configuration contactor assembly 100 includes a position sensing arrangement configured to detect an angular position of the cam shaft 105. The position sensing arrangement may include anon-contacting sensor or a contacting sensor, such as a potentiometer. The detected cam shaft position may be used to control motor operation, determine switch states, and communicate contactor state information to a vehicle controller.

[0051] In some embodiments, selection of a battery configuration state is achieved by rotating the cam shaft 105 to a mechanical hard stop corresponding to the desired state. In other embodiments, selection is achieved by counting motor revolutions or partialrevolutions. In still other embodiments, selection is achieved based on feedback from the position sensing arrangement.

[0052] In some embodiments, the compact battery configuration contactor assembly is configured to transition to a predetermined safe state upon detection of a fault condition, loss of power, or receipt of an error signal. The safe state may include opening one or more switches to electrically isolate at least one battery portion or placing the assembly in the fully open state.

[0053] The compact battery configuration contactor assembly described with reference to FIGs. 1 A-1E provides a technical solution to the problem of reconfiguring electrical connections between battery portions in high-current, high-voltage systems while minimizing size, complexity, and electrical stress. By integrating multiple switch assemblies and a motor-driven cam shaft within a single housing, the contactor assembly reduces the number of discrete components and interconnections required to achieve multiple battery configuration states.

[0054] The coordinated actuation of multiple switches by a common cam shaft enables precise control over the sequence and timing of switch transitions. As a result, selected battery configuration states can be established directly from other states without requiring an intermediate fully open condition. This capability reduces voltage transients, limits arcing, and improves reliability during reconfiguration, particularly in applications where battery connections are changed under load.

[0055] In addition, the disclosed arrangement of contacts and current paths provides improved performance during fault conditions. In particular embodiments, electromagnetic forces generated by high current flow during a short-circuit event act to increase contact force between mating contact surfaces, thereby reducing contact separation and thermal damage. This behavior contrasts with contactor designs in which electromagnetic forces reduce contact force under fault conditions.

[0056] By providing a compact, purpose-built contactor assembly capable of selectively establishing series, parallel, fully open, and single-battery connection states, the present disclosure enables battery systems w ith enhanced operational flexibility. These features facilitate controlled charging, battery balancing, inrush current mitigation, and fault isolation, while maintaining a reduced package size and improved safety. Accordingly, the compact battery configuration contactor assembly described herein is particularly well suited for electric vehicles and other battery-powered systems requiring robust and flexible battery reconfiguration.

[0057] For further explanation, FIG. 2 sets forth a flow chart illustrating an example method of operating a compact battery configuration contactor assembly in accordance with at least one embodiment of the present disclosure. The method of FIG. 2 may be performed using any of the compact battery configuration contactor assemblies described herein, including the compact battery configuration contactor assembly 100 described with reference to FIGs. 1 A-1E.

[0058] The method of FIG. 2 includes connecting 202 the compact battery configuration contactor assembly to a power distribution unit and to a plurality of battery portions. In some embodiments, the plurality of battery7portions includes a first battery portion and a second battery portion forming part of a vehicle battery system or other energy storage system. The compact battery configuration contactor assembly electrically interfaces with terminals of the battery portions and with the power distribution unit to selectively establish different electrical interconnection states between the battery portions and the power distribution unit.

[0059] In some embodiments, connecting 202 includes electrically coupling the compact battery configuration contactor assembly to enable selective establishment of a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery -only connection state. The selected battery configuration state may be chosen based on an operating mode of the system, such as propulsion, charging, battery balancing, startup, shutdown, or fault handling.

[0060] The method of FIG. 2 further includes rotating 204 a cam shaft of the compact battery configuration contactor assembly to change respective switch states of a plurality’ of switches within the assembly. Rotation of the cam shaft may be driven by a motor in response to a control signal generated by a controller, such as a vehicle control unit or battery management system. In some embodiments, the cam shaft is rotated in a first direction to establish a first battery configuration state and rotated in an opposite direction to establish a different battery configuration state.

[0061] Rotation of the cam shaft causes a plurality' of cams mounted on the cam shaft to rotate simultaneously. Each cam engages a corresponding rocker associated with a movable contact of a switch assembly. Depending on the angular orientation of the cam. the cam applies a force to the rocker to move the movable contact into or out of engagement with a fixed contact, thereby opening or closing an electrical current path. By rotating the cam shaft to different angular positions, different subsets of the sw itches are opened or closed to establish the desired battery configuration state.

[0062] In some embodiments, rotating 204 the cam shaft includes rotating the cam shaft to apredetermined angular position corresponding to a selected battery configuration state. The predetermined angular position may be determined by driving the cam shaft to a mechanical hard stop, by counting motor revolutions or partial revolutions, by using feedback from a position sensing arrangement coupled to the cam shaft, or by a combination thereof. In some embodiments, feedback from the position sensing arrangement is also used to confirm the established battery configuration state.

[0063] In some embodiments, rotating 204 the cam shaft is performed such that transitions between battery configuration states occur with overlapping actuation of the switches. In particular embodiments, at least one switch remains closed during a transition between battery configuration states, thereby avoiding complete interruption of current flow during reconfiguration. Such operation reduces electrical transients, arcing, and stress on the electrical system during switching events.

[0064] In some embodiments, rotating 204 the cam shaft includes sequencing the actuation of switches when transitioning to a parallel connection state to limit inrush current. For example, cam profiles and angular orientations may be selected such that one or more switches are closed in a controlled sequence to temporarily maintain a controlled impedance path while combining the first battery portion and the second battery portion in parallel.

[0065] In some embodiments, the method further includes detecting a fault condition or abnormal operating condition and rotating the cam shaft to establish a predetermined safe state. The safe state may include opening one or more switches to electrically isolate one or more battery portions or establishing the fully open state. In some embodiments, the safe state is established automatically in response to loss of power to the motor or receipt of an error signal.

[0066] Accordingly, the method illustrated in FIG. 2 enables controlled, reliable reconfiguration of electrical connections between battery portions using a compact battery configuration contactor assembly, while reducing size and complexity, limiting inrush current, avoiding unnecessary7interruption of current flow, and improving safety during fault conditions.

[0067] For further explanation, FIG. 3 sets forth a flow chart illustrating another example method of operating a compact battery configuration contactor assembly in accordance with at least one embodiment of the present disclosure. The method of FIG. 3 may be performed using any of the compact battery configuration contactor assemblies described herein, including the compact battery configuration contactor assembly 100 described with reference to FIGs. 1A-1E.

[0068] The method of FIG. 3 includes providing 302 a batten- configuration contactor assembly that includes a motor-driven cam shaft and a plurality of switches enclosed within a single housing. In some embodiments, the battery configuration contactor assembly is a purpose-built, non-modular device configured to selectively establish multiple electrical interconnection states between battery portions of a battery system. The battery- configuration contactor assembly may be installed within an electric vehicle, an energy storage system, or another battery-powered system.

[0069] In some embodiments, providing 302 the battery configuration contactor assembly includes electrically coupling the contactor assembly to a first battery- portion, a second battery portion, and a power distribution unit. The contactor assembly- is thereby positioned to selectively configure electrical connections between the first battery portion and the second battery portion in accordance with system operating requirements.

[0070] The method of FIG. 3 further includes controlling 304 rotation of the cam shaft. Controlling rotation of the cam shaft may include generating control signals to drive a motor coupled to the cam shaft in a selected direction and for a selected duration. In some embodiments, controlling 304 rotation of the cam shaft is performed by a controller, such as a vehicle control unit or battery management system, based on an operating mode, battery condition, charging state, or detected fault condition.

[0071] In some embodiments, controlling 304 rotation of the cam shaft includes determining a target angular position of the cam shaft corresponding to a desired battery- configuration state and rotating the cam shaft toward the target angular position. The target angular position may be determined using one or more of a mechanical hard stop, a count of motor revolutions or partial revolutions, feedback from a position sensing arrangement coupled to the cam shaft, or combinations thereof. In some embodiments, feedback from the position sensing arrangement is used to confirm that the cam shaft has reached the target angular position.

[0072] The method of FIG. 3 further includes selectively establishing 306, in response to rotation of the cam shaft, one of a plurality- of battery- configuration states between the first battery portion and the second battery portion. The battery- configuration states may include a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery -only connection state.

[0073] In some embodiments, selectively establishing 306 the battery- configuration state includes opening and closing different subsets of switches within the battery configuration contactor assembly by coordinated actuation of cams mounted on the cam shaft. Rotation of the cam shaft causes the cams to engage corresponding rockers associated with movablecontacts of the switches, thereby opening or closing electrical current paths in a predetermined manner to establish the selected battery’ configuration state.

[0074] In some embodiments, selectively establishing 306 the battery configuration state is performed such that transitions between selected battery configuration states occur without completely interrupting current flow. In particular embodiments, at least one switch remains closed during a transition between battery configuration states, thereby reducing electrical transients, arcing, and stress on the electrical system.

[0075] In some embodiments, selectively establishing 306 the battery configuration state includes sequencing the actuation of switches when transitioning to the parallel connection state to limit inrush current. For example, one or more switches may be closed in a controlled sequence to temporarily maintain a controlled impedance path while electrically combining the first battery portion and the second battery portion in parallel.

[0076] In some embodiments, the method further includes selectively establishing a first-battery-only connection state or a second-battery-only connection state to enable balancing of charge levels between the first battery portion and the second battery portion. Such balancing may be performed during charging, maintenance, or other operating modes.

[0077] In some embodiments, the method further includes detecting a fault condition and controlling rotation of the cam shaft to establish a predetermined safe state. The safe state may include electrically isolating one or more battery portions or establishing the fully open state. In some embodiments, the safe state is established automatically in response to loss of poyver or receipt of an error signal.

[0078] Accordingly, the method illustrated in FIG. 3 enables controlled, flexible reconfiguration of battery' connections using a compact battery configuration contactor assembly, yvhile reducing system complexity, limiting inrush current, avoiding unnecessary interruption of current flow, and improving operational safety7.

[0079] For further explanation, FIG. 4 sets forth a flow chart illustrating another example method of operating a compact battery configuration contactor assembly in accordance with at least one embodiment of the present disclosure. The method of FIG. 4 may be performed using any of the compact battery configuration contactor assemblies described herein, including the compact battery configuration contactor assembly 100 described with reference to FIGs. 1A-1E.

[0080] The method of FIG. 4 is similar to the method of FIG. 3 in that the method of FIG. 4 includes providing a battery configuration contactor assembly including a motor-driven cam shaft and a plurality of switches enclosed within a single housing, controlling rotation of thecam shaft, and selectively establishing one of a plurality of battery' configuration states between a first battery portion and a second battery portion.

[0081] In addition, the method of FIG. 4 includes sensing 402 an angular position of the cam shaft. In some embodiments, sensing 402 the angular position of the cam shaft is performed using a position sensing arrangement operatively coupled to the cam shaft. The position sensing arrangement may include a non-contacting sensor, such as a magnetic or optical sensor, or a contacting sensor, such as a potentiometer.

[0082] In the method of FIG. 4, controlling 304 rotation of the cam shaft includes controlling 404 rotation of the cam shaft based on the sensed angular position. In some embodiments, the sensed angular position is compared to a target angular position corresponding to a desired battery configuration state. Rotation of the cam shaft is controlled until the sensed angular position indicates that the target angular position has been reached.

[0083] In some embodiments, controlling 404 rotation of the cam shaft based on the sensed angular position includes adjusting a direction, speed, or duration of motor actuation to accurately position the cam shaft. Feedback from the position sensing arrangement may be used to provide closed-loop control of the cam shaft position, thereby improving positioning accuracy and repeatability when establishing battery' configuration states.

[0084] In some embodiments, sensing 402 the angular position of the cam shaft is also used to determine a current battery configuration state and to communicate the determined state to a controller, such as a vehicle control unit or battery management system. This information may be used for system monitoring, diagnostics, or coordination with other vehicle functions.

[0085] Accordingly, the method illustrated in FIG. 4 enables precise, feedback-controlled reconfiguration of battery' connections using a compact battery configuration contactor assembly, thereby improving reliability, accuracy, and robustness of battery configuration transitions.

[0086] For further explanation, FIG. 5 sets forth a flow chart illustrating another example method of operating a compact battery configuration contactor assembly in accordance with at least one embodiment of the present disclosure. The method of FIG. 5 may be performed using any of the compact battery configuration contactor assemblies described herein, including the compact battery configuration contactor assembly 100 described with reference to FIGs. 1A-1E. The method of FIG. 5 is similar to the method of FIG. 3 in that the method of FIG. 5 includes all of the steps of FIG. 3.

[0087] In the method of FIG. 5, selectively establishing 306 one or more of the plurality of battery configuration states includes selecting and establishing 502 a battery configurationstate in a manner that avoids complete interruption of current flow. In particular embodiments, the batten- configuration state is selected such that, during a transition from a first batten- configuration state to a second batten- configuration state, at least one of the switches within the batten configuration contactor assembly remains closed. By maintaining at least one closed switch during the transition, electrical current continues to flow through the contactor assembly while the cam shaft is rotated to establish the selected battery configuration state. Such operation enables make-before-break or overlapping switching behavior, which reduces electrical transients, limits arcing at contact surfaces, and decreases electrical and mechanical stress on system components during reconfiguration.

[0088] The flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, apparatuses, and methods, according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved.

[0089] Advantages and features of the present disclosure can be further described by the following statements:

[0090] 1. A battery configuration contactor assembly comprising: a single housing enclosing a motor-driven cam shaft and a plurality of switches mechanically actuated by rotation of the cam shaft and operatively coupled to the cam shaft, wherein rotation of the cam shaft selectively configures electrical connections between a first battery portion and a second battery portion among a plurality of battery configuration states including at least: a series connection state, a parallel connection state, a fully open state, a first-battery -only connection state, and a second-battery-only connection state.

[0091] 2. The battery’ configuration contactor assembly of statement 1, wherein the plurality of switches each comprise at least one fixed contact and at least one movable contact.

[0092] 3. The battery' configuration contactor assembly of statement 1 or 2, wherein each switch includes a rocker cartying the movable contact, the rocker being mechanically actuated by a corresponding cam mounted on the cam shaft.

[0093] 4. The battery’ configuration contactor assembly of any of statements 1-3. wherein the cam shaft carries a plurality of cams that differ from one another by at least one of camprofile, angular orientation, or axial position along the cam shaft.

[0094] 5. The battery’ configuration contactor assembly of any of statements 1-4, wherein at least one fixed contact is substantially C-shaped and defines an inner contact surface engaged by the movable contact.

[0095] 6. The battery' configuration contactor assembly of any of statements 1-5, wherein rotation of the cam shaft actuates a plurality of the switches simultaneously.

[0096] 7. The battery’ configuration contactor assembly of any of statements 1-6, wherein transitions between at least two of the battery configuration states occur without interrupting current flow through at least one of the syvitches.

[0097] 8. The battery' configuration contactor assembly of any of statements 1-7, wherein the switches are configured to provide bi-stable contact positions.

[0098] 9. The battery' configuration contactor assembly of any of statements 1-8, wherein the fixed contacts and movable contacts are arranged such that electrical current floyving through the contactor assembly during a short-circuit event generates electromagnetic forces that increase a contact force between mating contact surfaces.

[0099] 10. The battery configuration contactor assembly of any of statements 1-9, wherein the increased contact force reduces arcing or thermal damage during the short-circuit event.

[0100] 11. The battery' configuration contactor assembly of any of statements 1-10, further comprising a position sensing arrangement operatively coupled to the cam shaft and configured to determine an angular position of the cam shaft.

[0101] 12. The battery configuration contactor assembly of any of statements 1-11, wherein the motor is controlled based on the determined angular position of the cam shaft to select one of the battery' configuration states.

[0102] 13. The battery configuration contactor assembly of any of statements 1-12, wherein the battery configuration state is determined by at least one of a mechanical hard stop, a count of motor revolutions, or an angular position sensor.

[0103] 14. A battery' system comprising a first battery portion; a second battery portion; a power distribution unit; and a battery’ configuration contactor assembly comprising a single housing enclosing a motor-driven cam shaft and a plurality of switches operatively coupled to the cam shaft, wherein rotation of the cam shaft selectively establishes electrical connections between the first battery portion and the second battery' portion among a plurality' of battery' configuration states including a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery-only connection state, and wherein the battery configuration contactor assembly electrically couples the first batteryportion and the second battery portion to the power distribution unit.

[0104] 15. The battery system of statement 14. wherein the battery’ system is part of an electric vehicle.

[0105] 16. The battery system of statement 14 or 15, wherein the first-battery-only connection state and the second-batter -only connection state are used to balance charge levels between the first battery portion and the second battery portion.

[0106] 17. The battery system of any of statements 14-16, wherein the battery configuration contactor assembly limits inrush current when transitioning to the parallel connection state.

[0107] 18. A method of configuring a battery system, the method comprising: providing a battery configuration contactor assembly including a motor-driven cam shaft and a plurality of switches enclosed within a single housing; controlling rotation of the cam shaft; and selectively establishing, in response to rotation of the cam shaft, one of a plurality of battery configuration states between a first battery portion and a second battery portion, the battery configuration states including a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery -only connection state.

[0108] 19. The method of statement 18, further comprising sensing an angular position of the cam shaft; wherein controlling rotation of the cam shaft includes controlling rotation of the cam shaft based on the sensed angular position.

[0109] 20. The method of statement 18 or 19, wherein selectively establishing the battery configuration states includes selectively establishing the battery configuration states without interrupting current flow through at least one of the switches.

[0110] It will be understood from the foregoing description that modifications and changes may be made in various embodiments of the present disclosure without departing from its true spirit. The descriptions in this specification are for purposes of illustration only and are not to be construed in a limiting sense. The scope of the present disclosure is limited only by the language of the following claims.

Claims

CLAIMSWhat is claimed is:

1. A batery configuration contactor assembly comprising:a single housing enclosing a motor-driven cam shaft and a plurality of switches mechanically actuated by rotation of the cam shaft and operatively coupled to the cam shaft,wherein rotation of the cam shaft selectively configures electrical connections between a first batery portion and a second batery portion among a plurality of batten- configuration states including at least:a series connection state,a parallel connection state,a fully open state,a first-batery-only connection state, anda second-batery -only connection state.

2. The batery configuration contactor assembly of claim 1, wherein the plurality of switches each comprise at least one fixed contact and at least one movable contact.

3. The batery configuration contactor assembly of claim 2, wherein each switch includes a rocker carry ing the movable contact, the rocker being mechanically actuated by a corresponding cam mounted on the cam shaft.

4. The batery configuration contactor assembly of claim 3, wherein the cam shaft carries a plurality’ of cams that differ from one another by at least one of cam profile, angular orientation, or axial position along the cam shaft.

5. The batery configuration contactor assembly of claim 2, wherein at least one fixed contact is substantially C-shaped and defines an inner contact surface engaged by the movable contact.

6. The batery7configuration contactor assembly of claim 1, wherein rotation of the cam shaft actuates a plurality’ of the switches simultaneously.

7. The batery configuration contactor assembly of claim 1, wherein transitions between at least two of the batery configuration states occur without interrupting current flow through at least one of the switches.

8. The batery’ configuration contactor assembly of claim 1, wherein the switches are configured to provide bi-stable contact positions.

9. The batery configuration contactor assembly of claim 1, wherein the fixed contacts and movable contacts are arranged such that electrical current flowing through thecontactor assembly during a short-circuit event generates electromagnetic forces that increase a contact force between mating contact surfaces.

10. The battery configuration contactor assembly of claim 9, wherein the increased contact force reduces arcing or thermal damage during the short-circuit event.

11. The battery configuration contactor assembly of claim 1, further comprising a position sensing arrangement operatively coupled to the cam shaft and configured to determine an angular position of the cam shaft.

12. The battery configuration contactor assembly of claim 11, wherein the motor is controlled based on the determined angular position of the cam shaft to select one of the battery configuration states.

13. The battery configuration contactor assembly of claim 11. wherein the battery configuration state is determined by at least one of a mechanical hard stop, a count of motor revolutions, or an angular position sensor.

14. A battery system comprising:a first battery portion;a second battery portion;a power distribution unit; anda battery7configuration contactor assembly comprising a single housing enclosing a motor-driven cam shaft and a plurality of switches operatively coupled to the cam shaft.wherein rotation of the cam shaft selectively^ establishes electrical connections between the first battery' portion and the second battery' portion among a plurality' of battery configuration states including a series connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second-battery- only connection state, andwherein the battery' configuration contactor assembly electrically couples the first battery' portion and the second battery' portion to the power distribution unit.

15. The battery system of claim 14, wherein the battery system is part of an electric vehicle.

16. The battery' system of claim 14, wherein the first-battery-only connection state and the second-battery-only connection state are used to balance charge levels between the first battery portion and the second battery portion.

17. The battery system of claim 14, wherein the battery configuration contactor assembly limits inrush current when transitioning to the parallel connection state.

18. A method of configuring a battery system, the method comprising:providing a battery configuration contactor assembly including a motor-driven cam shaft and a plurality of switches enclosed within a single housing;controlling rotation of the cam shaft; andselectively establishing, in response to rotation of the cam shaft, one of a plurality' of battery configuration states between a first battery portion and a second battery portion, the battery configuration states including a senes connection state, a parallel connection state, a fully open state, a first-battery-only connection state, and a second- battery-only connection state.

19. The method of claim 18, further comprising sensing an angular position of the cam shaft; wherein controlling rotation of the cam shaft includes controlling rotation of the cam shaft based on the sensed angular position.

20. The method of claim 18, wherein selectively establishing the battery configuration states includes selectively establishing the battery configuration states without interrupting current flow through at least one of the switches.

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