Active Ripple Energy Storage Circuit for Contactor-Free BCCM-ISC Integration

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Solution Overview

Problem

The integration of battery current control modules (BCCMs) with inverter system controllers (ISCs) in automotive power systems is challenging due to disconnecting circuitry, which increases package size and weight, and requires high-current contactors.

Innovation Solution

A new circuit topology is proposed that integrates a BCCM with an ISC without using high-current contactors, by interfacing add-on circuitry directly with the ISC and using relays for disconnecting during drive mode, thereby reducing packaging size and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If battery current control modules are integrated with inverter system controllers using traditional disconnecting circuitry, then functional integration is achieved, but package size and weight increase

Engineering Contradiction:

Improveintegration capabilityVSAvoidpackage weight

Core Design Contradiction:

Adaptability or versatilityVSWeight of stationary object

Solution Approach 1:

The patent merges the BCCM and ISC into a single integrated controller by eliminating separate disconnecting circuitry. The unified controller directly interfaces both the battery and inverter, combining functions that were previously separated into distinct modules with individual disconnect mechanisms.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and removes the high-current contactors and disconnecting circuitry from the system. By taking out these heavy components, the integration is achieved without the associated weight penalty, leaving only the essential control functionality.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If traditional disconnecting circuitry is used for BCCM-ISC integration, then circuit isolation is achieved, but package size increases

Engineering Contradiction:

Improvecircuit isolationVSAvoidpackage size

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent removes the bulky disconnecting circuitry and high-current contactors while maintaining circuit isolation through the unified controller's internal switching mechanisms. This extraction eliminates the need for large physical disconnect components.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The unified controller serves multiple functions simultaneously - it acts as both the BCCM and ISC, providing circuit isolation, power management, and inverter control all through a single integrated device, eliminating the need for separate disconnecting circuitry for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If high-current contactors are used for disconnecting during drive mode, then circuit protection is achieved, but system weight and complexity increase

Engineering Contradiction:

Improvecircuit protectionVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the high-current contactors from the system. Circuit protection during drive mode is achieved through the unified controller's internal switching capabilities rather than external contactor mechanisms.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical contactor system with an electronic switching system integrated into the unified controller. This substitution eliminates heavy mechanical components while maintaining circuit protection functionality through electronic switching mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution allows for efficient integration of BCCMs and ISCs, reducing packaging size and weight, and eliminating the need for high-current contactors, while maintaining bidirectional power flow between the AC grid and the traction battery.

Implementation Method 1

a transformer, a second switching bridge connected between the AC/DC power converter and transformer... the transformer, electric machine, and switching bridges form an isolated DC/DC power converter

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an active ripple energy storage circuit connected between the AC/DC power converter and the second switching bridge

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS20250038649A1Configurable active ripple energy storage circuit with intermediate bus for integrated inverter system controller-battery current control module system

Publication Date: 2025.01.30 FORD GLOBAL TECH LLC

AI summary

A vehicle includes an electric machine, a traction battery, a first switching bridge connected between the electric machine and traction battery, an AC/DC power converter, a transformer, a second switching bridge connected between the AC/DC power converter and transformer, a switch bank connected with a secondary side of the transformer and that connects the secondary side between the electric machine and first switching bridge, and an active ripple energy storage circuit connected between the AC/DC power converter and the second switching bridge.