Battery Bypass Circuit for Cell Failure Isolation
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Solution Overview
Problem
In electric vehicle battery systems, a failing battery cell can disrupt the entire system, leading to shut-downs and 'walk-home' conditions, as cells are often connected in series, and existing technologies lack effective means to isolate or manage failing cells without losing overall power.
Innovation Solution
A controllable by-pass circuit that disconnects or regulates current to failing battery cells or modules, using switches and a controller to detect and respond to cell failures, allowing normal operation without affected cells, and optionally managing current flow to prevent further degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery cells are connected in series to meet power requirements, then system power output is improved, but system reliability deteriorates because failure of one cell shuts down the entire system
Solution Approach 1:
The patent divides the battery system into independent parallel modules, each with its own series-connected cells. This segmentation allows individual modules to be isolated and removed without affecting other modules, maintaining system operation even when one module fails. The controller detects module-level failures and reconfigures the circuit to continue operating with remaining healthy modules.
Solution Approach 2:
The patent extracts the failing module from the overall battery system by opening switches that disconnect the problematic module while keeping other modules connected. This extraction removes the harmful effect of the failing cell without requiring shutdown of the entire system, allowing continued operation at reduced capacity.
2Reliability
If a failing cell is disconnected from the circuit to prevent system shut-down, then system reliability is improved, but system power output deteriorates
Solution Approach 1:
The patent merges multiple parallel battery modules to compensate for power loss when one module is disconnected. By having multiple modules operating in parallel, the system can tolerate the removal of individual modules while maintaining sufficient overall power output. The controller manages the distribution of load across remaining healthy modules.
Solution Approach 2:
The patent changes the operational parameters of the battery system by dynamically reconfiguring which modules are active. When a module fails, the controller adjusts the circuit configuration to change the effective number of parallel modules, thereby adapting the system's power output characteristics while maintaining reliability.
3Adaptability or versatility
If individual cell monitoring and by-pass circuitry is added to each cell, then cell-level control capability is improved, but device complexity deteriorates
Solution Approach 1:
The patent merges the monitoring and control functions at the module level rather than requiring individual cell-level components for each cell. Multiple cells within a module share common monitoring and by-pass circuitry, reducing the overall number of components needed while still providing effective control over cell failures through module-level management.
4Reliability
If parallel battery modules are used to provide redundancy, then system reliability is improved, but device complexity deteriorates due to additional switching and control circuitry
Solution Approach 1:
The patent implements universal controller logic that handles multiple functions: normal operation management, failure detection, module isolation, and power distribution across parallel modules. This multi-functional controller reduces the need for separate dedicated circuits for each function, thereby managing complexity while providing comprehensive reliability protection.
Data Source
AI summary
A by-pass circuit for a battery system that disconnects parallel connected cells or modules from a battery circuit or controls the current through the parallel connected cells or modules. If a cell has failed or is potentially failing in the system, then the by-pass circuit can disconnect the cell or module from other cells or modules electrically coupled in parallel. If a cell or module has a lower capability than another cell or module, then the by-pass circuit can control the current to the cell or module to maximize the performance of the system and prevent the system from creating a walk-home condition.