Traction Battery Connection Simulator for Controller Testing
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Solution Overview
Problem
The unpredictable nature of high-voltage traction battery connector pin connections, due to variations in pin length, seating depth, and angle, leads to momentary voltage conditions such as overvoltage and reverse voltage biasing, potentially causing immediate or latent damage to battery controller components, which may not be evident until a sufficient number of connections are made.
Innovation Solution
A traction battery connection simulator that includes multiple power supplies and switching devices to simulate a traction battery, programmed to connect and disconnect in a controlled sequence to a controller under test, allowing for voltage and current measurements to ensure they fall within predetermined ranges, and to log any anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If hot plug connection is used to connect battery controller to traction battery during manufacturing and service, then ease of operation is improved, but reliability deteriorates due to unpredictable pin mating order causing overvoltage and reverse voltage biasing
Solution Approach 1:
The patent applies preliminary action by implementing a controlled connection sequence where pins are connected in a predetermined order rather than randomly. The system activates power supplies to individual pins or groups of pins in sequence, ensuring that voltage is applied only after proper connection is established, thereby preventing overvoltage and reverse voltage conditions before they can occur
Solution Approach 2:
The patent applies dynamics by making the connection process adaptive and controllable. The system dynamically manages the connection state by selectively activating power supplies based on connection detection, and can dynamically disconnect power if abnormal conditions are detected during the connection process, transforming a static random connection into a dynamic controlled process
2Productivity
If multiple pins are connected simultaneously during hot plug connection, then productivity is improved, but object-affected harmful factors worsen due to momentary unpredictable voltage conditions
Solution Approach 1:
The patent applies segmentation by dividing the connection process into discrete stages corresponding to different pin groups. Instead of connecting all pins simultaneously or leaving them to connect randomly, the system segments the power supply activation into controlled groups, connecting and stabilizing one group before activating the next, thereby eliminating voltage stress while maintaining efficient connection
Solution Approach 2:
The system performs preliminary detection and controlled activation of power supplies before full power connection is established. By preliminarily managing the connection sequence and detecting proper mating before full power application, the system prevents harmful voltage conditions while still achieving rapid connection
3Ease of manufacture
If connector pins are made with variations in length, seating depth, and angle for ease of manufacture, then ease of manufacture is improved, but reliability deteriorates due to random pin mating order
Solution Approach 1:
The patent applies dynamics by implementing a control system that adapts to the actual connection state regardless of pin variations. The system dynamically detects which pins are properly connected and adjusts power supply activation accordingly, making the connection process robust to manufacturing variations in pin length, seating depth, and angle while ensuring reliable operation
Data Source
AI summary
A traction battery connection simulator is disclosed comprising a plurality of power supplies connected to simulate a traction battery and a plurality of switching devices that selectively connect the power supplies to a controller under test. The simulator further comprises a controller programmed to selectively connect at least one of power supplies to the controller under test for a predetermined period of time before connecting remaining power supplies. The controller may also be programmed to disconnect at least one power supplies from the controller under test for a predetermined period of time before disconnecting remaining power supplies. Voltages associated with each power supply and currents through each switching device may be compared to corresponding predetermined ranges. An indicator may be set in response to at least one of the voltages and currents being outside of a corresponding predetermined range.