Vehicle Battery Contactor Opening Order Based on Wear Estimation
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Solution Overview
Problem
The premature failure of contactors in energy storage systems of vehicles due to mechanical and electrical wear, leading to increased maintenance costs and reduced lifespan of the switching arrangement, is a significant challenge.
Innovation Solution
A characterization model is developed to estimate contactor wear based on system parameters such as current, voltage, temperature, inductance, and altitude, which is used to control the order of contactor opening and predict maintenance needs, thereby distributing wear evenly among contactors and extending the lifespan of the switching arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If contactors are frequently opened and closed to manage battery pack connections, then the switching arrangement can adapt to varying power requirements, but mechanical and electrical wear increases leading to premature contactor failure
Solution Approach 1:
The system performs preliminary assessment of contactor wear status before switching operations. By evaluating real-time parameters (current, voltage, temperature) against historical data and wear models, the system determines which contactors are suitable for opening/closing operations, preventing worn contactors from being subjected to additional stress that would accelerate failure.
Solution Approach 2:
The system dynamically adjusts operational parameters based on contactor wear status. When a contactor shows signs of wear, the system modifies switching patterns, redistributes current loads, or adjusts voltage levels to reduce stress on vulnerable contactors while maintaining overall system adaptability to power requirements.
2Power
If multiple battery packs are connected in parallel to meet higher power requirements, then the energy storage system can provide sufficient power, but the complexity of managing contactor wear across multiple contactors increases
Solution Approach 1:
The system implements continuous feedback monitoring of each contactor's operational status, wear indicators, and environmental parameters. This feedback loop enables the control system to automatically adjust switching patterns and load distribution across multiple contactors, optimizing wear management without requiring complex manual intervention or system reconfiguration.
Solution Approach 2:
The wear management system serves multiple functions simultaneously: it monitors contactor health, predicts failures, optimizes switching patterns, redistributes loads, and provides maintenance scheduling. This multi-functional approach manages the complexity of multiple contactors through a unified system rather than separate control mechanisms for each contactor.
3Ease of operation
If contactor opening order is randomized or sequential, then the switching arrangement operates simply, but uneven wear distribution leads to premature failure of specific contactors
Solution Approach 1:
The contactor opening order is dynamically determined based on real-time wear status rather than following a fixed sequence. The system continuously evaluates which contactors can safely be opened next based on their current wear level, operational history, and environmental conditions, creating an adaptive switching pattern that extends overall system lifespan while maintaining operational simplicity.
Data Source
AI summary
A computer system includes processing circuitry configured to provide a characterization model for each one of a plurality of contactors of a switching arrangement, each contactor being configured to connect and disconnected an associated battery pack of an energy storage system of a vehicle by closing and opening, respectively, the characterization model defining contactor wear for contactor opening with regards to a plurality of system parameters, the system parameters comprising at least current and voltage during contactor opening, determine the system parameters during operation of the switching arrangement, estimate, for each one of the contactors, the contactor wear by applying the determined system parameters to the corresponding characterization model; control the order in which the contactors are opened in response to the estimated contactor wear, and/or predicting maintenance of contactor, or contactor exchange, in response to the estimated contactor wear.