Battery Control ASIC for Integrated EV Power Conversion
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Solution Overview
Problem
Conventional power conversion modules and components in electric vehicles face packaging and integration challenges due to increasing power demands, especially with 800-volt battery systems, requiring additional voltage and temperature sensors and balancing circuits, which complicate vehicle electrical systems.
Innovation Solution
The integration of bidirectional DC-DC and DC-AC converter control components in application-specific integrated circuits (ASICs) for battery cells, enabling efficient voltage and current management, communication, and safety features, such as active balancing and cell isolation, to optimize battery performance and reduce hardware complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional power conversion modules are used to meet increasing power demands, then power capacity is improved, but device complexity and packaging difficulty increase
Solution Approach 1:
The patent combines multiple power conversion modules into a single integrated power conversion device. This device includes a first DC-DC converter, a second DC-DC converter, and a DC-AC converter all integrated within one module, thereby meeting high power demands while reducing packaging complexity and improving integration.
Solution Approach 2:
The integrated power conversion device performs multiple functions: it can operate as a DC-DC converter for battery charging/discharging, as a DC-AC converter for inverter operations, and includes integrated control circuits for monitoring and managing power flow. This multi-functionality eliminates the need for separate standalone components.
2Measurement precision
If additional voltage and temperature sensors are added to 800-volt battery systems, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The control circuit is integrated within the power conversion device, combining voltage sensing, temperature sensing, and power conversion control into a single unit. This eliminates the need for separate standalone sensor modules and reduces overall system complexity while maintaining precise measurement capabilities.
3Reliability
If balancing circuits are added between battery cells, then reliability is improved, but device complexity increases
Solution Approach 1:
The balancing function is integrated into the control circuit of the power conversion device. The control circuit monitors battery cell voltages and performs active balancing by regulating power flow between cells, eliminating the need for separate passive balancing circuits while improving reliability.
4Adaptability or versatility
If standalone power conversion components are used, then adaptability is improved, but ease of operation deteriorates due to system integration challenges
Solution Approach 1:
Multiple power conversion functions (DC-DC conversion, DC-AC conversion, voltage sensing, temperature sensing, and cell balancing) are merged into a single integrated power conversion device. This simplifies system installation and operation while maintaining the adaptability to handle various power conversion requirements.
Data Source
AI summary
Power and controller integrated circuits for electric vehicle applications are enabled. For example, a system can comprise a plurality of battery cells, and a plurality of application specific integrated circuits (ASICs) electrically coupled to the plurality of battery cells, wherein one or more ASICs of the plurality of ASICs comprises a respective control ASIC, and wherein the ASICs comprise respective bidirectional direct current to alternating current (DC-AC) converters and charge or discharge the plurality of battery cells.