Battery Control Device Segmented ICs External Pin Wiring
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Solution Overview
Problem
In electric and hybrid vehicles, the high voltage generated by connecting multiple battery modules in series or series-parallel poses a risk of damaging battery control devices due to high current and voltage exposure, which existing connector designs fail to adequately mitigate.
Innovation Solution
A battery control device with multiple cell controller ICs connected in series, where the GND and VCC terminals of adjacent ICs are externally connected via separate connectors to prevent high current flow and voltage exposure, using auxiliary connection members to ensure safe voltage detection and current limitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple battery modules are connected in series or series-parallel to increase voltage output, then the power and energy storage capacity are improved, but the risk of high voltage and high current damaging the battery control device increases
Solution Approach 1:
The battery system is divided into multiple battery modules, each with its own control circuit. The control device is segmented into multiple ICs (first cell controller IC and second cell controller IC) that are connected in series, with each IC controlling a specific cell group. This segmentation allows the high voltage to be distributed across multiple lower-voltage ICs, reducing the voltage stress on each individual component while maintaining the overall high power output capability.
Solution Approach 2:
An auxiliary connection member (pin) is introduced as an intermediary element to connect the GND terminal side wiring of the first cell controller IC to the VCC terminal side wiring of the second cell controller IC externally. This auxiliary connection acts as a mediator that manages the high voltage and current flow between ICs, preventing direct exposure of sensitive internal circuits to harmful high voltage levels while enabling the series-parallel battery configuration.
2Reliability
If a special connector with varying pin lengths is used to connect battery cells in series-parallel, then the voltage detection lines are properly connected from low potential side, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The control function is segmented across multiple ICs (first cell controller IC and second cell controller IC), with each IC responsible for controlling a specific cell group. This segmentation eliminates the need for a complex special connector with varying pin lengths, as each IC can use standard connectors while maintaining proper voltage detection through the series connection architecture.
Solution Approach 2:
The connection architecture moves from a single-plane connector design to a multi-dimensional configuration where ICs are connected in series through external auxiliary connection members. This dimensional change allows voltage detection lines to be properly connected from the low potential side without requiring complex connector geometries, simplifying manufacturing while maintaining detection accuracy.
3Power
If multiple cell controller ICs are connected in series to control cell groups, then the voltage handling capability is improved, but the device complexity increases due to additional connectors and wiring
Solution Approach 1:
The auxiliary connection member (pin) serves a dual function: it connects the GND terminal side wiring of the first cell controller IC to the VCC terminal side wiring of the second cell controller IC, and simultaneously provides the necessary external connection for high voltage management. This merging of functions reduces the overall number of separate connectors and wiring elements needed, simplifying the device while maintaining improved voltage handling capability.
Data Source
AI summary
A battery control device that controls a battery module in which a plurality of cell groups, in each of which a plurality of cells are connected in series, are connected in series or series-parallel, includes: a plurality of cell controller ICs that control each of the plurality of cell groups; and one or more connectors that are provided for connecting the plurality of cell controller ICs to the battery module; wherein: the plurality of cell controller ICs include first and second cell controller ICs that are provided in sequence, so as to control two or more of the cell groups that are connected in series; and an auxiliary connection member (a pin) is provided for connecting GND terminal side wiring of the first cell controller IC and VCC terminal side wiring of the second cell controller IC together, externally to the battery control device.