Battery Control Unit Hardware Path for Fast Solid-State Switching
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Solution Overview
Problem
Existing battery systems with electromechanical switches face limitations in cost, space, power dissipation, and reliability due to the use of relays and fuses, which are prone to failure and have slow switching times.
Innovation Solution
A control unit with a programmable microcontroller and a driver circuit that includes a comparator circuit, amplification circuit, delay circuit, and priming circuit, allowing for fast switching times and robust operation by separating the driver circuit from the microcontroller, enabling efficient solid state switch control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If electromechanical switches (relays) are used in battery protection systems, then the system is simple to implement, but the switching time is slow and power dissipation is high
Solution Approach 1:
The patent replaces electromechanical relay switches with solid-state MOSFET switches controlled by a microcontroller and driver circuit. This substitution eliminates mechanical moving parts, reducing switching time from milliseconds to microseconds while lowering power dissipation. The MOSFETs are integrated into the busbar structure, maintaining simplicity while achieving fast switching performance.
Solution Approach 2:
The patent extracts the switching function from traditional electromechanical relays and implements it separately using solid-state MOSFETs with dedicated driver circuits. This allows independent optimization of switching speed and control logic, achieving fast switching times without compromising system simplicity.
2Reliability
If electromechanical switches (relays) are used in battery protection systems, then the implementation is straightforward, but the reliability is limited due to mechanical failure
Solution Approach 1:
The patent replaces mechanical relay switches with solid-state MOSFET switches, eliminating mechanical wear and contact failure modes. The solid-state implementation significantly improves reliability by removing moving parts that are prone to mechanical failure, while the integrated control system maintains overall system simplicity.
Solution Approach 2:
The patent uses solid-state MOSFETs with no mechanical wear components, effectively creating a non-consumable switching element. Unlike mechanical relays that degrade over time due to contact wear, the solid-state switches maintain consistent performance throughout their operational lifetime, improving long-term reliability.
3Area of stationary object
If electromechanical switches (relays) are used in battery protection systems, then the system is easy to implement, but the installation space requirements increase
Solution Approach 1:
The patent merges the MOSFET switches directly into the busbar structure, combining the electrical connection function with the switching function. This integration eliminates the need for separate relay housings and mounting space, reducing overall installation space while maintaining system simplicity through unified design.
Solution Approach 2:
The patent nests the MOSFET switches within the busbar assembly, placing the switching components inside or along the existing electrical connection structure. This nesting approach maximizes space utilization by eliminating empty space between separate components, achieving compact installation without increasing system complexity.
4Loss of energy
If electromechanical switches (relays) are used in battery protection systems, then the system is simple to implement, but the power dissipation increases due to continuous power consumption
Solution Approach 1:
The patent replaces electromechanical relays with solid-state MOSFET switches, which have significantly lower on-resistance and thus lower conduction losses. The solid-state implementation reduces power dissipation during both switching and conduction states, while the integrated control system maintains overall simplicity.
Solution Approach 2:
The patent implements periodic switching control through the microcontroller, which activates the MOSFETs only when needed for protection or power management. This periodic activation rather than continuous operation reduces average power dissipation, while the control software maintains system simplicity through straightforward logic.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves fast reaction and switching times, reduced power dissipation, and increased reliability by utilizing a hardware path for monitoring and safety shutdowns, allowing for flexible programming of turnoff conditions and operation modes.
Implementation Method 1
The driver circuit comprises a comparator circuit that is configured for comparing a sensor signal received via the sensor interface with a threshold signal received from the microcontroller and for outputting an interrupt signal via a switching interface in response to an inadmissible operation condition of the battery system
Implementation Method 2
The driver circuit comprises an amplification circuit that is configured for amplifying the sensor signal
Implementation Method 3
The driver circuit comprises a delay circuit that is configured for delaying the interrupt signal received from the comparator circuit
Implementation Method 4
The driver circuit comprises a priming circuit that is configured for priming the switching interface
Data Source
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Figure 3~5
Figure 6
AI summary
The present invention relates to a control unit (20) for a battery system (10) that comprises a sensor interface (21) configured for being connected to a current sensor (19); a switching interface (22) configured for being connected to a solid state switch (14); a programmable microcontroller (23) configured for storing at least one programmed turnoff condition of the battery system (10) and outputting at least one threshold signal based on a respective turnoff condition; and a driver circuit (30) being interconnected as hardware path between the sensor interface (21) for receiving a sensor signal and the switching interface (22) for outputting an interrupt signal. The driver circuit (30) is further interface connected to the microcontroller (23) for receiving the least one threshold signal and comprises at least one comparator circuit (50) that is configured for comparing the sensor signal with the at least one threshold signal and for outputting the interrupt signal in an inadmissible operation condition of the battery system (10).