Battery Disconnect Unit Layout for Shorter High-Voltage Harnesses
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Solution Overview
Problem
The increasing complexity of high voltage battery systems due to the growing number of battery packs complicates the design and poses safety risks due to the extended length of high voltage cables.
Innovation Solution
A battery device and system that includes a battery pack, a battery disconnect unit (BDU) with high voltage operation elements, and a battery pack control module (BPCM) to monitor and diagnose the battery pack state, thereby reducing circuit complexity and safety risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the number of battery packs is increased to provide higher voltage battery systems, then the power output is improved, but the wire harness length and circuit complexity increase
Solution Approach 1:
The patent divides the battery management system into distributed control units, with each battery pack having its own control unit that can independently monitor and diagnose its state. This segmentation allows multiple battery packs to be managed without proportionally increasing central circuit complexity, as each unit operates semi-autonomously.
Solution Approach 2:
The patent introduces a communication network as an intermediary between battery packs and the central management system. This allows data exchange and control signals to be transmitted without requiring direct physical wiring connections between all components, thereby reducing wire harness length and complexity while maintaining system coordination.
2Power
If the number of battery packs is increased to provide higher voltage battery systems, then the power output is improved, but the wire harness length increases
Solution Approach 1:
The patent introduces a communication network as an intermediary between battery packs and the central management system. This allows data exchange and control signals to be transmitted without requiring direct physical wiring connections between all components, thereby reducing wire harness length and complexity while maintaining system coordination.
3Power
If extensive high voltage cables are used to connect multiple battery packs, then the power distribution capability is improved, but the safety risks increase
Solution Approach 1:
The patent divides the battery management system into distributed control units, with each battery pack having its own control unit that can independently monitor and diagnose its state. This segmentation allows multiple battery packs to be managed without proportionally increasing central circuit complexity, as each unit operates semi-autonomously.
Solution Approach 2:
The patent implements continuous monitoring and diagnosis functions that provide real-time feedback on battery pack status, including temperature, voltage, and current parameters. This feedback mechanism enables early detection of potential safety issues and allows the system to respond appropriately, reducing safety risks associated with extensive high voltage cable usage.
Data Source
AI summary
Discussed is a battery device that includes: a battery pack including battery cells; a battery disconnect unit (BDU) including high voltage operation elements connected to the battery pack and to monitor a battery pack current flowing in the battery pack; and a battery pack control module (BPCM) to diagnose a state of the battery pack based on a battery state information indicating the state of the battery pack and transmit control instructions to the BDU based on a diagnosis result. The BDU includes: a current measuring unit to measure the battery pack current based on a result of detecting the battery pack current; a high voltage measuring unit to measure the battery pack voltage of the battery pack; an insulation resistance measuring unit to measure an insulation resistance of the battery pack; and a power DC-DC unit to generate a power voltage required for operation of the BDU.