Battery Module Converter Network for Low-Voltage EV Power
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Solution Overview
Problem
Conventional power supply systems in electric vehicles experience high stress on DCDC converter components due to high input voltage and output current, leading to component deterioration, and require heavy, expensive auxiliary batteries that occupy significant space.
Innovation Solution
A power supply system with a voltage converter network directly connected to individual battery modules of the high voltage battery pack, reducing input voltage to the converters, eliminating the need for an auxiliary battery, and utilizing a parallelized structure of converters for redundancy and efficient voltage conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a DCDC voltage converter is used to convert high voltage to low voltage, then voltage conversion is achieved, but the converter components experience large stress and deterioration
Solution Approach 1:
The high voltage battery pack is divided into multiple battery modules, each connected to a separate voltage converter. This segmentation distributes the conversion stress across multiple converters rather than concentrating it in a single DCDC converter, reducing the stress and deterioration on each individual converter component.
Solution Approach 2:
The patent introduces an intermediate structure where battery modules are directly connected to voltage converters, eliminating the need for a single DCDC converter interface. This intermediary configuration allows direct voltage conversion at the module level, reducing the stress on converter components.
2Power
If a conventional auxiliary battery is used to provide low voltage power, then power supply to low voltage loads is achieved, but the system becomes heavy, expensive and occupies significant space
Solution Approach 1:
The patent extracts the auxiliary battery from the system by using voltage converters directly connected to battery modules to provide low voltage power. This eliminates the need for a separate auxiliary battery, reducing weight, cost, and space requirements while maintaining the power supply function.
Solution Approach 2:
The voltage converters serve multiple functions: they convert high voltage to low voltage for power supply, and can also function as auxiliary power sources. This multi-functionality eliminates the need for a dedicated auxiliary battery, achieving weight and space reduction while maintaining power supply capability.
3Device complexity
If a single DCDC converter is used for voltage conversion, then the structure is simplified, but the converter components are susceptible to high stress and deterioration
Solution Approach 1:
Instead of using a single DCDC converter, the system segments the conversion function across multiple voltage converters, each connected to individual battery modules. This segmentation reduces the stress on each converter while maintaining a relatively simple overall structure through modular design.
4Reliability
If auxiliary battery is used as energy reservoir, then power supply stability is improved, but the battery occupies huge space in safe location inside vehicle
Solution Approach 1:
The patent extracts the energy storage function from a separate auxiliary battery and distributes it across multiple battery modules that are already part of the high voltage system. This eliminates the need for a separate auxiliary battery volume while maintaining power supply stability through the distributed module structure.
Solution Approach 2:
The battery modules serve dual purposes: they are part of the high voltage battery pack for high voltage loads, and simultaneously serve as energy reservoirs for low voltage loads through direct connection to voltage converters. This multi-functionality eliminates the need for separate auxiliary battery space.
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
Reduces stress on converter components, minimizes system weight and volume, ensures continuous power supply to safety-critical loads, and optimizes energy storage without the need for a separate auxiliary battery.
Implementation Method 1
a voltage converter network (106), which is configured to electrically insulate the low voltage output terminal (116a, 116b) from the high voltage battery pack (110) and to convert at least a part of the module voltages into the predetermined low voltage
Data Source
AI summary
The present disclosure relates to a power supply system (100), which comprises a high voltage battery pack (110) comprising a plurality of battery modules (102), which are electrically connected in series to form the high voltage battery pack (110), which is configured to output a predetermined high voltage as a sum of module voltages provided by the plurality of battery modules (102). The power supply system (100) further comprises a low voltage output terminal (116a, 116b), which is configured to output a predetermined low voltage to at least one electric load, and a voltage converter network (106), which is configured to electrically insulate the low voltage output terminal (116a, 116b) from the high voltage battery pack (110) and to convert at least a part of the module voltages into the predetermined low voltage. The voltage converter network (106) comprises at least one voltage converter (108), which is electrically connected to at least one of the plurality of battery modules (102) and is configured to convert the module voltage provided by the at least one of the plurality of battery modules (102) into the predetermined low voltage and to output the predetermined low voltage as an output voltage to the low voltage output terminal (116a, 116b), and a controller, which is configured to control an operation of the at least one voltage converter.