Integrated Battery Module Converters for EV Contactor Power
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Solution Overview
Problem
Conventional electric vehicles rely on a separate low-voltage battery to power control electronics and high-voltage contactors, which can lead to failure or depletion issues when the low-voltage battery is depleted, preventing the vehicle from starting even though the high-voltage battery pack has ample energy.
Innovation Solution
The integration of primary and secondary module converters within each battery module of the high-voltage battery pack allows for the elimination of the low-voltage battery, with the primary module converter powering the battery controller and high-voltage contactors, and the secondary module converter used for activation, reducing power drain and enhancing system robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate low-voltage battery is used to power control electronics and high-voltage contactors, then the vehicle can start and operate, but the system becomes vulnerable to failure when the low-voltage battery is depleted
Solution Approach 1:
The patent merges the low-voltage power supply function into the high-voltage battery pack by integrating module converters within the battery modules. These converters can provide low-voltage power directly from the high-voltage battery cells, eliminating the need for a separate low-voltage battery and reducing system complexity while maintaining reliability.
Solution Approach 2:
The high-voltage battery pack is designed to perform multiple functions: it provides high-voltage power for propulsion and, through integrated module converters, also provides low-voltage power for control electronics and contactor activation. This multi-functionality eliminates the need for dedicated low-voltage battery systems.
2Ease of operation
If a low-voltage battery is used to power the low-voltage bus, then control electronics and contactors can be powered, but the system requires additional components and potential failure points
Solution Approach 1:
The patent combines the low-voltage power supply function into the high-voltage battery pack structure. Module converters are integrated within battery modules, allowing the high-voltage battery to directly provide low-voltage power without requiring separate low-voltage battery components.
Solution Approach 2:
The patent extracts the low-voltage power conversion function from the traditional separate low-voltage battery system and integrates it directly into the high-voltage battery module structure, eliminating the need for distinct low-voltage battery components.
3Object-affected harmful factors
If the high-voltage contactors are deactivated to isolate the battery pack, then safety is improved during servicing, but power cannot be supplied to the low-voltage bus
Solution Approach 1:
The patent segments the power conversion function into multiple module converters distributed within battery modules. Each module converter can independently provide low-voltage power, ensuring that low-voltage power availability is maintained even when high-voltage contactors are deactivated for safety isolation.
Solution Approach 2:
The module converters act as intermediaries between the high-voltage battery cells and the low-voltage bus. They can operate independently of the high-voltage contactor state, providing low-voltage power even when the high-voltage contactors are open for safety isolation during servicing.
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
This solution ensures the electric vehicle can start even with a depleted low-voltage battery, as the primary module converter provides continuous power to the battery controller and contactors, and the secondary module converter minimizes power loss, enhancing operational reliability and efficiency.
Implementation Method 1
a primary module converter, constantly connected to the battery cells. The power output from the primary module converter is used to power a battery controller and close the contactors
Data Source
AI summary
Described herein are battery modules comprising integrated module converters, electric-vehicle battery systems comprising such modules, and methods of operating thereof. An electric-vehicle battery system comprises a high-voltage battery pack and high-voltage contactors that controllably isolate the pack's high-voltage area from other areas in the vehicle. The pack comprises multiple battery modules with battery cells and a primary module converter constantly connected to these cells. Each module has a lower voltage than the entire pack. The power output from the primary module converters is used to operate a battery controller and to close/activate the contactors in response to the switch position (e.g., an ignition switch). The primary module converters can be either constantly activated or controllably activated in response to the switch moving into an activated position. For example, a secondary module converter, with a lower power rating, can be used for this primary module converter activation.