Integrated Battery Module Converters for EV Contactor Activation
Find Innovative SolutionsGenerate Solutions
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 issues when the low-voltage battery fails or is depleted, preventing the vehicle from starting even though the high-voltage battery pack has ample energy, due to the lack of power to activate the contactors.
Innovation Solution
The integration of primary and secondary module converters within each battery module of the high-voltage battery pack, allowing the primary module converters to power the battery controller and activate the high-voltage contactors, eliminating the need for a low-voltage battery and ensuring continuous power availability for vehicle operation.
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 complexity increases and reliability decreases when the low-voltage battery fails
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 generate low-voltage power from the high-voltage battery cells, eliminating the need for a separate low-voltage battery and reducing overall system complexity while maintaining reliability.
Solution Approach 2:
The high-voltage battery pack is given multi-functionality by enabling it to serve both as the primary high-voltage power source and as the low-voltage power source through integrated module converters. This universal approach eliminates the need for separate low-voltage battery systems and ensures reliable vehicle operation.
2Power
If a low-voltage battery is used to power the high-voltage contactors, then the contactors can be activated, but power losses occur and the system requires additional components
Solution Approach 1:
The patent combines the low-voltage power generation function directly within the high-voltage battery pack using module converters. This eliminates the need for separate low-voltage batteries and DC-DC converters, reducing power losses associated with multiple conversion stages and additional components.
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 enables electric vehicles to start and operate without a low-voltage battery, as the primary module converters provide power to the battery controller and contactors, ensuring reliable activation and reducing power losses and complexity in the system.
Implementation Method 1
Each of the multiple battery modules comprises battery cells and a module converter, constantly connected to the battery cells
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.