Battery Pack Switching Circuitry for Dynamic Cell Reconfiguration
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Solution Overview
Problem
Battery packs in electric vehicles are inefficient due to their fixed structure, which is affected by weak or damaged cells, leading to premature failure and increased waste and costs, as the performance is dependent on the weakest cells, and current control methods focus mainly on safety rather than optimizing energy usage.
Innovation Solution
A multi-level power cell pack switching circuitry that allows reconfiguration of power cells based on performance parameters like current, voltage, and state of health, enabling dynamic connection and disconnection of cells in series or parallel to optimize performance and extend battery life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed battery pack structure is used with series-connected cells, then the voltage range is sufficient for motor operation, but the pack performance is limited by the weakest cells and cannot be dynamically optimized
Solution Approach 1:
The patent implements a dynamic switching network that allows the battery pack to transition between different series-parallel configurations based on real-time cell state monitoring. The system dynamically reconfigures cell connections to maintain optimal performance by excluding degraded cells from active duty while keeping them available for future use, thus resolving the contradiction between fixed structure and adaptive performance.
Solution Approach 2:
The battery pack is segmented into multiple series strings that can be independently controlled through the switching network. This segmentation allows the system to selectively activate or deactivate specific cell groups based on their state of health, enabling the pack to maintain reliable operation even when individual cells or strings degrade, thereby addressing both adaptability and reliability concerns.
2Reliability
If redundant cells are added to compensate for weak cells, then the battery pack can maintain performance, but the material cost and pack capacity increase by more than 60%
Solution Approach 1:
The system implements a cell retirement and recovery mechanism where degraded cells are selectively disconnected from the active circuit through the switching network and moved to a standby or retired status. This allows the battery management system to maintain pack performance using only the healthy subset of cells, eliminating the need to add redundant capacity upfront. The retired cells remain in the pack but are electrically isolated, effectively reducing the required total cell count by over 60% while maintaining reliability.
3Object-affected harmful factors
If the entire pack is disconnected when a single cell reaches safety limits, then safety is ensured, but the majority of healthy cells cannot continue operating
Solution Approach 1:
The switching network enables the extraction and isolation of individual cells or small groups of cells that reach safety limits, removing them from the active circuit while leaving the remainder of the pack operational. The system monitors each cell's state and selectively disconnects only those cells that require attention, allowing healthy cells to continue providing power and maintaining productivity while ensuring safety through targeted isolation of problematic cells.
Solution Approach 2:
The switching network acts as an intermediary between the cells and the load, providing granular control over which cells are connected to the circuit. This intermediary layer enables selective disconnection of individual cells that reach safety thresholds while maintaining connections to healthy cells, thus resolving the all-or-nothing disconnect problem and preserving operational availability without compromising safety.
4Power
If dozens of cells are connected in series to support high voltage and current, then the motor needs are met, but any damaged or weak cell affects the entire pack performance
Solution Approach 1:
The system employs a dynamic reconfiguration capability that allows the battery pack to transition between different series-parallel arrangements based on real-time cell health assessment. When cells degrade, the switching network dynamically redistributes the voltage and current pathways to maintain the required power output using only healthy cells, thus preserving both high power capability and adaptability to changing cell conditions.
Solution Approach 2:
The switching network provides multi-functionality by enabling the same battery pack to operate in multiple configuration modes (different series-parallel combinations) depending on cell state. This universal control architecture allows the system to meet various power requirements while adapting to different cell health scenarios, effectively decoupling the power output capability from the presence of any single cell and thereby resolving the vulnerability to individual cell failures.
Data Source
AI summary
A multi-level power cell pack switching circuitry having a plurality of first level cell circuits, and additional plurality of cell circuits of consecutively progressing levels, with switching and control configured to facilitate dynamically changing serial and/or parallel connections between cells and cell circuits.