Battery Pack Contactor Switching for Adaptive Charging
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Solution Overview
Problem
Current battery systems for electric vehicles face challenges in efficiently managing multiple battery packs across varying charging voltage modes, requiring adaptive configurations between series and parallel connections to optimize energy usage and charging efficiency.
Innovation Solution
A battery system with a controller that dynamically switches contactor switches to connect battery packs in series or parallel configurations based on charging voltage modes, ensuring optimal power distribution to auxiliary loads and balancing energy usage between packs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple battery packs are used to accommodate varying charging voltages, then adaptability to different charging infrastructures is improved, but device complexity increases due to the need for reconfiguration mechanisms
Solution Approach 1:
The battery system dynamically reconfigures the connection topology between battery packs using contactor switches, transitioning between series and parallel arrangements based on detected charging voltage levels. This dynamic adaptation allows the system to optimize performance for different charging infrastructures without requiring manual intervention or permanent structural changes.
Solution Approach 2:
The same battery packs serve multiple functions by being reconfigurable between series connection (for high-voltage fast charging) and parallel connection (for standard charging or propulsion). This multi-functionality eliminates the need for separate battery systems for different charging scenarios, reducing overall system complexity while maintaining adaptability.
2Productivity
If battery packs are reconfigured between series and parallel connections, then charging efficiency is improved, but reliability may deteriorate due to switching operations and contactor wear
Solution Approach 1:
The controller detects the charging voltage level in advance and proactively initiates the contactor switching sequence to prepare the appropriate battery configuration before charging begins. This preliminary action ensures that the battery system is already optimally configured when high-voltage charging starts, preventing inefficient charging transitions and reducing the frequency of switching operations.
Solution Approach 2:
The system continuously monitors charging voltage and battery pack status, using this feedback to determine when reconfiguration is necessary. This closed-loop control ensures that contactor switching occurs only when needed, minimizing wear and potential failure points while maintaining optimal charging efficiency throughout the charging process.
Data Source
AI summary
A battery system and a method include an auxiliary power module configured to support auxiliary loads. A first contactor switch connected between first and second battery packs, and a second contactor switch is in series with the first contactor switch. A controller determines whether to open or close first and second contactor switches depending on whether the battery packs are being charged in a high voltage mode or a low voltage mode. The contactor switches are both closed when in the high voltage mode and at least one of the contactor switches is opened when in the low voltage mode. At least one of the first and second battery packs operate to power the auxiliary power module while charging at least one of the first and second battery packs regardless of whether the battery packs are in the high voltage mode or the low voltage mode.