High-Voltage Battery Pack Layout for Redundant Low-Voltage Power
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Solution Overview
Problem
Current electrical vehicle systems face challenges with redundant power supply systems due to the complexity and cost associated with adding more DC/DC converters, which affect safety and efficiency, particularly in achieving high ASIL classification on the 12V system.
Innovation Solution
A high-voltage battery pack with independent high-voltage and low-voltage output terminals, eliminating the need for additional DC/DC converters by directly connecting series-connected battery cells to low-voltage DC buses, providing improved power distribution and monitoring capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional DC/DC converters are added to achieve redundant power supply and high ASIL classification, then safety and reliability are improved, but device complexity and cost increase
Solution Approach 1:
The battery pack is segmented into multiple independent battery strings (first string, second string, etc.), each capable of independently supplying power to different DC buses. This segmentation enables redundant power supply paths without requiring additional DC/DC converters, as each string can operate independently to maintain system reliability.
Solution Approach 2:
Each battery string is designed to serve multiple functions: it can supply power to high-voltage DC buses, low-voltage DC buses, or both simultaneously. This multi-functionality allows the same battery component to provide redundant power supply paths, achieving high ASIL classification without adding separate DC/DC converters for each function.
2Reliability
If additional DC/DC converters are added to achieve redundant power supply, then reliability is improved, but weight increases
Solution Approach 1:
The battery pack is divided into multiple independent battery strings that can operate autonomously. Each string can provide redundant power supply to critical loads without requiring additional weight-intensive DC/DC converter hardware, thereby achieving reliability improvements while minimizing weight increase.
Solution Approach 2:
The patent extracts the DC/DC conversion function from separate converter units and integrates it directly into the battery pack structure through the battery management system and internal wiring. This eliminates the need for external DC/DC converters, reducing system weight while maintaining redundant power supply capability.
3Reliability
If additional DC/DC converters are added to achieve redundant power supply, then safety is improved, but cost increases
Solution Approach 1:
The battery pack is segmented into multiple independent strings that can be manufactured and assembled using standard battery module configurations. This approach leverages existing manufacturing capabilities without requiring expensive custom DC/DC converter assemblies, thereby achieving safety improvements through design rather than through costly additional components.
Solution Approach 2:
The battery strings are designed with universal functionality to supply both high-voltage and low-voltage DC buses directly. This eliminates the need for expensive DC/DC converters and their associated cooling systems, control electronics, and interconnections, significantly reducing manufacturing cost while maintaining redundant power supply for safety.
4Power
If DC/DC converters are used for power transfer, then power distribution is enabled, but energy loss increases
Solution Approach 1:
The patent removes the intermediate DC/DC conversion step from the power distribution path. Battery strings are directly connected to both high-voltage and low-voltage DC buses through controlled switching, eliminating the energy losses that occur in DC/DC converter efficiency and their associated cooling requirements.
Data Source
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AI summary
A high-voltage battery pack (5) for an electrical system (14). The high-voltage battery pack (5) comprises a high-voltage output terminal (18) configured for being connected to a high-voltage electrical load (4) of the electrical system; a plurality of battery cells (27) connected to form at least one string (28-31) of series connected battery cells, wherein the battery cells of the at least one string (28-31) are connected to the high-voltage output terminal (18) for supplying high-voltage electrical power to the high-voltage electrical load (4); a first low-voltage output terminal (19) configured for being connected to a first low-voltage electrical load (S1, B2, 36) of the electrical system, wherein a first subset (38) of the series connected battery cells is configured for supplying low-voltage electrical power to the first low-voltage electrical load (S1, B1, 36); and a second low-voltage output terminal (20) configured for being connected to a second low-voltage electrical load (S2, B2, 37) of the electrical system, wherein a second subset (39) of the series connected battery cells is configured for supplying low-voltage electrical power to the second low-voltage electrical load (S2, B2, 37).