Vehicle Battery Reconfiguration for Multi-Voltage Charging
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Solution Overview
Problem
Existing transportation vehicles with high-voltage on-board electrical systems face inefficiencies and increased weight and production costs due to the need for large electric currents and component upgrades when using charging columns with different voltage levels, leading to voltage differences that can overload components.
Innovation Solution
A method involving a switching unit, interconnection unit, and DC-to-DC converter to manage voltage differences by connecting battery subregions in parallel or series, transferring energy between high-voltage and low-voltage systems, and using capacitors for stabilization, reducing voltage levels efficiently and safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the high-voltage on-board electrical system uses a higher voltage level (e.g., 800V), then the electric currents are smaller and line cross-sections can be reduced, but the vehicle cannot use charging columns that provide only 400V
Solution Approach 1:
The battery unit's voltage output is made dynamically adjustable through the interconnection unit, which can reconfigure battery modules between series and parallel connections. This allows the system to adapt its voltage level (400V or 800V) based on the charging column being used, resolving the contradiction between energy efficiency at high voltage and compatibility with various charging infrastructures
Solution Approach 2:
The system changes the electrical parameter (voltage level) of the battery unit by reconfiguring the interconnection of battery modules. The interconnection unit switches between series connection (800V) and parallel connection (400V) of battery subunits, enabling the vehicle to match the voltage requirements of different charging columns while maintaining optimal electrical losses
2Adaptability or versatility
If the voltage level of the on-board electrical system is changed to match a charging column, then compatibility is achieved, but voltage differences can cause overloading of components
Solution Approach 1:
The switching unit is activated in advance to disconnect the battery unit from the on-board electrical system before the voltage level change occurs. This preliminary disconnection prevents voltage differences during the transition period from causing component overloading, while still allowing the system to adapt to different charging column voltages
Solution Approach 2:
The switching unit acts as an intermediary element between the battery unit and the on-board electrical system. It mediates the voltage level change process by controlling the connection state, ensuring that voltage transitions occur safely without causing harmful voltage differences that could overload components
3Adaptability or versatility
If the interconnection unit reconfigures battery modules to change voltage level, then adaptability to charging columns is achieved, but the switching process takes time
Solution Approach 1:
The switching unit is activated in advance to disconnect the battery unit before the interconnection unit reconfigures the battery modules. This preliminary action sequence allows the voltage level change to occur without causing harmful voltage differences, and the overall switching process is optimized to minimize time loss while maintaining safety
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 method enhances efficiency, reduces operating costs, and increases convenience by allowing quick mode changes without component overload, enabling the use of various charging infrastructures and minimizing energy loss.
Implementation Method 1
Electrical energy is channeled by a DC-to-DC converter from the high-voltage on-board electrical system into the low-voltage on-board electrical system
Implementation Method 2
the high-voltage on-board electrical system has at least one capacitor assigned to it by which a voltage stabilization is effected
Data Source
AI summary
A method for operating a transportation vehicle having a high-voltage on-board electrical system and a low-voltage on-board electrical system connected by a DC-to-DC converter. The high-voltage on-board electrical system is connected by a switching unit to a battery unit having two subregions able to be connected electrically in series and electrically in parallel by an interconnection unit. In the method, the switching unit is opened, and the subregions are connected electrically in parallel by the interconnection unit. Electrical energy is channeled from the high-voltage on-board electrical system to the low-voltage on-board electrical system by the DC-to-DC converter reducing the voltage of the high-voltage on-board electrical system. In response to the voltage of the high-voltage on-board electrical system differing from the voltage present at the battery unit by no more than a tolerance value, the switching unit is closed. Also disclosed is a transportation vehicle and a computer program product.