Modular Battery Safety Architecture for ASIL Compliance
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Solution Overview
Problem
High-voltage lithium ion batteries used in electric and hybrid vehicles pose a hazard due to exceeding operating limits, requiring stringent safety integrity levels (ASIL C or D), which complicates software and hardware design and necessitates different battery systems based on safety requirements, especially since hybrid vehicles often only meet low ASIL B standards.
Innovation Solution
A safety architecture that allows switching between ASIL-B and ASIL-C or ASIL-D modes by combining batteries with data processing units, enabling redundant signal monitoring and actuator activation between modules, and utilizing a master/slave architecture to ensure high safety integrity levels without the need for multiple sensors or actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage lithium ion batteries are used to meet high safety integrity levels (ASIL C or D), then safety is improved, but hardware complexity and cost increase
Solution Approach 1:
The battery management system is divided into multiple independent modules (first module, second module, etc.), each capable of functioning independently at ASIL B level. These modules communicate via bus connections, allowing the system to achieve higher overall safety integrity through modular architecture rather than requiring each individual component to meet ASIL C or D requirements.
Solution Approach 2:
Multiple ASIL B modules are combined to form a battery management system that achieves ASIL C or D level safety integrity. The modules work together through bus communication, with each module monitoring and controlling specific battery parameters, collectively providing the required high safety level without requiring each module to be individually complex.
2Reliability
If different battery systems are used based on safety requirements, then safety integrity is improved, but system versatility deteriorates
Solution Approach 1:
A universal modular battery management system architecture is designed that can operate at different safety integrity levels (ASIL B, C, or D) by configuring and connecting modules in different ways. The same basic module design can be used across different applications, with the system achieving higher safety levels through redundant module configurations and communication paths rather than requiring completely different hardware systems.
Solution Approach 2:
The system allows dynamic configuration of module connections and communication paths via bus interfaces. Modules can be added, removed, or reconfigured depending on the required safety integrity level, enabling the same hardware platform to adapt to different safety requirements (ASIL B for hybrid vehicles, ASIL C or D for electric vehicles) without requiring completely different system designs.
3Reliability
If redundant hardware is implemented in each module to achieve high safety integrity, then reliability is improved, but device complexity and cost worsen
Solution Approach 1:
The redundancy required for high safety integrity is extracted from individual modules and implemented at the system level through bus communication between modules. Instead of each module containing redundant hardware components, the system achieves redundancy through multiple modules communicating and cross-monitoring each other's status, thereby reducing individual module complexity while maintaining overall system reliability.
Solution Approach 2:
The bus communication system acts as an intermediary that enables redundancy and cross-monitoring between modules without requiring direct redundant hardware connections. Modules communicate status, sensor data, and control signals through the bus, allowing the system to achieve high safety integrity through information exchange rather than through complex redundant hardware architecture in each module.
Data Source
AI summary
A security architecture, a battery, and a motor vehicle that has a corresponding battery are configured to be used to combine battery packs of a lower security integrity level into a battery system that has a higher security integrity level. The security architecture is for at least two batteries and each battery includes at least one electrochemical cell. The at least two batteries are each combined with at least one data processing unit to form a respective module. The security architecture is configured such that input signals of at least one second module are processed by the at least one data processing unit of at least one first module.