High-Voltage Battery System with Segmented Modules and External Fuses
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Solution Overview
Problem
High-voltage battery systems face challenges in being charged using existing infrastructure, require complex and heavy components for internal short circuit protection, and pose safety risks during assembly, disassembly, and transport due to applied voltage on connections.
Innovation Solution
A high-voltage battery system with internal isolation and a divided charging connection system, featuring a series circuit of cells connected via intermediate electrodes and fuses outside the housing, allowing for safe handling and use of lower voltage charging devices, and a power supply with a converter to manage voltage for electric machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the battery system uses a high rated voltage to reduce cable dimensions and component weight, then the voltage increases and power transmission efficiency improves, but the compatibility with existing charging infrastructure deteriorates since charging stations with more than 800 V are hardly available
Solution Approach 1:
The battery system is divided into multiple battery modules, each capable of being charged independently or in combination. This segmentation allows the system to accept lower voltage charging from existing infrastructure while maintaining the capability for higher voltage operation when multiple modules are connected in series.
2Reliability
If electrical fuses are provided between battery modules to limit damage from internal short circuits, then the safety improves, but the complexity of the system increases and the mean time to repair extends due to difficult fuse replacement
Solution Approach 1:
The fuse is extracted from the battery module housing and placed in the connection piece that connects battery modules. This allows the fuse to be easily accessible for replacement without disassembling the battery module itself, significantly reducing the mean time to repair while maintaining safety functionality.
Solution Approach 2:
The connection piece serves as an intermediary component that houses the fuse and provides a standardized interface between battery modules. This intermediary design simplifies fuse replacement by making it an external operation rather than requiring internal module disassembly.
3Power
If voltage is applied to the connections for normal battery operation, then the electrical functionality is maintained, but the safety risk during assembly, disassembly, and transport increases due to potential-free connections being necessary
Solution Approach 1:
The switch in the connection piece dynamically changes the electrical state of the connection based on operational needs. During assembly, disassembly, or transport, the switch opens to create a potential-free connection for safety. During normal operation, the switch closes to restore electrical functionality. This dynamic switching resolves the contradiction between safety and functionality.
4Reliability
If the fuse is arranged inside the battery housing to protect against internal short circuits, then the protection effectiveness improves, but the weight and size of the battery housing increase
Solution Approach 1:
The fuse is extracted from the battery housing and relocated to the connection piece between modules. This extraction reduces the weight and size of the battery housing while maintaining the protective function of the fuse. The connection piece becomes the designated location for fuse placement, optimizing the overall system design.
Data Source
AI summary
A battery system, in particular for a motor vehicle, to a power supply comprising the battery system for an electric machine, in particular a vehicle drive, and to a method for charging the battery system.