Vehicle Battery Shutdown Control Using Switch-Fuse Coordination
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Solution Overview
Problem
Current energy storage systems for vehicles face challenges in providing enhanced safety, cost-effectiveness, and flexibility, particularly in managing high voltage levels during accidents or faults, where existing fuses and switches may be damaged or ineffective.
Innovation Solution
An energy storage system that includes high voltage switches and fuses, capable of identifying conditions requiring immediate shutdown, measuring current levels, and either opening the switch or actively triggering the fuse to safely disconnect the system, thereby avoiding damage and ensuring safety without relying solely on automatic fuse activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fuse is used to automatically shut down the energy storage system during overcurrent, then safety is improved, but the system cannot be reset without replacement and may not trigger at certain current levels
Solution Approach 1:
The system dynamically switches between two protection modes: using the high voltage switch for immediate disconnection when current is below a safe threshold, and actively triggering the fuse when current exceeds the threshold but remains below the overcurrent value. This dynamic adaptation resolves the contradiction by providing both rapid response capability and system resetability.
Solution Approach 2:
The system changes the operational parameter (protection method) based on the measured current value. When current I is below the safe opening level, the high voltage switch is used; when I exceeds this level but remains below the overcurrent threshold, the fuse is actively triggered. This parameter-based decision-making enables both safety and operational flexibility.
2Speed
If the high voltage switch is opened immediately during overcurrent to shut down the system, then response time is improved, but the switch and surrounding components may be damaged due to high current levels
Solution Approach 1:
The system changes the protection method based on the measured current parameter. When current is below a predetermined safe level, immediate switch opening is performed. When current exceeds this level but remains below the overcurrent threshold, the system transitions to active fuse triggering, avoiding switch damage while maintaining rapid response.
Solution Approach 2:
The fuse acts as an intermediary protection mechanism when current levels are too high for safe switch opening. Instead of directly opening the switch under high current conditions, the system uses the fuse as a mediator to disconnect the circuit, thereby protecting the switch and surrounding components from damage.
3Strength
If the fuse is actively triggered instead of opening the high voltage switch, then component damage is prevented, but the system complexity increases
Solution Approach 1:
The control system monitors current parameter and changes the protection strategy accordingly. The system includes a measurement unit for current detection, a evaluation unit for determining whether to use switch opening or fuse triggering, and a control unit for executing the selected protection method. This parameter-driven approach manages complexity while providing comprehensive protection.
4Device complexity
If a fixed overcurrent threshold is used for fuse activation, then simplicity is maintained, but flexibility for different vehicle types and states is reduced
Solution Approach 1:
The system dynamically adjusts the safe opening current level based on vehicle type, operating state, and component characteristics. Rather than using a fixed threshold, the control system adapts the parameter to match specific application requirements, enabling the same system architecture to serve multiple vehicle types and operational scenarios.
Data Source
AI summary
An energy storage system for a vehicle, includes one or more battery units for storing electrical energy; at least one high voltage switch for connection and disconnection of the one or more battery units to at least one load, such as an electrical machine; a fuse for disconnection of the one or more battery units when the energy storage system experiences an overcurrent being above a predetermined overcurrent value. The energy storage system is configured to during use, identify if a condition has occurred which requires immediate shutdown of the energy storage system.