Battery String Disengagement for Fault Isolation Without Vehicle Shutdown
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Solution Overview
Problem
High-voltage battery systems in vehicles face challenges due to component failures, leading to unnecessary vehicle shutdowns and operational disruptions when traditional disengagement methods introduce complexity and cost.
Innovation Solution
A system and method for selectively disconnecting individual battery string modules while maintaining operation using a control system that opens contactors to isolate faulty modules, allowing other modules to continue supplying current to the inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the HVIL circuit is triggered to disable high-voltage buses upon component failure, then safety is improved, but the entire vehicle is rendered inoperable until the issue is fixed
Solution Approach 1:
The battery pack is divided into multiple independent battery strings (first battery string, second battery string, etc.), each with its own disengagement mechanism. When a fault occurs in one string, only that specific string is disconnected while other strings remain operational, allowing the vehicle to continue functioning with reduced power capacity.
Solution Approach 2:
The faulty battery string is extracted or removed from the operational system by opening its dedicated contactor, isolating the problematic component while preserving the functionality of the remaining healthy battery strings and the overall vehicle system.
2Productivity
If contactors are opened to disengage faulty battery strings, then operational continuity is improved, but additional monitoring and control complexity increases
Solution Approach 1:
The control system is segmented into multiple independent control paths, with each battery string having its own dedicated contactor and monitoring logic. This modular approach allows the system to manage multiple battery strings independently without requiring a single complex centralized control mechanism.
Solution Approach 2:
Each battery string module includes integrated fault detection and self-isolation capabilities, where the system automatically detects faults and opens the appropriate contactors without requiring complex external monitoring, allowing the system to manage itself during fault conditions.
3Reliability
If the entire high-voltage system is disabled upon component failure, then system safety is improved, but operational disruptions and downtime increase
Solution Approach 1:
The high-voltage system is segmented into multiple independent battery strings that can operate autonomously. When a fault occurs in one string, the system isolates only that string while maintaining operation of other strings, thereby preventing complete system shutdown and reducing operational downtime.
Solution Approach 2:
The faulty battery string is extracted from the operational system through dedicated disengagement mechanisms, removing the harmful element while preserving the functionality of the remaining system components and maintaining continuous vehicle operation.
Data Source
AI summary
A machine includes a plurality of battery string modules that supply electric current to an inverter of the machine. The machine also includes a control system that opens at one contactor coupled to at least one battery string module of the plurality of battery string modules to disconnect the at least one battery string module. The other battery string modules of the plurality of battery string modules, apart from the at least one battery string module, continue supplying electric current to the inverter of the machine while the at least one battery string module is disconnected.