EV Battery Switch Box for Series-Parallel Fast Charging
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Solution Overview
Problem
Existing electric vehicle charging systems face challenges in achieving fast and optimized charging without overheating components, particularly in heterogeneous charging station infrastructures, and require a compact, robust design to handle high voltages and currents.
Innovation Solution
A charging system comprising a switch box that interconnects two battery systems in parallel or serial modes based on the charging station's voltage capabilities, with a control unit to manage switching and balancing loads, allowing for balanced charging without the need for a DCDC converter and featuring a compact, thermally managed design with conductive sheet metal connections for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batteries are connected in parallel to increase charging current, then charging speed is improved, but heat generation increases causing overheating
Solution Approach 1:
The patent employs dynamic switching between parallel and series connections based on real-time charging conditions. The system transitions from parallel connection (high current, fast charging) to series connection (lower current, reduced heat) as charging progresses or when temperature thresholds are approached, optimizing both charging speed and thermal management throughout the charging process
2Ease of operation
If a DCDC converter is added to balance charging between batteries, then charging balance is improved, but device complexity increases
Solution Approach 1:
The patent removes the DCDC converter from the system and replaces it with a switching mechanism that directly connects batteries in parallel or series configurations. This extraction of the complex conversion device simplifies the overall system while achieving charging balance through topological reconfiguration rather than active power conversion
Solution Approach 2:
The switching mechanism acts as an intermediary between the charging source and batteries, enabling flexible connection reconfiguration. By introducing this switching intermediary, the system achieves charging balance and thermal management without requiring complex DCDC conversion circuitry
3Adaptability or versatility
If switching elements are used to reconfigure battery connections, then adaptability to different charging stations is improved, but device complexity increases
Solution Approach 1:
The switching mechanism is designed to perform multiple functions: it enables parallel connection for high-current charging, series connection for high-voltage charging, and can be reconfigured based on charging station capabilities. This multi-functional switching core allows the system to adapt to various charging standards and station types without requiring separate dedicated circuits for each mode
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
Enables fast, balanced, and efficient charging of electric vehicle batteries across various charging stations, minimizing overheating and component stress while maintaining a compact and robust construction.
Implementation Method 1
conductive sheet metal connections for improved heat dissipation
Implementation Method 2
conductive sheet metal connections for improved heat dissipation
Implementation Method 3
a plurality of switching elements to control electrical connections between the charging port, a first battery, and a second battery
Data Source
AI summary
The disclosure relates to a charging system (1) for an electric vehicle comprising a first battery system (2) and a second battery system (3) interconnected to each other by a switch box (4) interconnected to a charging device (8) during charging Each battery system (2, 3) comprising at least one battery (21) and at least one thereto connected electrical load (22). The switch box (4) interconnects the first battery system (2) and the second battery system (3) with the charging device (8) in a parallel mode in a parallel manner or in a serial mode in a serial manner.