Traction Battery Voltage Adaptation for Charging Compatibility
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Solution Overview
Problem
High-voltage traction batteries in motor vehicles face challenges in rapid charging due to existing communication protocols that prevent initiation of charging at charging columns with lower maximum voltage, resulting in a wide-meshed charging network.
Innovation Solution
A method that allows high-voltage traction batteries to be charged by adapting the charging voltage using a charging voltage adapter, which connects traction battery modules in series or parallel to match the available charging column voltage, and includes insulation testing to ensure safety and compliance with communication protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If a high-voltage traction battery (e.g., 800 V) is used to achieve short charging time, then charging speed is improved, but compatibility with existing charging columns (e.g., 400 V) deteriorates
Solution Approach 1:
The traction battery system dynamically reconfigures its voltage level by switching between series and parallel connections of battery modules. The control unit detects the charging column's voltage capability and adapts the battery configuration accordingly - using series connection for high voltage (800V) when available to minimize charging time, and parallel connection for low voltage (400V) when compatible with the charging column, thus resolving the contradiction between charging speed and compatibility
Solution Approach 2:
The invention changes the electrical parameter (voltage level) of the traction battery system by altering the connection topology of battery modules. The control unit adjusts the battery configuration parameter based on the charging column's capabilities, enabling the system to operate at different voltage levels (400V or 800V) to match available charging infrastructure, thereby maintaining both fast charging capability and broad compatibility
2Adaptability or versatility
If charging columns with lower voltage (e.g., 400 V) are used to increase network coverage, then adaptability is improved, but charging speed deteriorates
Solution Approach 1:
The system dynamically adapts its voltage output based on the charging column type. When connected to a low-voltage charging column (400V), the control unit configures battery modules in parallel to match the column's voltage capability. This dynamic adaptation enables the vehicle to utilize the broader network of existing low-voltage charging columns while maintaining the option for fast charging when high-voltage columns are available
3Adaptability or versatility
If existing communication protocols are followed to ensure standardization, then compatibility is improved, but charging initiation at high-voltage batteries with low-voltage columns deteriorates
Solution Approach 1:
The control unit performs preliminary detection of the charging column's voltage capability before initiating the charging process. Based on this advance knowledge, the battery configuration is pre-adjusted to the appropriate voltage level (series or parallel connection), ensuring that the battery's voltage matches the charging column's output before charging begins. This preliminary action prevents communication protocol conflicts and enables seamless charging initiation across different voltage levels
Data Source
AI summary
A method charges a traction battery (42) with a stationary charging column (20). The method includes registering a charging process by the vehicle charging controller (50) to the charging column charging controller (22) with a low voltage value (U1) as a requested charging voltage (UR). The method then controls an insulation test carried out by the charging-column-side insulation tester (26). The method reports the maximum charging column voltage (UL) to the vehicle charging controller (50), and if the reported maximum charging column voltage (UL) corresponds to a high voltage value (U2) higher than the low voltage value (U1): registering a charging process by the vehicle charging controller (50) to the charging column charging controller (22) with the high voltage value (U2) as a requested charging voltage (UR) and setting the charging voltage adapter (44) to a charging voltage (UL) corresponding to the high voltage value (U2).