Bidirectional Battery Coupling for Electric Trailer Range Extension
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Solution Overview
Problem
The range of electrically driven vehicle combinations is limited by the capacity of the high-voltage battery, and existing solutions for extending range often require complex electrical couplings or increase installation and maintenance costs.
Innovation Solution
A power adaptation and charging control unit that bidirectionally transfers energy between the high-voltage batteries of a towing vehicle and a trailer using a plug-in cable, incorporating a DC/DC power converter and charge controller to manage voltage differences and ensure safety, with a master battery management unit coordinating energy flow and safety protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a trailer with an additional electric drive is used to extend the range of the vehicle combination, then the range is extended, but the electrical coupling complexity and installation costs increase
Solution Approach 1:
The power adaptation and charging control unit acts as an intermediary device that simplifies the electrical coupling between towing vehicle and trailer. It provides standardized interfaces and automatic voltage matching, eliminating the need for complex custom electrical connections while enabling bidirectional energy transfer for range extension.
Solution Approach 2:
The power adaptation and charging control unit serves multiple functions: it enables bidirectional energy transfer, adapts voltage levels between different battery systems, provides charging control, and ensures safe operation. This multi-functionality in a single device reduces overall system complexity compared to separate components for each function.
2Ease of manufacture
If direct high-voltage connection between batteries is made without voltage regulation, then energy transfer is simple, but hazardous compensation currents flow that can damage batteries
Solution Approach 1:
The DC/DC power converter serves as an intermediary between the two high-voltage battery systems, providing controlled energy transfer. It regulates voltage differences and prevents harmful compensation currents while maintaining simple plug-in connectivity, thus preserving both connection simplicity and battery safety.
Solution Approach 2:
The power adaptation and charging control unit dynamically adjusts electrical parameters (voltage, current) based on the state of charge and temperature of both batteries. This parameter adaptation enables safe energy transfer across different operating conditions without compromising battery integrity.
3Ease of manufacture
If the DC/DC power converter is integrated with the charge controller as one component, then installation effort and costs are reduced, but the functional complexity of the single component increases
Solution Approach 1:
The DC/DC power converter and charge controller are merged into a single integrated power adaptation and charging control unit. This consolidation reduces the number of separate components to be installed and connected, thereby reducing installation effort and costs while maintaining all necessary functions through internal modular architecture.
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 range extension while moving, reduces installation effort and costs, and ensures safe operation by preventing hazardous voltages and managing battery conditions, thereby enhancing the overall efficiency and safety of the vehicle combination.
Implementation Method 1
The power adaptation and charging control unit has a DC/DC power converter for adapting the voltage level of the first high-voltage battery of the towing vehicle and of the second high-voltage battery of the trailer
Implementation Method 2
An electric drive positioned in a tractor unit of the vehicle combination is supplied with power by a high-voltage battery, which is also placed in the tractor unit
Data Source
AI summary
An arrangement is for increasing the range of an electrically driven vehicle combination. The arrangement includes a power adaptation and charging control unit for bidirectionally transmitting voltage between a first high-voltage battery of a towing vehicle of the vehicle combination and a second high-voltage battery of a trailer of the vehicle combination.