Bypass Switch for Series Battery Arrays
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric motor vehicles powered by arrays of series-connected batteries face interruptions due to battery failures, leading to sudden stops, which can be dangerous and inconvenient.
Innovation Solution
A system with an electrically-operated bypass switch and a switch activator module that forms a closed electrical bypass circuit path across a faulty battery, allowing the vehicle to continue operating by bypassing the failed battery and maintaining power continuity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If series-connected batteries are used to power the electric motor vehicle, then the power output is sufficient, but the system reliability deteriorates due to battery failures causing interruptions
Solution Approach 1:
The battery array is segmented into multiple series-connected member batteries, allowing individual isolation of failed units through bypass switches while maintaining operation of remaining batteries. This segmentation enables the system to maintain power output while improving reliability by preventing single-point failures from shutting down the entire system.
Solution Approach 2:
Bypass switches are pre-installed across each member battery terminal in the battery array before operation begins. These switches remain in the open position during normal operation but are ready to be activated immediately upon detecting a battery failure, ensuring uninterrupted power supply without requiring system shutdown for repairs.
2Reliability
If bypass switches are installed across each battery terminal, then the uninterrupted power supply is achieved, but the device complexity increases
Solution Approach 1:
The bypass switches are integrated into the existing battery array structure and control system, serving dual functions: normal operation mode and failure bypass mode. The same switch infrastructure supports both standard power delivery and emergency bypass operations, reducing the need for separate dedicated bypass components and minimizing overall system complexity.
Solution Approach 2:
The control system automatically detects battery failures and activates the appropriate bypass switches without requiring external intervention or complex manual procedures. The system self-manages the bypass operation through automated monitoring and control, simplifying the user interface while maintaining high reliability through intelligent autonomous operation.
Data Source
AI summary
An apparatus, system, and method are disclosed for assuring uninterruptible battery power for a typical electric motor vehicle powered by an array of series-connected member batteries. Such assurance results from a provision of an electrically-operated bypass switch configured to form a closed electrical bypass circuit path across a faulty first member battery upon activation, thus keeping the vehicle powered up. In one embodiment, the bypass switch is a double-pole multi-contact selector switch connected to each member battery and complimented by a pole-connect switch. For an atypical electric motor vehicle, such as with a multiple battery array parallel configuration, a backup battery may be provided and connected with the faulty battery array in series to displace the bypassed member battery, thus maintaining equal voltage outputs from the battery arrays.