CAN-to-PLC Battery Charging Link Without Dedicated Data Cables
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Solution Overview
Problem
Existing battery charging systems require dedicated communication cables, which are prone to damage due to their combination with bulky power cables and the frequent connection/disconnection in motive power applications.
Innovation Solution
A module that converts data from a battery management system's CAN bus to power line carrier (PLC) signals, allowing communication between the battery and charger solely through the power line, eliminating the need for dedicated communication cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated communication cables are combined with bulky power cables for battery charging, then communication between battery and charger is enabled, but the communication cables are prone to damage due to frequent connection/disconnection
Solution Approach 1:
The patent combines communication and power transmission functions into a single power line interface. The communication module transmits data modulated onto the power line signals, eliminating the need for separate communication cables. This merging of functions reduces cable assembly complexity and improves reliability by removing vulnerable communication cables from the frequent connection/disconnection cycle.
Solution Approach 2:
The power line is made multi-functional by enabling it to carry both power transmission and communication data simultaneously. The communication module modulates data onto the existing power line signals, allowing the same physical infrastructure to serve dual purposes. This eliminates dedicated communication cables and simplifies the overall system architecture.
2Ease of manufacture
If dedicated communication cables are used with power cables, then data transmission is reliable, but manufacturing cost and assembly time increase
Solution Approach 1:
The power line is transformed into a multi-functional medium that simultaneously carries power and communication data. The communication module modulates digital signals onto the power line voltage variations, enabling data transmission through the existing power infrastructure without requiring additional communication cables, thereby reducing manufacturing complexity while maintaining communication integrity.
Solution Approach 2:
The communication module acts as an intermediary that translates communication data into modulated power line signals. This mediator converts digital communication protocols into voltage variations that can be transmitted through the power line infrastructure, enabling data transmission without direct communication cables while preserving data integrity through structured modulation schemes.
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
This solution simplifies the charge cable construction, reduces manufacturing costs and time, and minimizes the risk of communication cable damage, while ensuring efficient communication for dynamic charging profiles.
Implementation Method 1
A second winding of the transformer is connected to a power line of the battery
Data Source
AI summary
An apparatus to communicate with a battery management system (BMS) of a battery includes a memory and a processor coupled to the memory. The apparatus further includes a first electrical conductor configured to connect the processor to a controller area network (CAN) bus connected to the battery management system (BMS) of the battery. The apparatus further includes a second electrical conductor configured to connect the processor to a first winding of a transformer of the battery. A second winding of the transformer is connected to a power line of the battery. The processor is further configured to receive first data from the BMS via the CAN bus. transmit second data based on the first data to the battery charger via the power line. receive third data from the battery charger via the power line. and transmit fourth data based on the third data to the BMS via the CAN bus.