Cell-Level Battery Control Assembly for Universal EV Charging
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Solution Overview
Problem
There is a conflict between user and manufacturer objectives for battery control assemblies and electric drivetrains, where users desire compatibility with various charging situations and manufacturers aim for low manufacturing costs by minimizing components, leading to a need for a universal battery control assembly that can handle different charging types and voltages.
Innovation Solution
A battery control assembly with cell-level control units that can operate as inverters, connected in series and equipped with DC-DC converters, allowing for flexible charging and discharging capabilities, including AC and DC current handling, and featuring a modular design with few components for universal usability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the battery control assembly is designed with multiple components to handle different charging situations, then compatibility with various charging types and voltages is improved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The battery control assembly is designed with cell-level control units that can operate in multiple modes (AC charging, DC charging, AC discharging) through a unified H-shaped circuit topology. The same hardware infrastructure supports different charging types and voltages by reconfiguring switch states, eliminating the need for separate dedicated components for each charging scenario.
Solution Approach 2:
The patent employs dynamically reconfigurable switch networks within each cell-level control unit that can change their connectivity state based on the charging type and voltage level. The H-shaped circuit with controllable switches allows the system to adapt its internal configuration in real-time to match external charging requirements, providing versatility without adding permanent structural complexity.
2Adaptability or versatility
If the battery control assembly is designed with multiple components to handle different charging situations, then compatibility with various charging types and voltages is improved, but manufacturing cost increases
Solution Approach 1:
The battery control assembly uses identical cell-level control units with H-shaped circuits for all battery cells, regardless of charging type or voltage level. This standardized modular design allows mass production of uniform components, reducing per-unit manufacturing costs while maintaining compatibility with AC charging, DC charging, and AC discharging scenarios through software-controlled switch configurations.
Solution Approach 2:
The system achieves adaptability to different charging voltages and types by changing the operational parameters (switch states, connection configurations) of identical hardware components rather than manufacturing different physical components. This parameter-based reconfiguration allows a single manufacturing process to produce universally compatible control units.
3Reliability
If cell-level control units are connected in series with multiple switches, then operational flexibility and reliability are improved, but device complexity increases
Solution Approach 1:
The H-shaped circuit introduces asymmetric switch placement and control logic where switches are positioned at specific locations (S1, S2, S3, S4) with predetermined functions. This asymmetric design simplifies the control strategy by assigning specific roles to each switch position, making the system more reliable through consistent control patterns while avoiding the complexity of symmetric multi-switch configurations.
Solution Approach 2:
The battery control assembly divides the system into independent cell-level control units, each with its own H-shaped circuit and switches. This segmentation isolates potential failure points to individual cells rather than affecting the entire battery system, improving reliability through modular fault containment while keeping each module's switching complexity manageable through standardized designs.
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
The solution enables a battery system that is flexible and universally compatible with different charging scenarios, reducing component complexity and manufacturing costs while maintaining operational reliability and adaptability for various electric vehicle applications.
Implementation Method 1
each of the cell-level control units includes a cell-level switching unit being operable as a cell-level inverter
Data Source
AI summary
A battery control assembly for a battery system. The battery control assembly includes a plurality of cell-level control units, each including a cell-level switching unit being operable as a cell-level inverter. The plurality of cell-level control units are arranged in three control unit strings and the cell-level control units of each control unit string are electrically connected in series. First ends of each control unit string are electrically connected to a corresponding AC charging terminal. Second ends of the control unit strings are electrically connected in series via a first end switch and a second end switch. Moreover, at least one of the control unit strings includes an inner connection terminal. Furthermore, an electric drivetrain for an electric vehicle having such a battery control assembly is presented.