Isolation Contactor Unit for Hybrid Vehicle Subsystem Swapping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In electrical energy storage systems, particularly in hybrid and electric vehicles, swapping out high voltage sub-systems during the design and testing phase requires costly and time-consuming changes to contactors and control schemes due to unique performance capabilities and operating voltages, hindering efficient experimental setup and system optimization.
Innovation Solution
A compact isolation contactor unit with integrated feedback capabilities, featuring a contactor, driver, and integrated circuit that allows independent control and monitoring of voltage and current, enabling safe and efficient isolation and feedback without the need for hardware or software changes when swapping components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactors and control schemes are customized for each high voltage sub-system, then the sub-system can operate at its unique performance capabilities and operating voltage, but the system complexity and reconfiguration cost increase significantly during design and testing
Solution Approach 1:
The patent implements a universal contactor design that can handle multiple high voltage sub-systems with different operating voltages and performance characteristics. The contactor incorporates adaptive control circuitry that automatically detects and configures itself to the connected sub-system's requirements, eliminating the need for custom contactors for each sub-system while maintaining optimal operation.
Solution Approach 2:
The contactor design allows dynamic adjustment of operational parameters such as switching thresholds, timing characteristics, and protection levels based on the detected sub-system characteristics. This parameter adaptability enables a single contactor design to serve multiple sub-systems with unique performance capabilities without requiring physical reconfiguration.
2Adaptability or versatility
If contactors are reconfigured for each high voltage sub-system swap, then the sub-system can be optimized for its specific operating voltage, but the time and cost of swapping increase
Solution Approach 1:
The contactor is pre-configured with a library of operational parameters and control schemes for various sub-system types. Upon connection, the control circuitry automatically detects the sub-system identity and pre-loads the appropriate configuration, eliminating the need for manual reconfiguration during swapping operations.
Solution Approach 2:
The contactor incorporates dynamic reconfiguration capabilities where control parameters are adjusted in real-time based on the connected sub-system's operating characteristics. This dynamic adaptation allows rapid swapping between sub-systems while maintaining optimized performance for each specific voltage and performance profile.
3Manufacturing precision
If custom control schemes are implemented for each sub-system, then the sub-system can be precisely controlled, but the overall system control complexity increases
Solution Approach 1:
The contactor control system incorporates feedback mechanisms that continuously monitor sub-system operational parameters and automatically adjust control settings to maintain optimal performance. This closed-loop control eliminates the need for complex manual control schemes while preserving precise control capability across different sub-systems.
Solution Approach 2:
The control circuitry within the contactor autonomously configures and adjusts control parameters based on detected sub-system characteristics, eliminating the need for external complex control schemes. The system self-adapts to each sub-system's requirements, maintaining precise control while simplifying the overall control architecture.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A contactor unit includes an input lead 12 connectable to a first lead of an energy output device 20, an output lead 14 connectable to a first lead of a voltage bus, a contactor 100 that connects and disconnects the input lead 12 from the output lead 14, a driver 106 configured to operate the contactor 100, a serial data link connectable to a system controller that is external to the contactor unit, and an integrated circuit (IC) 108 positioned within the contactor unit and configured to output a control command to the driver 106 to open the contactor 100 based on at least one of a current in either the input lead 12 or the output lead 14 and a voltage differential across the contactor 100, and output a contactor control status via the serial data link.