Dual-Output Battery Current Control Circuit for Compact EV Integration

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The integration of battery current control modules (BCCMs) with inverter system controllers (ISCs) in automotive vehicles is challenged by disconnecting circuitry, leading to increased package size and material counts, which complicates electric level integration and reduces packaging efficiency.

Innovation Solution

A new circuit topology integrates BCCMs and ISCs without high-current contactors, using a bi-directional AC/DC-DC/AC power converter and a bi-directional CLLC DC/DC converter, allowing for package level integration and reducing the need for additional DC/DC converters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If BCCMs and ISCs are integrated with disconnecting circuitry, then power management control is improved, but package size increases and packaging efficiency decreases

Engineering Contradiction:

Improvepower management controlVSAvoidpackage size

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The patent combines the BCCM and ISC into a single integrated controller unit, merging previously separate power management functions into one consolidated device. This integration eliminates the need for separate disconnecting circuitry and reduces the overall package size while maintaining full power management control capabilities.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated controller performs multiple functions including battery current control, inverter system control, and disconnect operations that were previously handled by separate components. This multi-functional design eliminates the need for additional DC/DC converters and high-current contactors, reducing package volume while enhancing adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If disconnecting circuitry is added for integration, then power management capability is improved, but device complexity increases

Engineering Contradiction:

Improvepower management capabilityVSAvoidcircuit complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the disconnecting circuitry directly into the integrated controller structure, eliminating the need for separate high-current contactors and additional DC/DC converters. This consolidation reduces device complexity while maintaining power management capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts and eliminates unnecessary intermediate components such as high-current contactors and separate DC/DC converters from the system architecture. By removing these redundant elements and integrating their functions directly into the controller, the overall device complexity is reduced while preserving essential power management capabilities.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If additional DC/DC converters are used for integration, then power conversion flexibility is improved, but packaging efficiency decreases

Engineering Contradiction:

Improvepower conversion flexibilityVSAvoidpackaging volume

Core Design Contradiction:

Adaptability or versatilityVSVolume of stationary object

Solution Approach 1:

The integrated controller incorporates universal power conversion capabilities that can perform DC/DC conversion, AC/DC conversion, and bidirectional power flow management within a single unit. This eliminates the need for multiple dedicated DC/DC converters while maintaining power conversion flexibility across different operating modes.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple power conversion functions including AC/DC conversion and DC/DC conversion into a single integrated power converter unit. This merging of functions reduces the total packaging volume by eliminating the need for separate converter modules while preserving the flexibility to operate in various power conversion modes.

Inventive Principle:

Principle #5Merging (Combining)

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 integration reduces package size by 50% and eliminates the need for high voltage circuits, enhancing packaging efficiency and facilitating coordinated power management across vehicle systems.

Implementation Method 1

a transformer connected between the second switching bridge and AC/DC power converter

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12485767B2Battery current control module with dual DC voltage output

Publication Date: 2025.12.02 FORD GLOBAL TECH LLC

AI summary

A circuit arrangement includes an AC/DC power converter, a transformer connected between a second switching bridge and the AC/DC power converter, a third switching bridge connected between the AC/DC power converter and transformer, a first switch bank connected between a first switching bridge and the transformer such that operation of the first switch bank selectively disconnects the first switching bridge from the circuit arrangement without disconnecting the second switching bridge from the circuit arrangement, and a second switch bank connected between the AC/DC power converter and a traction battery.