Dual-Storage Battery Switching Between Series and Parallel Charging
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Solution Overview
Problem
Existing vehicle battery systems require multiple contactors to manage charging voltages of 400 V and 800 V, leading to inefficiencies and increased weight and manufacturing costs, while also posing a risk of electric shock during collisions or short circuits.
Innovation Solution
A battery and power storage system with a configuration that reduces the number of contactors by using a controller to switch between series and parallel connections of two power storage modules, employing a main contactor and control cutoff fuse at opposite ends to prevent electric shock, and integrating a three-phase motor and inverter for efficient voltage management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple contactors are used to manage charging voltages of 400 V and 800 V, then voltage management capability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The main contactor is designed to perform multiple functions: it serves as the primary disconnecting device for both 400V and 800V charging modes, and also acts as a safety device for collision protection. This multi-functionality eliminates the need for separate contactors for different voltage modes, reducing the overall number of contactors while maintaining full voltage management capability.
Solution Approach 2:
The patent combines the functions of multiple contactors into a single main contactor. Instead of having separate contactors for 400V mode and 800V mode, the main contactor handles both voltage configurations by working in conjunction with the switching contactors and the cutoff fuse, thereby simplifying the system structure.
2Adaptability or versatility
If multiple contactors are used to manage charging voltages, then voltage management capability is improved, but weight increases
Solution Approach 1:
The main contactor is designed to perform multiple functions: it serves as the primary disconnecting device for both 400V and 800V charging modes, and also acts as a safety device for collision protection. This multi-functionality eliminates the need for separate contactors for different voltage modes, reducing the overall number of contactors and thereby reducing the total weight of the contactor system.
3Reliability
If main contactor and sub contactor are disposed at positive and negative end portions, then safety during collision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the safety function from the multi-contactor configuration and implements it through a single main contactor combined with a cutoff fuse. The main contactor is positioned to handle both positive and negative terminal disconnection, and the cutoff fuse provides additional safety by melting to break the circuit during severe collisions, thereby achieving collision safety with a simpler configuration.
Solution Approach 2:
The patent combines the safety functions of multiple contactors into a single main contactor system. Instead of having separate main and sub contactors at different positions, the main contactor is designed to handle both terminals, and the cutoff fuse provides supplemental safety, merging multiple safety functions into a unified system.
4Adaptability or versatility
If voltage converter is used for charging, then compatibility with different charging equipment is improved, but energy efficiency deteriorates
Solution Approach 1:
The patent employs dynamic switching of the battery module connection configuration instead of using a static voltage converter. The controller switches between series connection (for 800V charging) and parallel connection (for 400V charging) of the battery modules, allowing the system to adapt to different charging voltages directly without energy-intensive conversion processes.
Data Source
AI summary
A battery includes two storages, a positive node connecting positive terminals of the two storages, a negative node connecting negative terminals of the two storages, a main contactor, a cutoff fuse, a connection circuit connecting the negative terminal of the first storage and the positive terminal of the second storage, a first contactor provided in the connection circuit, a second contactor provided between the positive node and a first connection portion connecting the positive terminal of the second storage and the connection circuit, a third contactor provided between the negative node and a second connection portion connecting the negative terminal of the first storage and the connection circuit, and a controller switching between a first state where the two storages are connected in series and chargeable at a first voltage and a second state where the two storages are connected in parallel and chargeable at a second voltage.