Energy Storage System Range Extender Bypass Control

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Solution Overview

Problem

Existing energy storage systems in electric vehicles face challenges in efficiently configuring and controlling multiple energy sources to meet both mileage and power demands, especially in heavy-duty applications, and ensuring system security when faults occur.

Innovation Solution

An energy storage system with a range extender comprising DC-to-DC converters and a by-pass, allowing for parallel coupling of energy storage systems to an electric load in normal operation and direct coupling through a by-pass in fault protection mode to maintain power supply.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If multiple energy sources or hybrid energy sources are introduced into the vehicle driving system to meet both mileage demand and power demand simultaneously, then the system can satisfy both energy requirements without excessively increasing battery size, but the configuration and control between the multiple energy sources becomes complicated

Engineering Contradiction:

Improveability to meet both mileage demand and power demandVSAvoidconfiguration and control complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The energy storage system is segmented into a first energy storage system (for mileage demand) and a second energy storage system (for power demand), with dedicated DC-to-DC converters for each. This segmentation allows independent optimization and control of each subsystem, reducing overall system complexity while maintaining the ability to meet both mileage and power demands simultaneously

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

DC-to-DC converters are introduced as intermediary devices between the energy storage systems and the electric load. These converters simplify the control architecture by providing standardized interfaces and automatic load sharing, reducing the complexity of direct multi-source configuration and control

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If a range extender with multiple energy storage systems and DC-to-DC converters is used to improve system adaptability, then both mileage and power demands can be met, but the system may fail completely when faults occur in the range extender components

Engineering Contradiction:

Improvesystem operation under various conditionsVSAvoidsystem security when faults occur

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

A by-pass switch is pre-configured in parallel with the DC-to-DC converter to provide a backup current path. When faults occur in the DC-to-DC converter or energy storage systems, the by-pass switch automatically activates to maintain current flow to the electric load, ensuring continued operation and preventing complete system failure

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The by-pass switch is strategically placed at critical points in the circuit to provide localized protection. This allows the system to maintain functionality in specific regions even when other parts experience faults, enhancing overall system reliability while preserving adaptability

Inventive Principle:

Principle #3Local quality

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

Enables efficient operation of electric loads under various conditions without large hardware or software changes, ensuring continued operation even if the range extender fails, thereby enhancing system security.

Implementation Method 1

a first DC-to-DC converter, selectably coupled between the first energy storage system and the electric load

Methodology Applied

Scientific EffectDC-to-DC conversion:

Implementation Method 2

a second DC-to-DC converter, selectably coupled between the second energy storage system and at least one of an output side of the first DC-to-DC converter and an input side of the electric load

Methodology Applied

Scientific EffectDC-to-DC conversion:

Data Source

PatentEP3078536B1Energy storage system with range extender and energy management and control method

Publication Date: 2022.12.07 GENERAL ELECTRIC CO

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AI summary

A system comprises a first energy system 100, a range extender 120, and a controller. The range extender 120 has a second energy system, first and second converters, and a by-pass. The first converter 212 is selectably coupled between the first energy system and an electric load 160, the second converter is selectably coupled between the second energy system and at least one of an output side of the first converter and an input side of the electric load, and the by-pass is selectably coupled between the first energy system and at least one of the output side of the first converter, an output side of the second converter and the input side of the electric load. The controller may control the first energy system and the range extender to work in a normal operation mode and a fault protection mode, in the normal operation mode, the first and second energy systems are parallel coupled to the electric load through the first and second converters, respectively, and in the fault protection mode, the first energy system is coupled to the electric load through the by-pass, and the second energy system is decoupled from the electric load. The present invention further relates to a method for supplying power to the electric load using said system.