Exchangeable EV Battery Connector Current Limiting Architecture

Solution Overview

Problem

The large and robust connectors required for high-current exchangeable batteries in electric vehicles are not miniaturized, posing challenges for efficient power transfer and user safety.

Innovation Solution

A power supply device with a first exchangeable battery, a moving object connector, a first power converting section, a second battery connected in parallel, and a control section that regulates current output to miniaturize the connector, allowing for efficient power transfer and safety features like constant current control and relay switching.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a robust connector is used to handle high current (200-300 A) for motor acceleration, then the connector can withstand the high current, but the connector size becomes large

Engineering Contradiction:

Improveconnector current withstanding capabilityVSAvoidconnector size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The power supply system is divided into two separate batteries: a first battery connected through the miniaturized connector for low-current operations, and a second battery for high-current operations. This segmentation allows the connector to be sized for lower current while the system as a whole can still deliver high current through the parallel battery configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The control section acts as an intermediary that manages power distribution between the two batteries and the load. It intelligently routes current from the first battery through the miniaturized connector during normal operation, and can supplement with the second battery when high current is needed, without requiring the connector to handle the full high current load.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If a miniaturized connector is used, then the connector size is reduced, but the connector cannot handle high current (200-300 A) for motor acceleration

Engineering Contradiction:

Improveconnector sizeVSAvoidconnector current withstanding capability

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The power supply system is divided into two separate batteries: a first battery connected through the miniaturized connector for low-current operations, and a second battery for high-current operations. This segmentation allows the connector to be sized for lower current while the system as a whole can still deliver high current through the parallel battery configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the operational parameters by introducing a second battery that can supplement or replace the first battery when high current is required. The control section adjusts current distribution dynamically, allowing the miniaturized connector to operate within its current limits while the system achieves high current output through coordinated battery management.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If a single battery is used for both high and low current demands, then the system is simpler, but the battery and connector must be oversized to handle peak current

Engineering Contradiction:

Improvebattery system complexityVSAvoidconnector size

Core Design Contradiction:

Device complexityVSVolume of moving object

Solution Approach 1:

The power supply system is divided into two separate batteries: a first battery connected through the miniaturized connector for low-current operations, and a second battery for high-current operations. This segmentation allows the connector to be sized for lower current while the system as a whole can still deliver high current through the parallel battery configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The two-battery system provides multi-functionality: the first battery handles normal operation and charging, while the second battery supplements during high-current acceleration or can replace the first battery when fully charged. This universal configuration allows the system to adapt to different power demands without requiring a single oversized battery and connector.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Device complexity

If a single battery is used for both high and low current demands, then the battery and connector must be oversized to handle peak current, but production costs increase

Engineering Contradiction:

Improvebattery system complexityVSAvoidproduction cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The power supply system is divided into two separate batteries: a first battery connected through the miniaturized connector for low-current operations, and a second battery for high-current operations. This segmentation allows the connector to be sized for lower current while the system as a whole can still deliver high current through the parallel battery configuration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system changes the operational parameters by introducing a second battery that can supplement or replace the first battery when high current is required. The control section adjusts current distribution dynamically, allowing the miniaturized connector to operate within its current limits while the system achieves high current output through coordinated battery management.

Inventive Principle:

Principle #35Parameter changes

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 the miniaturization of the connector, suppresses high current firing incidents, allows for continuous vehicle operation with dual battery support, and reduces production costs by managing high and low current demands effectively.

Implementation Method 1

a first power converting section connected between the moving object connector and a load

Methodology Applied

Scientific EffectElectrical energy conversion:

Implementation Method 2

a second battery connected to a power supply line in parallel to the first battery

Methodology Applied

Scientific EffectElectrical energy storage: Battery (electricity)

Implementation Method 3

a relay configured to be switched between a connected state and a disconnected state

Methodology Applied

Scientific EffectElectromagnetic switching: Relay

Implementation Method 4

a second power converting section configured to convert an AC power into a DC power and to supply the DC power to the power supply line

Methodology Applied

Scientific EffectAC to DC conversion:

Data Source

PatentEP3958431B1Power supply device

Publication Date: 2023.12.06 YAZAKI CORP

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AI summary

An objective of the present invention is to miniaturize a connector for connecting an exchangeable battery to an electric vehicle. A power supply device includes a first battery which is exchangeable and includes a battery connector for connection to a moving object; a moving object connector which is disposed at the moving object and connectable to the battery connector; a first power converting section connected between the moving object connector and a load; a second battery connected to a power supply line in parallel to the first battery wherein the power supply line is configured to connect the first power converting section to the load; and a control section which is configured to control the first power converting section in such a way that a current which is output from the first battery to the first power converting section via the moving object connector has a first value or a smaller value.