Integrated Control ASIC for Electric Vehicle Battery Management

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Solution Overview

Problem

The increasing power demands in electric vehicles pose packaging and integration challenges, particularly with 800-volt battery systems requiring additional voltage and temperature sensors, and conventional power conversion modules becoming larger, necessitating innovative solutions for efficient power management and control.

Innovation Solution

The development of integrated circuits, specifically control and power ASICs, that include bidirectional DC-DC and DC-AC converters, sensors, and communication components to manage and balance battery cell voltages, currents, and temperatures, enabling efficient power conversion and cell health monitoring, while reducing the need for external components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If conventional power conversion modules are used to meet increasing power demands, then power delivery capability is improved, but packaging size and integration complexity increase

Engineering Contradiction:

Improvepower delivery capabilityVSAvoidpackaging size

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

The patent integrates control circuits and power conversion modules into a unified modular architecture where control ASICs are embedded within power conversion modules. This merging of control and power functions into single integrated units reduces overall packaging volume while maintaining high power delivery capability through efficient space utilization.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power conversion modules are designed with universal functionality to handle multiple operations including DC-DC conversion, DC-AC inversion, battery charging, and discharge operations. This multi-functionality eliminates the need for separate dedicated circuits for each function, thereby reducing packaging size while meeting increasing power demands.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Measurement precision

If additional voltage and temperature sensors are added to 800-volt battery systems, then measurement precision and safety are improved, but device complexity increases

Engineering Contradiction:

Improvevoltage and temperature sensing accuracyVSAvoidsensor quantity and circuit complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent integrates voltage and temperature sensing functions directly into the power conversion module ICs, combining measurement capabilities with power conversion functions in a single integrated circuit. This reduces the total number of discrete sensor components and simplifies the overall system architecture while maintaining high measurement precision for battery management.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If additional balancing circuits are added to 800-volt battery systems, then battery cell balance and reliability are improved, but device complexity and packaging size increase

Engineering Contradiction:

Improvebattery cell balance and system reliabilityVSAvoidcircuit quantity and system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent integrates balancing circuit functionality directly into the power conversion module ICs, merging balancing operations with power conversion functions in a single integrated unit. This approach maintains reliable battery cell balancing while reducing the total number of discrete balancing circuits and simplifying system architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The power conversion module ICs are designed with universal functionality that includes both power conversion operations and battery cell balancing capabilities. This multi-functionality allows a single integrated circuit to perform multiple tasks that would traditionally require separate dedicated circuits, thereby reducing device complexity while maintaining high reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If separate control and power circuits are used, then functional separation and ease of manufacture are improved, but integration efficiency and packaging density decrease

Engineering Contradiction:

Improvefunctional separation for manufacturingVSAvoidintegration efficiency and packaging density

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent integrates control circuits and power conversion modules into unified modular units with standardized interfaces, maintaining functional separation for manufacturing purposes while achieving high integration density. The modular design allows separate fabrication of control and power components that are then assembled into integrated modules, balancing manufacturing ease with packaging efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP4108508A1Controller integrated circuit for electric vehicle applications

Publication Date: 2022.12.28 VOLVO CAR CORP

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AI summary

Power and controller integrated circuits for electric vehicle applications are enabled. For example, a system can comprise a plurality of battery cells, and a plurality of application specific integrated circuits (ASICs) electrically coupled to the plurality of battery cells, wherein one or more ASICs of the plurality of ASICs comprises a respective control ASIC, and wherein the ASICs comprise respective bidirectional direct current to alternating current (DC-AC) converters and charge or discharge the plurality of battery cells.