EV Low-Voltage Battery Testing via DC-DC Converter Diagnostics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Electric vehicles face challenges in maintaining their low voltage safety performance capacity batteries, which can lead to vehicle operation failures due to varying battery pack types, high voltages, and damaged systems post-accidents, making it difficult to access and discharge the battery packs safely.
Innovation Solution
A maintenance device that couples to the electric vehicle's electrical circuitry to test the low voltage battery system, using electrical connectors to couple with the battery terminals and DC-to-DC converter, and includes measurement circuitry and a controller to assess the battery and converter conditions, capable of discharging or charging the battery pack while interfacing with the vehicle's databus to control and monitor the battery pack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If standardized connection methods are used for battery maintenance, then ease of operation is improved, but adaptability to different battery pack types deteriorates
Solution Approach 1:
The maintenance device incorporates a universal interface design with multiple connection types (e.g., different electrical connectors, mechanical coupling methods) that can adapt to various battery pack types while maintaining standardized operational procedures. The device includes reconfigurable circuitry and adjustable parameters that enable it to work with different battery chemistries, voltages, and physical configurations through a consistent user interface and maintenance workflow.
2Power
If high voltage battery packs are used for electric vehicle power, then power is improved, but safety and difficulty of maintenance deteriorates
Solution Approach 1:
The maintenance device implements preliminary safety actions including automatic voltage detection, isolation switch activation, and grounding sequence control before any maintenance operations begin. The system performs pre-maintenance diagnostics to identify potential hazards and automatically configures safety protocols based on the detected battery pack characteristics and maintenance task type.
Solution Approach 2:
The maintenance device serves as an intermediary between the high voltage battery pack and the maintenance personnel/environment. It includes isolation transformers, current-limiting circuitry, and controlled discharge paths that mediate the high voltage energy, making it safe to handle while maintaining the full power capability of the battery pack for vehicle operation.
3Reliability
If comprehensive battery system testing is performed, then reliability of vehicle operation is improved, but device complexity increases
Solution Approach 1:
The maintenance device divides comprehensive battery system testing into separate modular test functions (e.g., individual cell voltage measurement, pack-level capacity testing, thermal imaging, electrical connection resistance measurement). Each module can be independently activated based on the specific maintenance needs, allowing comprehensive diagnostics when required while keeping the device simpler for routine maintenance tasks.
Data Source
AI summary
A maintenance device for coupling to electrical circuitry of an electric vehicle for testing the low voltage battery system of the electric vehicle includes electrical connectors to configured to couple to terminals of a low voltage battery of the low voltage battery system of the vehicle and electrically couple to a DC-to-DC convertor of the vehicle which is used to charge the low voltage battery. Measurement circuitry couples to the electrical connectors. A controller coupled to the measurement circuitry is configured to measure a parameter of the low voltage battery and a parameter of the DC-to-DC convertor and responsively determine a condition of the low voltage battery and the DC-to-DC convertor.