Integrated Controller for EV Battery Modules
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Solution Overview
Problem
Existing energy storage systems for hybrid electric vehicles face challenges such as overheating, weight, complexity, ease of incorporation, ease of service, and cost, particularly due to the need for specific battery packs designed for specific voltage requirements and the reliance on separate control boxes that can fail, rendering the entire system inoperable.
Innovation Solution
The energy storage system comprises modular battery arrays with a master-slave configuration using a CAN bus for communication, an integrated energy storage controller module, and a high voltage junction box, along with thermal management and a plug-in bussed electrical center, allowing for flexible voltage configurations and redundancy without a separate control box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate control boxes are used for each battery pack, then control functionality is provided, but system complexity increases and reliability decreases
Solution Approach 1:
The patent integrates the control box functionality directly into the battery pack assembly, eliminating separate control boxes. The control electronics are housed within the battery pack itself, merging previously separate components (battery cells and control system) into a single integrated unit. This reduces the number of separate components in the energy storage system while maintaining full control functionality.
Solution Approach 2:
The integrated control box within each battery pack serves multiple functions: monitoring battery cell voltages, managing thermal conditions, controlling charge/discharge operations, and communicating with other battery packs and the hybrid vehicle control system. This multi-functional design eliminates the need for separate dedicated control components.
2Ease of operation
If separate control boxes are used for each battery pack, then control functionality is provided, but system reliability worsens due to potential failure points
Solution Approach 1:
The energy storage system is divided into multiple independent battery packs, each with its own integrated control box. This segmentation creates modular units that can operate semi-independently. If one battery pack or its control system fails, other battery packs can continue to function, providing redundancy and improving overall system reliability.
Solution Approach 2:
Each integrated control box continuously monitors battery pack conditions (voltage, temperature, current) and provides feedback to the hybrid vehicle control module. This real-time monitoring and feedback mechanism allows for proactive management of battery health and immediate response to potential failures, enhancing system reliability.
3Manufacturing precision
If battery packs are specifically designed for particular HEV design specifications, then performance requirements are met, but adaptability to different settings is reduced
Solution Approach 1:
The battery packs are designed with dynamic configurability, allowing the system to adapt to different voltage and capacity requirements. The modular architecture enables battery packs to be connected in series or parallel configurations, and the control system can dynamically adjust operating parameters based on the specific hybrid vehicle application, providing both precision and adaptability.
Data Source
AI summary
An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises an enclosure, at least one battery array located within the enclosure, and an energy storage controller module located within the enclosure and electrically connected to the battery array. The energy storage module further comprises a compliant tipped thermistor which may be installed within a flexible clip. The thermistor is positioned to monitor the temperature of one or more of the batteries within the energy storage system.