EV Battery Pack Maintenance Device for Safe Discharge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The maintenance of electric vehicle battery packs is challenging due to varying configurations, high voltages, and safety concerns, especially after accidents, where traditional methods fail to safely discharge or access the battery packs.
Innovation Solution
A battery pack maintenance device that includes load circuits for discharging and charging, input/output circuitry for communication with vehicle and battery pack systems, and specialized junction boxes for safe high-voltage connections, capable of interfacing with vehicle and battery pack controllers to manage and monitor battery operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional maintenance methods are used on battery packs, then the device complexity is low, but the reliability and safety are insufficient due to inability to handle high voltages and varying configurations
Solution Approach 1:
The patent introduces a specialized maintenance device that acts as an intermediary between the technician and the battery pack. This device includes isolation switches, junction boxes, and control circuitry that mediate the interaction, allowing safe access to high-voltage battery packs while protecting operators from electrical hazards. The intermediary device handles the complexity of high-voltage systems, varying configurations, and safety protocols, thereby improving reliability without requiring technicians to directly manage these complex aspects.
Solution Approach 2:
The maintenance device is designed with universal functionality to handle various battery pack configurations and high-voltage systems. It includes adaptive circuitry that can detect and accommodate different battery chemistries, voltages, and connector types. The device performs multiple functions including isolation, discharge control, charging, and communication with battery management systems, making it applicable across different electric and hybrid vehicle models while maintaining safety and reliability.
2Productivity
If battery packs are accessed for maintenance after accidents, then the productivity is improved by enabling maintenance, but the object-affected harmful factors increase due to high voltages and potential damage
Solution Approach 1:
The maintenance device implements preliminary protective actions before maintenance begins. Isolation switches are engaged to disconnect the battery pack from the vehicle system, and the device verifies the battery is in a safe state before allowing access. The system performs preliminary checks for damage, proper connection, and appropriate isolation, preventing harmful effects from high voltage before they can affect operators or equipment during maintenance operations.
3Ease of operation
If specialized maintenance equipment is introduced to handle high voltages and varying configurations, then the ease of operation is improved, but the device complexity increases
Solution Approach 1:
The maintenance device incorporates self-service features that automatically detect battery pack characteristics, configure appropriate isolation and discharge parameters, and guide operators through maintenance procedures. The system self-adjusts to different battery configurations without requiring manual setup, and provides automated diagnostics and control, reducing the operational burden on technicians while managing the inherent complexity of handling high-voltage systems.
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 safe and efficient maintenance of electric vehicle battery packs by safely accessing and discharging them, even in accident-damaged states, while ensuring operator safety and handling varying configurations and high voltages.
Implementation Method 1
one or more loads for connecting to a battery pack for use in discharging the battery pack
Implementation Method 2
charging circuitry for use in charging the battery pack
Data Source
AI summary
The present invention includes a battery maintenance device for performing maintenance on battery packs of hybrid and/or electrical vehicles (referred herein generally as electric vehicles). In various embodiments, the device includes one or more loads for connecting to a battery pack for use in discharging the battery pack, and/or charging circuitry for use in charging the battery pack. Input/output circuitry can be provided for communicating with circuitry of in the battery pack and/or circuitry of the vehicle.