Dual Battery Module Switching for EV Power Redundancy
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Solution Overview
Problem
Current power supply systems for electric vehicles lack sufficient redundancy to ensure continuous operation of critical systems during high voltage battery failures, leading to limited power availability and safety concerns.
Innovation Solution
A dual power supply and distribution system with two high voltage battery modules, each connected to a DCDC converter and a back-to-back switch unit, monitored by a Microcontroller unit, allowing for individual module failure detection and disconnection without affecting high voltage loads, ensuring power is redirected to low voltage critical systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single high voltage battery is used to power all high voltage loads, then the system structure is simple, but the system lacks redundancy and cannot ensure continuous operation during battery failure
Solution Approach 1:
The high voltage battery system is segmented into multiple independent battery modules (first battery module, second battery module), each capable of independently powering high voltage loads. This segmentation enables redundancy where if one module fails, the other can continue to supply power, thus improving reliability without requiring a completely complex dual-power-supply architecture
2Reliability
If a 12V backup battery is used for critical systems, then power is available during high voltage battery failure, but the backup battery has very limited power supply capacity requiring safe stop in limited time
Solution Approach 1:
The power supply is segmented into primary high voltage battery modules for normal operation and a secondary 12V backup battery for emergency situations. This hierarchical segmentation allows the system to use the high capacity high voltage batteries during normal operation while having a dedicated backup system for emergency power, optimizing both reliability and energy usage across different operational states
3Adaptability or versatility
If DCDC converters are used to convert high voltage to low voltage, then power conversion is achieved, but the conversion process may fail affecting all electrical loads
Solution Approach 1:
The power conversion system is segmented into multiple independent DCDC converters (first DCDC converter, second DCDC converter), each associated with specific battery modules. This segmentation ensures that if one converter fails, the other converters can continue to provide power conversion services, maintaining system reliability while preserving the necessary voltage conversion adaptability
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
The system achieves redundancy by disconnecting failing battery modules, maintaining power to critical low voltage systems, enabling the vehicle to remain operational during high voltage battery failures, and optimizing power usage by redirecting remaining power from failing modules to essential low voltage equipment.
Implementation Method 1
a first DCDC converter for converting high voltage DC to low voltage DC, and the second battery module is connected to a second DCDC converter for converting high voltage DC to low voltage DC
Data Source
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AI summary
The disclosure relates to a power supply and distribution system (1) for an electric vehicle, comprising a high voltage battery pack (2) with a first battery module (3) and a second battery module (4), wherein the first battery module (3) and the second battery module (4) each has an individual power output connector; and wherein the high voltage battery pack (2) is monitored and controlled by a first Battery Electrical Control Module (BECM1); wherein the first battery module (3) is connected to a first DCDC converter for converting high voltage DC to low voltage DC, and the second battery module (4) is connected to a second DCDC converter for converting high voltage DC to low voltage DC; and wherein the first battery module (3) and the second battery module (4) are individually connected to high voltage loads via a dual back-to-back switch unit (SW), the dual back-to-back switch (SW) comprising a first back-to-back switch (SW1) connected to the first battery module (3), a second back-to-back switch (SW2) connected to the second battery module (4) and a first Microcontroller unit (MCU1) in communication with the first Battery Electrical Control Module (BECM1), the first Microcontroller unit (MCU1) controlling the first back-to-back switch (SW1) and the second back-to-back switch (SW2); wherein the first back-to-back switch (SW1) and the second back-to-back switch (SW2) are connected in parallel to the high voltage equipment of the electrical vehicle; and wherein the first back-to-back switch (SW1) and the second back-to-back switch (SW2) are arranged to be individually controlled by the first Microcontroller unit (MCU1). The disclosure further relates to a method for controlling the power supply system (1) for an electric vehicle.