Integrated EV BMS Charger DC-DC Layout With Shared Cold Plate
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Solution Overview
Problem
Current electric vehicle power systems require multiple individual electrical components distributed across the vehicle, leading to increased non-recurring engineering costs, bill of material costs, volume, and mass, while lacking integrated features for efficiency and safety.
Innovation Solution
A combined Battery Management System (BMS)/Charger/Direct Current Converter (DC-DC) system that integrates multiple components into a single unit, reducing external connections, harnessing requirements, and enhancing safety and reliability by sharing components and thermal management systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple individual electrical components are distributed across the vehicle, then each component can perform its specific function independently, but the non-recurring engineering costs, bill of material costs, volume, and mass increase
Solution Approach 1:
The patent combines the charger, DC-DC converter, and BMS into a single integrated power management system. This merging eliminates the need for separate housings, mounting structures, and external connections for each component, thereby reducing overall system volume while maintaining all individual functions within the unified architecture.
Solution Approach 2:
The integrated power management system performs multiple functions simultaneously - charging the battery, converting DC voltage levels, and managing battery safety. This multi-functionality allows a single component to replace three separate components, reducing volume, mass, and cost while preserving functional independence through internal modular design.
2Adaptability or versatility
If multiple individual electrical components are distributed across the vehicle, then each component can be optimized for its specific function, but the harnessing requirements and external connections increase
Solution Approach 1:
By merging the charger, DC-DC converter, and BMS into one unit, the patent eliminates the need for extensive external wiring harnesses that would connect separate components. Internal connections are made through integrated circuit boards and direct electrical contacts, significantly reducing harness complexity while maintaining functional optimization through dedicated internal circuits for each function.
3Reliability
If multiple individual electrical components are distributed across the vehicle, then redundancy can be achieved, but the costs and development time increase
Solution Approach 1:
The integrated system achieves redundancy through internal design rather than requiring multiple separate units. The unified architecture includes redundant protection circuits, backup power management pathways, and fault tolerance mechanisms built into the single system, reducing manufacturing costs while maintaining reliability.
4Volume of stationary object
If components are integrated into a single unit, then packaging volume and weight are reduced, but thermal management becomes more challenging
Solution Approach 1:
The patent integrates the thermal management system into the unified power management component. A single cooling mechanism serves all heat-generating elements (charger, DC-DC converter, and BMS) within the integrated unit, efficiently managing thermal loads while maintaining compact packaging. The shared thermal pathway reduces overall system volume compared to separate cooling systems for each component.
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
This integration results in reduced packaging volume and weight, lower costs, shorter development times, and improved safety through reduced external connections and thermal management, while ensuring efficient power management and protection of batteries from overcharging.
Implementation Method 1
thermal management systems
Implementation Method 2
thermal management systems
Implementation Method 3
Charger
Implementation Method 4
Direct Current Converter (DC-DC)
Data Source
AI summary
A combined battery management system, charger, and direct current converter (BCD) for an electric vehicle is disclosed. The combined unit includes an enclosure enclosing: an on board charger (OBC); a direct current converter (DC-DC); and a single cold plate thermally coupled to both the OBC and the DC-DC, the single cold plate configured to provide cooling for both the OBC and the DC-DC. The combined unit also includes a plurality of 12V terminal posts on the enclosure, at least one of the plurality of 12V terminal posts for 12V in and at least two of the plurality of 12V terminal posts for 12V outs.