EV Generator Power Architecture With Dual Batteries and DC/DC Transfer
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Solution Overview
Problem
Current vehicle systems face challenges in efficiently generating and storing electrical power for both propulsion and external loads, particularly in hybrid and electric vehicles, where the integration of prime movers, transmissions, and energy sources is complex, and existing solutions often require multiple batteries and inverters, which increase cost and reduce packaging flexibility.
Innovation Solution
A vehicle drive system incorporating a prime mover, an electric motor, and a high-power generator, where the electric motor is configured to generate energy from the prime mover and drive the generator using power from an electric energy source, allowing for the integration of a secondary battery system that provides optimal voltage for accessories and maximizes range or time at the worksite, and uses a DC/DC converter to transfer energy between systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple batteries and inverters are used to generate and store electrical power, then power supply capability is improved, but system cost and device complexity increase
Solution Approach 1:
The patent combines multiple battery systems (traction battery and secondary battery) into a unified power architecture where they work together through a DC/DC converter. This merging approach allows the system to achieve higher power supply capability while reducing the number of separate inverter systems needed, thereby lowering overall system complexity and cost.
Solution Approach 2:
The secondary battery system is designed to serve multiple functions: it provides optimal voltage for vehicle accessories, extends the vehicle's operating range, and can function as a distributed energy resource. This multi-functionality reduces the need for separate dedicated systems, thereby reducing device complexity while maintaining high power supply capability.
2Power
If multiple batteries and inverters are used to generate and store electrical power, then power supply capability is improved, but manufacturing cost increases
Solution Approach 1:
By merging the traction battery and secondary battery into a coordinated power system managed through a DC/DC converter, the patent reduces the need for multiple expensive inverter systems. This consolidation lowers manufacturing costs while maintaining enhanced power supply capability for both propulsion and external loads.
Solution Approach 2:
The DC/DC converter acts as an intermediary between the two battery systems, enabling efficient energy transfer and voltage matching. This intermediary approach allows the system to achieve high power supply capability without requiring multiple complex inverter systems, thereby reducing manufacturing costs.
3Power
If traditional power generation systems are used in hybrid vehicles, then power generation capability is maintained, but fuel consumption and emissions increase
Solution Approach 1:
The system enables the vehicle to serve itself as a distributed energy resource, where the secondary battery can power external loads and accessories without requiring the prime mover to run continuously. This self-service capability reduces fuel consumption and emissions while maintaining power generation capability through the electric motor and generator system.
Solution Approach 2:
The electric motor is designed to function both as a propulsion device and as a generator for power generation. This multi-functionality allows the system to maintain power generation capability while operating in electric mode only when needed, thereby reducing fuel consumption and emissions compared to traditional hybrid systems that rely more heavily on the prime mover.
4Power
If traditional battery systems are used in electric vehicles, then propulsion power is provided, but packaging flexibility is reduced
Solution Approach 1:
The patent divides the battery system into two separate systems: a traction battery dedicated to propulsion and a secondary battery for accessories and external power supply. This segmentation allows each battery to be optimized for its specific function and packaged in locations best suited for its thermal and spatial requirements, thereby improving packaging flexibility while maintaining propulsion power capability.
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 solution enables efficient power generation and storage, reduces fuel consumption and emissions, provides packaging flexibility, and allows for the use of renewable energy sources, while minimizing the need for expensive power electronics and inverters, thereby enhancing the vehicle's ability to operate as a distributed energy resource.
Implementation Method 1
an electric motor in direct or indirect mechanical communication with the first prime mover... The electric motor is configured to generate energy for storage in the energy source via rotation using power from the first prime mover
Implementation Method 2
a high power generator coupled to the electric motor. The electric motor is configured to generate energy for storage in the energy source via rotation using power from the first prime mover and drives the generator using energy from the electric energy source
Data Source
AI summary
A vehicle includes a first prime mover and a first prime mover driven transmission. A vehicle drive system for the vehicle includes an electric energy source, an electric motor in direct or indirect mechanical communication with the first prime mover, and a high power generator coupled to the electric motor. The electric motor is configured to generate energy for storage in the energy source via rotation using power from the first prime mover and drives the generator using energy from the electric energy source.