EV Junction Box Series-Parallel Battery Switching
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Solution Overview
Problem
Current battery management systems in electric and hybrid vehicles lack efficient mechanisms for fast charging and fail-safe operations, particularly in scenarios involving battery or controller failures, and are prone to accidental short circuits.
Innovation Solution
A power system with dual battery packs and a switch configuration that connects batteries in series for charging and in parallel for driving, utilizing electromagnetic switches and a junction box to control connections, ensuring safe operation and preventing short circuits, while also allowing for flexible power architecture adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional battery management systems are used with single battery configuration, then system simplicity is maintained, but fast charging capability and fail-safe operation are insufficient
Solution Approach 1:
The power system is segmented into multiple independent battery packs (first battery pack, second battery pack) that can operate independently or in combination. This segmentation enables fail-safe operation where the vehicle can continue driving if one battery pack fails, while also providing fast charging capability through parallel connection during charging mode.
Solution Approach 2:
The system dynamically reconfigures the battery connections based on operating mode through switching elements. In charging mode, batteries are connected in parallel to enable fast charging; in driving mode, they are connected in series to provide driving power. This dynamic reconfiguration allows the system to adapt to different operational requirements.
2Adaptability or versatility
If multiple switching elements are used to control battery connections, then connection flexibility is improved, but system cost, weight, and footprint increase
Solution Approach 1:
The switching elements are designed to perform multiple functions: they control both the charging mode connections (parallel configuration) and driving mode connections (series configuration). This multi-functionality reduces the overall number of switching elements required compared to having separate switching mechanisms for each mode.
Solution Approach 2:
The patent merges the charging mode control and driving mode control into a unified switching system where the same switching elements serve both purposes. This consolidation reduces the total number of switching components needed in the system.
3Power
If batteries are connected in series for driving, then driving voltage is sufficient, but charging speed is limited
Solution Approach 1:
The system dynamically switches between series connection (for driving mode to achieve sufficient voltage) and parallel connection (for charging mode to enable fast charging). This dynamic reconfiguration allows the system to optimize for the current operational requirement without being constrained by a fixed connection topology.
Solution Approach 2:
By segmenting the battery system into separate battery packs that can be independently connected, the system enables flexible configuration where batteries can be connected in series for driving or in parallel for charging, thus achieving both sufficient driving voltage and fast charging capability.
4Reliability
If traditional single battery system is used, then system weight is reduced, but fast charging capability and fail-safe operation are compromised
Solution Approach 1:
The power system is divided into multiple battery packs that can be independently managed. This segmentation provides fail-safe operation capability where the vehicle can continue operating if one battery pack fails, while the modular structure allows for efficient space utilization that minimizes the overall system weight.
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 fast charging, ensures vehicle drivability even with battery failures, prevents short circuits, reduces system cost, weight, and footprint by using fewer switching elements, and provides a flexible power management system.
Implementation Method 1
a plurality of switching elements to control connections between the charging port, the first battery, and the second battery
Data Source
AI summary
Embodiments include a junction box for an electric vehicle. The junction box includes a charging port to receive power from an external power source, and a plurality of switching elements to control electrical connections between the charging port, a first battery, and a second battery. On/off states of the plurality of switching elements control whether the charging port, the first battery and the second battery are connected in a first configuration or a second configuration.