EV Power Connection Architecture for Battery-Bypass Propulsion
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Solution Overview
Problem
Existing methods for propelling electric vehicles when battery power is depleted or insufficient, and manufacturing electric vehicles with electrical components, are inefficient and pose safety risks due to the need for specialized environments and high-voltage handling.
Innovation Solution
A method involving a power connection element on the vehicle that allows direct connection to an external electric power source, enabling the electric motor to propel the vehicle without a battery pack, and a disconnecting mechanism to ensure safety and efficiency during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a battery pack is used as the energy supply unit for propelling the vehicle, then the vehicle can operate under normal conditions, but the vehicle cannot be propelled when the battery pack is depleted or broken
Solution Approach 1:
The power connection element is designed to accept multiple types of power sources - both the internal battery pack (energy supply unit) and external power sources. This multi-functionality allows the vehicle to operate with different power sources depending on availability, resolving the contradiction between reliable operation and adaptability to different conditions.
Solution Approach 2:
The system dynamically switches between different power sources based on availability. The control unit monitors the state of the battery pack and automatically selects whether to use internal battery power or external power through the power connection element, ensuring continuous propulsion capability while adapting to changing conditions.
2Reliability
If specialized manufacturing routines and environments are used for handling high voltage, then safety is improved, but manufacturing complexity and costs increase
Solution Approach 1:
The manufacturing process is segmented into distinct phases: assembly of the power train without the energy supply unit, followed by separate assembly of the energy supply unit. This segmentation allows the majority of manufacturing to occur using existing, less complex processes, while safety-critical high voltage connections are established only when necessary during the final assembly stage.
Solution Approach 2:
The power connection element and electric motor are pre-assembled and tested without the energy supply unit before final assembly. This preliminary action allows verification of the power train functionality using lower voltage or simulated conditions, reducing the need for specialized high voltage manufacturing environments while maintaining safety.
3Ease of manufacture
If the energy supply unit is assembled early in the manufacturing process, then integration is simplified, but manufacturing costs and risks increase due to early exposure to high voltage requirements
Solution Approach 1:
The vehicle assembly is divided into modules: the power train (electric motor, power connection element) is assembled separately from the energy supply unit (battery pack). This modular segmentation allows the power train to be manufactured using existing manufacturing lines without specialized high voltage facilities, while the energy supply unit is integrated later in a controlled environment.
Solution Approach 2:
The energy supply unit is extracted from the early manufacturing process and introduced at a later stage. By removing the high voltage component (energy supply unit) from the initial assembly phase, the manufacturing process can proceed using standard facilities, and safety risks are minimized by introducing the high voltage element only when necessary for final integration.
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 simple and safe propulsion of electric vehicles using external power sources, reducing manufacturing costs and safety risks by allowing assembly in conventional manufacturing lines and separate assembly.
Implementation Method 1
an electric motor connected to a location in the vehicle intended for mounting of an energy supply unit intended for driving of the electric motor
Data Source
AI summary
A method for propelling of a vehicle comprising a power train with an electric motor connected to a location in the vehicle intended for mounting of an energy supply unit intended for driving of the electric motor during normal operating conditions of the vehicle is described. The method comprises the steps of: connecting an electric power source to a power connection element mounted on the vehicle and being connected to the electric motor and to the location, disconnecting the location in order to accomplish a direct connection between the power connection element and the electric motor and propelling the vehicle by means of the electric motor powered by electricity from the electric power source. A method for manufacturing of a vehicle comprising a power train with an electric motor and a vehicle comprising a power train with an electric motor are also described herein.