EV Power Control Architecture With Dual CAN and Smart Pre-Charging
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Solution Overview
Problem
Existing electric vehicle power and control systems lack efficiency and capacity in charging and power distribution, and are not easily customizable to support third-party components or systems.
Innovation Solution
An electric vehicle power and control system incorporating an electronic control unit with dual CAN bus interfaces, a battery management system for cell balancing and monitoring, and a power control and distribution box with high voltage bus bars and smart pre-charging, integrated with a battery module housing system using billet aluminum and composite carbon fiber chassis, enabling efficient charging and power distribution while being adaptable to various components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a traditional power and control system is used, then the system structure is simple, but charging efficiency and power capacity are insufficient
Solution Approach 1:
The power and control system is divided into modular components: electronic control unit, battery management system with base unit and stack units, power control and distribution box, and battery module housing system. This segmentation allows each module to be optimized independently for charging efficiency while maintaining manageable system complexity through standardized interfaces and dual CAN bus communication protocols.
2Power
If battery capacity is increased, then power output is improved, but risk of overcharging and over-discharging increases
Solution Approach 1:
The battery management system continuously monitors cell voltages and temperatures through stack units connected via daisy chain wiring harness, providing real-time feedback to the base unit. The system implements cell balancing algorithms and protective controls that automatically adjust charging parameters to prevent overcharging and over-discharging, enabling high battery capacity operation while maintaining safety through active monitoring and control.
3Adaptability or versatility
If the system is designed for specific components, then integration is easy, but adaptability to third-party components is limited
Solution Approach 1:
The electronic control unit is designed with dual CAN bus interfaces that can communicate with multiple different component types including battery management systems, motor controllers, charging systems, and third-party accessories. The standardized communication protocols and modular architecture allow the same control unit to adapt to various components without requiring custom integration hardware, enhancing versatility while managing interface complexity through standardized communication layers.
4Power
If multiple battery modules are integrated, then power capacity increases, but assembly complexity and storage space requirements increase
Solution Approach 1:
The battery system is organized into modular housing units that can be stacked to achieve desired capacity. Each module contains integrated battery cells with built-in management circuitry, allowing modules to be assembled in series or parallel configurations. This segmentation enables scalable capacity expansion while maintaining ease of manufacture through standardized module interfaces and simplified assembly procedures for multiple modules.
Data Source
AI summary
An electric vehicle power and control system includes an electronic control unit, a battery management system (BMS), a power control and distribution box, and a battery module housing system. The electronic control unit includes a computer having dual CAN bus interfaces. It is configured to interface with a touch screen monitor having a six degrees of freedom inertial measurement unit. The battery management system includes a base unit and a plurality of stack units configured for battery cell balancing and monitoring cell voltage and temperature. The power control and distribution box includes bus bars to connect at least one of fuses, contactors, a smart pre-charger, and isolation and current monitors. The battery module housing system includes battery cells integrated with at least one of the battery management system plurality of stack units.