EV Power Supply System Shared Relay Pre-Charge Resistor
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Solution Overview
Problem
Existing power supply systems for electric vehicles are complex and unstable due to the high number of components required for safe and efficient power distribution, particularly in high-output, large-capacity battery systems.
Innovation Solution
A power supply system with a battery module, switching devices, pre-charge resistors, and rupture switches, including pyrotechnic switches, is designed to reduce the number of relays and simplify the circuit configuration, while enhancing stability by using shared components for the power load unit, battery unit, and charging unit, and incorporating rupture switches to manage overcurrents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate relays and pre-charge resistors are used for power load unit, battery unit, and charging unit, then safety and reliability are improved, but device complexity and number of components increase
Solution Approach 1:
The patent implements a shared relay and pre-charge resistor configuration where a single relay and pre-charge resistor are commonly used by the power load unit, battery unit, and charging unit. This multi-functional approach reduces the total number of components while maintaining safety and reliability through centralized control and protection mechanisms.
Solution Approach 2:
The patent merges previously separate protection components into shared components. The relay and pre-charge resistor are combined into a common configuration that serves multiple units (power load unit, battery unit, charging unit), thereby reducing component count while maintaining protective functions through intelligent control logic.
2Power
If high-output, large-capacity batteries are used to supply high-power to vehicle motor, then power output capability is improved, but safety risks and stability issues worsen
Solution Approach 1:
The patent implements preliminary protection actions through pre-charge resistors that limit inrush current before full power connection, and relays that establish controlled connection sequences. These preliminary actions prevent sudden high-current shocks to the battery and connected units, ensuring safe operation when high-power batteries are activated.
Solution Approach 2:
The pre-charge resistor acts as a cushioning element that absorbs and limits the initial current surge when high-capacity batteries are connected to the power system. This beforehand cushioning protects the battery and connected units from damaging inrush currents while enabling subsequent high-power operation.
3Reliability
If more relays and protection components are added to manage high currents safely, then safety is improved, but system size and manufacturing complexity increase
Solution Approach 1:
The patent employs universal relays and pre-charge resistors that serve multiple protection functions across different units (power load unit, battery unit, charging unit). This multi-functionality reduces the total component count, simplifying manufacturing assembly and reducing complexity while maintaining comprehensive safety coverage.
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
The system reduces the number of relays, simplifies the circuit, and increases stability by using shared components and pyrotechnic switches to manage high currents, thereby enhancing safety and reducing system size.
Implementation Method 1
the rupture switch may include a pyrotechnic switch
Data Source
AI summary
The present invention discloses a power supply system capable of supplying electric power to a vehicle, in particular, an electric vehicle, while reducing the number of components and improving stability. An embodiment of the present invention discloses a power supply system comprising: a battery comprising battery cells; a first switching device formed between one electrode of the battery and a power load unit comprising a motor that receives power from the battery; a pre-charge resistor having one end electrically connected to the other electrode of the battery; and a second switching device formed between the other end of the pre-charge resistor and the other electrode of the battery.