Integrated High-Side Contactor Driver With Fault Isolation
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Solution Overview
Problem
Existing battery management systems for electrified machines face issues with increased component count, cost, and low reliability due to the use of external pilot/interposed relays and low-side driver circuits for controlling high-current, high-voltage contactors, leading to incompatibility and operational inefficiencies.
Innovation Solution
A high-side driver integrated into the battery pack controller is used to control contactors, electrically isolating the controller pins from the low-voltage digital processing core, and includes a field-effect transistor to manage voltage, with current sensing and fault diagnosis capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external pilot/interposed relays and low-side driver circuits are used to control contactors, then the control function is achieved, but the component count increases and reliability decreases
Solution Approach 1:
The patent integrates the high-side driver circuitry directly into the battery pack controller, merging previously separate components (controller, driver circuitry, and contactor control functions) into a single integrated unit. This eliminates external pilot relays and interposed components, reducing overall system complexity while maintaining control functionality and improving reliability through fewer connection points and components.
Solution Approach 2:
The patent extracts the driver circuitry from external separate components and incorporates it directly into the battery pack controller internal architecture. By taking out the need for external pilot relays and integrating the driving function internally, the system achieves simpler architecture with reduced component count while preserving the essential control function.
2Adaptability or versatility
If low-side driver circuits are used to control contactors, then the control function is achieved, but incompatibility and operational inefficiencies occur
Solution Approach 1:
The patent inverts the traditional low-side switching approach by implementing a high-side driver circuit that switches the positive voltage rail instead of the negative rail. This inversion allows for better control of contactor coils, improved compatibility with various contactor types, and enhanced operational efficiency by enabling more precise control timing and reducing unwanted coil energization.
Solution Approach 2:
The patent changes the electrical parameters of the control circuit by transitioning from low-side switching (switching ground reference) to high-side switching (switching voltage source). This parameter change enables better adaptability to different contactor configurations and improves operational efficiency through optimized voltage control and reduced electrical interference.
3Reliability
If the controller pins are not electrically isolated from the digital processing core, then the circuit is simpler, but the reliability decreases due to voltage conflicts
Solution Approach 1:
The patent introduces electrical isolation circuitry as an intermediary barrier between the controller pins and the digital processing core. This isolation layer (using optocouplers or transformer coupling) mediates the electrical connection, allowing control signals to pass while preventing voltage conflicts and ground loops between different voltage domains, thereby ensuring reliable operation without excessive complexity.
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 approach reduces component count, enhances reliability, and ensures efficient operation of contactors by integrating the high-side driver within the battery pack controller, providing fault diagnosis and protection against excessive current.
Implementation Method 1
The driver circuit may include an electronic switch, such as a field-effect transistor, that is configured on the high side of the contactor to control voltage from an energy source to the contactor.
Data Source
AI summary
A driving circuit to control/drive a contactor using a high-side driver integrated into the battery pack controller. The driver circuit may electrically isolate the controller pins of the battery pack controller (which interface the contactors) from the low-voltage digital processing core of the battery pack controller. The driver circuit may provide techniques to diagnose a fault by monitoring the voltage at the output of the driver as compared to the reference voltage. The driver circuit may include an electronic switch, such as a field-effect transistor, that is configured on the high side of the contactor to control voltage from an energy source to the contactor.