High Voltage Charging Apparatus Offline Battery Boost
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Solution Overview
Problem
Hybrid electric vehicles (HEVs) face challenges in charging their high voltage batteries, as they are often depleted when left unattended or during malfunctions, and current charging methods require the battery to be online, making it difficult to recharge without external assistance.
Innovation Solution
A high voltage charging apparatus (HVCA) using a low voltage energy storage device (LV ESD) to boost the voltage of the high voltage battery pack, allowing offline charging by connecting a booster pack with a DCDC converter and communications module to coordinate the charging process via a CAN bus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the HV battery is charged while connected to vehicle components (on-line charging), then the battery can receive necessary control messages to enable charging, but the battery remains vulnerable to discharge when left unattended or during malfunctions
Solution Approach 1:
The charging system is segmented into on-line charging (connected to vehicle components) and off-line charging (disconnected from vehicle loads). The off-line charging apparatus includes a DC-DC converter and control module that can independently charge the HV battery without requiring connection to vehicle components, thus resolving the contradiction between charging reliability and charging accessibility.
Solution Approach 2:
The off-line charging apparatus acts as an intermediary between the LV battery and HV battery. It includes a DC-DC converter that steps up voltage from the LV battery to charge the HV battery, and a control module that communicates with the HV battery control module via CAN bus to enable charging without direct connection to vehicle components.
2Ease of operation
If the vehicle uses keyless start features and extended parking periods, then convenience is improved, but the HV battery can be depleted through extended use or accidental leaving
Solution Approach 1:
The off-line charging apparatus provides a preliminary charging capability that can be activated before the vehicle is needed. When the HV battery voltage drops below a threshold during extended parking or accidental leaving, the apparatus can automatically or manually charge the battery using the LV battery or external power source, preventing complete depletion and ensuring the vehicle can be started when needed.
3Productivity
If standard HEV charging methods are used, then the battery can be charged during vehicle operation, but the battery cannot be recharged when the vehicle is not running or during malfunctions
Solution Approach 1:
The off-line charging apparatus provides universal charging capability that works in multiple scenarios: during vehicle operation, during extended parking, when the vehicle is not running, and during malfunctions. It can charge the HV battery from the LV battery or external power sources, making the charging system adaptable to various conditions beyond just vehicle operation.
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 safe and efficient charging of the high voltage battery pack while disconnected from vehicle loads, providing a quick alternative to existing methods and preventing battery discharge due to extended use or malfunctions.
Implementation Method 1
A high voltage charging apparatus (HVCA) using a low voltage energy storage device (LV ESD) to boost the voltage of the high voltage battery pack
Data Source
AI summary
A portable high voltage charging apparatus (HVCA) can be configured to controllably charge a hybrid electric vehicle (HEV) traction battery using energy provided by a low voltage (LV) lead acid vehicle battery. An HVCA can include a DCDC converter configured to boost a lower input voltage from the LV battery to a higher output voltage provided to the HV battery. The HVCA can be configured with a traction battery interlock, allowing offline charging of the traction battery. In an example embodiment, an HVCA can be configured to communicate with an HV battery control module via a CAN bus. An HVCA can be configured to transfer energy to the HV battery for a predetermined time period, then automatically stop the transfer process. An HVCA can be configured to receive user input to start and/or stop a charging process. An example embodiment can include a supplemental charger to boost LV battery voltage.