Integrated BCCM-ISC Converter Topology Without High-Current Contactors

Solution Overview

Problem

The integration of battery current control modules (BCCMs) with inverter system controllers (ISCs) in automotive power systems is challenging due to disconnecting circuitry, which requires high-current contactors and increases packaging size and weight.

Innovation Solution

A new circuit topology is proposed that integrates a BCCM with an ISC without using high-current contactors, by directly interfacing add-on circuitry with the ISC and using relays for disconnecting during drive mode, thus forming an isolated DC/DC power converter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If disconnecting circuitry with high-current contactors is used to integrate BCCM with ISC, then the system can achieve proper isolation during drive mode, but the packaging size and weight increase

Engineering Contradiction:

Improvesystem isolationVSAvoidpackaging weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The patent combines the BCCM and ISC into a single integrated controller, eliminating the need for separate disconnecting circuitry with high-current contactors. The integrated design uses shared circuitry and control logic to achieve both charging and drive functions without requiring additional heavy isolation components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated controller performs multiple functions including battery charging, drive mode control, and isolation management through a unified architecture. The same controller handles both AC/DC conversion during charging and DC/DC conversion during drive mode, eliminating the need for dedicated disconnecting circuitry.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If disconnecting circuitry with high-current contactors is used to integrate BCCM with ISC, then the system can achieve proper isolation during drive mode, but the packaging size increases

Engineering Contradiction:

Improvesystem isolationVSAvoidpackaging area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines the BCCM and ISC into a single integrated controller, eliminating the need for separate disconnecting circuitry with high-current contactors. The integrated design uses shared circuitry and control logic to achieve both charging and drive functions without requiring additional heavy isolation components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the disconnecting function from separate high-current contactor circuitry and integrates it into the controller's control logic. This eliminates the need for physical isolation components and reduces the packaging area required for disconnecting circuitry.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If traditional integration method with separate BCCM and ISC is used, then system functions are well-defined, but complex disconnecting circuitry is required

Engineering Contradiction:

Improvesystem function definitionVSAvoidcircuitry complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the BCCM and ISC into a single integrated controller, eliminating the need for separate disconnecting circuitry with high-current contactors. The integrated design uses shared circuitry and control logic to achieve both charging and drive functions without requiring additional heavy isolation components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated controller performs multiple functions including battery charging, drive mode control, and isolation management through a unified architecture. The same controller handles both AC/DC conversion during charging and DC/DC conversion during drive mode, eliminating the need for dedicated disconnecting circuitry.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution reduces packaging size and weight, eliminates the need for high-current contactors, and allows for efficient bidirectional power flow between the AC grid and the traction battery, while maintaining controlled power delivery.

Implementation Method 1

a transformer, a second switching bridge connected between the AC/DC power converter and transformer

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an electromagnetic interference filter

Methodology Applied

Scientific EffectElectromagnetic filtering: Filter (electronic)

Data Source

PatentUS12319156B2Magnetic integration of high voltage to low voltage DC/DC power converter with inverter system controller battery current control module system

Publication Date: 2025.06.03 FORD GLOBAL TECH LLC

AI summary

An automotive power system includes an AC/DC power converter, a transformer, a switching bridge connected between the AC/DC power converter and transformer, and a switch bank connected with a secondary side of the transformer. The switch bank connects the secondary side between an electric machine and another switching bridge such that the electric machine, first switching bridge, transformer, and second switching bridge form an isolated DC/DC power converter. The system further includes one or more switches configured to directly connect the traction battery between the AC/DC power converter and second switching bridge.