Galvanically Isolated Energy Control Connectors for High-Voltage Packs
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Solution Overview
Problem
Large electrically powered systems with high and low voltage equipment pose risks due to confusing connectors and potential exposure to high voltage, and existing solutions like fiber optic cables are costly and may not provide complete functionality.
Innovation Solution
An energy device control system with external control devices isolated from high voltage cells using non-galvanic connectors for communication and control, ensuring safe operation and maintenance by separating high voltage connectors from those for power conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber optic cables are used for communication between control devices and energy devices, then communication functionality is provided, but the system becomes more expensive and requires additional protective equipment
Solution Approach 1:
The patent introduces an intermediary isolation device that acts as a mediator between the high voltage energy device and the low voltage control device. This isolation device provides galvanic isolation while maintaining communication functionality, eliminating the need for complex fiber optic cable systems with additional protective equipment.
2Ease of operation
If low voltage connectors are distributed throughout the system for control and communication, then control functionality is enabled, but it becomes confusing to identify which connectors control which energy devices
Solution Approach 1:
The patent merges the control connector and the energy connector into a single integrated connector assembly. This combination allows maintenance personnel to identify and disconnect both control and energy connections simultaneously, eliminating confusion about which connectors control which energy devices.
Solution Approach 2:
The system performs preliminary identification and grouping of connectors, where control connectors are pre-associated with their corresponding energy connectors through integrated design or labeling systems. This preliminary organization ensures that personnel can easily identify connector relationships before maintenance operations begin.
3Adaptability or versatility
If multiple connectors are distributed throughout the system for both control and energy, then system functionality is enhanced, but the risk to lower voltage circuits and maintenance safety increases
Solution Approach 1:
The patent segments the connector system into distinct high voltage and low voltage sections within an integrated assembly. This segmentation allows the system to maintain full functionality while physically separating voltage domains, reducing the risk of voltage interference and improving maintenance safety through clear visual and physical differentiation.
Solution Approach 2:
The isolation device serves as an intermediary element that protects low voltage control circuits from high voltage energy devices. This mediator provides galvanic isolation, blocking harmful voltage transients and electrical interference while allowing control signals to pass through, thus enhancing safety without sacrificing 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
The system provides safe and efficient control of energy devices by protecting control circuitry from high voltage risks, allowing safe maintenance and operation without direct contact, and maintaining reliable communication and power transfer.
Implementation Method 1
an external control device that is external to the energy source enclosure and that is coupled with the energy source enclosure via one or more second external connectors that are external to the energy source enclosure such that the external control device is galvanically isolated from the one or more high voltage energy device cells inside the energy source enclosure
Data Source
AI summary
An energy device control system may include an energy source enclosure that can be coupled with external loads via first external connectors outside of the energy source enclosure. The system also may include an external control device coupled with the energy source enclosure via second external connectors such that the external control device is galvanically isolated from energy device cells inside the energy source enclosure. The external control device may communicate with internal control components of the energy source enclosure via the second external connectors to control charging and/or discharging of the device cells via the first external connectors.