Battery-Ultracapacitor HESS Layout for Flexible Mild-Hybrid Start-Up
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Solution Overview
Problem
Existing mild-hybrid powertrain systems employing hybrid energy storage systems (HESS) face challenges in achieving operational flexibility and cost-effectiveness for medium-duty and heavy-duty commercial vehicle applications, often requiring additional components that increase complexity and cost.
Innovation Solution
A mild-hybrid energy storage system architecture that includes a battery, an ultracapacitor connected in parallel, dedicated pre-charge circuits, and main contactors, along with a control module to independently manage the operation of these components, optimizing energy storage and release for efficient engine starting and operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a hybrid energy storage system includes both battery and ultracapacitor with dedicated pre-charge circuits and main contactors, then operational flexibility and performance are improved, but device complexity increases
Solution Approach 1:
The system divides the energy storage function into two separate components: battery and ultracapacitor, each with its own dedicated pre-charge circuit and main contactor. This segmentation allows independent control and optimization of each component's operation, enabling flexible operational modes while maintaining manageable complexity through modular architecture
Solution Approach 2:
The control module dynamically selects between different operational modes (battery-only, ultracapacitor-only, or hybrid operation) based on real-time system conditions. The independent control of pre-charge circuits and main contactors enables dynamic reconfiguration of the system architecture to match operational requirements, achieving adaptability without permanent complexity
2Reliability
If additional components are added to meet operational requirements, then reliability and performance are improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the system into independent battery and ultracapacitor subsystems with dedicated protection circuits, the patent achieves high reliability through redundancy and isolation. Each component can be manufactured and tested independently using standard processes, preventing the need for complex integrated manufacturing that would increase costs
Solution Approach 2:
The control module acts as an intermediary that manages the interaction between battery and ultracapacitor components. It coordinates pre-charge operations and main contactor switching to ensure reliable operation while using off-the-shelf components that can be manufactured through conventional processes, balancing reliability with manufacturing cost
3Duration of action of stationary object
If ultracapacitor is used to reduce battery load and smooth transitions, then battery life is improved, but ultracapacitor leakage increases
Solution Approach 1:
The dedicated ultracapacitor pre-charge circuit activates before main contactor closure to gradually charge the ultracapacitor and minimize inrush current. This preliminary action reduces stress on the ultracapacitor and battery while limiting energy loss during switching transitions, addressing both battery life extension and leakage reduction
Solution Approach 2:
The control module continuously monitors system conditions and adjusts ultracapacitor charging and discharging operations in real-time. By providing feedback control, the system optimizes energy transfer between components, minimizing ultracapacitor leakage while maintaining battery protection benefits
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 proposed architecture achieves low cost, high reliability, and high performance by optimizing energy storage and release, reducing the need for additional components, and ensuring rapid DC bus pre-charging and engine start-up, while minimizing ultracapacitor leakage and complexity.
Implementation Method 1
A UC, sometimes referred to as a supercapacitor, is a high-capacity capacitor with lower voltage limits that bridges the gap between electrolytic capacitors and rechargeable batteries. Such UCs can reduce the load on the battery of a HESS by absorbing fast voltage and/or current transients
Implementation Method 2
An energy storage system including a battery, such as a Lithium-ion battery, is needed to realize mild-hybrid value
Implementation Method 3
the passive battery pre-charge circuit includes a resistor connected between the terminal of the battery and an input of a pre-charge switch
Data Source
AI summary
A mild-hybrid energy storage system architecture is provided, comprising: a battery; an ultracapacitor connected in parallel with the battery; a passive battery pre-charge circuit connected between a terminal of the battery and a DC bus; a battery main contactor connected in parallel with the battery pre-charge circuit between the terminal of the battery and the DC bus; a passive ultracapacitor pre-charge circuit connected between a terminal of the ultracapacitor and the DC bus; an ultracapacitor main contactor connected in parallel with the ultracapacitor pre-charge circuit between the terminal of the ultracapacitor and the DC bus; and a control module configured to independently control operation of the battery pre-charge circuit, the battery main contactor, the ultracapacitor pre-charge circuit and the ultracapacitor main contactor.