Modular Battery Pack with Fail-Safe PCB Isolation
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Solution Overview
Problem
Current electric vehicle battery systems face challenges such as limited operation duty cycle, complex battery standardization requirements, and inefficient battery exchange mechanisms, which hinder widespread adoption of plug-in recharge electric vehicles. Additionally, existing systems do not efficiently utilize disparately aged or charged batteries and require heavy, large batteries for extended range driving, affecting vehicle efficiency and range.
Innovation Solution
A modular, intelligent battery pack system with fail-safe mechanisms and distributed intelligence allows for quick exchange and monitoring of batteries, enabling efficient use of batteries of varying ages and charges, and supports flexible energy management based on driving range requirements, using a hierarchical arrangement of cells, packs, and racks with power switching and mixing capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If heavy, large batteries are used for extended range driving, then vehicle range is improved, but vehicle efficiency deteriorates
Solution Approach 1:
The battery system is divided into multiple modular battery packs that can be independently exchanged. Each pack contains multiple battery modules arranged in series, allowing the system to provide extended range through multiple packs while maintaining efficiency by using lighter individual packs that can be quickly swapped rather than carrying one large, heavy battery system.
2Reliability
If complex battery standardization requirements are imposed, then battery exchange reliability is improved, but device complexity increases
Solution Approach 1:
The battery packs are designed with universal mechanical and electrical interfaces that work across different pack configurations. The standardized connector design and modular architecture allow the same interface standards to serve multiple functions including mechanical attachment, electrical connection, and communication protocols, reducing overall system complexity while ensuring reliable exchanges.
3Ease of operation
If inefficient battery exchange mechanisms are used, then productivity is worsened, but ease of operation is improved
Solution Approach 1:
The battery exchange mechanism replaces manual mechanical operations with an automated robotic system. The robot performs the complete exchange sequence including approach, alignment, connector engagement, and verification automatically, dramatically increasing exchange speed while keeping the user interface simple and easy to operate through minimal user input requirements.
4Adaptability or versatility
If batteries of varying ages and charges are not efficiently utilized, then loss of energy increases, but adaptability worsens
Solution Approach 1:
The system assigns specific battery packs to specific vehicle applications based on their state of charge and age characteristics. Fresh, fully charged packs are assigned to vehicles requiring extended range, while older or partially charged packs are assigned to vehicles with shorter range requirements. This local optimization of battery placement maximizes the utility of each pack's specific characteristics and minimizes energy waste.
Data Source
AI summary
A fail safe battery pack is disclosed and claimed wherein first and second housings are affixed together. A plurality of battery cells reside within and fixedly engage the first and the second housings. First and second printed circuit boards (PCBs) reside within first and second lattice structures of the first and second housings. A variable bias device resides in the first and/or second lattice structure of the first and second housing and engages the first and/or second PCBs. When the bias of the variable bias device is sufficiently large it overcomes a plurality of fixed mechanically biased devices operating between the PCB and the plurality of battery cells and tending to separate same and causes the PCB to electrically communicate with the plurality of battery cells. When the bias of the variable bias device is sufficiently small, the plurality of fixed mechanically biased devices separates the PCB and the plurality of battery cells rendering the battery cells in an electrically safe condition.