Modular Battery Pack Series-Parallel Charging Modes
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Solution Overview
Problem
Emerging high-voltage battery packs with capacities exceeding the maximum charging voltage of legacy DC fast-charging stations cannot achieve a full state of charge, leading to backward compatibility issues with existing charging infrastructure.
Innovation Solution
A modular battery pack system comprising identical battery modules connected in series or parallel, controlled by a switching circuit that adjusts charge and drive modes to accommodate varying voltage capacities, ensuring compatibility with legacy charging stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If battery pack voltage capacity is increased to extend electric driving range, then driving performance is improved, but compatibility with legacy charging stations deteriorates
Solution Approach 1:
The battery pack is divided into multiple modular battery modules (e.g., four modules) that can be independently connected or disconnected. This segmentation allows the system to reconfigure its voltage output by connecting modules in series for high voltage operation or in parallel for lower voltage operation, thereby maintaining compatibility with legacy charging stations while preserving high voltage capability for extended range.
Solution Approach 2:
The battery pack incorporates dynamic switching capability through control circuitry and switching devices that can reconfigure the connection topology of battery modules in real-time. This dynamic reconfiguration allows the system to adapt its voltage output based on the charging station type (legacy or modern), enabling the same battery pack to operate across different voltage requirements without physical modification.
2Power
If battery pack voltage is increased to 800-1000 VDC for high-performance operation, then propulsion capability is improved, but ability to charge at legacy 400-500 VDC stations deteriorates
Solution Approach 1:
The high-voltage battery pack is segmented into modular units that can be electrically reconfigured. By connecting battery modules in parallel rather than series, the system reduces its output voltage from 800-1000 VDC to 400-500 VDC, enabling compatibility with legacy charging stations while maintaining the physical battery infrastructure designed for high-voltage operation.
Solution Approach 2:
The battery pack system achieves multi-functionality by being capable of operating in multiple voltage modes (high-voltage series configuration and low-voltage parallel configuration) using the same physical components. This universal design allows the battery pack to serve both high-performance propulsion applications and legacy charging infrastructure without requiring separate systems.
3Quantity of substance
If modular battery modules are added to increase voltage capacity, then energy storage capability is improved, but system complexity increases
Solution Approach 1:
The battery pack is structured as modular units that can be systematically arranged and connected. This segmentation approach, while increasing component count, provides structured organization that facilitates standardized manufacturing, assembly, and maintenance procedures, thereby managing complexity through modularity rather than monolithic design.
Solution Approach 2:
Multiple identical or similar battery modules are combined to achieve the desired voltage and capacity. This combining approach allows for standardized module design that simplifies manufacturing and assembly, as each module can be produced using the same processes and then systematically connected to form the complete battery pack with required electrical characteristics.
Data Source
AI summary
A modular battery pack system includes a battery pack and controller. The battery pack has first and second battery modules interconnected via electrical cables, with each module having a battery cell string. The pack has first, second, and third electrical connectors and four switches that selectively connect the strings to one or more of the electrical connectors. A DC charging connector is electrically connected to one of the cables between the first electrical connectors of the battery modules, and electrically connects the pack to an off-board DC fast-charging station. In response to input signals corresponding to a requested mode, the controller commands an open/closed state of each of the switches, via switching control signals, to establish a series charge mode, a parallel charge mode, and one or more of a series and/or parallel drive mode of the battery pack. A motor vehicle includes the system.