Modular Battery for Electrified Vehicle Range Extension
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Solution Overview
Problem
Electrified vehicles rely heavily on vehicle-mounted batteries that are not designed to be removed for charging, limiting the flexibility and range of the vehicle, as they are typically charged on-board through regenerative braking or external power sources without the option for remote charging.
Innovation Solution
A modular battery system that is selectively removable from the vehicle for charging at a remote location, connected to the vehicle's electric machine via a DC-to-DC converter and contactor, allowing for extended vehicle range by reducing reliance on vehicle-mounted batteries and internal combustion engines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vehicle-mounted battery is designed to be permanently mounted for the entire battery life, then the reliability and stability of the power supply system is improved, but the flexibility and ease of operation for charging is worsened
Solution Approach 1:
The power supply system is segmented into two independent battery units: a vehicle-mounted battery (VMB) permanently installed for vehicle operation, and a modular battery (MB) that can be removed and charged externally. This segmentation allows each battery to serve its specific function optimally while providing charging flexibility through the removable MB.
Solution Approach 2:
The system dynamically switches between power sources based on operational needs. The control system automatically manages power distribution from the VMB, MB, or both batteries together, and can transition between different charging modes (external charging of MB, regenerative braking charging of VMB) to optimize flexibility and reliability.
2Ease of operation
If the vehicle-mounted battery is charged without removal using regenerative braking, then the ease of operation is improved, but the energy efficiency and range extension capability is worsened
Solution Approach 1:
The modular battery is pre-charged externally at convenient locations (home, office, charging stations) before vehicle use. This preliminary charging action extends the vehicle's range without requiring the vehicle to be stationary for regenerative braking charging, thereby improving energy efficiency while maintaining operational convenience.
Solution Approach 2:
The system utilizes regenerative braking to automatically recharge the vehicle-mounted battery during vehicle operation, providing self-service charging that recovers energy during deceleration. This complements the externally charged modular battery to provide multiple energy recovery pathways.
3Device complexity
If a single battery pack is used to power the vehicle, then the device complexity is reduced, but the range extension and energy efficiency is worsened
Solution Approach 1:
The power supply system is divided into two independent battery units: a vehicle-mounted battery (VMB) permanently installed for vehicle operation, and a modular battery (MB) that can be removed and charged externally. This segmentation allows each battery to serve its specific function optimally while providing charging flexibility through the removable MB.
Solution Approach 2:
The control system merges the power output from both the VMB and MB to simultaneously power the motor, thereby extending the vehicle's operational range. The system intelligently combines power from both sources based on their charge states and power requirements, achieving range extension without proportionally increasing system complexity.
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
Enables convenient charging of the modular battery at home or office, extending the vehicle's range by depleting the modular battery first and then switching to the vehicle-mounted battery, thereby conserving the life of both batteries and reducing reliance on other power sources.
Implementation Method 1
a DC-to-DC converter is provided between the modular battery and an electric machine, the DC-to-DC converter configured to increase the voltage provided by the modular battery and supply the increased voltage to the electric machine
Implementation Method 2
The vehicle-mounted battery includes a plurality of battery cells providing power to a motor
Data Source
AI summary
An exemplary aspect of the present disclosure relates to an electrified vehicle including, among other things, a vehicle-mounted battery and a modular battery. The modular battery is selectively removable from the vehicle, and is configured to be charged at a location remote from the vehicle. The vehicle is selectively powered by at least one of the modular battery and the vehicle-mounted battery.