Modular Li-Ion Battery Pack Layout for Variable EV Voltage and Capacity
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Solution Overview
Problem
Existing battery systems for construction machines, such as compact wheel loaders and compact excavators, face challenges due to mismatched mechanical and electric requirements with standard 400V or 600V modules designed for automotive and commercial industries, limiting adaptability and efficiency.
Innovation Solution
A modular lithium-ion battery system with scalable elementary battery modules, each equipped with a Battery Management Unit (BMU) and capable of various configurations through series/parallel connections, allowing for customizable voltage and energy capacity to match specific electric vehicle requirements, along with adaptive electronic control units for balancing and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If standard 400V or 600V battery modules designed for automotive and commercial industries are reused for construction machines, then cost is reduced and existing technology is leveraged, but mechanical and electric requirements mismatch occurs, limiting adaptability
Solution Approach 1:
The battery system is divided into modular units (battery modules) that can be independently configured. Each module contains battery cells arranged in series to achieve a nominal voltage, and modules can be connected in series or parallel to create different system configurations matching specific construction machine requirements for voltage and energy capacity.
Solution Approach 2:
The battery system configuration is made dynamic and adaptable through the ability to reconfigure module connections. The system can switch between different series/parallel arrangements to match varying electric requirements of different construction machine models, making the system flexible rather than fixed.
2Adaptability or versatility
If battery modules are configured based on automotive or commercial applications with fixed voltages, then manufacturing standardization is achieved, but mechanical integration and electric requirements of various construction machine models cannot be met
Solution Approach 1:
The battery system采用模块化设计，将电池系统分割为标准化的电池模块单元。每个模块具有统一的机械接口和电气参数，便于根据不同施工机械的空间和电气需求进行灵活组合和集成。
Solution Approach 2:
电池模块设计为通用化单元，可同时适用于不同类型的施工机械。通过标准化的模块接口和配置方式，同一套模块系统可以适配多种机械模型，实现一个平台多种应用的多功能性。
3Power
If elementary battery modules are connected in series to increase voltage, then voltage requirement is met, but energy capacity increases proportionally, which may exceed requirements
Solution Approach 1:
The system enables dynamic configuration where modules can be connected in series to increase voltage or in parallel to increase capacity, depending on the specific requirements. This dynamic reconfigurability allows precise matching of voltage and capacity to actual needs without over-provisioning.
4Ease of manufacture
If a single standardized battery module design is used across all applications, then manufacturing cost is reduced, but specific electric requirements of different construction machine models cannot be satisfied
Solution Approach 1:
采用模块化设计将电池系统分割为标准单元，每个单元采用统一的设计规范便于标准化生产。同时通过模块的灵活组合满足多样化需求，实现了制造标准化与应用定制化的统一。
Solution Approach 2:
标准化的电池模块设计为通用平台，可通过不同的串并联配置适应不同的电压和容量需求，使单一模块设计能够服务于多种应用场景，降低整体制造成本。
Data Source
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AI summary
A lithium ion battery system (5) presenting a plurality of configurations in which elementary battery modules (6) are arranged respectively in different configurations with different voltages and energy capacities, each configuration matching with at least one electric requirement of a range of electric vehicles, the elementary battery modules (6) of each configuration being arranged in a string number of strings (7) connected in parallel to each other, each string (7) comprising a module number of elementary battery modules (6), the configuration having a configuration voltage and a configuration energy capacity, wherein each string (7) further includes a first electronic control unit for balancing a state of charge of each elementary battery module (6) within said string (7), and wherein the battery system (5) further includes at least one second electronic control unit for balancing a state of charge of the strings (7) relative to each other, wherein each elementary battery module (6) includes a Battery Management Unit (BMU) to supervise and monitor the elementary battery module (6).